Construction is all about efficiency. You want to get in and out as quickly as possible with as few people as possible for as little money as possible. One of the biggest hold ups on a job site can be caused by a guy running an excavator who doesn’t really know what he’s doing. If you’re the one working the equipment, having excellent control over the machine is going to help you get your project done quicker.

Excavator controls are essential for maximizing productivity on construction sites. By mastering the controls, operators can perform tasks more precisely, reduce cycle times, and enhance safety. This guide explores various control types, techniques, and best practices to optimize excavator performance, ultimately benefiting your construction projects.

There are a few different types of excavator controls, and we’re going to dig deep on each.

What Are the Main Types of Excavator Controls?

Standard Controls vs. ISO Controls

Most excavators have two different setups for the controls—SAE controls and ISO controls. SAE controls are the standard for most manufacturers. With these controls, the left joystick operates the boom and stick, and the right joystick operates the bucket. If I move the left joystick one way, the boom and stick go that way. It’s a one-to-one movement. ISO controls are different. With ISO controls, the left joystick does the boom and bucket, and the right joystick does the stick.

You move the left stick one way, and the boom goes a direction. For some people, this is a more intuitive setup. I’ve run both kinds, and I prefer the ISO controls, but that’s just because of how my brain works. Different strokes for different folks. Knowing what the differences are and which setup you like is crucial, as you can save yourself a lot of time and money by going with the control configuration that best fits your style.

Auxiliary Controls for Versatility

Excavators also have auxiliary controls for things like grapples, augers, and breakers. All of a sudden, you have all kinds of cool things you can do with your machine. If you’re in and out with a project, the time saved by being able to switch functions on the fly can be jaw dropping. Know what all the little buttons and levers do on your machine. You can learn how to do some amazing things with your excavator that might make you the hero on your next project.

Electric vs. Hydraulic Controls

Some of the new electric control systems they’ve been coming out with make the machine even more responsive and precise. These systems are also lighter, which can help contribute to better fuel economy and performance. Traditional hydraulic controls are what you’ll find on most machines out there, and they work just fine. Controls, like any part of the machine, will need to be maintained, and it’s important that you know what you’ve got in case it fails.

How Do Excavator Controls Affect Operator Comfort and Safety?

Ergonomics of Excavator Design

Ergonomically placed controls make for new human engineering in the way operators feel comfortable. Many excavators today have adjustable seats, armrests, and controls that can be adjusted to fit an operator’s preference, making it more comfortable and less fatiguing to use day in and day out. This ergonomic design not only makes it more comfortable, but it helps the operator stay more focused, allowing better performance and fewer mistakes when running the machine.

Integration of Safety Features

Safety features built into the controls such as automatic shut-off systems, load-sensing technology, emergency stops, and others also enhance safety. Operators must be familiar with these features so they can respond quickly and safely if necessary to prevent accidents and maintain a safe work environment. Furthermore, many excavators come equipped with cameras and sensors to improve the operator’s ability to see surrounding objects, thus reducing the chance of hitting or running over something or someone on the job site.

Training and Familiarization

Periodic safeties and re-training the operators how to operate the machine correctly can alleviate comfort and prevent something bad from happening. A well-trained operator is more likely to respond correctly during an emergency or run more securely, creating a safer environment for everyone.

What Techniques Can Operators Use to Master Excavator Controls?

Building Basic Skills

 Make sure you’re practicing those basic moves you use every day like digging, lifting, and dumping. Before long, you’ll have complete control over the machine because you’ve been working with the controls and know what to do. If you’re new to operating a machine, start with those simple tasks to build your confidence before moving on to anything complex. You’ll get to know the response of the machine to what you’re telling it to do with the controls, and the learning curve won’t be nearly as steep.

Utilizing Simulator Training

Simulator training can be good. There are sophisticated simulators out there that you can use to train on, which replicates what it’s like in the field. Many manufacturers have created simulators that you can use to get your hands on the controls of an excavator without the risk of running the machine in real life. It’s beneficial for getting the hang of using the controls and functions because it feels so much like the real thing. Then when you have to use the machine in a real-life situation, it’s not new to you.

Peer Learning and Mentorship

Teaming up with someone more experienced can be extremely beneficial. Talk to an expert operator and have them walk you through what they do and how they use it. Operators who are old hands at this can give you invaluable ability on how to operate the machine with the controls and how to troubleshoot. The information they can impart to you can save you tons of time in learning how to effectively and efficiently operate the machine.

How Does Control Configuration Impact Productivity?

Personalizing Control Settings

How your controls are set up makes a big difference in how fast you can get things done. The more comfortable and the better you are with your control setup, the faster you can push the machine to finish a project. Everyone is different. Everyone wants their controls different than the other person. I’ve seen people put their controls everywhere. The angle of the control stick, the way the button moves, how the button operates, which button is on top and which one is on the bottom—every one of those can affect how good you are with the machine. For some people, the wrong arrangement will lead to mistakes and take a long time to get anything done.

Balancing Speed and Precision

You’ve got to know what the sweet spot is for whatever the job is. For instance, if you’re working on a project where you’re going to do a lot of grading or trenching, there’s probably going to be a spot where for that task you need to run the control slower if you’re going to do a good job.

If you’re going to move a bunch of dirt, then you probably need to trot the control a bit. But understanding that sweet spot and where those control settings need to be for what you’re asking the machine to do is extremely important for maximizing speed and accuracy. You need to know, ‘Okay, for the project, this is what I’m doing and this is what I need to set this control at to do it right.

Implementing Workflow Optimization

From an operator standpoint, if you can pre-plan and pre-determine what you’re going to do before you do it, that’s as big a key as anything. Think ahead about what you’re going to do and how you can set up your controls to make that job efficient. A load, move, dump scenario involves work with the bucket and then work with the machine to move from Point A to Point B.

Can you use your control setup to shrink the overall cycle time and the amount of physical work you have to do with the machine to move dirt? Think about your controls as a way to save time by cutting down on unnecessary cycles or movements. To me, the way an operator uses the controls equals the way they resolve an issue. If you’re good with the controls, you find a way to use them to solve the problem.

What Role Does Technology Play in Modern Excavator Controls?

Advancements in Control Technology

There are all sorts of new systems on machines. A lot of excavators today have joystick controls, the machine communicates well, and you can use GPS and telematics to track your progress. GPS can literally tell you how deep and at what angle you need to dig a hole. You can be dead-on accurate using the GPS to dig the hole to spec. Telematics can monitor the machine’s operation in real-time or track your progress. These systems can provide data about your work and performance patterns that would allow you to see how the machine was used and access production data. This information can help prevent machine failures, reduce maintenance, and down time.

Remote Control Capabilities

Excavators can be operated remotely from a safer distance in hazardous environments. These remote control features improve operator safety because you’re not physically running the machine while digging or working in a hazardous area. The operator can perform the task from a safe location, giving them the ability to walk away if anything goes sideways. Understanding and using these types of tech can offer you a real advantage in construction. Mastering these technologies improve not just your ability to run the machine but your ability to be safe while running the machine.

Integration of Automation

Another trend you’ll see more of is automation. The ability to automate tasks that require precision and a skilled operator should be embraced. Automated controls can be beneficial during digging and trenching work done in situations where exact measurements and poses are critical. There are many situations in grading and trenching where a perfectly flat trench is necessary. You can use the controls to accomplish that, but it may be easier to leave it to the machine to do the work. By letting the machine do the repetitive work, you can concentrate on other things or run the machine around where it can be more effective.

How Can Operators Ensure Effective Communication with Excavator Controls?

The relationship between communicating what you want from the controls and what the machine then does for you is one that is not learned overnight. You have controls to make the machine do work, and it
is up to you to understand those controls that make the machine do the work. You need to know how each of those controls feel to you and how they make the machine perform.

The sensitivity of the controls and why you set it up a certain way on the machine boils down to this: it’s you talking to the machine. The faster you figure out how to talk to the machine, and the better you become at it, the quicker you will learn to speak the proper language to talk to the machine. How do you do it and how do you learn to speak the machine’s language? Practice, a lot of it, and maybe someone explaining what you’re doing, and you getting feedback on your work.

Talking about what you’re doing and understanding the depth of the hole is critical. Use hand signals or radios to tell the guys on the ground the angle or depth for something you’re digging. Practice within your team on how you talk to each other, or how you signal or winch, work gives everyone the same comfort level. Everybody knows what you’re going to do before you do it so they can get the hell out of your way. Use a trained dog on earthmovers. Teach them the language on how to communicate and work safely. Then the dog will understand what you’re telling it to do.

Also, encourage operators to talk things through because they might have ideas that no one else has considered. Develop your business and personal style into something that is understanding and inclusive. This way, if your operator has a great idea, he’s going to say it, because he won’t be afraid you’ll cut his head off if he says it. Asking him to speak up and contribute with ideas, and asking if there is a better way to solve a problem out there, can improve productivity.

What Common Mistakes Should Operators Avoid When Using Excavator Controls?

The most common mistake made by inexperienced operators is overcontrolling the machine. Over-controlling causes jerky movements and is the number one reason for imprecise work. That’s why you need to focus on being smooth and under control at all times. If you let the machine control you, have an Energy Shot, force yourself to calm down. Get relaxed, take deep breaths and do some 5-10 seconds breathe in/breathe out breathing cycle. Use any method available to force yourself to relax and take deep breaths. A steady hand will take you a lot further when you’re operating machinery.

Another big mistake is not looking around before you move. If you’re going to do anything – move the machine, pick up a bucket, or begin to dig – look around again to make sure there isn’t anything immediately around you that you’re going to squish, crunch, or break. Operators can also forget to recognize cabinets, spindle-high gear benches, or the people from other Trades working around them. Every time you get in the machine and before you dig the first shovel full of dirt, look around and make sure where you are and where your key switches are and if you have a spotter around you while you perform your safety check.

Think about the job you are there to do and solely focus on that task. Being distracted will get you in trouble with an excavator. Somebody needs to drive home the point during training that operating an excavator demands complete focus while you’re running it.

How Can Regular Maintenance of Controls Enhance Performance?

You need to look at your controls every morning to make sure they work. Actuate each control, and pay attention to how they feel and how the machine reacts. Feel if the joysticks twitch. If you have old-fashioned controls and levers, make sure the levers don’t stick or are hard to move. Check to see if the trigger-type systems or paddles on the joysticks don’t work. In a new electronic system, see if the triggers, pads, or thumb-wheels work. Every morning, run through your controls to make sure everything is working for you. You need to keep a control log to ensure someone doesn’t miss the control device causing an issue.

Professional Service. Folks need to also call professionals on a regular basis to come by and look at what is under the hood in regards to the operation of the controls, whether it is electric, hydraulic, or a combination. A well-maintained machine is efficient, performs better, and provides safety for you and your people. Follow the guidelines set by the manufacturer on maintaining the machine so that you don’t have any unexpected, unwanted surprises about failures. Adhering to maintenance schedules helps ensure the machine does not break and keeps it in good shape.

Moreover, fostering a culture of accountability among operators regarding maintenance can lead to better equipment care. Encouraging operators to take ownership of their machines can enhance pride in their work and motivate them to prioritize maintenance.

Summary

Operator controls are everything. The better you understand control movement and use, the better you’re going to be running an excavator. Make sure you train yourself in all the controls you have at your disposal and that you know how to train if you are weak on any item. You must understand how to operate all of the controls you can use to run an excavator and use them to operate the excavator, as well as the power booster.

You have to train yourself to be able to operate a machine with a thumb on one hand, and you also have to be able to operate a machine with pedal steer with the other hand. Be very aware that the future lies in the use of electronic, joystick-operated controls. Control types have had a significant impact on how companies run machines and reduce fatigue in operators. Do your company and your people a favor by training your operators how to operate your equipment the right way. For more information or professional advice, feel free to contact us.