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Retrofit Locomotive Engine

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A Midwestern manufacturer was using a locomotive to transfer a highly conductive material in an environment where ambient temperatures commonly reached 130+ F. The average duty cycle of the generator and drive motors was 4-6 hours. The customer was spending over $1,000,000 / year in replacement generator and drive motor parts alone. A crew of three worked 7 days a week 10-12 hours per day removing and replacing failed components. The environment was such that a hydraulic drive system was considered as an option, but duty cycle was still a concern due to the environment.


  • An exhaustive study of the application was done.
  • The equipment was observed in operation and production and maintenance personnel were consulted.
  • A system design was submitted and approved.
    • Total cost < $200,000
  • We consulted with customer maintenance personnel during installation and emphasized proper maintenance and troubleshooting of the system.


  • Main drive components have been in operation over 25,000 (twenty-five thousand) hours of operation without replacement.
  • Total maintenance cost of equipment is under $150,000 / year.
  • There is no longer a dedicated crew of drive motor & generator replacement workers.