Die Cast Hydraulic and Mechanical Maintenance Engineer

Job Title: Die Casting Hydraulic & Mechanical Maintenance Engineer Location: Top Die Casting: 13910 Dearborn Avenue South Beloit Illinois 61080 Department: Maintenance / Operations Reports To: Maintenance Manager / Plant Manager Employment Type: Full-Time

Position Summary:

We are looking for a highly skilled and hands-on Hydraulic & Mechanical Maintenance Engineer with experience in aluminum die casting equipment and all associated secondary machinery. This role is essential to ensuring maximum uptime, performance, and reliability of the entire die casting cell, including shot end systems, hydraulic circuits, trim presses, robots, ladles, extractors, spray systems, temperature control units (TCUs), hot oil units, and material handling equipment.

The ideal candidate will have an expert-level understanding of hydraulic and mechanical systems, preventive and predictive maintenance programs, troubleshooting, and the integration of auxiliary equipment within die casting operations.

Key Responsibilities:

Hydraulic & Mechanical System Maintenance

• Diagnose, repair, and maintain hydraulic and mechanical systems on high-pressure die casting (HPDC) machines (e.g., Buhler, Die Cast Press, etc.).
• Inspect and troubleshoot hydraulic circuits, accumulators, pumps, valves, manifolds, cylinders, and servo systems.
• Perform preventive maintenance (PM) and predictive diagnostics to reduce unplanned downtime.
• Monitor and adjust hydraulic shot systems (shot sleeve, piston rings, intensifier systems) for performance and wear.
• Maintain and repair toggle and locking systems, platen guides, tie bars, and other structural machine components.

Secondary Equipment Expertise

• Troubleshoot and maintain all secondary machinery used in the die casting cell:
• Trim presses (hydraulic and mechanical)
• Robots (ABB.) for part extraction or spray
• Spray systems (automatic and manual)
• Ladles and extractors
• Temperature control units (TCUs)
• Conveyors, blow-off stations, part cooling stations
• Leak testers, vision systems, deburring equipment
• Calibrate and maintain lube systems for die and plunger tip lubrication.

Root Cause Analysis & Troubleshooting

• Quickly identify root causes of mechanical failures, downtime, or quality defects caused by mechanical or hydraulic issues.
• Document failures and corrective actions to ensure knowledge retention and process improvement.

Installation & Continuous Improvement

• Support installation, commissioning, and integration of new die casting and secondary equipment.
• Recommend and implement equipment upgrades, redesigns, and reliability improvements.
• Participate in cross-functional improvement teams with Engineering and Production.

Documentation & Safety

• Maintain detailed maintenance logs, machine repair history, and PM checklists.
• Ensure all machinery complies with safety regulations (lockout/tag out, guarding, etc.)
• Read and interpret technical manuals, hydraulic schematics, mechanical drawings, and OEM documentation.

Qualifications:

Education & Experience:

• Associate's or Bachelor's degree in Mechanical Engineering, Industrial Maintenance, or related field preferred.
• 5+ years of experience in mechanical/hydraulic maintenance in a high-pressure aluminum die casting environment.

Technical Skills:

• Deep understanding of hydraulic systems, fluid power theory, and mechanical machine components.
• Ability to read and interpret hydraulic and pneumatic schematics.
• Familiarity with die casting machinery and secondary systems common in automotive or industrial casting plants.
• PLC diagnostic capability is a plus (Allen-Bradley, Siemens, BRX, etc.).
• Welding, machining, and fabrication skills are a plus.
• CMMS experience for maintenance tracking.

Soft Skills:

• Strong analytical and troubleshooting ability.
• Excellent communication and documentation skills.
• Hands-on, proactive, and team-oriented mindset.
• Ability to manage multiple priorities in a fast-paced manufacturing environment.

Work Environment & Physical Requirements:

• Plant floor-based role with exposure to heat, noise, molten metal, and moving equipment.
• Ability to lift up to 50 lbs., bend, climb, and perform mechanical work in tight spaces.
• Willing to support off-shift and weekend work when urgent repairs are needed.

Preferred Certifications:

• Fluid Power Certification (IFPS)
• OSHA 10/30 Hour Certification
• Industrial Maintenance Certifications or OEM Training (e.g., Buhler, ABB)

Compensation & Benefits:

• Competitive salary based on experience
• Full benefits package (Medical, Dental, Vision, 401(k), etc.)
• Paid vacation and holidays
• Training and career development opportunities

Apply Today: [Email ... your resume and cover letter.) Join our team and become a key player in driving equipment reliability and operational excellence in our aluminum die casting operations.