You’re about to buy a used excavator. But what if it breaks down? Repairs will eat up your profit faster than a fleet of cats at a fresh fish market. The good news? Once you know the common problems and the real cost to fix them, you can negotiate better and avoid buying a problem machine in the first place. Here’s what you need to know.

Repairing common excavator problems like hydraulic leaks, engine failures, undercarriage wear, swing motor issues, and electrical faults typically costs between $500 to $6,000, depending on the part and labor. For used equipment buyers, understanding these costs helps avoid overpaying and reduces post-purchase surprises. This guide breaks down each problem with real repair estimates and tables—so you can make smarter buying decisions and protect your investment. Whether you’re inspecting machines in China or planning local repairs, this is the cost breakdown you need to see.

The Worst of the Common Excavator Problems Let’s diagnose each problem in detail—and reveal the worst financial hit you’ll take to get it fixed.

How Much Does It Cost to Fix a Leaking Hydraulic System?

Hydraulic systems are the heart of an excavator. They power the machine’s ability to move and function. Leaks or failures can mean big downtime and expenses to get fixed.

Common Signs of Hydraulic Problems:

• Sluggish or jerky movements: Indicates potential fluid loss or contamination.
• Visible oil leaks: Especially around hoses, cylinders, or the pump area.
• Unusual noises: Such as whining or grinding sounds during operation.

Repair vs. Replacement Costs:

Inspection Tips Before Buying:

• Check for oil stains: Around the base of cylinders and under the machine.
• Operate all functions: To detect any sluggishness or irregular movements.
• Review maintenance records: Look for recent hydraulic system services or replacements.

Is a Bad Excavator Engine Worth Repairing?

The engine is the heart of the excavator, and there are a lot of factors that come into play for deciding whether you can get by with a repair, or you need to replace it altogether. If you don’t have a good engine, it’s going to cost you money every time you turn around, because you won’t be able to operate efficiently. You bought the machine so you could make money, right? If it doesn’t have an engine, you are not going to do that! Fix it before you buy it! That’s the bottom line.

Symptoms of Engine Issues:

The following signs are red flags for engine trouble that should not be ignored:

• Hard starting: This could indicate fuel delivery problems or wear in key engine components.
• Excessive smoke: Blue smoke often means burning oil, while black smoke suggests improper fuel combustion.
• Loss of power: A significant drop in performance, especially under load, is usually caused by issues with the fuel system or worn engine components.

Repair vs. Replacement Cost Analysis:

When faced with engine failure, it’s crucial to compare repair vs. replacement costs to make an informed decision. Here’s a breakdown:

Decision Factors:

Here are several factors to consider when deciding whether to repair or replace a bad engine:

• Machine age and value: Older machines may not justify the cost of a full rebuild, especially if it’s not expected to last.
• Downtime implications: Engine repairs, especially a full rebuild, can take weeks, which could severely delay your project timelines.
• Warranty considerations: A new or remanufactured engine often comes with a warranty, offering protection against future breakdowns.

Is That Worn Undercarriage Worth Replacing?

Keeping the undercarriage clean is critical to its overall performance. It is also crucial to schedule and stick to an undercarriage maintenance program that includes inspection and proper lubrication—a poorly maintained undercarriage will shorten the life of the machine and cost you more money in the long run. Never underestimate the undercarriage. If the machine is not doing what it is supposed to do, you need to inspect the undercarriage. It is a key point in the machine for watchers.

Key Components to Inspect:

The undercarriage consists of several crucial parts that should be regularly inspected for wear:

• Track Chains: Elongation or excessive wear can lead to poor machine stability and operational inefficiency.
• Sprockets: Worn sprockets with sharp or hooked teeth can damage the track chains and cause operational issues.
• Rollers and Idlers: These parts are vital for smooth movement and stability. Leaks or uneven wear are early indicators of problems.

Replacement Costs:

Replacement costs can vary based on the size of the excavator and the brand. Here’s an estimate:

Inspection Tips:

To avoid costly undercarriage repairs, follow these tips during inspection:

• Measure track tension: Excessive tension can cause faster wear, while too little tension can lead to slippage.
• Check for uneven wear patterns: Uneven wear may indicate that the alignment is off, which can lead to further issues.
• Review service history: Ensure that the undercarriage has been properly maintained. Regular lubrication and timely adjustments can extend the life of these components.

Fixing Swing Motor or Turntable Problems: What’s the Price?

The swing system allows the upper structure to rotate on an excavator. Problems in this area will cause slow operation and less productivity on the job site.

Indicators of Problems:

The following symptoms typically signal that the swing motor or turntable is malfunctioning:

• Delayed or jerky rotation: This often points to hydraulic flow issues or wear in the swing motor.
• Grinding noises: A clear sign of worn bearings or damaged gears in the swing system.
• Excessive play: Loose components or worn swing gears can result in poor rotational accuracy.

Repair and Replacement Costs:

Here’s an estimate of repair and replacement costs based on common swing motor issues:

Inspection Tips:

To diagnose issues with the swing motor, check the following:

• Operate swing function: Engage the swing and listen for any unusual noises, such as grinding or whining.
• Check for oil leaks: Leaking oil around the swing motor or bearing area is a common sign of wear.
• Inspect gear teeth: Look for visible signs of wear or chipping, which may indicate a more serious issue.

How Much to Repair Excavator Electrical Issues?

The electrical system works the monitor and manages many other functions on an excavator. If it fails, you can experience many operational problems, and it will cost you production.

Common Electrical Issues:

Here are some of the most common electrical problems found in excavators:

• Non-responsive controls: This could indicate issues with the wiring or faulty sensors.
• Warning lights or error codes: When the machine’s control panel shows error codes, it’s a clear sign of a malfunction.
• Battery drainage: Persistent battery issues may point to electrical shorts or faulty components.

Repair Costs:

The table below outlines common electrical issues and their respective repair costs:

Inspection Tips:

For electrical faults, consider these tips:

• Run system diagnostics: Many excavators come with onboard diagnostic tools that can identify faults in the electrical system.
• Inspect wiring: Look for frayed or corroded wires that could cause intermittent faults or failures.
• Test all controls: Check that all controls are responsive. Non-functional buttons or joysticks might indicate issues within the electrical system.

Excavator Repair Cost Comparison Table

Repairing an excavator can cost anywhere from $500 and up for basic maintenance or small issues. However, if the problem is major, you may spend several thousand dollars repairing or replacing parts. Here’s an estimate of repair costs for common excavator problems.

Additional Breakdown:

Hydraulic Leaks: The cost varies depending on the part affected—whether it’s a hose, cylinder, or pump. Minor issues can be fixed quickly and cheaply, while replacing pumps or motors can lead to high expenses.

Engine Trouble: While minor repairs may cost around $1,000 (such as fixing a few sensors or injectors), extensive issues like overheating or severe wear may require a full engine rebuild or replacement, which can cost upwards of $6,000.

Undercarriage: This is one of the most significant repair areas for excavators, as wear on components like tracks, rollers, and sprockets is inevitable. Full undercarriage replacement is expensive, and the decision to repair or replace depends on the overall wear percentage.

Swing System: Poor lubrication and excessive wear on swing components like motors and bearings are common causes of swing issues. Early detection can keep repair costs on the lower end, but neglect can result in the need for full replacement.

Electrical Faults: Electrical problems can range from minor issues, like a blown fuse, to more costly repairs, such as faulty sensors or control modules. Replacing electrical components is often less expensive than addressing mechanical issues.

Case Study: A Buyer from Chile Spent $300 to Prevent a $3,000 Repair

These are the moments that can make or break your decision to purchase from overseas. These are the moments where HIXEN has your back and takes the extra steps to ensure you are getting quality used equipment – not a piece of junk you’ll regret purchasing. Without our thorough inspection and proactive follow-through, that small one-dollar part could have turned into a 3,000−3,000−4,000 bill on your end.

Lesson:

Remember that it’s cheaper to deal with problems before the product leaves the supplier. Issues are much more expensive once they’ve arrived. A 360° inspection video can help you catch problems before they get too bad.

How to Avoid Expensive Repairs Before You Buy

Want to avoid unexpected repair costs?

Pre-purchase inspections are crucial for preventing hidden issues that may not be immediately visible. Here’s your must-do checklist for inspecting used excavators before committing to a purchase:

Must-Do Checklist Before Buying:

🧠 Pro Tip:

Dealing with suppliers who have real-time machine inspection videos like HIXEN does. This video gives you a bit more comfort that you’re not going to get a machine with hidden problems you didn’t anticipate.

Buyer FAQs

Q1: What is the most expensive excavator part to repair?

A: Typically the engine is the most expensive. For the higher-end stuff like Komatsu or CAT rebuilds, you’re looking at probably 4,000or4,000or6,000 for an engine rebuild, plus the labor or the time to do it. Then, of course, replacement is even more costly.

Q2: Is it worth buying a used machine with a minor hydraulic leak?

A: Yes, that’s fine as long as it’s external and not a critical piece like the pump. The pump is going to cost a little more to fix. Something like a valve or a cylinder, odds are it’s just a rod seal, and they can probably fix it for $500 or less. Odds are that won’t hurt a thing.

Q3: How much does a Komatsu vs CAT engine rebuild cost?

A: Usually, to rebuild the engine in a Komatsu is 3,000to3,000to5,000, and CAT is a little bit more, 4,000to4,000to6,000.

Q4: Can I ask the supplier to fix minor issues before shipping?

A: Yes, you can. Usually, the better suppliers like HIXEN take care of small repairs like that before they ship it. They want you to get a good machine, but make sure to ask before you finalize the purchase.

Q5: How do I estimate repair costs if I can’t inspect in person?

A: Ask for detailed video inspections, with a checklist. Also ask for who maintained it, the service records, and if they have photos they can send you. The more they can tell you, the better you can develop a plan and budget accordingly.

Conclusion

It doesn’t have to be a huge money pit to repair a used excavator. The key is knowing what you’re getting into beforehand. You do that by inspecting it beforehand, and looking at things a couple of different ways. It might be something simple, but if you don’t check it before you buy, it’s your problem once you own it.

Get those detailed inspections. Make sure the guys are shooting you videos in real-time, not just sending you old videos. Talk about any issues before you buy it. If I’m buying this machine, then this is a repair; I need to know about it before I buy it. Also talk to your supplier about repair costs and if they will work with you to fix any issues before the machine gets to you.

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