EZSUNSWAY 116063 Control Box Instruction Manual

1. Introduction

This manual provides essential information for the safe and effective use of the EZSUNSWAY 116063 Control Box. This control box is designed as a direct replacement component for specific SkyJack Scissor Lift models. Please read this manual thoroughly before installation and operation to ensure proper function and safety.

2. Product Overview

The EZSUNSWAY 116063 Control Box is a critical component for controlling the movement and functions of compatible SkyJack Scissor Lifts. It features a joystick controller for precise motion, an emergency stop button for immediate shutdown, and a diagnostic display for operational feedback. The unit is constructed from durable materials to ensure reliability and longevity in demanding work environments.

Figure 2.1: EZSUNSWAY 116063 Control Box with joystick, emergency stop, and gauge.

Figure 2.2: Detailed view of the control box components, including joystick, emergency stop, and connector.

3. Compatibility

The EZSUNSWAY 116063 Control Box is compatible with the following SkyJack Scissor Lift models and their specified serial number ranges:

• SkyJack SJIII 3220: Serial Numbers 609331-611286
• SkyJack SJIII 4620: Serial Numbers 66430-66658
• SkyJack SJIII 4626: Serial Numbers 704419-706174
• SkyJack SJIII 4830: Serial Numbers 86983-87564
• SkyJack SJIII 4832: Serial Numbers 86983-87564
• SkyJack SJIII 6826: Serial Numbers 75518-75578
• SkyJack SJIII 6832: Serial Numbers 82403-82753

This control box is also known by part numbers: 116063, 115985, 117228, 117900, 117899.

Figure 3.1: Control box compatibility with SkyJack Scissor Lifts.

4. Setup and Installation

The EZSUNSWAY 116063 Control Box is designed for direct replacement. While installation is generally straightforward, it is recommended that installation be performed by qualified personnel familiar with SkyJack Scissor Lift systems and safety procedures.

4.1 Safety Precautions

• Always disconnect power to the scissor lift before attempting any installation or maintenance.
• Ensure the scissor lift is on a stable, level surface and properly secured.
• Refer to the original equipment manufacturer's (OEM) service manual for specific wiring diagrams and installation instructions for your SkyJack model.
• Wear appropriate personal protective equipment (PPE).

4.2 Installation Steps (General)

1. Power Disconnection: Turn off the scissor lift and disconnect all power sources (battery, shore power).
2. Access Control Box: Locate and access the existing control box on the scissor lift.
3. Disconnect Wiring: Carefully disconnect all electrical connectors and wiring from the old control box, noting their positions for reinstallation.
4. Remove Old Unit: Unmount and remove the old control box.
5. Install New Unit: Mount the EZSUNSWAY 116063 Control Box in the same location.
6. Reconnect Wiring: Reconnect all electrical connectors and wiring to the new control box, ensuring secure connections. Double-check all connections against the OEM wiring diagram.
7. Secure Components: Ensure all components are securely fastened and no loose wires are present.
8. Initial Test: Reconnect power and perform a functional test according to the scissor lift's operational manual.

5. Operating Instructions

Familiarize yourself with the controls before operating the scissor lift. Always follow the safety guidelines provided by the SkyJack Scissor Lift manufacturer.

Figure 5.1: Key operational components of the control box.

• Thumb Steering Rocker (Joystick): This controls the direction and speed of the scissor lift's movement. Push forward, backward, left, or right to maneuver the lift. The sensitivity and response may vary based on the speed setting.
• Lift Function Button: Activates the lifting and lowering mechanisms of the scissor lift. Typically, a separate control on the joystick or a dedicated button will control the upward and downward motion.
• Diagnostic Display (Gauge): Provides visual feedback on the system's status, such as battery charge, error codes, or other operational parameters. Consult your SkyJack Scissor Lift manual for interpretation of specific readings.
• Emergency Stop Button: A prominent red button designed to immediately cut all power to the lift's functions in an emergency. Pressing this button will stop all movement. To reset, twist or pull the button as indicated on the control box, then restart the lift's power.
• Speed Select Button: Allows the operator to choose between different speed modes (e.g., high/low speed for driving, or fine control for lifting). Select the appropriate speed for the task and environment.

Always ensure the work area is clear of obstacles and personnel before operating the lift. Perform daily pre-operation checks as recommended by the scissor lift manufacturer.

6. Maintenance

Regular maintenance ensures the longevity and reliable operation of your control box. While the EZSUNSWAY 116063 Control Box is designed for durability, periodic checks are recommended.

• Cleaning: Keep the control box clean and free from dirt, dust, and debris. Use a soft, dry cloth. Avoid using harsh chemicals or excessive moisture, which can damage electronic components.
• Inspection: Periodically inspect all cables and connectors for signs of wear, damage, or corrosion. Ensure all connections are secure.
• Functionality Check: Regularly test the joystick, buttons, and emergency stop function to ensure they respond correctly.
• Storage: If the scissor lift is stored for an extended period, ensure the control box is protected from extreme temperatures and moisture.

7. Troubleshooting

If you experience issues with the control box, consider the following basic troubleshooting steps:

• No Power/No Response:
  • Check if the emergency stop button is engaged. Disengage it if necessary.
  • Verify that the scissor lift's main power is connected and turned on.
  • Inspect all electrical connections to the control box for looseness or damage.
  • Check the scissor lift's battery charge level.
• Erratic Movement/Controls Not Responding:
  • Ensure all connections are secure and free from corrosion.
  • Check for any obstructions around the joystick or buttons.
  • If a diagnostic display is present, note any error codes and consult the SkyJack Scissor Lift's service manual.
• Gauge/Display Issues:
  • Ensure the control box is receiving power.
  • Check for loose connections to the display unit.

For complex issues or if troubleshooting steps do not resolve the problem, it is recommended to contact a qualified service technician or the product support team.

8. Specifications

9. Warranty and Support

EZSUNSWAY is committed to providing quality products and customer satisfaction. The product quality is guaranteed. For any questions, technical assistance, or support regarding the EZSUNSWAY 116063 Control Box, please contact our customer service department.

Please refer to your purchase documentation or the EZSUNSWAY official website for specific warranty terms and contact information.