How to avoid water damage on joysticks and control boxes for aerial work platforms

A control box is a complex piece of electronics, essential for the correct and safe use of any machine. While these parts are designed for outdoor use, they have one major enemy: water. Keeping the housing waterproof is essential for preventing a total machine failure.

What happens when water gets in?

Once moisture is inside the housing, it begins to cause hidden damage.

• Corrosion: Water causes the metal pins and circuit boards (PCBs) to rust or ‘oxidise’. This leads to ‘intermittent’ problems where the machine works one minute and stops the next.

• Ghost movements: One of the most dangerous results of water damage is ‘ghosting’. This is when the machine begins to move on its own because the damp electronics are sending false signals.

• Freezing: In cold weather, trapped water can freeze inside the joystick. This can physically block the handle or break internal plastic parts when an operator tries to force it to move.

How does water get in?

Water usually finds its way into a control unit through very small openings. Even a tiny crack that looks ‘harmless’ can lead to expensive repairs. Keep an eye on these elements to avoid water damage:

• Base & thumb cap rubber boot: The flexible rubber parts at the base of the joystick handle and around the thumb cap are your first line of defence. If this rubber is torn or has a small hole, rain or humidity will seep directly into the internal components.

• Seal: There is a critical seal between the joystick and the control box. If this is not seated perfectly during installation, water can run down the joystick and flood the entire electronics cabinet.

• Decals: On top of the control box, there are often decals covering the buttons. If these are peeling or cracked, water can enter the microswitches underneath.

• Cable entry plug: Control boxes have cable entry points that are sealed with plastic plugs. If one of these plugs is missing or damaged, water can enter the box and reach the internal electronics.

Maintenance tips

Preventing water damage is much cheaper than replacing a control system.

• Never use a pressure washer: You should never point a high-pressure hose directly at a joystick or control box. The pressure is strong enough to force water past even the best seals.

• Daily inspection: Check the rubber boots and stickers for any signs of wear. If you see a hole, no matter what size, replace the part immediately.

• Cover: When the machine is not in use, especially overnight or in heavy rain, use a protective cover over the control box to keep it dry.

By keeping your joystick housing waterproof, you ensure your machine remains reliable and, most importantly, safe for everyone on site.

Our contribution

When choosing replacement parts, the quality of the materials determines how long the repair will last. Our rubber boots and seals are designed and tested to be water-resistant and sunproof. Unlike lower-quality materials, they do not crack when exposed to UV rays or freezing temperatures, which is essential for keeping the housing watertight.