OEM Controls: Revised MARCH 15, 2003 Printed in U.S.A. 3120344

TECHNICAL SUPPLEMENT
OEM
Controls
Revised MARCH 15, 2003 PRINTED IN U.S.A. 3120344

TECHNICAL SUPPLEMENT
JLG Industries (Australia) JLG Industries (UK) JLG Deutschland GmbH JLG Industries (Italia)
P.O. Box 5119 Unit 12, Southside Max Planck Strasse 21 Via Po. 22
11 Bolwarra Road Bredbury Park Industrial Estate D-27721 Ritterhude/lhlpohl 20010 Pregnana Milanese - MI
Port Macquarie Bredbury Bei Bremen Italy
N.S.W. 2444 Stockport Germany
Phone: (39) 02 9359 5210
Australia SK6 2sP Phone: (49) 421 693 500
Phone: (61) 2 65 811111 England Fax: (49) 421 693 5035 Fax: (39) 02 9359 5845
Fax: (61) 2 65 810122 Phone: (44) 870 200 7700
Fax: (44) 870 200 7711
JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska
Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI. Krolewska
80-Suite 71 2132 HJ Foofddorp N-1412 Sofienyr 00-060 Warsawa
13092-310 Campinas-SP The Netherlands Norway Poland
Brazil Phone: (31) 23 565 5665 Phone: (47) 6682 2000
Phone: (48) 91 4320 245
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493 Fax: (47) 6682 2001
Fax: (55) 19 3295 1025 Fax: (48) 91 4358 200
JLG Industries (Europe) JLG Industries (Pty) Ltd. Plataformas Elevadoras JLG Industries (Sweden)
Kilmartin Place, Unit 1, 24 Industrial Complex JLG Iberica, S.L.. Enkopingsvagen 150
Tannochside Park Herman Street Trapadella, 2 Box 704
Uddingston G71 5PH Meadowdale P.I. Castellbisbal Sur SE - 175 27 Jarfalla
Scotland Germiston 08755Castellbisbal
Sweden
Phone: (44) 1 698 811005 South Africa Spain
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334 Phone: (34) 93 77 24700 Phone: (46) 8 506 59500
Fax: (27) 11 453 1342 Fax: (34) 93 77 11762 Fax: (46) 8 506 59534
MANUAL EFFECTIVITY
30 June 1990 - Original Issue of Manual
November 15, 2001 - Revised Manual
March 15, 2003 - Revised Manual
3120344
TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.

SECTION 1 - CHARACTERISTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
SECTION 2 - ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2-1 CONTROLLER ADJUSTMENT (ADJUSTED BY CIRCUIT BOARD WITH TRIMPOTS) .2-1
2-2 CONTROLLER ADJUSTMENT (ADJUSTED BY MODULE AND ANALYZER) . . . . . . . .2-2
2-3 CONTROLLER SEALING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2-4 SWITCH ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
SECTION 3 - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3-1 PRINTED CIRCUIT BOARD TERMINAL BOARD CONNECTIONS . . . . . . . . . . . . . . . . .3-1
3-2 TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3-3 TROUBLESHOOTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-4 1600235 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-5 1600239 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-6 1600242 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-7 1600245 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-8 1600257 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-9 1600263 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-10 1600270 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-11 1600271 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-12 1600272 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-13 1600273 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-14 1600274 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-15 1600278 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-16 1600283 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-17 1600284 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-18 1600287 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-19 1600288 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-20 1600306 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-21 1600317 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-22 1600318 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-23 1600330 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-24 1600334 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
SECTION 4 - REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4-1 CONTROLLER WITH SINGLE GATE & NO ROCKER SWITCH . . . . . . . . . . . . . . . . . . . . . . .4-2
4-2 CONTROLLER WITH SINGLE GATE & ROCKER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-3 CONTROLLER WITH ROUND GATE & LIFT CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4-4 CONTROLLER WITH ROUND GATE & TRIGGER GRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
4-5 SPEED CONTROLLER WITH SNAIL/CREEP SPEED SWITCH . . . . . . . . . . . . . . . . . . . . . .4-20
3120344 i
TABLE OF CONTENTS
SECTION NO. TITLE PAGE NO.
ii 3120344
SECTION 1 CHARACTERISTICS
S
E
OEM CONTROLLER TECHNICAL SUPPLEMENT C
USAGE T
OEM Controllers have been used on the various JLG products either as standard or optional equipment. OEM
I
Controllers were offered as standard equipment on various “A,” “AJ,” “AJP,” “ic,” “E,” “M,” “S,” “SC,” “SCJ,” “SJ” & O
“SX” Boom Lift Models & “E” Scissor Lifts and as optional equipment on “H,” “HA,” “HT” & “HX” Boom Lift Models.
N
FEATURES
The OEM Controller converts manual input into proportional electrical output signals for the commanding propor- 1
tional flow control valves. The OEM Controller is a seal unit and can withstand hostile and rugged outdoor
weather conditions. The controller handle/stem enters the housing through a sealed entrance, reducing the possi-
bilities of water entering the housing. C
Adjustment of these controllers is done through trimpots on a circuit board (which may be attached to the control-
H
ler or separately mounted in the platform console box) or through a handheld analyzer which adjusts the person-
ality setting in an external module.
A
R
Drive, Steer, Lift and Swing Controllers (All Controllers except 1600272)
These OEM Controllers incorporate a mechanical safety lock whereby the operator must make an additional
A
motion to unlock the control handle prior to operation.This feature eliminates the possibility of the control being C
accidentially energized while in the neutral position. The control handle is spring loaded, and will automatically
return to neutral-off position should should the operator accidentically lose grip of the handle. This feature gives T
the operator positive control of the machine at all times, requiring the operator to hold the control handle during the
duration of the desired function.
E
R
Speed Controller (1600272 Controller Only)
This OEM Controller features a creep/snail function. I
THEORY OF OPERATION
S
T
PWM Output (Pulse Width Modulation)
Because of the mass of the spool, shifting it a very small distance would be very difficult to do without overshoot-
I
ing the mark. This overshoot is called hystersis and makes precise control of the function very difficult. PWM out- C
put provides a pulsed current to the spool which actually vibrates the spool so that it is never at rest and very easy
to shift. As you move the handle/stem, the electronics change the time period the pulse is on within that cycle. As
S
you move the handle away from center, the on time period or width of the cycle pulse will increase and as you you
move the handle back towards the center, the pulse will decrease. The percentage of on time to off time of the
PWM signal is called the Duty Cycle, if it is on for 80% it is called an 80% duty cycle.
Current Regulated Output

This controller is also current regulated. Ohms Law dictates that current always equals voltage divided by resis-
tance. If the supply voltage or the coil resistance should change, Ohms Law dictates that the output current must
also change which affects the speed of the function accordingly. Current regulated output feature senses a change
in voltage or resistance in the circuit and adjusts the duty cycle of the PWM signal so that the output current
remains a constant current. Because the current is constant and the resistance is machine dependant, the duty
cycle will vary in an attempt to supply the supply the required level of output. This feature ensures that the func-
tion speed the operator chooses to select always remains the same, within the limits of Ohms Law.
IRS (Integrated Ramp System)

OEM Controllers are calibrated to provide a maximum ramp time of 2 seconds. This feature limits the rate of
change of the output, eliminating jerky response associated with sudden handle movements. Any change in the
handle position will result in a smooth change in function speed. The 2 seconds is measured between the Thresh-
old and HI or LO Range setting.
3120344 1-1
S IDENTIFICATION
E (NOTE: REFER TO OEM P/N ON LABEL ATTACHED TO CONTROLLER OR CIRCUIT BOARD)
PQ PART NUMBER JLG PART NUMBER
C DESCRIPTION
EMS4M4001 1600080 CONTROLLER ASSEMBLY
T (4.5” HANDLE WITHOUT ROCKER SWITCH)
I Single gate. Unsealed Electrical Assembly. One V3 Microswitch.
Adjustable pots for threshold, high range, ramp rate and low range.
O (H & HT)
N
(4.5” HANDLE WITHOUT ROCKER SWITCH)
1 Single gate. Unsealed Electrical Assembly. Two V3 Microswitches.
(H & HT)
C
H EMS4M4508 1600092 CONTROLLER ASSEMBLY
A Single gate. Unsealed Electrical Assembly. Three V3 Microswitches.
R Adjustable pots for threshold, high range, ramp rate and low range.
(H, HA, HT, HTW & HX Models Drive Lift, Swing, Tele Functions)
A
C EMS4M4509 1600093 CONTROLLER ASSEMBLY
T Single gate. Unsealed Electrical Assembly. Two V3 Microswitches.
E Adjustable pots for threshold, high range, ramp rate and low range.
(H & HT Drive Function)
R
I EMS4M4797 1600096 CONTROLLER ASSEMBLY
S Single gate. Unsealed Electrical Assembly. Two V3 Microswitches.
T Adjustable pots for threshold, high range, ramp rate and low range.
(60H, 70H & 80H Drive Function)
I
C JS5M9414 1600230 CONTROLLER ASSEMBLY
S (STANDARD KNOB WITHOUT ROCKER SWITCH)
Round Gate. Has 6 Pin Male Plug. Non-adjustable/Uses Separate
Circuit Card for Adjustment.
(600S/600SJ/660SJ Lift and Swing Functions)
MS4M9719 1600231 CONTROLLER ASSEMBLY

(SWITCH GRIP HANDLE WITH THUMB ROCKER SWITCH)
Single Gate. Has 6 Pin Male Plug. Non-adjustable/Uses Separate
(600S/600SJ/660SJ Drive & Steer Functions)

(E Series Scissor Lifts Drive & Steer Functions)
1-2 3120344
IDENTIFICATION (CONTINUED) S
(NOTE: REFER TO OEM P/N ON LABEL ATTACHED TO CONTROLLER OR CIRCUIT BOARD)
PQ PART NUMBER JLG PART NUMBER DESCRIPTION
E
C
(SWITCH GRIP HANDLE WITH THUMB ROCKER SWITCH) T
Single Gate. Has 9 Pin Female Connector. Non-adjustable/Uses
Separate Circuit Card for Adjustment. I
(600A-AJ/600S-SJ/601S/660SJ Drive & Steer Functions) O
JS5M9902 1600242 CONTROLLER ASSEMBLY
N
(STANDARD KNOB WITHOUT ROCKER SWITCH)
Round Gate. Has 9 Pin Female Connector. Non-adjustable/Uses
Separate Circuit Card for Adjustment.
1
(600A-AJ/600S-SJ/601S/660SJ Lift and Swing Functions)

C
(SWITCH GRIP HANDLE WITH THUMB ROCKER SWITCH) H
A
(40ic/45ic Drive & Steer Functions) R
A
(6.5” HANDLE WITHOUT ROCKER SWITCH) C
Single gate. Unsealed Electrical Assembly. Two V3 Microswitches. T
(H & HT Drive Function)
E
R
I
Single gate. Unsealed Electrical Assembly. Three V3 Microswitches. S
(H, 45HA, HT & HX Lift, Swing, Tele Functions)
T
I
C
Single gate. Unsealed Electrical Assembly. Two V3 Microswitches. S
(60H, 70H & 80H Drive Function)

(E Series Scissor Lifts Drive & Steer Functions)
DJS6M11759 1600263 CONTROLLER ASSEMBLY

(TRIGGER GRIP HANDLE WITHOUT ROCKER SWITCH)
Round Gate. Has 6 Pin Female Connector. Adjustable pots for
threshold, high range, ramp rate and low range.
(600SC-SJC/660SJC Drive & Steer Functions)
3120344 1-3
S IDENTIFICATION (CONTINUED)
E PQ PART NUMBER JLG PART NUMBER DESCRIPTION
C EMS4M11100 1600270 CONTROLLER ASSEMBLY
T (SWITCH GRIP HANDLE WITH THUMB ROCKER SWITCH)
I Separate Circuit Card for Adjustment.
O (450A/450AJ Drive & Steer Functions)
N BJS5M11101 1600271 CONTROLLER ASSEMBLY

1 Separate Circuit Card for Adjustment.
(450A/450AJ Lift and Swing Functions)
C RS11T6507 1600272 CONTROLLER ASSEMBLY

H (SPEED CONTROL WITH SNAIL/CREEP SWITCH)
A Has 9 Pin Female Connector. Adjustable pots for threshold, high

range, ramp rate and low range.
R (450A/450AJ Lift and Swing Functions)
A MS4M11440 1600273 CONTROLLER ASSEMBLY
C (SWITCH GRIP HANDLE WITH THUMB ROCKER SWITCH)
T Single Gate. Has 9 Pin Female Connector. Non-adjustable/Uses
Separate Module for Adjustment.
E (E45A-AJ/M45A-AJ/E300A-AJ-AJP/E400A-AJ-AJP/M400A-AJ-AJP/
R E450A-AJ-AJP/M450A-AJ-AJP Drive & Steer Functions)
I JS5M11486 1600274 CONTROLLER ASSEMBLY

S (STANDARD KNOB WITHOUT ROCKER SWITCH)
T Separate Module for Adjustment.
I (E45A-AJ/M45A-AJ/E400A-AJ-AJP/M400A-AJ-AJP/E450A-AJ-AJP/
M450A-AJ-AJP Lift & Swing Functions)
C
S EMS4M11264 1600275 CONTROLLER ASSEMBLY
Single gate. Unsealed Electrical Assembly. Two V3 Microswitch.
(80HX Drive, Lift, & Swing Functions)
EJS5DM11326 1600278 CONTROLLER ASSEMBLY

Round Gate. Has 9 Pin Female Connector. Non-adjustable. Includes
two Separate Circuit Boards for Adjustment.
(450A/450AJ Lift & Swing Functions)

(400S/460SJ/600A-AJ/600S-SJ/601S/660SJ/800A-AJ Drive & Steer
Functions)
1-4 3120344
IDENTIFICATION (CONTINUED) S
PQ PART NUMBER JLG PART NUMBER DESCRIPTION
E
C
(STANDARD KNOB WITHOUT ROCKER SWITCH) T
Separate Circuit Card for Adjustment. I
(400S/460SJ/600A-AJ/600S-SJ/600SC-SJC/601S/660SJ/660SJC/ O
800A-AJ Lift & Swing Functions)
N
Single Gate. Has 9 Pin Female Connector. One V3 Microswitch.
1
(100SX/110SX-SXJ/120SXJ Drive & Steer Functions)
C
JS5M11431 1600288 CONTROLLER ASSEMBLY H
Round Gate. Has 9 Pin Female Connector. Non-adjustable. Includes
A
two Separate Circuit Boards for Adjustment. R
(450A/450AJ Lift & Swing Functions) A
JS5M11890 1600306 CONTROLLER ASSEMBLY C
(STANDARD KNOB WITHOUT ROCKER SWITCH) T
Separate Circuit Card for Adjustment. E
(110SX/120SX120SXJ Lift & Swing Functions) R
I
(STANDARD KNOB WITHOUT ROCKER SWITCH) S
T
(400S/450A-AJ Series II/460SJ/600A-AJ/600S-SJ/601S/660SJ/800A- I
AJ/800S/860SJ Lift and Swing Functions)
C
MS4M12148 1600318 CONTROLLER ASSEMBLY S
(400S/450A-AJ Series II/460SJ/600A-AJ/600S-SJ/601S/660SJ/800A-
AJ/800S/860SJ Drive & Steer Functions)
DJS6M12426 1600330 CONTROLLER ASSEMBLY

(TRIGGER GRIP HANDLE WITHOUT ROCKER SWITCH)
Round Gate. Has 6 Pin Female Connector. Adjustable pots for
threshold, high range, ramp rate and low range.
(600SC-SJC/660SJC Drive & Steer Functions)

(Gradall Transformer)
3120344 1-5
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1-6 3120344
SECTION 2 ADJUSTMENTS
2.1 1600080 ADJUSTMENT

1600086 ADJUSTMENT
1600092 ADJUSTMENT S
1600093 ADJUSTMENT
1600096 ADJUSTMENT
E
1600230 ADJUSTMENT C
1600231 ADJUSTMENT T
1600235 ADJUSTMENT
1600239 ADJUSTMENT
I
1600242 ADJUSTMENT O
1600245 ADJUSTMENT N
1600246 ADJUSTMENT
1600247 ADJUSTMENT
1600248 ADJUSTMENT 2
1600257 ADJUSTMENT
1600263 ADJUSTMENT
1600270 ADJUSTMENT A
1600271 ADJUSTMENT
Figure 2-1. Trimpot Assignments
D
1600272 ADJUSTMENT
1600275 ADJUSTMENT 1. THRESHOLD ADJUSTMENT
J
1600278 ADJUSTMENT
a. Move controller handle approximately 1 inch so
U
1600283 ADJUSTMENT
1600284 ADJUSTMENT
LED light turns on. S
1600287 ADJUSTMENT
b. Turn "Threshold" trimpot CW to increase function
speed, CCW to decrease function speed.
T
1600288 ADJUSTMENT
c. Adjust "Threshold" trimpot so that the function
M
1600306 ADJUSTMENT
1600330 ADJUSTMENT
just starts to move after the LED light comes on. E
NOTE: Trimpots may be on controller or on a separate cir-
2. HI RANGE ADJUSTMENT N
cuit board located in the platform console box. NOTE: It is important that there is a change in function T
speed when the controller handle is backed off
NOTE: Controller trimpot adjustments are necessary after approximately 8° to 10°. This insures full propor- S
installation of the new or reworked electrical assem- tional flow over the entire handle travel.
bly (printed circuit board), valve servo section or
other electrical circuit components. When adjusting a. Stroke handle fully.
any controller seek to match the valves electrical b. Back off controller handle approximately 10°.
operating range by setting the controller trimpots.
c. If function slows down, the controller is at or
below maximum output; if this is satisfactory, do
LED’s on the circuit board show if the controller works. not adjust further.
The "A" terminal LED lights when the handle is moved in
the "A" direction. "B" terminal LED lights when moved in d. If function speed is too slow, turn "Hi Range
the "B" direction. trimpot CW to increase speed. If function is too
slow, turn "Hi Range" trimpot CW to increase
speed. If function is too fast, turn trimpot CCW
All adjustments must be done in the following order:
to decrease speed. Repeat steps "a" through "d."
Threshold, Hi Range, Lo Range, IRS. (See Figure 2-1)
3. LO RANGE (CREEP) ADJUSTMENT
The following instructions show how to set up the control-
ler by observing function response: a. Position Creep Switch to ON.
NOTE: Before proceeding, position creep switch to "OFF," b. Stroke handle fully.
Ignition "ON," and depress Footswitch. c. Adjust "Lo Range" trimpot for desired output or
function speed. CW increases speed/output,
CCW decreases speed/output.
3120344 2-1
4. IRS (RAMP RATE) ADJUSTMENT 2. Seal each trimpot adjustment screw with a drop of
enamel paint, fingernail polish, Loctite #495 Super
a. Turning the "Ramp Rate" trimpot CW increases Bonder or equivalent (do not use super glue) to
S the time it takes to turn ON or OFF when the
handle is moved; CCW decreases the time.
prevent maladjustment due to vibration (See Figure
E b. Trimpot has wide adjustment range, therefore it
2-3 Item 1)
C will be necessary to make 2 to 3 turns to notice

a difference in function response.
T
I
O WHEN THE CONTROLLER HANDLE IS RETURNED TO CENTER
AND THE CONTROLLER OUTPUT RAMPS TO (0), THE POWER IS
N DISCONNECTED TO THE BOARD.
NOTE: Disconnect wires from A and B terminals of mal-

2 functioning controller and connect to same termi-
nals of another controller on console known to be
working properly. Note wire colors, DO NOT
CROSS, as function direction will reverse. If mal-
A function continues, the controller is okay, and the
D problem is most likely at the control valve. Figure 2-2. Detail of Potentiometer Shaft
J
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S 2.2 1600273 ADJUSTMENT
T 1600274 ADJUSTMENT
1600317 ADJUSTMENT
M 1600318 ADJUSTMENT
E NOTE: Refer to Service and Maintenance Manual of the
N specific model machine to be serviced for the cor-
rect calibrations required.
T
S
2.3 CONTROLLER SEALING INSTRUCTION.
Figure 2-3. Detail of Trimpots

TO ENSURE LONG TERM SAFE OPERATION OF CONTROLLER,
ELECTRICAL ASSEMBLY MUST BE PROPERLY ADJUSTED AND
SEALED WITH BONDI NG AGENT. USE LOCTITE SUPER
BONDER #495 OR EQUIVALENT AS BONDING AGENT. APPLY 2.4 SWITCH ADJUSTMENT PROCEDURES
BONDING AGENT AS SHOWN BELOW.
1. Center Off Switch Adjustment Procedure (Figure
Apply small drop of bonding agent on potentiometer shaft and gear at one end of slot after null adjustment. The setscrewshould be tight prior to application (See Figure 2-1 Item 1).
2-4).
NOTE: Excessive bonding agent at item 1 could work down
shaft and cause seisure of the shaft to bushing. Be a. With joystick in neutral, the cam shall be posi-
careful to confine the application to a small amount tioned such that the switch roller is in the center
in this area. of the detent.
b. As the cam is rotated and the roller rises up the
1. Apply small drop of the bonding agent to gear and ramp the switch shall be set such that it "makes"
cam. The cam should be adjusted and the set- (Click is heard) no earlier than 50% rise of the
screw tight prior to application (See Figure 2-2 Item ramp and no later than 75% rise of the ramp
2). (See Figure 2-4).
2-2 3120344
c. Further cam rotation shall cause the red switch switch lever near the roller with small pliers (See Fig-
actuator to recede further into switch housing ure 2-6).
after the click is heard.
d. Upon returning joystick to neutral, the switch
S
shall release (click is heard) not earlier that 75%
rise of the ramp and not later than 25% rise of
E
the ramp. C
T
I
O
N
2
Figure 2-4. Center Off Switch Adjustment Procedure
Figure 2-6. Fine Adjustment Procedure
A
D
1. Directional Switch Adjustment Procedure (See Fig-
ure 2-5). J
a. Position is controlled by positioning of center off U
switch since cam is a combined assembly. S
b. Set switch to "make" (click is heard) just before
center off switch "makes." In no case shall it
T
"make" before 50% cam rise. M
c. Further rotation shall cause the red switch actau-
tor to recede further into switch housing after
E
click is heard. N
d. Upon returning joystick to neutral, the switch
shall release (click is heard) not earlier that 75%
T
rise of the ramp and not later than 25% rise of S
the ramp
Figure 2-5. Directional Switch Adjustment Procedure
NOTE: Switch position can be initially set through loosen-

ingthe screws, positioning and retightening. Fine
adjustments can be made via careful bending of the
3120344 2-3
S
E
C
T
I
O
N
A THIS PAGE INTENTIONALLY LEFT BLANK

D
J
U
S
T
M
E
N
T
S
2-4 3120344
SECTION 3 TROUBLESHOOTING
3.1 PRINTED CIRCUIT BOARD TERMINAL

BOARD CONNECTIONS
Common terminals present on all controller buss bars.
(See Figures 3-1 and 3-2)
(+) - Positive voltage 12VDC or 24VDC depending on the

controller.
(–) - Negative side of supply voltage.
(X) - Auxiliary output: Supply voltage is present whenever
S
the controller is turned on. Output current must not E
exceed 3 amps.
C
(A) - Output terminal to proportional coil when the control-
ler handle is moved in the "A" direction. T
(B) - Output terminal to proportional coil when the control- I
ler handle is moved in the "B" direction.
O
N
Figure 3-2. Dual Coil Wiring
3
3.2 TESTING PROCEDURES
1. Trouble Shooting Tip - Disconnect wires from A and T
B terminals of malfunctioning controller and connect
to same terminals of another controller to same ter- R
minals of another controller on console known to be
working properly. Note wire coloers and connec-
O
tions. DO NOT CROSS WIRES, as the function U
direction will reverse. If malfunction continues, the-
controller is OK, and the problem is most likely at B
the control valve. L
E
Figure 3-1. Single Coil Wiring S
H
O
O
T
I
N
G
3120344 3-1
2. When testing the amperage, disconnect the wire at

the terminal block and put the meter in-line.
S
E
C
T
I
O
N
T
R
O
U
B
L
E
S
H
O
O
T
I
N
G 3.3 TROUBLESHOOTING PROCEDURES
c. If there is an in-line fuse, check to see if it is
blown.
1. The function will not operate when the handle is d. Check the controller on/off switch and the con-
moved. The LEDs do not light. nections. Voltage should be present at the (x)
terminal whent he controller is turned on.
a. Check that voltage is present at the positive (+) e. Check that the valve wiring is not shorted to
input terminal. ground. The LEDs will not light.
b. Check tha ground is connected to the negative
(–) terminal.
3-2 3120344
f. Check that valve wiring is not open. The LEDs

will light, but the intensity will not vary. 3.5 1600239 CONTROLLER
g. Check trimpot settings. Fully CCW (counter-
clockwise) turns output off, CW (clockwise) turns
output fully on.
2. The function jumps or lurches when turned on.
a. Perform "Threshold" adjustment procedures.
3. Function speed reacts too slowly or too quickly in
relation to handle deflection.
S
a. Check "IRS" (Ramp) trimpot adjustment. CW
E
(clockwise) increases ramp time, CCW (counter-
clockwise) decreases ramp time.
C
4. Controller will not switch between "HI" and "LO"
T
range. I
a. Check to see that source voltage is present at O
the "R" terminal when in "HI" range, and absent
when in "LO" range.
N
b. Check trimpot adjustments.
3
T
R
O
U
3.6 1600242 CONTROLLER
3.4 1600235 CONTROLLER B
L
E
S
H
O
O
T
I
N
G
3120344 3-3
3.7 1600245 CONTROLLER 3.9 1600263 CONTROLLER
S
E
C
T
I
O
N
3 3.10 1600270 CONTROLLER
T
R
O 3.8 1600257 CONTROLLER
U
B
L
E
S
H
O
O
T
I
N
G
3-4 3120344
S
E
C
T
I
O
N
T
R
3.12 1600272 CONTROLLER 3.14 1600274 CONTROLLER O
U
B
L
E
S
H
O
O
T
I
N
G
3120344 3-5
S
E
C
T
I
O
N
T
R
O
U
B
L
E
S
H
O
O
T
I
N
G
3-6 3120344
S
E
C
T
I
O
N
T
R
3.17 1600284 CONTROLLER O
U
B
L
E
S
H
O
O
T
I
N
G
3120344 3-7
S
E
C
T
I
O
N
T
R
O
U
B
L
E
S
H
O
O
T
I
N
G
3-8 3120344
S
E
C
T
I
O
N
T
R
O
U
B
L
E
S
H
O
O
T
I
N
G
3120344 3-9
S
E
C
T
I
O
N
T
R
O 3.22 1600318 CONTROLLER 3.24 1600334 CONTROLLER
U
B
L
E
S
H
O
O
T
I
N
G
3-10 3120344
SECTION 4 REPAIR PARTS
TABLE OF CONTENTS
FIGURE DESCRIPTION PAGE
4-1 CONTROLLER WITH SINGLE GATE & NO ROCKER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 CONTROLLER WITH SINGLE GATE & ROCKER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3 CONTROLLER WITH ROUND GATE & LIFT CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-4 CONTROLLER WITH ROUND GATE & TRIGGER GRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-5 SPEED CONTROLLER WITH SNAIL/CREEP SPEED SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 4-20
S
E
C
T
I
O
N
R
E
P
A
I
R
P
A
R
T
S
3120344 4-1
FIGURE 4-1.CONTROLLER WITH SINGLE GATE & NO ROCKER SWITCH
S
E
C
T
I
O
N
R
E
P
A
I
R
P
A
R
T
S
4-2 3120344
FIGURE 4-1. CONTROLLER WITH SINGLE GATE & NO ROCKER SWITCH
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

CONTROLLER WITH SINGLE GATE & NO ROCKER Ref.
SWITCH
HANDLE COMPONENTS - STANDARD KNOB Ref.
1600080 Controller Assembly Ref. A
1600086 Controller Assembly Ref. D
1600092 Controller Assembly Ref. B
1600247 Controller Assembly Ref. B S
1600248 Controller Assembly Ref. B E
1600275 Controller Assembly Ref. —
C
1 7003927 Knob, Upper 1 T
2
3
7003928
7003930
Spring
Knob, Lower
1
1
I
4 Boot Options: 1 O
Use 7003966 1600080/1600086/1600093/1600096 Controller 1 N
(Was p/n 7003931)
7003966 1600092/1600246/1600247/1600248/1600275 1
Controllers 4
5 Tube, Interlock Options: 1
7003945 Short Handle (4 1/2”) 1600080/1600086/
1600275 Controllers R
7003932 Long Handle (6 1/2”) 1600092/1600093/
1600096/1600246/1600247/1600248
E
Controllers P
6 7003937 Ring, Retaining 1
7 7003938 Clamp, Boot 1
A
8 to 11 Not Used I
12 7003933 Gasket 1 R
13 to 22 Not Used
23 Use 7003961 Microswitch (Was p/n 7003934) A/R
1600080 Controller Assembly 1 P
1600086 Controller Assembly
2
3
A
1600093 Controller Assembly 2 R
1600096 Controller Assembly 2 T
1600246 Controller Assembly 2
S
24 to 28 Not Used
29 7003935 Gear, Slave 1
30 Not Used
3120344 4-3
FIGURE 4-1. CONTROLLER WITH SINGLE GATE & NO ROCKER SWITCH (CONTINUED)

31 Shaft Options: 1
Not Available Short Handle (4 1/2”) 1600080/1600086 Control-
lers
7019118 Long Handle (6 1/2”) 1600092/1600093/
1600096/1600246/1600247/1600248
Controllers
7019155 Short Handle (3 1/2”) 1600275 Controllers
30 to 33 Not Used
34 Spring, Return Options: 1
7003946 1600080/1600086/1600093 Controllers
S 7003936 1600092/1600096/1600246/1600247/1600248/
E 1600275 Controllers
C 35
36 to 49
7003950
Not Used
Plate, Retainer 1
T 46 Electrical Assembly Options (Includes 1

I 7003942
Potentiometer):
O 7003942 1600086 Controller Assembly
N Use 7019120 1600092 Controller Assembly (Was p/n 7003947
- No Longer Available
7003944 1600093 Controller Assembly
4 7003948 1600096 Controller Assembly
7019120 1600246 Controller Assembly (Recommend Pur-
chasing Complete Assembly)
R 7019120 1600247 Controller Assembly (Recommend Pur-
E 7019120 1600248 Controller Assembly (Recommend Pur-
P chasing Complete Assembly)
A 7019120 1600275 Controller Assembly (Recommend Pur-

I
R
P
A
R
T
S
4-4 3120344
FIGURE 4-1. CONTROLLER WITH SINGLE GATE & NO ROCKER SWITCH (CONTINUED)
S
E
C
T
I
O
N
R
E
P
A
I
R
P
A
R
T
S
3120344 4-5
FIGURE 4-2. CONTROLLER WITH SINGLE GATE & ROCKER SWITCH
S
E
C
T
I
O
N
R
E
P
A
I
R
P
A
R
T
S
4-6 3120344
FIGURE 4-2. CONTROLLER WITH SINGLE GATE & ROCKER SWITCH

CONTROLLER WITH SINGLE GATE & ROCKER Ref.
SWITCH
1600257 Controller Assembly Ref. C
1600273 Controller Assembly Ref. E
1600287 Controller Assembly Ref. D S
1600318 Controller Assembly Ref. B E
C
1 Handle Assembly (See items 101-110 for 1 T
2
Breakdown)
Boot and Sleeve Options: 1
I
7003965 Sleeve (1600231/1600235/1600239/1600245/ O
1600257/1600270 Controllers) N
7003966 Boot (1600231/1600235/1600239/1600245/
1600257/1600270 Controllers)
7019161 Boot and Sleeve (1600273/1600283/1600287/
1600318/1600334 Controllers)
4
7003938 Clamp, Boot (Not Shown) (1600287 Controllers)
3 Cast Housing Assembly Options: 1 R
7003950 1600231/1600239/1600245/1600270/1600334
Controllers E
See Item 5 1600235/1600257 Controllers (Items 3 & 5 Cast as P
1 Piece)
7019160 1600273/1600283/1600287/1600318 Controllers
A
4 Bracket, Mounting Options: A/R I
Not Required
7019159
1600231/1600235/1600257 Controllers
1600239/1600245/1600270/1600273/1600283/
0
1
R
1600287 Controllers
7022823 1600318/1600334 Controllers 1 P
5 Plate, Mounting (Left Side) Options: 1
7019148 1600235/1600257 Controllers A
Not Available 1600231/1600239/1600245/1600270/1600318 R
Controllers
7019158 1600273/1600283/1600287/1600318/1600334
T
Controllers S
6 Plate, Pot Mounting Options: 1
7003995 1600235/1600257 Controllers
Not Available 1600231/1600239/1600245/1600270/1600287
Controllers (Maybe Part of Electrical Assembly
7019157 1600273/1600283 Controllers
7022822 1600318/1600334 Controllers
7 Electric Assembly Options: 1
7003999 1600235 Controllers
Not Available 1600231/1600239/1600245/1600273 Controllers
3120344 4-7
FIGURE 4-2. CONTROLLER WITH SINGLE GATE & ROCKER SWITCH (CONTINUED)
7019124 1600270/1600287 Controllers
7019156 1600283/1600334 Controllers
Potentiometer Options: 1
Use 7011925 1600235/1600257 Controllers (Was p/n
7003997)
7003974 1600239/1600245/1600273 Controllers
S Not Available 1600231/1600270/1600283/1600287/
1600318 Controllers
E 8 Not Used
C 9 7019115 Stand-Off 2
T 10
7003963
Shaft & Sector Gear Options:
1600231/1600239/1600245 Controllers
1
I 7019100 1600235 Controllers

O 7019102 1600257 Controllers
N 7019155 1600273/1600283/1600287/1600318/1600334
Controllers
11 7019151 Tie-Strap A/R
4 12 Clamp, Wire A/R
Not Required 1600231/1600235/1600239/1600257/1600245/ 0
R 7019154
1600270/1600287 Controllers
1600273/1600283/1600318/1600334 Controllers 2
E 13 Strip, Terminal Options: A/R
P 7003991 1600235/1600257 Controllers (3 Position) 1
7003986 1600273/1600318 Controllers (3 Position) 1
A Not Required 1600231/1600239/1600245 Controllers 0
I 7019153 1600270/1600283/1600287 Controllers 1
(5 Position)
R 7022828 1600334 Controllers (5 Position) 1
14 Screw Options: A/R
P 7003994 1600231/1600235/1600239/1600245/1600257/
1600270/1600273/1600287/1600318 Controllers
2
A 7019155 1600283 Controllers 8

R 7019117 1600334 Controllers 7
15 Potentiometer Coupling Options: 1
T 7019114 1600231/1600235/1600239/1600245/1600257/
S 1600270 Controllers
7019163 1600273/1600283/1600287/1600318/1600334
Controllers
16 7019162 Spring 1
17 Bearing Options: 2
7019111 1600231/1600235/1600239/1600245/1600257/
1600270/1600273/1600283/1600287/1600318
Controllers
4-8 3120344
18 7019110 Spacer, Head Gear 2
19 7019112 Washer/Bushing 1
20 7003946 Spring, Return & Bushing Kit 1
21 7019103 Pin 4
22 Not Serviced Rivet A/R
23 Bar, Mounting (Right Side) Options: 1
Not Required 1600231/1600235/1600257 Controllers
7019168 1600239/1600245/1600270/1600273/1600283/
1600287/1600318/1600334 Controllers
24 7003992 Washer 1
25 7003993 Nut 1 S
26 7003935 Gear, Slave 1
27 Screw Options: 2
E
7003969 1600231/1600235/1600239/1600245/1600257/ C
1600270/1600273/1600283/1600287/1600318
Controllers
T
7003940 1600334 Controllers I
28
29
7003941 Washer
Microswitch Options:
2
A/R
O
7003961 1600231/1600235/1600245/1600257/1600270 2 N
Controllers
7003961 1600287/1600334 Controllers 1
Not Required 1600239/1600273/1600283/1600318 Controllers 0 4
30 Insulator Options: A/R
7019108 1600231/1600235/1600245/1600257/1600270
Controllers
1
R
7019138 1600287 Controllers 1 E
Not Required 1600239/1600273/1600283/1600318/1600334
Controllers
0
P
31 Insulator Options: A/R A
7019107 1600231/1600235/1600245/1600257/1600270
Controllers
1 I
Not Required 1600239/1600273/1600283/1600287/1600318/ 0 R
1600334 Controllers
32 Screw Options: A/R
7003998 1600231/1600235/1600245/1600257/1600270 2 P
Controllers A
7019106 1600287/1600334 Controllers 2
Not Required 1600239/1600273/1600283/1600318 Controllers 0 R
33 7003933 Gasket 1 T
34
7003988
Setscrew/Screw
1600231/1600235/1600239/1600245/1600270/
1
S
1600287 Controllers
35 Cam Assembly, Microswitch Options: A/R
Not Available 1600231/1600235/1600245/1600257 Controllers 1
7019125 1600270 Controllers 1
Not Required 1600239/1600273/1600283/1600318 Controllers 0
7019179 1600287/1600334 Controllers 1
3120344 4-9
36 Nut/Cam Assembly Options: A/R
7019113 1600231/1600235/1600239/1600245/1600257/ 1
37 Heatsink Options: A/R
Not Required 1600231/1600235/1600239/1600245/1600257/ 0
1600273/1600283/1600318/1600334 Controllers
Not Available 1600270/1600287 Controllers 1
HANDLE ASSEMBLY Ref.

S Not Available
7003978
1600231/1600270/1600287 Controllers
1600235/1600239/1600245/1600257 Controllers
Ref.
Ref.
E 7022812 1600273 Controllers Ref.
C 7022810 1600283/1600318/1600334 Controllers Ref.
T 101 Axle Options: A/R

I Not Required 1600231/1600235/1600239/1600245/1600257/ 0
O 7019164
1600270 Controllers
1600273/1600283/1600287/1600318/1600334 1
N Controllers
102 Coupling Options: 1
7003984 1300231/1600235/1600239/1600245/1600257/
4 1600270/1600287 Controllers
7019194 1600273/1600283/1600318/1600334 Controllers
103 Rocker Options: 1
R 7003981 1600231/1600235/1600239/1600245/1600257/
E 1600270 Controllers
7019165 1600273/1600283/1600287/1600318/1600334
P Controllers
A 104 7003983 Setscrew 2
I 105
7003972
Boot, Switch Options:
1600231/1600235/1600239/1600245/1600257/
1
R 1600273/1600283/1600287/1600318/1600334
Controllers
P 106 Handle Options: A/R
A 7003973 1600231/1600235/1600239/1600245/1600257/
1600273/1600283/1600287/1600318/1600334
2
R Controllers
T 7019126 1600270 Controllers (Includes Both Halves and

Gasket
1
S 107 Switch, Micro Options: A/R

7003982 1600231/1600235/1600245/1600257/1600270 2
Controllers
Use 7019121 1600239 Controllers (Note: This Kit includes 2 1
Microswitches, 2 Diodes and Harness to Buss Bar)
7019166 1600283/1600287/1600318/1600334 Controllers 1
(Note: This Kit includes 2 Microswitches and 2
Diodes)
4-10 3120344
108 Nut Options: 4
7003979 1600231/1600235/1600239/1600245/1600257/
1600270 Controllers
7019167 1600273/1600283/1600287/1600318/1600334
Controllers
109 7003980 Screw 4
110 Gasket Options: A/R
7003989 1600231/1600235/1600239/1600245/1600257/ 2
1600273/1600283/1600287/1600318/1600334
Controllers
Not Available 1600270 Controllers (Part of Item 106) 0
S
E
C
T
I
O
N
R
E
P
A
I
R
P
A
R
T
S
3120344 4-11
FIGURE 4-3. CONTROLLER WITH ROUND GATE AND LIFT CAP
S
E
C
T
I
O
N
R
E
P
A
I
R
P
A
R
T
S
4-12 3120344
FIGURE 4-3. CONTROLLER WITH ROUND GATE AND LIFT CAP

PISTOL GRIP HANDLE CONTROLLER ASSEMBLIES
1600271 Controller Assembly (Not Shown) Ref. B
S
1 Mechanical Assembly Component Options: 1 E
1A
Not Available
70039511
1600230/1600242/1600271 Mechanical Assembly
Cap, Solid (1600230/1600242/1600271 Control-
1
1
C
lers) T
1B Not Available Cap, Lift (1600230/1600242/1600271 Control-
lers)
1 I
1C 7003957 Clip, Retaining (1600230/1600242/1600271 1 O
Controllers) N
1D 7003958 Retainer, Spring (1600230/1600242/1600271 1
Controllers)
1E 7003959 Spring (1600230/1600242/1600271 Controllers) 1 4
1F 7003960 Bushing (1600230/1600242/1600271 Control- 1
lers)
1G 7019104 Base Assembly (1600230/1600242/1600271 1 R
Controllers)
Not Available 1600278 Mechanical Assembly 1 E
1A 7003951 Cap, Solid (1600278 Controllers) 1 P
1B
1C
Not Available
7003957
Cap, Lift (1600278 Controllers)
Clip, Retaining (1600278 Controllers)
1
1
A
1D Not Available Retainer, Spring (1600278 Controllers) 1 I
1E Not Available Spring (1600278 Controllers) 1 R
1F Not Available Bushing (1600278 Controllers) 1
1G 7019105 A8 Base Assembly (1600278 Controllers) 1
7019141 1600274/1600284/1600288/1600306/1600317 1 P
Mechanical Assembly (Includes Base, Handle Cap
& Rod & Item 25 Boot) A
1A 7019197 Knob and Rod (1600274/1600284/1600288/ 1 R
1600317 Controllers)
1B 7022808 Cap, Lift (1600274/1600284/1600288/1600317 1
T
Controllers) S
1C Not Required Clip, Retaining (1600274/1600284/1600288/ 1
1600317 Controllers)
1D Not Required Retainer (1600274/1600284/1600288/1600317 1
Controllers)
1E 7003928 Spring (1600274/1600284/1600288/1600317 1
Controllers)
1F Not Required Bushing (1600274/1600284/1600288/1600317 1
Controllers)
1G Not Available Base Assembly (1600274/1600284/1600288/ 1
1600317 Controllers) (Purchase p/n 7019141)
3120344 4-13
FIGURE 4-3. CONTROLLER WITH ROUND GATE AND LIFT CAP (CONTINUED)
2 Gate Options: 1
7019169 1600288/1600306 Controllers
7019150 1600274/1600284/1600317 Controllers
3 Screw Options: 4
Not Available 1600271 Controllers
7003952 1600230/1600242/1600274/1600278/1600284/
4 Plate, End 1
S Not Available 1600271/1600278 Controllers (Not Shown)
4A Not Available 1600230/1600242 Controllers
E 4B 7019170 1600274/1600288/1600306/1600317 Controllers
C 5 Plate Options: A/R
T Not Required
7019142
1600230/1600242/1600271/1600278 Controllers
1600274 Controllers
0
2
I 7019171 1600284/1600288/1600306/1600317 Controllers 2
O 6 PC Board Assembly Options (See Items 101-109 for A/R
Breakdown):
N Not Required 1600230/1600242/1600271/1600274/1600278/ 0
Not Available 1600278 Controllers (Note: Was p/n 7019140. No 1
4 Longer Available. Order Individual Circuit Cards)
7019172 1600288 Controllers 1
R 7
Not Required
Screw Options:
1600230/1600242/1600271 Controllers
A/R
0
E 7019173 1600274/1600278/1600284/1600288/1600306/ 12
P 8
1600317 Controllers
Spacer, Cam Options: 2
A Not Available 1600230/1600242/1600271 Controllers
I Not Required 1600278 Controllers
7019174 1600274/1600284/1600288/1600306/1600317
R Controllers
9 7019111 Bearing, Gear 4
P 10
Not Required
E-Clip Options:
1600230/1600242/1600271 Controllers
A/R
A 7019145 1600274/1600278/1600284/1600288/1600306/
R 11
1600317 Controllers
Gear, Drive Options: A/R
T Not Required 1600271/1600278 Controllers 0
S 7003977 1600230/1600242/1600274/1600284/1600288/
2
12 Shaft Options: 2
(Purchase Item 1G)
7019147 1600274/1600284/1600288/1600306/1600317
Controllers
4-14 3120344
13 Cam Assembly Options: A/R
Not Available 1600230/1600242 Controllers (Not Shown) 2
7019193 Coupling, Cam (1600230/1600242 Controllers) 1
Not Available Spacer, Cam (1600230/1600242 Controllers) 1
Not Available Cam, 4 Hole (1600230/1600242 Controllers) 2
Not Available Cam (1600230/1600242 Controllers) 3
Not Available 1600278 Controllers 2
7019175 1600288/1600306 Controllers 2
14 Spacer, Cam A/R
Not Required 1600230/1600242/1600271/1600274/1600284/ 0 S
1600317 Controllers
7019176 1600278/1600288/1600306 Controllers 2
E
15 Shaft Options: A/R C
Not Available 1600230/1600242/1600278 Controllers (Purchase
Item 1G)
T
7019177 1600288/1600306 Controllers 2 I
Not Required 1600271/1600274/1600284/1600317 Controllers 0 O
16 Plate Options: A/R
Not Required 1600230/1600242/1600271 Controllers 0
N
7019142 1600288/1600306 Controllers 4
17
7019142 1600274/1600278/1600284/1600317 Controllers
Microswitch Options:
2
A/R
4
7003961 1600230/1600242/1600278/1600288/1600306 2
7003961
Controllers
1600271 Controllers 4
R
Not Required 1600274/1600284/1600317 Controllers 0 E
18 Insulator Options: A/R P
7019138 1600230/1600242/16020278/1600288/1600306
Controllers
2
A
7019138 1600271 Controllers 4 I
19
Not Required 1600274/1600284/1600317 Controllers
Screw Options:
0
A/R
R
7019139 1600230/1600242/1600278/1600288/1600306 4
7019139
Controllers
1600271 Controllers 8
P
Not Required 1600274/1600284/1600317 Controllers 0 A
20 Gear, Slave A/R R
7003976 1600230/1600242/1600274/1600284/1600288/
1
T
Not Required 1600271/1600278 Controllers 0 S
21 Potentiometer/Electrical Assembly Options: A/R
Not Available 1600230 Electrical Assembly Controllers 1
7003962 1600230 Controllers Potentiometer Only 2
(Includes Nut & Washer
Not Available 1600242/1600274/1600284 Electrical Assembly 1
Controllers
7003974 1600242/16002741600284 Controllers Potenti- 2
ometer Only
3120344 4-15
Not Available 1600271 Electrical Assembly Controllers (Pur- 1
chase Microswitches Item 17 Separately)
Not Available 1600278 Controllers Potentiometer Only 2
(Includes Nut & Washer
Not Available 1600278 Controllers Clamp Only 2
Not Available 1600278 Controllers Potentiometer Adapter 2
Only
7019178 1600288/1600306 Controllers Potentiometer 2
Only
S 7022818 1600317 Controllers (Includes Two Potentiome- 1
E ters, Harness and Female Connector)
22 Washer Options: A/R
C Not Available 1600230/1600242/1600278 Controllers (Part of 2
T Item 21)
I Not Required
7003992
1600271 Controllers
1600274/1600284/1600288/1600306/1600317
0
2
O Controllers
N 23
Not Available
Nut Options:
1600230/1600242/1600278 Controllers (Part of
A/R
2
Item 21)
4 Not Required
7003993
1600271 Controllers
1600274/1600284/1600288/1600306/1600317
0
2
Controllers
R 24 Setscrew Options: A/R
Not Available 1600230/1600242/1600278 Controllers 2
E Not Required 1600271 Controllers 0
P 7019149 1600284/1600288/1600306/1600317 Controllers 2
A 25
Not Available
Spacer Options:
A/R
2
I Not Required 1600271 Controllers 0
R 7019144 1600274/1600278/1600284/1600288/1600306/
1600317 Controllers
2
26 Screw Options: 2
P 7019143 1600230/1600242/1600274/1600278/1600284/ 1
1600288/1600306/1600317 Controllers
A Not Required 1600271 Controllers 0
R 27 Use 7022813 Boot & Flange Kit (Includes Item 29) 1
T 28
Use 7022814 Boot (Was p/n 7003955)
Spacer, Cam Options: A/R
S Not Required 1600230/1600242/1600271/1600274/1600278/ 0
1600284 Controllers
7019174 1600288/1600317 Controllers 2
7019146 1600306 Controllers 2
29 Bezel/Plate, Plastic Options: 1
Use 7022813 1600230/1600242/1600271/1600274/1600284/
1600288/1600306 Controllers (Was p/n 7003954)
7022815 1600278/1600317 Controllers
30 7003956 Gasket 1
31 7003953 Washer 4
4-16 3120344
32 Screw Options: 4
7003952 1600230/1600242/1600271 Controllers
7019137 1600274/1600284 Controllers
7022817 1600278/1600317 Controllers
7022811 1600288/1600306 Controllers
33 Not Used
34 Gimble (Inner) Options: 1
7019122 1600242/1600278/1600288 Controllers
Not Available 1600230/1600271/1600274/1600306/1600317
Controllers
35 Gimble (Outer) Options: 1 S
7019123 1600242/1600278/1600288 Controllers
Not Available 1600230/1600271/1600274/1600306/1600317
E
Controllers C
36 Not Available Setscrew 2
T
PC BOARD ASSEMBLY (1600278 & 1600288 Ref. I
CONTROLLERS ONLY)
1600278 Controllers (Note: Was p/n 7019140 which Ref.
O
is no longer available. Purchase individual circuit N
cards.)
7019172 PC BOARD ASSEMBLY (1600288 CONTROLLERS Ref.
ONLY) 4
101 7019136 Screw 4mm x 12mm 8
102 7019135 Washer, Wavy 4mm 8 R
103 7019134 Cover, Heatsink 2 E
104 PC Board Assembly (Lift) Options: 1
7019133 1600278 Controllers 1
P
7019190 1600288 Controllers 1 A
105
7019132
PC Board Assembly (Swing) Options:
1600278 Controllers
1
1
I
7019189 1600288 Controllers 1 R
106 7019131 Stand-Off 8
107
108
7019130
7019129
Bracket
Starwasher 4mm
1
8
P
109 7019128 Nut 4mm 8 A
110 Not Available Harness, PC Board (Not Shown) 1 R
T
S
3120344 4-17
FIGURE 4-4. CONTROLLER WITH ROUND GATE AND TRIGGER GRIP
S
E
C
T
I
O
N
R
E
P
A
I
R
P
A
R
T
S
4-18 3120344
FIGURE 4-4. CONTROLLER WITH ROUND GATE AND TRIGGER GRIP

CONTROLLER ASSEMBLY Ref. B
1 Handle Assembly Options: 1

2 7022800 Boot 1
3 7022801 Flange 1
4 7022802 Screw 4
5 7022803 Washer 4
S
6 7022804 Screw 4 E
7
8
7022805
7003993
Gate
Nut
1
2
C
9 7003992 Flatwasher 2 T
10 7022806 Gear, Slave 2 I
11
12
7022826
7019153
Digisensor
Strip, Terminal
2
1
O
13 7003986 Strip, Terminal 1 N
14 7019138 Insulator 2
15 7019139 Screw 4
16 7003961 Microswitch 2
4
17 7019149 Setscrew 2
18 7022807 Nut 4
R
E
P
A
I
R
P
A
R
T
S
3120344 4-19
FIGURE 4-5.SPEED CONTROLLER WITH SNAIL/CREEP SPEED SWITCH
S
E
C
T
I
O
N
R
E
P
A
I
R
P
A
R
T
S
4-20 3120344
FIGURE 4-5. SPEED CONTROLLER WITH SNAIL/CREEP SPEED SWITCH

1600272 CONTROLLER ASSEMBLY Ref. E
1 7019181 Seal 1
2 7019182 Switch, Rotary 1
3 Not Serviced Plate 1
4 7019183 Screw, Flathead 2
5 7019184 Spacer 4
6 7019135 Washer 4
7 7019185 Screw 2
8 7019186 Screw 2
9 7019136 Screw 2
S
10 7019187 Board, Circuit with Potentiometer 1 E
10A 4460265
4460268
Plug - 9 Position (Part of Console Box Harness)
Socket, Female (Part of Console Box Harness)
1
9
C
4460266 Receptacle - 9 Position (Part of p/n 7019187) 1 T
4460267 Pin, Male (Part of p/n 7019187) 9 I
11
12
7019163
Not Serviced
Coupling, Potentiometer
Heatsink
1
1
O
N
R
E
P
A
I
R
P
A
R
T
S
3120344 4-21
FIGURE 4-5. SPEED CONTROLLER WITH SNAIL/CREEP SPEED SWITCH (CONTINUED)

S
E
C
T
I
O
N
R
E
P
A
I
R
P
A
R
T
S
4-22 3120344
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Customer Support Toll Free: (877) 554-5438
Fax: (717) 485-6417
JLG Worldwide Locations

JLG Industries (Australia) JLG Industries (UK) JLG Deutschland GmbH JLG Industries (Italia)
P.O. Box 5119 Unit 12, Southside Max Planck Strasse 21 Via Po. 22
11 Bolwarra Road Bredbury Park Industrial Estate D-27721 Ritterhude/lhlpohl 20010 Pregnana Milanese - MI
Port Macquarie Bredbury Bei Bremen Italy
N.S.W. 2444 Stockport Germany Phone: (39) 02 9359 5210
Australia SK6 2sP Phone: (49) 421 693 500 Fax: (39) 02 9359 5845
Phone: (61) 2 65 811111 England Fax: (49) 421 693 5035
Fax: (61) 2 65 810122 Phone: (44) 870 200 7700
Fax: (44) 870 200 7711
JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska
Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI. Krolewska
80-Suite 71 2132 HJ Foofddorp N-1412 Sofienyr 00-060 Warsawa
13092-310 Campinas-SP The Netherlands Norway Poland
Brazil Phone: (31) 23 565 5665 Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493 Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Fax: (55) 19 3295 1025
JLG Industries (Europe) JLG Industries (Pty) Ltd. Plataformas Elevadoras JLG Industries (Sweden)
Kilmartin Place, Unit 1, 24 Industrial Complex JLG Iberica, S.L. Enkopingsvagen 150
Tannochside Park Herman Street Trapadella, 2 Box 704
Uddingston G71 5PH Meadowdale P.I. Castellbisbal Sur SE - 175 27 Jarfalla
Scotland Germiston 08755Castellbisbal Sweden
Phone: (44) 1 698 811005 South Africa Spain Phone: (46) 8 506 59500
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334 Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
Fax: (27) 11 453 1342 Fax: (34) 93 77 11762

OEM Controls: Revised MARCH 15, 2003 Printed in U.S.A. 3120344

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TECHNICAL SUPPLEMENT

Revised MARCH 15, 2003 PRINTED IN U.S.A. 3120344

November 15, 2001 - Revised Manual

March 15, 2003 - Revised Manual

SECTION NO. TITLE PAGE NO.

SECTION 2 - ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

SECTION 3 - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

SECTION 4 - REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

SECTION NO. TITLE PAGE NO.

Current Regulated Output

IRS (Integrated Ramp System)

MS4M9719 1600231 CONTROLLER ASSEMBLY

MS4M9723 1600235 CONTROLLER ASSEMBLY

MS4M10156 1600245 CONTROLLER ASSEMBLY

MS6M10628 1600257 CONTROLLER ASSEMBLY

DJS6M11759 1600263 CONTROLLER ASSEMBLY

N BJS5M11101 1600271 CONTROLLER ASSEMBLY

C RS11T6507 1600272 CONTROLLER ASSEMBLY

A Has 9 Pin Female Connector. Adjustable pots for threshold, high

I JS5M11486 1600274 CONTROLLER ASSEMBLY

EJS5DM11326 1600278 CONTROLLER ASSEMBLY

MS4M11404 1600283 CONTROLLER ASSEMBLY

DJS6M12426 1600330 CONTROLLER ASSEMBLY

MS4M13289 1600334 CONTROLLER ASSEMBLY

2.1 1600080 ADJUSTMENT

C will be necessary to make 2 to 3 turns to notice

NOTE: Disconnect wires from A and B terminals of mal-

Figure 2-3. Detail of Trimpots

Figure 2-5. Directional Switch Adjustment Procedure

NOTE: Switch position can be initially set through loosen-

A THIS PAGE INTENTIONALLY LEFT BLANK

3.1 PRINTED CIRCUIT BOARD TERMINAL

(+) - Positive voltage 12VDC or 24VDC depending on the

2. When testing the amperage, disconnect the wire at

f. Check that valve wiring is not open. The LEDs

3.7 1600245 CONTROLLER 3.9 1600263 CONTROLLER

3 3.10 1600270 CONTROLLER

3.11 1600271 CONTROLLER 3.13 1600273 CONTROLLER

3.15 1600278 CONTROLLER

3.16 1600283 CONTROLLER 3.18 1600287 CONTROLLER

3.19 1600288 CONTROLLER

3.20 1600306 CONTROLLER

3.21 1600317 CONTROLLER 3.23 1600330 CONTROLLER

4-1 CONTROLLER WITH SINGLE GATE & NO ROCKER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 4-2

FIGURE 4-1.CONTROLLER WITH SINGLE GATE & NO ROCKER SWITCH

FIGURE 4-1. CONTROLLER WITH SINGLE GATE & NO ROCKER SWITCH

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

T 46 Electrical Assembly Options (Includes 1

A 7019120 1600275 Controller Assembly (Recommend Pur-

FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.

FIGURE 4-2. CONTROLLER WITH SINGLE GATE & ROCKER SWITCH

FIGURE 4-2. CONTROLLER WITH SINGLE GATE & ROCKER SWITCH

I 7019100 1600235 Controllers

A 7019155 1600283 Controllers 8

HANDLE ASSEMBLY Ref.

T 101 Axle Options: A/R

T 7019126 1600270 Controllers (Includes Both Halves and

S 107 Switch, Micro Options: A/R

FIGURE 4-3. CONTROLLER WITH ROUND GATE AND LIFT CAP

FIGURE 4-3. CONTROLLER WITH ROUND GATE AND LIFT CAP

FIGURE 4-4. CONTROLLER WITH ROUND GATE AND TRIGGER GRIP

FIGURE 4-4. CONTROLLER WITH ROUND GATE AND TRIGGER GRIP