Why Repair Instead of Replace?
Many motors fail prematurely from problems that are easily repairable - bearing failure, winding insulation breakdown, rotor issues. These motors have decades of useful life remaining if properly repaired. Replacement should be the last option, not the first.
💵 Repair vs. Replace Cost Comparison
| Motor Size | New Motor Cost | Typical Repair Cost | Your Savings |
|---|---|---|---|
| 5 HP | $800-1,200 | $400-600 | $400-600 (50%) |
| 25 HP | $2,500-3,500 | $1,000-1,800 | $1,200-2,000 (50%) |
| 50 HP | $4,500-6,500 | $1,800-3,000 | $2,500-3,500 (50%) |
| 100 HP | $8,000-12,000 | $3,000-5,500 | $4,500-7,000 (50%) |
| 250 HP | $20,000-30,000 | $7,000-12,000 | $10,000-18,000 (50%) |
Plus: Repaired motors often last 15-20 years with proper maintenance. You're not just saving money today - you're getting decades more service.
Additional Advantages of Repair:
- Faster Than Ordering: Most repairs completed in 3-7 days vs. weeks for new motor delivery.
- Perfect Fit: Your repaired motor drops right back in. No mounting modifications needed.
- Environmentally Responsible: Reduces waste and preserves resources.
- Tax Benefits: Repairs are typically fully deductible in year incurred vs. depreciation schedule.
- Preserves Rare Motors: Obsolete or special motors that can't be replaced must be repaired.
Motor Types We Repair & Rewind
We service all motor types and brands - if it has windings, we can rewind it:
AC Induction Motors
Types:
- Single-phase (1/4 HP - 10 HP)
- Three-phase (1/2 HP - 500 HP)
- TEFC (Totally Enclosed Fan Cooled)
- ODP (Open Drip Proof)
- TENV (Totally Enclosed Non-Ventilated)
Common Repairs: Rewind, bearing replacement, rotor repair, shaft machining
Explosion-Proof Motors
Classes: Class I Div 1 & 2, Class II, Class III
Groups: C, D, E, F, G
Specialized rewind procedures maintain UL/CSA listings. Proper clearances, flameproof joints, and approved materials.
Severe Duty Motors
Applications:
- Mining & aggregate
- Sawmills
- Washdown environments
- High vibration
- Inverter duty
Built to withstand harsh conditions with heavier construction and better insulation systems.
DC Motors
Types:
- Shunt wound
- Series wound
- Compound wound
- Permanent magnet DC
- Brushless DC (BLDC)
Services: Armature rewind, field coil rewind, commutator service, brush replacement
Brake Motors
AC motors with integrated electromagnetic brakes for instant stopping.
Services: Motor rewind, brake adjustment, brake coil replacement, spring replacement, friction disc service
High Voltage Motors
Voltages: 2300V, 4000V, 4160V, 6900V, 13,200V
Specialized insulation systems (VPI, resin-rich), surge testing, and high-pot testing. Form-wound coils for larger motors.
Wound Rotor Motors
Slip-ring motors for variable speed or high starting torque applications.
Services: Stator rewind, rotor rewind, slip ring service, brush holder repair, carbon brush replacement
Gearmotor Units
Motors with integrated gearboxes.
Services: Motor repair/rewind, gearbox inspection, oil change, seal replacement, gear inspection, complete unit testing
Our Complete Repair Process
Every motor repair follows our proven 10-step process to ensure quality results:
Inspection & Diagnosis
Thorough examination to identify all problems, not just symptoms.
- Visual inspection for obvious damage
- Insulation resistance test (megger)
- Continuity testing of all windings
- Bearing condition assessment
- Shaft runout measurement
- Frame condition check
- Nameplate verification
- Photograph all damage
- Document findings on inspection report
Written Quote & Approval
Detailed quote with all recommended work clearly explained.
- Itemized pricing for each repair
- Explanation of problems found
- Repair vs. replace recommendation
- Estimated completion time
- Alternative options if applicable
- No work begins until you approve
Disassembly & Parts Removal
Careful disassembly to preserve reusable components.
- Remove all external components (junction box, conduit fittings, mounting hardware)
- Mark end bell positions for proper reassembly
- Remove bearings using proper pullers
- Extract rotor carefully to avoid damage
- Remove old windings if rewind needed
- Clean and inspect all parts
- Identify parts needing replacement
Stator Core Preparation
Prepare stator for new windings if rewind required.
- Burn-out or Chemical Strip: Remove old windings (chemical stripping preferred for better insulation preservation)
- Core Testing: Verify core integrity with core loss tester
- Slot Cleaning: Remove all old varnish and insulation residue
- Inspection: Check for damaged laminations, corrosion, loose core
- Repair: Address any core damage before rewinding
Precision Rewinding
Wind new coils to exact OEM specifications.
- Winding Data: Use original winding data or calculate from motor parameters
- Wire Selection: Correct gauge magnet wire, insulation class (Class F or H typical)
- Slot Insulation: Install appropriate slot liners
- Coil Winding: Wind coils using computer-controlled winding machine for consistency
- Coil Installation: Insert coils into stator slots
- Wedge Installation: Secure coils with proper wedges
- Lead Connections: Wye or delta configuration per nameplate
- Lead Support: Proper lacing and bracing
Varnish Treatment (VPI)
Vacuum Pressure Impregnation for superior insulation.
- Pre-heat: Remove moisture from windings
- Vacuum Stage: Remove air from between turns
- Varnish Flood: Flood winding with insulating varnish under vacuum
- Pressure Stage: Force varnish deep into winding
- Bake: Cure varnish at controlled temperature
- Result: Monolithic winding with excellent moisture resistance and mechanical strength
Rotor Service
Inspect and repair rotor assembly.
- Squirrel Cage Rotors: Check for broken bars, inspect end rings, test for core problems
- Wound Rotors: Rewind if needed, service slip rings, check connections
- Shaft Inspection: Check for wear, scoring, bending
- Shaft Repair: Machine or repair as needed, build up worn areas with metalizing
- Key/Keyway: Inspect and repair
- Dynamic Balance: Balance rotor to ISO standards (typically G2.5 or G6.3)
Frame & Component Reconditioning
Restore frame and associated parts.
- Bearing housing inspection and repair
- Bearing fit verification (proper press fit critical)
- Frame straightening if needed
- Mounting holes/threads repaired
- Sandblast and paint frame
- Fan cleaning or replacement
- Fan cover repair
- Junction box recondition
Assembly & Testing
Reassemble motor and verify performance.
- Bearing Installation: Install new bearings with proper heat/press methods
- Reassembly: Install rotor, align end bells, torque all fasteners per spec
-
Electrical Testing:
- Insulation resistance (megger): Verify >100 megohms typically
- Surge test: Identify turn-to-turn faults
- Hi-pot test: Verify insulation integrity at 2x voltage + 1000V
- Continuity: Check all phases balanced
- No-Load Run Test: Run motor without load, check current draw, noise, vibration, temperature
- Load Test: Apply load if possible, verify performance matches nameplate
Final Inspection & Documentation
Quality check and provide complete records.
- Final visual inspection
- Verify all tests passed
- Create new nameplate if original damaged
- Rotation direction verification and marking
- Touch-up paint as needed
- Package for shipment/pickup
-
Documentation Provided:
- Test report with all measurements
- Before/after photos
- Parts replaced list
- Warranty certificate
- Maintenance recommendations
Common Motor Failure Causes
Understanding why motors fail helps prevent repeat failures:
Bearing Failure
Causes: Over-greasing, under-greasing, misalignment, contamination, wrong bearing type, excessive radial/axial load
Prevention: Proper lubrication schedule, laser alignment, proper coupling selection, vibration monitoring
Winding Insulation Failure
Causes: Overheating (overload, poor ventilation, phase loss), moisture contamination, voltage spikes, age degradation
Prevention: Proper ventilation, surge protection, moisture seals, load monitoring, VFD filters
Rotor Problems
Causes: Broken rotor bars, damaged end rings, excessive starting cycles, mechanical impact, poor casting quality
Prevention: Reduce start frequency, soft starters, proper motor sizing, avoid mechanical shock
Shaft & Mechanical
Causes: Shaft bending, keyway damage, shaft wear, loose rotor, bearing failure cascade
Prevention: Proper alignment, avoid side loads, correct coupling type, proper mounting
Contamination
Causes: Dust ingress, moisture, chemical exposure, oil/grease on windings
Prevention: Proper enclosure type (TEFC vs ODP), environmental seals, regular cleaning
Other Causes
Electrical supply problems (voltage imbalance, harmonics), improper installation, manufacturing defects, operating outside design parameters
Repair Turnaround Times
| Service Type | Standard Turnaround | Rush Service |
|---|---|---|
| Rewind Only (fractional - 25 HP) | 3-5 days | 24-48 hours |
| Rewind Only (25-100 HP) | 5-7 days | 2-3 days |
| Rewind Only (100-500 HP) | 7-10 days | 3-5 days |
| Complete Rebuild (rewind + bearings + shaft) | 5-10 days | 3-5 days |
| Bearing Replacement Only | 1-2 days | Same day |
| Testing & Evaluation Only | 1-2 days | Same day |
| Explosion-Proof Rewind | 7-14 days | 4-7 days |
| DC Motor Rewind (armature + field) | 7-10 days | 3-5 days |
Rush Service Premium: 50-100% surcharge depending on urgency. Available 24/7 for critical equipment.
Motor Repair Pricing
Pricing varies based on motor size, type, and extent of damage. Here are typical ranges:
Standard AC Motor Rewind Pricing:
| Motor Size | Rewind Only | Complete Rebuild |
|---|---|---|
| 1-5 HP | $300-600 | $500-900 |
| 5-10 HP | $500-900 | $800-1,400 |
| 10-25 HP | $800-1,500 | $1,200-2,200 |
| 25-50 HP | $1,200-2,500 | $1,800-3,500 |
| 50-100 HP | $2,000-4,000 | $3,000-6,000 |
| 100-200 HP | $3,500-7,000 | $5,000-10,000 |
| 200-500 HP | $6,000-15,000 | $9,000-20,000 |
Specialty Motor Pricing Multipliers:
- Explosion-Proof: Add 25-40% to standard pricing
- High Voltage (>600V): Add 30-50% to standard pricing
- DC Motors: Add 20-35% to standard pricing
- Wound Rotor: Add 40-60% to standard pricing
- Severe Duty: Add 15-25% to standard pricing
Additional Services:
| Service | Price Range |
|---|---|
| Bearing Replacement (per bearing) | $75-300 + bearing cost |
| Shaft Machining/Repair | $200-800 |
| Dynamic Balancing | $150-500 |
| Load Testing | $200-600 |
| Vibration Analysis | $150-400 |
| Frame Repair/Straightening | $300-1,500 |
| Sandblast & Paint | $200-800 |
Our Warranty
What's Covered (1 Year)
- Rewinding workmanship
- Insulation system
- All installed parts
- Bearing installation
- Shaft repair work
- Assembly procedures
- Testing accuracy
- Mechanical repairs
What's NOT Covered
- Misuse or abuse
- Operating outside nameplate ratings
- Improper installation after pickup
- Lightning or power surge damage
- Contamination after delivery
- Accidents or external damage
- Normal bearing wear (unless premature)