Western States Equipment has made significant strides in rail maintenance technology. Since 2016, the team has worked to improve hi-rail excavator rail gear, starting with rented machines and evolving into custom-built solutions. The latest achievement is a newly engineered drive system that brings enhanced functionality, reliability, and cost-efficiency to the rail industry.

The journey began with a challenge from a railroad operator. While undercutting track ballast, the operator asked if the excavator could move slowly and steadily enough on hi-rail gear to avoid stalling the undercutter bar. The existing drive system couldn’t deliver the required hydraulic flow or consistent speed. After extensive testing and adjustments, it became clear that a complete redesign was necessary.

In 2023, Western States secured internal support to develop a new rail gear design. The team partnered with Rexroth Hydraulics to source a prototype vane-type motor capable of fine adjustments and increased torque. This motor became the foundation for a more capable and efficient drive system.

The design process focused on scalability and serviceability. The new system can be adapted to fit multiple excavator models, from the 310 to the 335, using consistent components. This approach simplifies maintenance and supports fleet consistency.

The new drive system includes several improvements based on years of customer feedback and field experience. Bearings are now greaseable and rebuildable, extending their lifespan and reducing costs. The system features three braking mechanisms—dynamic, service, and emergency—for added safety.

A limited slip valve ensures even power distribution to all wheels, enabling true four-wheel drive. Custom WSECO wheels with redesigned rail flanges offer longer life and better performance. The modular design allows for faster assembly and easier repairs, thanks to smaller, lighter components and thoughtful engineering.

The final design required several adjustments to support the increased torque and horsepower. Precision machining, careful component selection, and multiple rounds of assembly ensured the system met high standards for performance and durability.

The result is a product that delivers nearly double the torque and tractive effort compared to previous models. This achievement reflects the team’s dedication to creating a solution that is not only powerful but also practical and cost-effective.

The new drive system is a major milestone, but it’s not the end of the journey. Western States continues to innovate, guided by customer feedback and a commitment to excellence. With each new project, the team gains more insight and capability, ready to tackle the next challenge in rail maintenance.