Top 12 Common Sany Excavator Problems And Solution

Introduction Sany excavators are widely used in construction and excavation projects, but like any heavy machinery, they can experience problems. Addressing these problems promptly is crucial to ensure smooth operations and prevent costly downtime. In this blog, we will explore some of the common Sany excavator problems and discuss the importance of addressing them in a timely manner.

See More: Top11 Worst Yanmar Tractor Models To Avoid In 2024

 Sany Excavator Problems And Solution

1.  Hydraulic Pump Problems

Hydraulic pump problems can significantly impact the performance of an excavator. When the hydraulic pump is not functioning properly, it can lead to a decrease in power and efficiency, making it difficult to complete tasks efficiently. There are several potential causes for hydraulic pump problems, including wear and tear, contamination, and improper maintenance.

Wear and Tear

One of the most common causes of hydraulic pump problems is wear and tear. Over time, the internal components of the pump can become worn or damaged, resulting in decreased performance. Regular maintenance and inspections can help identify any signs of wear early on and prevent further damage.


Contamination can also cause issues with the hydraulic pump. Dirt, debris, and other contaminants can clog the pump and reduce its effectiveness. Regularly cleaning and maintaining the hydraulic system can help prevent these issues.


If you’re experiencing hydraulic pump problems with your excavator, there are several steps you can take to fix the issue:

  1. Inspect the pump for any signs of damage or wear. If you notice any issues, it may be necessary to replace or repair the pump.
  2. Check the hydraulic fluid levels and quality. Low fluid levels or contaminated fluid can also cause problems with the pump. If necessary, drain and replace the fluid to ensure optimal performance.
  3. Regularly clean and maintain the hydraulic system. This includes inspecting and cleaning the filters and ensuring proper lubrication of all moving parts.

By following these steps and practicing regular maintenance, you can prevent and address hydraulic pump problems, ensuring optimal performance and efficiency for your excavator.

Sany Excavator Problems

2. Failure to Start

When it comes to operating a Sany excavator, one of the most frustrating problems you can encounter is a failure to start. This issue can have serious consequences, causing delays in your work schedule and potentially leading to financial losses. Imagine showing up to a construction site, ready to get to work, only to find that your excavator won’t start. It’s a situation no one wants to be in.

There can be several reasons behind this problem. It could be a simple issue like a dead battery or a loose connection, or it could be something more complex like a faulty starter motor or a fuel system problem. Troubleshooting the issue is crucial to getting your excavator up and running again.


To resolve the problem and get your excavator running, here are some troubleshooting steps you can take:

  1. Check the battery and make sure it has enough charge.
  2. Inspect the connections and ensure they are tight and secure.
  3. Check the fuel system and make sure there is fuel in the tank and that the filters are clean.
  4. If everything checks out, it may be necessary to call in a professional to diagnose and fix the problem.

Remember, a failure to start can happen to any piece of machinery, and it’s important not to panic. By following these troubleshooting steps, you can quickly identify and resolve the issue, getting your Sany excavator back in action and minimizing any potential downtime. So, the next time you encounter a failure to start, don’t worry, just take a deep breath and start troubleshooting.

See More: Top Common Kubota BX2380 Problems And How To Fix Them?

3. Transmission System Problems in Excavators

Transmission system problems can significantly impact the functionality of an excavator. These issues can arise due to various reasons, such as wear and tear, lack of maintenance, or improper use of the machine. When the transmission system is not working properly, it can lead to issues like difficulty in shifting gears, loss of power, or even complete failure of the transmission.

Causes of Transmission System Problems

One common cause of transmission system problems is the lack of proper lubrication. The transmission system relies on lubricants to reduce friction and ensure smooth operation. If the fluid levels are low or the lubricant is contaminated, it can cause excessive wear and tear on the transmission components, leading to malfunctions. Regular maintenance and timely fluid changes can help prevent these issues.


Fixing transmission system problems requires a thorough understanding of the excavator’s transmission system. It is important to diagnose the problem accurately before attempting any repairs. In some cases, the issue may be resolved by simply topping up the transmission fluid or replacing a faulty sensor.

However, more complex problems may require the expertise of a professional technician. It is crucial to follow the manufacturer’s guidelines and recommended procedures when addressing transmission system issues to ensure the best possible outcome.

4. Overheating in Sany Excavators

Overheating is a common problem that can have serious consequences for Sany excavators. When an excavator overheats, it can lead to decreased performance and even potential damage to the engine and other components. The dangers of overheating should not be taken lightly, as it can result in costly repairs and downtime for the machine.

Common Causes of Overheating

  • Malfunctioning cooling system: A malfunctioning cooling system can be caused by issues such as a clogged radiator or a faulty thermostat.
  • Low coolant level: A low coolant level can prevent the system from effectively dissipating heat.
  • Extreme temperatures and overworking the machine: Operating the excavator in extreme temperatures or overworking the machine can also contribute to overheating.


Fortunately, there are effective methods to resolve overheating issues in Sany excavators. Regular maintenance and inspections are key to preventing overheating problems. This includes:

  • Checking and cleaning the radiator and cooling system
  • Ensuring proper coolant levels
  • Addressing any leaks or malfunctions promptly

It is also important to operate the excavator within its recommended temperature range and avoid overworking the machine.

5. Metal Fatigue in Sany Excavators

Metal fatigue is a common problem that can significantly impact the operation of Sany excavators. It refers to the weakening and deterioration of metal components due to repeated stress and strain over time. This can lead to structural failures, reduced efficiency, and even safety hazards.

Sany excavators are particularly susceptible to metal fatigue due to the heavy loads, constant vibrations, and repetitive motions they experience during operation.

Causes of Metal Fatigue

Several factors contribute to metal fatigue in Sany excavators:

  • Design and quality of materials: If the excavator is made with substandard materials or if the design does not adequately distribute stress, metal fatigue is more likely to occur.
  • Maintenance and lubrication: Improper maintenance and inadequate lubrication can accelerate the rate of metal fatigue. Lack of regular inspections and failure to detect early signs of fatigue can also lead to more serious problems in the long run.


To address and prevent metal fatigue in Sany excavators, it is important to implement practical solutions:

  • Regular maintenance and inspections: Conduct regular maintenance and inspections to identify any signs of fatigue or damage early on.
  • Adequate lubrication: Ensure proper lubrication to reduce friction and wear on metal components.
  • High-quality materials and design: Use high-quality materials and design excavators that can withstand the stresses and strains of their operation.
  • Operator training: Train operators on proper usage techniques and educate them about the signs of metal fatigue to prevent further damage.

6. Fuel Contamination in Excavators

Fuel contamination is a common issue that can have adverse effects on the performance of an excavator. When the fuel is contaminated, it can lead to engine problems, reduced power, and increased fuel consumption. Contaminants such as water, dirt, and debris can clog the fuel filters and injectors, preventing them from working properly. This can result in poor engine performance and even engine damage if not addressed promptly.

Sources of Fuel Contamination

There are several potential sources of fuel contamination in an excavator. One common source is water entering the fuel tank through condensation or leaks. Water can cause corrosion and rust in the fuel system, leading to blockages and malfunctions. Another source of contamination is dirt and debris entering the fuel tank through improper fuel handling or storage practices. It is important to ensure that fuel is stored in clean, sealed containers and that the fuel tank is kept clean and free from debris.


To resolve fuel contamination problems, it is essential to follow a step-by-step process:

  1. Drain and clean the fuel tank to remove any contaminants.
  2. Replace the fuel filters to ensure that clean fuel is being delivered to the engine.
  3. Use fuel additives that can help remove any remaining contaminants and improve the overall quality of the fuel.
  4. Regularly maintain and inspect the fuel system to prevent future contamination issues.

7. Track Tension Problems in Sany Excavators

Track tension problems can have serious consequences for Sany excavators. Improper track tension can lead to decreased stability and performance, increased wear and tear on the tracks, and even damage to other components of the machine. It is important to understand how track tension problems can arise in order to address them effectively.

Causes of Track Tension Problems

  • Improper adjustment: One common cause of track tension problems is improper adjustment. Over time, the tracks can become loose or too tight, affecting the overall performance of the excavator. It is important to regularly check and adjust the track tension according to the manufacturer’s guidelines.
  • This can help ensure that the tracks are properly aligned and provide optimal traction and stability.


Adjusting track tension correctly is crucial in resolving track tension problems. It is recommended to refer to the excavator’s manual or consult with a qualified technician for guidance on how to adjust the track tension properly.

This may involve loosening or tightening the track tension bolts or using specialized tools for adjustment. By following the correct procedures, operators can resolve track tension problems and improve the overall performance and longevity of the excavator.

The Importance of Proper Track Tension

Proper track tension is essential for the smooth operation and longevity of Sany excavators. By understanding the consequences of improper track tension, the causes of track tension problems, and the correct methods for adjusting track tension, operators can effectively address this issue and ensure optimal performance of their excavators.

Regular maintenance and inspections are key to identifying and resolving track tension problems before they lead to more serious issues. So, don’t overlook the importance of track tension in maintaining the efficiency and durability of your Sany excavator.

8. Causes of Excessive Corrosion in Sany Excavators

  • Exposure to harsh environmental conditions, such as saltwater or acidic soils
  • Poor maintenance, leading to the accumulation of dirt, debris, and moisture

Excessive corrosion is a common problem that can significantly impact the structural integrity of Sany excavators. When metal surfaces are exposed to moisture and oxygen, rust forms, weakening the components and resulting in premature failure and costly repairs. Two main causes contribute to corrosion in Sany excavators:

  1. Exposure to harsh environmental conditions: Saltwater or acidic soils can accelerate the rusting process and cause damage to the metal surfaces of the excavator.
  2. Poor maintenance: If the excavator is not regularly cleaned and protected, dirt, debris, and moisture can accumulate, promoting corrosion.

Solution to Remove and Prevent Corrosion in Sany Excavators

To address excessive corrosion in Sany excavators, several effective methods can be employed:

  • Regular cleaning and washing of the excavator, especially after exposure to corrosive substances, to remove dirt and debris that contribute to corrosion.
  • Applying protective coatings, such as paint or rust inhibitors, to create a barrier between the metal surfaces and the environment, preventing corrosion.
  • Inspecting the excavator for signs of corrosion and addressing any issues promptly to prevent further damage.

9. Electrical Complications in Sany Excavators

Electrical complications can be a frustrating issue to deal with in Sany excavators. These problems can arise due to various reasons, and it’s important to identify the common causes to effectively troubleshoot and fix them.

  • Faulty Wiring System: One of the most common causes of electrical issues is a faulty wiring system. Over time, the wiring in the excavator can get damaged or worn out, leading to electrical complications.
  • Malfunctioning Battery or Alternator: Another cause could be a malfunctioning battery or alternator. If the battery is not providing enough power or the alternator is not charging it properly, it can result in electrical problems.


To fix electrical complications in Sany excavators, you can follow these steps:

  1. Thoroughly inspect the wiring system. Look for any loose connections, damaged wires, or signs of corrosion. If you spot any issues, repair or replace the affected components.
  2. Check the battery and alternator for any faults. Test the battery’s voltage and ensure that it is within the recommended range. If the battery is faulty, replace it with a new one. Similarly, test the alternator’s output and replace it if necessary.
  3. Check the fuses and relays in the electrical system. If any of them are blown or faulty, replace them with the appropriate replacements.
  4. Clean and tighten all the electrical connections to ensure a secure and reliable connection.

Regular maintenance and inspections can go a long way in preventing electrical complications in Sany excavators. By identifying and addressing the common causes of electrical issues, you can ensure that your excavator operates smoothly and efficiently. Don’t let electrical problems hold you back from getting the job done.

10. Undercarriage Problems in Excavators

Undercarriage problems can significantly impact the performance and stability of excavators. These problems can arise from various issues, such as:

  • Worn-out tracks
  • Loose or damaged rollers
  • Misaligned idlers

When these components are not functioning properly, the excavator may experience:

  • Reduced traction
  • Increased vibration
  • Difficulty in maneuvering

Track Tension Issues

One common undercarriage problem faced by Sany excavators is track tension issues. Improper track tension can lead to premature wear and tear of the tracks, affecting the overall stability and performance of the machine. It is important to regularly check and adjust the track tension to ensure optimal operation.

Excessive Corrosion

Another common problem is excessive corrosion in the undercarriage components. This can be caused by exposure to harsh environmental conditions or lack of proper maintenance. Regular cleaning and applying protective coatings can help prevent corrosion and prolong the lifespan of the undercarriage.


To address undercarriage problems, there are several practical solutions available:

  • Regular inspection and maintenance of the undercarriage components is crucial to identify any issues early on and take appropriate action. This includes checking for wear and tear, loose or damaged parts, and proper lubrication.
  • Keeping the undercarriage clean and free from debris can also prevent potential problems.
  • In case of any damage or malfunctioning parts, it is important to replace them promptly to avoid further damage and ensure smooth operation.
  • Additionally, following the manufacturer’s guidelines and recommendations for undercarriage maintenance can help prevent problems and extend the lifespan of the excavator.

11. Oil Leakage in Sany Excavators

  • Faulty seals or gaskets
  • Loose or damaged fittings or connections
  • Excessive pressure or temperature

Oil leakage in Sany excavators can have serious consequences on the performance and functionality of the machine. When oil leaks from the excavator, it can lead to decreased hydraulic power, increased wear and tear on components, and potential damage to other parts of the machine. This can result in decreased efficiency and productivity, as well as increased maintenance and repair costs.


To fix oil leakage issues in Sany excavators, it is important to identify the root cause of the problem. This may involve inspecting the seals, gaskets, fittings, and connections for any signs of wear or damage.

If any components are found to be faulty, they should be replaced with new ones. It is also important to ensure that all fittings and connections are properly tightened to prevent any future leaks.

Regular maintenance and inspection of the hydraulic system can help to identify and address any potential issues before they become major problems.

12. Excavator Hydraulic Pump Issues

Excavators are powerful machines that play a crucial role in construction and excavation projects. However, like any mechanical equipment, they can encounter problems that affect their performance and operation.

One common problem that can arise in an excavator is hydraulic pump issues. The hydraulic pump is responsible for providing the necessary power to operate the various hydraulic systems in the machine. When the hydraulic pump malfunctions, it can significantly impact the excavator’s performance. It may lead to a loss of power, slow operation, or even a complete failure of the hydraulic systems.

Potential Causes

  • Worn-out pump
  • Leak in the hydraulic system
  • Contamination of the hydraulic fluid
  • Regular wear and tear over time


To fix hydraulic pump issues, it is recommended to first identify the root cause of the problem. The following solutions can be implemented:

  • Worn-out pump: Replace the worn-out pump with a new one.
  • Hydraulic fluid leak: Repair the leak and refill the system with clean fluid.

Preventive Measures

Implementing regular maintenance and inspection schedules can help prevent hydraulic pump problems in the future. The following measures should be taken:

  • Check hydraulic fluid levels regularly.
  • Inspect for leaks in the hydraulic system.
  • Ensure proper filtration of the hydraulic fluid.

By addressing hydraulic pump problems promptly and implementing preventive measures, excavator operators can ensure the smooth operation and longevity of their machines.

Regular maintenance, timely repairs, and a proactive approach to addressing potential issues can help avoid costly downtime and improve overall productivity on construction sites. Remember, a well-maintained excavator is a reliable and efficient tool for any construction project.

The Importance of Preventive Maintenance

Practicing preventive maintenance is key to avoiding costly repairs and minimizing downtime. Regularly inspecting and maintaining your excavator can help identify and address potential issues before they become major problems. By following a preventive maintenance schedule and performing routine tasks such as fluid checks, filter replacements, and component inspections, you can prolong the lifespan of your excavator and optimize its performance.

Remember, as the saying goes, “Prevention is better than cure.” Taking proactive measures to address common problems not only improves excavator performance but also saves time, money, and resources in the long run.


Leave a Comment