Understanding and Locating Control Pattern Swap Kits in Excavators

[MikePhua]

The Rise of Control Pattern Customization
As excavator technology evolved through the 1990s and 2000s, manufacturers began offering control pattern swap kits to accommodate operator preferences. These kits allow users to switch between two dominant joystick configurations: ISO (excavator style) and SAE (backhoe style). The ability to toggle between patterns became especially valuable for rental fleets, training environments, and contractors managing mixed operator backgrounds.
Terminology annotation:
• ISO Pattern: Left joystick controls swing and boom; right joystick controls stick and bucket.
• SAE Pattern: Left joystick controls swing and stick; right joystick controls boom and bucket.
• Pilot Manifold: A hydraulic control block that distributes pilot pressure to actuators based on joystick input.
• Rotary Selector Valve: A mechanical or hydraulic valve that redirects pilot flow to change control patterns.
Factory Installations and Aftermarket Kits
Some machines, such as the John Deere 225C, were equipped with control pattern swap kits at the factory or during dealer setup. These kits may be manual or electric, depending on model year and configuration. Manual systems typically use a rotary valve mounted near the pilot manifold, while electric systems rely on solenoids and switches within the cab.
In compact excavators like the Bobcat E50, the swap mechanism is often located under the operator’s seat or behind a service panel. Larger machines may house the selector valve in a side compartment or beneath the floor plate.
Recommendations for locating the swap kit:
• Inspect the right-hand front compartment near the pilot manifold
• Look for a rotary knob or lever with a 270-degree range of motion
• Check for wiring harnesses or toggle switches near the joystick base
• Consult the operator’s manual or service documentation for schematic references
Challenges in Zero Tail Swing Machines
Zero tail swing (ZTS) excavators, such as the JD 225C, present unique packaging challenges. Their compact design limits space for auxiliary components, making it harder to locate or install swap kits. In some cases, the control pattern selector is tucked into tight compartments or omitted entirely.
Operators have reported difficulty accessing the pilot manifold due to cramped layouts. Technicians working on ZTS machines often remove panels or tilt the cab to reach hydraulic blocks. While the design improves maneuverability, it complicates serviceability.
Suggestions for ZTS troubleshooting:
• Use a mirror and flashlight to inspect hidden compartments
• Trace pilot lines from joystick valves to the manifold
• Look for unused ports or capped fittings that may indicate swap kit potential
• Contact the manufacturer with serial number for build sheet verification
Retrofit Options and Dealer Support
For machines without factory-installed kits, retrofit solutions are available. These include:
• Manual rotary valves with mounting brackets and pilot line adapters
• Electric solenoid kits with toggle switches and wiring harnesses
• Universal kits compatible with multiple brands (requires custom plumbing)
Before purchasing a retrofit kit:
• Confirm pilot pressure range (typically 300–600 psi)
• Measure available space for valve installation
• Verify joystick valve type and pilot line routing
• Ensure warranty compliance if modifying newer machines
Dealers often stock brand-specific kits and may offer installation services. Some manufacturers, like Caterpillar and Komatsu, include swap kits as standard on mid-size excavators, while others offer them as optional upgrades.
Operator Training and Safety Considerations
Switching control patterns can dramatically affect machine behavior. Operators accustomed to one pattern may inadvertently cause unintended movement when switching. To mitigate risk:
• Clearly label control pattern selector position
• Provide training sessions for new operators
• Lock selector in preferred position during high-risk operations
• Use pattern-specific decals on joysticks and cab interior
In one incident, a crew member switched the pattern mid-shift without informing the operator, resulting in a bucket strike on a nearby structure. Since then, the company implemented a lockout policy and standardized ISO controls across its fleet.
Conclusion
Control pattern swap kits enhance excavator versatility and operator comfort, but locating and managing them requires attention to detail—especially in compact or older machines. Whether factory-installed or retrofitted, these systems offer a practical solution for adapting to diverse operator preferences. With proper identification, installation, and training, they can improve productivity and reduce operational errors across varied job sites.