Changing Controls on Backhoes

[MikePhua]

Backhoes are versatile and indispensable machines used in various construction, landscaping, and excavation tasks. One of the key components that ensure backhoes deliver efficient performance is the control system. Over time, operators may encounter a desire or a need to change the controls, whether to improve comfort, adapt to new operational preferences, or modernize an aging system. This article delves into why backhoe control systems are changed, how this process is carried out, and the considerations operators must take into account when modifying their machines.
Overview of Backhoe Control Systems
Backhoes are equipped with hydraulic controls that allow operators to manipulate different components of the machine, such as the boom, bucket, stabilizers, and wheels or tracks. These controls are essential for the backhoe’s functionality and can be either mechanical or hydraulic.
There are two main types of control systems on backhoes:

1. Standard Controls: These are the traditional mechanical lever systems that are still widely used in many older or more basic models. They often provide a direct mechanical connection between the operator’s hands and the machine’s hydraulic systems.
   
2. Pilot Controls (or Joystick Controls): These are more modern, electronic controls that use hydraulic pilot pressure to operate the machine’s functions. Joystick controls are generally preferred for their ease of use, precision, and less physical effort required by the operator.
   

Both types of controls serve the same purpose—giving the operator full control over the machine’s movements—but the method of operation differs significantly. Over time, however, the mechanical systems may begin to show signs of wear or may not provide the same level of precision and comfort as modern systems. This often prompts operators to seek a more efficient or user-friendly control system.
Why Change Controls on a Backhoe?
There are several reasons an operator may decide to replace or modify the control system on a backhoe:

1. Improved Operator Comfort
   Many older backhoe models feature mechanical controls that require significant effort to operate, especially during extended periods. Pilot or joystick controls, on the other hand, are lighter, more ergonomic, and require less physical strain, making them more suitable for long working hours.
   
2. Increased Precision
   The accuracy of modern joystick controls is far superior to the older mechanical levers. Pilot controls provide more precise movements, which can be especially useful for tasks requiring fine control, such as trenching or grading.
   
3. Compatibility with New Attachments
   Some newer attachments and hydraulic implements require a specific type of control system. Switching to joystick controls allows operators to take full advantage of these advanced attachments.
   
4. Upgrading for Technological Advancements
   As backhoe technology evolves, new systems such as electronic controls, programmable settings, and improved hydraulic flow rates become available. Upgrading the control system enables operators to utilize these advancements, leading to better efficiency and safety.
   
5. Wear and Tear
   In older machines, the mechanical control systems can suffer from wear, leading to reduced performance and reliability. When the components like the linkage or cables degrade, switching to a more durable hydraulic or electronic control system can solve the problem and restore machine performance.
   

Steps to Change Controls on a Backhoe
Upgrading or replacing the control system on a backhoe is a complex process that requires careful planning and execution. The steps involved typically include:

1. Assessing the Need for Change
   Before starting the upgrade, operators should carefully consider whether the control system truly needs changing. If the machine is functioning properly with the existing controls and if operator comfort is not significantly compromised, an upgrade may not be necessary. However, if precision is lacking or if the machine frequently experiences issues with the control system, replacing the controls may be a worthwhile investment.
   
2. Selecting the Right Control System
   The next step is to determine the best type of control system based on the work requirements. Some operators may prefer joystick controls for their ease of use, while others may stick with mechanical levers for simplicity. It is important to choose a system that is compatible with the backhoe’s make and model, as well as the specific tasks that need to be performed.
   
3. Gathering the Necessary Parts and Tools
   Depending on the type of control system being installed, operators may need to purchase several components, including joystick assemblies, hydraulic kits, new hydraulic hoses, wiring kits, and possibly a new valve block. It is critical to ensure that all parts are OEM (Original Equipment Manufacturer) or compatible replacements to maintain machine integrity and safety.
   
4. Disconnecting and Removing the Old Control System
   Disconnecting the old control system involves safely removing any electrical or hydraulic connections. This process should be done with caution to avoid damaging components or causing leaks. The mechanical control levers are typically unbolted, while hydraulic systems need to be depressurized before removal.
   
5. Installing the New Control System
   Once the old system is removed, the new control system can be installed. For joystick controls, this typically involves installing the joystick assembly, connecting the hydraulic lines to the valve blocks, and ensuring the electronic connections (if applicable) are made properly. The installation should follow the manufacturer’s instructions for each part, ensuring all hydraulic hoses and wiring are correctly installed.
   
6. Testing and Calibration
   After installation, the new system must be tested. Operators should check for leaks, ensure the valves are operating smoothly, and verify that all movements are responsive and precise. Calibration may also be required for electronic systems to ensure optimal performance.
   
7. Final Adjustments
   Any final adjustments should be made to ensure the control system operates within the desired parameters. This could involve adjusting the sensitivity of the joystick controls, tuning the flow rates of hydraulic fluid, or reprogramming certain functions.
   

Considerations When Changing Controls
Before deciding to replace the control system on a backhoe, it’s important to consider several factors:

1. Cost
   The cost of upgrading the control system can vary significantly depending on the complexity of the system and the machine’s model. Joystick controls, for instance, may be more expensive than traditional mechanical systems. Additionally, the installation of electronic controls may require specialized expertise, which could add to the cost.
   
2. Machine Compatibility
   Not all backhoes are easily retrofitted with new control systems. Some older models may require substantial modifications to accommodate modern joystick or pilot systems. In some cases, it might be more cost-effective to invest in a new machine rather than retrofit an older one.
   
3. Downtime
   The process of changing controls on a backhoe can result in significant downtime, particularly if the machine is being extensively modified. Operators should plan for this downtime and consider how it will affect their work schedule.
   
4. Operator Training
   After the new controls are installed, operators may need training to familiarize themselves with the new system, especially if switching from mechanical levers to joysticks. The transition can affect productivity initially as the operator adjusts to the new control layout and response.
   

Conclusion
Changing the control system on a backhoe can be a significant upgrade that improves the machine’s precision, ease of use, and overall efficiency. Whether upgrading from mechanical controls to joystick systems or replacing worn-out components, it is important to consider the costs, compatibility, and potential benefits. By following a structured process, operators can ensure the transition is smooth, and the new system enhances both performance and comfort.