How to install an electronic joystick on a forklift

07 April 2023

When it comes to creating a safe and comfortable work environment for forklift drivers, ergonomics are of the utmost importance. Installing a joystick can greatly improve operator comfort. The joystick works like an extension of the operator’s arm, enabling them to operate the machine with natural movements. This means they can work safely and efficiently, without placing extra and unnecessary stress on their bodies.

If a joystick malfunctions or reaches the end of its lifespan, it needs to be replaced. Joystick replacement can seem like a complicated job – which is why we have created this guide to help you along the way. Discover how to replace an electronic joystick in nine easy-to-follow steps.

1. Choose the right joystick

Electronic joysticks work by drawing on a power supply to send command signals to an electrohydraulic valve. There are various types of joysticks available, including proportional joysticks, analogue joysticks and digital joysticks. The right joystick is determined by the machine. Need help? Contact us. Send us the details of the forklift in question, and we will help you find the best joystick for the job.

2. Prepare the forklift

Before you start replacing an electronic joystick, the forklift must be made ready. First, ensure it is in a safe place to be worked on. Then make sure the forklift is turned off, the emergency stop is engaged, and the battery is disconnected.

3. Note how the old joystick is mounted

This is an important step that saves a lot of confusion later. Before disconnecting the existing joystick, take pictures of how it is installed and/or write down exactly how the connectors and cables are connected.

4. Electrostatic discharge (ESD) safety

ESD is the release of stored static electricity. It has the potential to cause harm to electronic parts, which you definitely want to avoid when installing a brand-new electronic joystick. If the new joystick has a visible printed circuit board (PCB), never handle the PCB directly; always hold it by the handle. Holding the joystick by the PCB can damage it before it is even installed.

5. Mount the joystick

The best place to mount the joystick is in a secure position that is easily accessible and comfortable for the forklift operator to use.

6. Connect the joystick wiring

If you are doing a same-for-same joystick replacement, the pictures you took before uninstalling the old joystick are going to be super handy now. The direct replacement is as simple as hooking up the new one in the same way as the old one. When installing a new or different type of joystick, you will need to connect the joystick’s wiring to the corresponding wiring on the forklift’s control system. Specific instructions will depend on the exact joystick being installed.

7. Test the joystick

Turn on the forklift and test the joystick to make sure it is connected properly and able to perform its function.

8. Joystick calibration

80% of available joysticks are plug-and-play, meaning they do not need to be calibrated. For the other 20%, you will need to follow the instructions in the manual to align the joystick’s functions with the forklift.

9. Final checks

Check all electrical connections and make sure the joystick is securely mounted. It is also a really good idea to consult the manufacturer’s instructions for additional steps that apply to your specific joystick and forklift.

Please note: This is a general guide. For specific joystick installation instructions, refer to the machine’s manual or contact us. Remember, it is important to follow all safety guidelines and procedures when installing a joystick on a forklift.

Ready to replace or upgrade a forklift joystick? Discover our range of joysticks here.