SANY excavators are known for their cost-effectiveness, reliability and parts availability. All these advantages making them a competitive choice for construction projects in Asia, Africa, South America and the Middle East. However, like most other brands excavators, there will be problems after long-term use, especially in key components such as hydraulic, electronic control and engine systems. For areas with harsh operating environments and limited maintenance technical conditions, Sany excavator problems are more likely to be exposed and affect work efficiency.

This article provides a detailed breakdown of common SANY excavator problems from a technical perspective. With each section, we’ll highlight the symptoms, analyze the causes,= and provide targeted repair strategies and maintenance tips, helping you reduce downtime and extend machine life.

1. Hydraulic System Failures

Common Symptoms:

• Sluggish boom or arm movement
• Weak digging force
• Overheating hydraulic pump
• Jerky or unstable cylinder motion

Technical Explanation:

The hydraulic system is the heart of the excavator, powering boom, arm, bucket and swing functions. SANY excavators typically use Kawasaki or Linde pumps. When oil contamination or improper pressure regulation occurs, operators may notice delays, reduced force or overheating.

Troubleshooting Table:

Sany excavator Problems	Technical Cause	Recommended Solution
Hydraulic oil contamination	Dirty oil causes valve sticking and wear	Replace hydraulic oil, flush the system, install new filters
Control valve jamming	Foreign particles restrict valve movement	Disassemble and clean main control valve
Insufficient pressure	Faulty pressure sensor or pump underperformance	Check system pressure with a gauge, re-calibrate pump
Motor inefficiency	Internal leakage in swing/travel motors	Inspect motors, replace seals or full units if needed

Maintenance Tips:

• Analyze oil samples every 250 hours (NAS class ≤8)
• Use ISO VG 46/68 quality anti-wear hydraulic oils
• Avoid mixing brands to prevent emulsification

2. Electrical System Malfunctions

Common Symptoms:

• Dead control panel or blinking indicator lights
• Start button unresponsive
• ECU errors and sensor failures
• CAN bus communication loss

Technical Explanation:

SANY’s electrical system integrates ECUs, sensors and wiring harnesses using CAN bus architecture. Dust, moisture or voltage instability can cause abnormal sensor readings, system freezes or startup failures.

Troubleshooting Table:

Sany excavator problems	Technical Diagnosis	Recommended Fix
Dead display	Power loss or blown fuses in the dashboard circuit	Check fuses and battery voltage, replace screen module
ECU errors	Overvoltage or burned ECU components	Replace ECU, reprogram with diagnostic tool
No start response	Faulty starter relay or low battery	Replace relay, ensure battery ≥24V
Sensor failure	Broken wire or connector corrosion	Repair wiring, clean terminals, replace sensor if needed

Maintenance Tips:

• Use IP67 waterproof connectors in high-humidity environments
• Test insulation resistance ≥10 MΩ every 1,000 hours
• Perform full system scan with diagnostic tool quarterly

3. Engine Starting Issues

Common Symptoms:

• Engine fails to crank or starts weakly
• Unstable RPM or black smoke after ignition
• Requires multiple attempts to start, especially in cold weather

Technical Explanation:

SANY uses engines from Cummins, Yuchai, or Mitsubishi. Startup problems are typically related to battery health, air in fuel lines, or injector carbon buildup. Cold weather and poor diesel quality exacerbate these issues.

Troubleshooting Table:

Sany excavator problems	Technical Diagnosis	Recommended Repair
Low battery voltage	Voltage <21V prevents ECU activation	Charge or replace the battery
Injector clogging	Poor atomization due to carbon or wax buildup	Clean or replace fuel injectors
Air in fuel system	Loose connections or damaged return lines	Bleed system, check fuel lines and fittings
Faulty glow plugs	Preheating failure in cold weather	Replace glow plugs, check temperature sensor

Maintenance Tips:

• Change diesel filters every 250 hours
• Use winter-grade diesel and fuel warmers in low temperatures
• Keep fuel tank sealed to prevent water entry

4. Overheating Problems

Common Symptoms:

• Coolant temperature rapidly rises after 20–30 minutes of operation
• Fan does not spin or spins too slowly
• Coolant leaks or boiling over
• Radiator clogged with dust or oil residue

Technical Explanation:

SANY machines use aluminum radiators and electric fans. If radiator fins are clogged or fan circuits fail, heat dissipation drops dramatically, especially under high load or in hot climates.

Troubleshooting Table:

Sany excavator problems	Technical Cause	Repair Recommendation
Radiator blockage	Dust and oil residue block airflow	Clean radiator with high-pressure air or water
Coolant leakage	Old hoses or tank cap failure	Replace hoses and seals
Fan malfunction	Relay failure or motor burnout	Replace fan relay or fan motor
Thermostat stuck	Fails to open cooling cycle in time	Replace thermostat

Maintenance Tips:

• Clean radiator every 100 hours
• Replace coolant every 1,000 hours
• Ensure fan voltage output is consistently 24V

5. Undercarriage and Track Wear

Common Symptoms:

• Track misalignment or slippage
• Travel motor noise or vibration
• Premature wear of track pads, rollers, or idlers
• Oil leaks from final drive or track adjuster

Technical Explanation:

SANY uses a hydraulic-adjustable track tensioning system. Operating in mud, gravel or rocky terrain accelerates wear, especially if cleaning and tension checks are neglected.

Troubleshooting Table:

Sany excavator problems	Technical Cause	Recommended Action
Loose track tension	Leaking tension cylinder or spring failure	Adjust or replace tensioner seals and springs
Excessive pad wear	Constant abrasion from rough surfaces	Replace pads, consider heavy-duty options
Idler noise	Bearing damage or grease loss	Disassemble and lubricate or replace roller assembly
Final drive leak	Old seals or overfilled oil	Replace seals, check vent and oil level

Maintenance Tips:

• Check track tension every 50 hours (sag gap: 20–30mm)
• Clean mud and debris daily from tracks
• Lubricate rollers every 1,000 hours

6. Boom and Arm Structural Cracks

Common Symptoms:

• Cracks near boom base or welds
• Loose bucket linkage or excessive play
• Bucket pins worn out, ears distorted
• Squeaking or metal-on-metal noise under heavy load

Technical Explanation:

Though SANY booms and arms use high-strength Q345 steel, repetitive high-load use or side-force digging leads to fatigue cracks. Poor welding quality or over-sized buckets may lead sany excavator problems.

Troubleshooting Table:

Sany Excavator Problems	Technical Diagnosis	Recommended Solution
Boom cracking	Concentrated stress or inadequate reinforcements	Weld with arc gouging and add reinforcement plates
Arm distortion	Excessive side loading or overcapacity operation	Replace arm, check bucket compatibility
Bucket ear damage	Misaligned pins or pin hole elongation	Replace bushings and use proper bucket size
Weld detachment	Non-standard or low-quality welding	Re-weld with CO2 or submerged arc techniques

Maintenance Tips:

• Perform ultrasonic or magnetic inspection every 1,000 hours
• Avoid oversized attachments; follow rated lift limits
• Reinforce boom base if operating under extreme conditions

7. Preventive Maintenance Schedule

Consistent maintenance is key to avoiding major Sany excavator problems. Here’s a recommended checklist:

Maintenance Item	Frequency	Key Notes
Hydraulic oil & filter	Every 500 hrs	Use only OEM filters; flush before refill
Coolant level check	Daily	Keep above MIN line; avoid mixing brands
Track tension inspection	Every 50 hrs	Adjust sag to 20–30mm standard
Injector cleaning	Every 500 hrs	Prevent clogging and misfiring
Idler/roller lubrication	Every 1,000 hrs	Use lithium grease or heavy-duty bearing oil
ECU & CAN diagnostics	Every 1,000 hrs	Scan for error codes and test signal stability
Boom structural check	Every 1,000 hrs	Inspect welds and linkages for cracks or deformation

Conclusion: Sany Excavator Problems Are Manageable

While SANY excavator problems do exist, they are largely preventable and repairable when tackled early with the right technical knowledge. This guide has outlined the most common sany excavator problems along with their causes and solutions. Whether you’re an equipment owner, rental company or technician, implementing a disciplined inspection and maintenance schedule can dramatically reduce downtime and increase the lifespan of your SANY equipment. For full repair manuals, error code charts or model-specific maintenance kits, we recommend contacting your authorized SANY dealer or technical support team.