Signs Your Motor Needs Rewinding (Before It Fails)

Know the signs before failure. Keep operations running smoothly.

Electric motors are the backbone of industrial operations—and when one goes down unexpectedly, everything stops. Downtime costs money, delays projects, and puts unnecessary strain on your team. The good news? Most motor failures don’t come out of nowhere. Your equipment gives warnings long before the windings give out.

Knowing the early signs can help you make informed decisions, schedule repairs ahead of time, and extend the life of your equipment.

Here’s what to watch for.

Common Warning Signs Your Motor May Need Rewinding

1. Unusual Noises or Vibrations

If a motor that’s normally smooth starts making humming, grinding, or buzzing noises, it may be a sign of internal electrical imbalance. Excessive vibration can also indicate winding issues, especially when bearings and alignment have already been ruled out.

2. Overheating or Running Hot

Windings deteriorate as temperatures rise. If your motor is consistently running hotter than usual—or shutting down due to thermal overload—it’s time to investigate the condition of the windings.

3. Reduced Performance or Torque

A drop in power, lagging startup, or inconsistent speeds can signal weakened windings. As insulation breaks down, the motor struggles to deliver the torque needed for normal operation.

4. Tripped Breakers or Electrical Faults

Frequent breaker trips, blown fuses, or unexplained electrical issues often point to shorted windings. These kinds of faults escalate quickly, so they should never be ignored.

5. High Energy Consumption

If energy use is climbing but output hasn’t changed, your windings may be losing efficiency. Damaged or deteriorating coils force the motor to work harder—driving up power costs.

Common Causes of Winding Failure

Understanding why windings fail can help you prevent the issue from recurring.

Thermal Stress

Continuous overheating is the leading cause of winding damage. Poor ventilation, overloaded motors, or high ambient temperatures accelerate insulation breakdown.

Contamination

Dirt, moisture, chemicals, and dust can seep into the motor, weakening insulation and causing short circuits over time.

Overloading

Running a motor beyond its designed load—even occasionally—puts excessive strain on the windings.

Vibration & Mechanical Issues

Loose parts, misalignment, or worn bearings increase vibration, which can cause winding insulation to crack or shift.

Age & Wear

Even well-maintained motors experience natural degradation. Over years of operation, insulation becomes brittle and less reliable.

Rewind or Replace? How to Decide

When windings fail, you have two options: rewind the motor or replace it entirely. Here’s how to choose.

Rewind When:

• The motor has a high-quality frame and core

• Replacement parts are hard to find or have long lead times

• The motor is part of legacy equipment that still performs well

• The damage is limited to the windings

• A rewind will restore it to original efficiency (or better)

  
  

Replace When:

• The motor has severe mechanical damage (shaft, bearings, frame)

• The core is compromised or overheated beyond repair

• Efficiency upgrades justify a new model

• The cost of rewinding outweighs the cost of a new motor

• The motor is small, low-value, or nearing end-of-life

If you’re not sure, our team can assess your motor and give you a clear, cost-effective recommendation.

Stay Ahead of Motor Failure

Catching winding issues early helps prevent costly downtime, emergency repairs, and lost productivity. Routine inspections and preventative maintenance ensure your equipment stays reliable and safe.

At Academy Pump and Motor, our technicians specialize in electric motor rewinding, repair, replacement, and full-service diagnostics for residential and industrial applications across Western Canada.

Keep your operations running smoothly. Visit academypump.ca#MotorRepair #PreventativeMaintenance