Excavators are indispensable in construction, mining, and infrastructure projects.
Throughout the country and especially in California, they are gaining popularity. The crawler excavator market is projected to reach USD 69.26 billion by 2035, growing at a CAGR of 2.7% from 2025.
That’s no doubt because the precise handing and maneuvering of the boom arm combines with a range of attachments to produce a really versatile machine.
But with that functionality comes complex systems. And with complex systems comes issues. They are also often used in demanding environments, which doesn’t help.
Once you get an understanding of the most common problems associated with used excavators, it becomes much easier to prevent and prepare. This is how companies minimize downtime and costs (while also massively improving safety).
1. Hydraulic System Failures
Hydraulic systems are the literal lifeblood of excavators. It’s how these machines move their boom arm to perform digging and lifting. Failures in these systems can stem from contaminated fluids, worn seals, or damaged hoses. A study by York Precision Machining & Hydraulics indicates that 80% of hydraulic failures are due to fluid contamination. To prevent this from ruining your excavator, make sure you have fluid checks as part of your regular maintenance.
2. Engine Overheating
Overheating can result from clogged radiators, low coolant levels, or malfunctioning thermostats. The American Journal of Engineering Research highlights that improper maintenance schedules significantly contribute to engine failures, in large part because companies miss easy-to-fix issues. Implementing a proactive maintenance plan can mitigate these risks of engine overheating.
3. Electrical System Issues
Faulty wiring and sensor failures cause unexpected shutdowns all the time. These are some of the most crucial but also delicate parts of the excavator. These are also among the hardest issues to diagnose and fix on site. Like so much else on the machine, regular inspections and timely replacements of worn-out components maintain your electrical system.
4. Undercarriage Wear and Tear
The undercarriage bears the brunt of an excavator’s operations. Components like tracks and rollers are prone to wear, especially in harsh terrains. CAT notes that undercarriage maintenance can account for up to 50% of total maintenance costs. Regular inspections and timely part replacements are again the solve for this one.
5. Quick Coupler Failures
Quick couplers allow for rapid attachment changes but can pose safety risks if not properly maintained. The CDC reports that this potentially deadly issue has three main causes: misconnection, cylinder failure, and opening the quick coupler in an unsafe position. Ensuring proper locking mechanisms and regular checks can prevent such accidents.
6. Operator Visibility Issues
Limited visibility can lead to tragic incidents. In May 2025, a pedestrian in Mumbai was fatally struck by an excavator operating in reverse. The operator claimed the bucket obstructed his view. Installing cameras and ensuring clear sightlines are essential safety measures. Luckily, many new models include cameras for safety.
7. Inadequate Maintenance Practices
Neglecting routine maintenance can exacerbate minor issues. For instance, a case study from Warren Forensics details a fatality resulting from servicing an unsupported excavator boom. That tragic event underlines just how important proper practices are. Adhering to manufacturer guidelines and safety protocols is non-negotiable, as is building a culture of safety that is always improving.
Overcome Common Excavator Issues
Proactive maintenance, operator training, and adherence to safety protocols are paramount in mitigating common excavator issues. By staying informed and vigilant, companies can ensure the longevity and safety of their equipment.
