Changing Komatsu Controls to Hitachi Configuration

[MikePhua]

When operating heavy equipment, the control configuration plays a significant role in operator comfort and machine efficiency. Many operators are accustomed to specific control layouts, and when transitioning between brands, such as from Komatsu to Hitachi, it can be a challenge to adapt. This article discusses the process of changing the control configuration from Komatsu to Hitachi on heavy machinery, providing insight into the benefits and challenges associated with such a modification.
Why Change from Komatsu Controls to Hitachi Configuration?

1. Operator Preference
   One of the main reasons for switching the control system is operator preference. Some operators may find the control layout on Hitachi machines more comfortable or intuitive compared to Komatsu. For example, Hitachi's joystick control system might be more favorable for operators used to that type of handling, while others may find Komatsu’s joystick layout more natural. Changing the control configuration ensures that the operators can continue to work with a system they are most familiar with.
   
2. Consistency Across Fleet
   In a fleet with mixed equipment brands, operators may need to switch between different machines regularly. By converting the control system to a uniform layout, the transition between machines becomes easier, improving productivity and minimizing downtime. Consistent control configurations help reduce confusion and improve safety.
   
3. Increased Productivity
   When operators are more comfortable with the controls, they are more likely to operate the machine efficiently. The ability to work with a control system they are familiar with can reduce mistakes, improve reaction times, and overall lead to better machine productivity.
   

Challenges of Changing Control Configurations

1. Complexity of the Conversion
   The process of changing the control layout between two different brands, such as Komatsu and Hitachi, can be complex. These systems often use different hydraulic circuits, software configurations, and hardware setups, which may not be compatible out of the box. The changeover requires modifying or replacing various components, such as joysticks, hydraulic systems, wiring, and even the machine's control panel.
   
2. Cost of Conversion
   Converting the control system from Komatsu to Hitachi is not a low-cost endeavor. Depending on the age of the equipment, the extent of the modifications, and the parts required, this could be a significant financial investment. Replacing joysticks, controllers, and wiring could add up, and in some cases, specialized knowledge and skills may be needed to install the new system correctly. The total cost might outweigh the benefits for some operators or businesses.
   
3. Potential for Machine Downtime
   The modification process can lead to significant downtime while the conversion is completed. Depending on the size and scope of the change, the machine may be out of commission for days or even weeks. During this time, production could be impacted, which could be detrimental to project timelines, especially if the equipment is used for critical tasks.
   
4. Training Requirements
   Once the conversion is complete, operators may need to be trained to use the newly configured system. Even though the control layout will be familiar to them, different systems may have slight variations in how they function. Proper training ensures that operators can handle the machine effectively, avoiding safety risks or productivity loss due to improper use.
   

Steps to Change Komatsu Controls to Hitachi Configuration

1. Assess the Compatibility
   Before starting the conversion, it’s important to evaluate the compatibility of the existing equipment with the Hitachi control system. This includes checking if the hydraulic systems are compatible and if the necessary electrical modifications can be made. Consulting with a professional or expert in hydraulic systems can help clarify these details and avoid costly mistakes.
   
2. Purchase the Necessary Components
   Once compatibility is confirmed, the next step is to source the required components. This includes Hitachi-specific joysticks, controllers, and any necessary hydraulic and electrical parts. It’s also essential to obtain the wiring diagrams and control schematics for both machines to ensure a smooth transition.
   
3. Disassemble the Existing Control System
   The existing Komatsu control system needs to be carefully removed. This involves disconnecting and disassembling the joysticks, control panels, and hydraulic connections. The process should be done with precision to avoid damage to any parts that might be reused or sold.
   
4. Install Hitachi Control System Components
   With the old system removed, the next step is to install the new Hitachi components. This involves carefully wiring and connecting the joysticks, controllers, and hydraulic systems to ensure that the machine functions properly with the new layout. It is critical to follow Hitachi's specifications during this process to avoid malfunctions or safety issues.
   
5. Calibrate the New System
   Once the new components are installed, calibration is required to ensure that the control system operates as intended. This may involve adjusting the hydraulic pressure, joystick sensitivity, and other settings specific to the Hitachi configuration. Calibration ensures the machine will perform optimally with the new system.
   
6. Testing the System
   After installation and calibration, thorough testing of the machine should be conducted to ensure that all systems are functioning correctly. This includes checking the responsiveness of the controls, hydraulic operations, and overall machine performance. Testing ensures that the machine is ready for use in its new configuration.
   

Conclusion
Changing the control configuration from Komatsu to Hitachi on heavy equipment can be beneficial for operators who are more comfortable with Hitachi controls or for those seeking to standardize their fleet. While the conversion can increase comfort and productivity, it is important to consider the challenges, such as the complexity of the conversion, cost, downtime, and potential training requirements. Careful planning and professional help can make the process smoother and more cost-effective, ensuring that the transition leads to improved efficiency without compromising machine functionality.