Reconfiguring Control Patterns on a Kobelco SK200 Excavator

[MikePhua]

The Kobelco SK200 and Its Global Footprint
The Kobelco SK200 excavator has long been a staple in mid-size earthmoving operations, offering a balance of hydraulic precision, fuel efficiency, and operator comfort. Manufactured by Kobelco Construction Machinery Co., Ltd., a division of Kobe Steel founded in 1930, the SK200 series has evolved through multiple generations. The 1995 SK200 model, often found in gray market imports, reflects the robust mechanical design of the era, with pilot-operated hydraulics and analog control systems.
Gray market machines—units originally built for overseas markets and later imported—often come with non-standard configurations, including control patterns that differ from North American norms. This can pose challenges for operators accustomed to SAE (Society of Automotive Engineers) control layouts, especially when the machine is set to ISO (International Standards Organization) pattern by default.
Terminology Annotation
- Control Pattern: The configuration of joystick movements that dictate boom, stick, bucket, and swing functions.
- 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 Lines: Low-pressure hydraulic lines that transmit joystick input to control valves.
- Pattern Changer Valve: A hydraulic selector that reroutes pilot flow to change control pattern.
Identifying the Control Configuration
Operators often discover mismatched controls when transitioning between machines. In the SK200, the control pattern is determined by the routing of pilot lines from the joysticks to the main control valve. A pattern changer valve may be present, but in some gray market units, it lacks full SAE compatibility or is configured differently.
In one case, the machine featured a set of color-coded pilot hoses—green, red, gray, blue, and two black lines—connected to the joysticks and routed toward the pattern changer. The operator noted that despite toggling the valve, the machine remained in ISO configuration, prompting a manual rerouting of pilot lines.
Manual Conversion Procedure
To convert the control pattern manually:

• Identify each pilot line by color and trace its path from joystick to control valve
  
• Label each hose according to its function (boom up/down, stick in/out, bucket curl/dump, swing left/right)
  
• Consult a hydraulic schematic for the SK200 to confirm valve port assignments
  
• Disconnect and reroute the pilot lines to match the desired SAE pattern
  
• Secure hoses with clamps and verify that no lines are kinked or under tension
  
• Test each function slowly to confirm correct response and avoid hydraulic shock
  

This process requires precision and patience. A misrouted line can cause erratic behavior or even damage components. It’s recommended to perform the conversion with the engine off and pilot pressure relieved.
Field Anecdotes and Practical Lessons
A mechanic in Illinois recalled converting a Kobelco SK200 imported from Japan. The machine had no pattern changer valve, and the pilot lines were routed directly to the valve block. After mapping each function and swapping the lines, he restored SAE controls and trained the operator on the new layout. He emphasized the importance of labeling each hose before disconnecting to avoid confusion.
Another technician in Alberta noted that some pattern changers only support partial reconfiguration—changing swing and boom but not stick and bucket. In such cases, full manual rerouting is the only solution.
Recommendations for Long-Term Operation
To ensure safe and consistent control behavior:

• Document the control pattern and pilot line routing in the machine’s service log
  
• Label joystick functions clearly for new operators
  
• Inspect pilot lines annually for wear, abrasion, or leaks
  
• Use hydraulic-rated zip ties and clamps to secure rerouted lines
  
• Consider installing a universal pattern changer valve if available for the model
  

Operators transitioning between ISO and SAE machines should receive orientation training to prevent operational errors. In high-volume fleets, standardizing control patterns across machines can reduce accidents and improve productivity.
Conclusion
Reconfiguring the control pattern on a Kobelco SK200 excavator, especially a gray market unit, requires a clear understanding of pilot hydraulics and joystick function mapping. Whether through a pattern changer valve or manual hose rerouting, the goal is to match machine behavior to operator expectations. In excavation, control fluency is more than convenience—it’s a matter of precision, safety, and confidence at the controls.