How to Avoid Motor and Pump

Repairs with Preventative

Maintenance

At Mader Electric, Inc., we feel that one of the most important things
we can do for our customers is help them understand how to care and
maintain their equipment.

With proper care and maintenance, you can prevent many motor and
pump repairs and save yourself time and money. Here are just a
few ways to prevent having to spend unnecessary amounts of money
repairing your equipment.

7260 15th St E Sarasota, FL 34243 | (855) 430-7984 | www.maderelectricinc.com

 TABLE OF CONTENTS
Chapter 1:
What Causes an Industrial Pump to Malfunction?

Chapter 2:
What Can I do to Prevent my Industrial Pump
from Needing Repair?

Chapter 3:
What Causes a Motor to Malfunction or Fail?

Chapter 4:
What Can I do to Prevent my Motor From
Needing Repair?

Chapter 5:
How to Repair a Motor or Pump in Florida

7260 15th St E Sarasota, FL 34243 | (855) 430-7984 | www.maderelectricinc.com

 PUMPS
Chapter 1:
What Causes an Industrial Pump to Malfunction?

Explaining why an industrial pump malfunction happens helps you to prevent

such failures, and gives you more insight into the meaning of abnormalities in
pump operation.

Accidents
Accidents can be caused
by everything from employee
error to natural catastrophe,
and leave you vulnerable
to industrial pump malfunc-
tion. Some accidents can be
avoided through the
installation of guardrails
or protective cages, other
through training programs
offered onsite and at
certified training facilities.

Contamination
The use of incorrect or dirty lubrication fluids will cause interior degradation of
your pump system, causing it to malfunction more quickly than should be
expected in the normal course of operation. Periodic fluid changes and frequent
filter replacement will eliminate most industrial pump malfunction related to
contamination.

7260 15th St E Sarasota, FL 34243 | (855) 430-7984 | www.maderelectricinc.com

 PUMPS
Improper Maintenance
There is more to system maintenance than changing the filters and fluids, and
failure to keep your equipment in top working order will eventually lead to
mechanical failure. It is also important to lubricate joints, check belts for wear,
make sure that fasteners are properly torqued, and be on the lookout for leaks
that may indicate a problem is developing.

Surface Degradation
Corrosion and rust can lead to
the failure of any mechanical
device. To avoid this, keep all
surfaces free of dust, grime
and other potential contami-
nants. Periodically refinishing
or painting exposed surfaces
will help prevent rust and
corrosion.

Obsolescence
Regardless of how well you
take care of your
machinery, industrial pump
malfunction is likely going to
happen eventually. To avoid
costly downtime, keep records of equipment age and the expected life
expectancy of components. By routinely replacing parts that are nearing the
end of their expected usefulness, you will have less downtime and avoid the
costs associated with unexpected equipment failure.

7260 15th St E Sarasota, FL 34243 | (855) 430-7984 | www.maderelectricinc.com

 PUMPS
Chapter 2:
What Can I do to Prevent my Industrial Pump
from Needing Repair?

The most important way to avoid industrial pump repair is to take a proactive
approach, keeping on top of minor problems before they can escalate into
major ones. There are several types of maintenance approaches that will help
you avoid pump repair, including:

Continuous Diagnostic Maintenance

Keep records of your
regular diagnostics and
compare them to
determine when the
machinery is not
operating at full poten-
tial. Ongoing diagnos-
tics will contribute to the
effectiveness of your
preventive objectives.

Preventive
Maintenance
Regular lubrication,
checking the torque of bolts and other typical maintenance practices can
prevent industrial pump repair for long periods of time. Your diagnostic results
will help you determine where a problem may be developing, so that the correct
steps can be taken before equipment failure occurs.

7260 15th St E Sarasota, FL 34243 | (855) 430-7984 | www.maderelectricinc.com

 PUMPS
Reactive Maintenance
This type of maintenance plan is the least effective at avoiding industrial pump
repair because it delays action until a problem has already developed enough
to interfere with system functions. Some reactive steps will always be required
because some parts can fail without warning, but the primary goal should be to
avoid the reactive process when and where it can be avoided through
preventive and predictive practices.

Predictive Maintenance
All machinery has a calculated life span, and repairs or replacement will
eventually be required. By maintaining careful records of the age and expected
obsolescence date of your equipment, older parts can be scheduled for
replacement before they fail, keeping your machinery operating more efficiently
and eliminating most, but not all, equipment downtime.

By incorporating all four types into your regular maintenance plans, your
industrial pumps will last longer, perform better and you’ll avoid costly repairs.
Our customers rely on their pumps to perform optimally, and regular
maintenance is how they do it. There is no way to anticipate all pump failures
and industrial pump repair could become a priority without warning, but keeping
accurate records and making sure your equipment is operating within the
factory-designated guidelines will keep the repairs to a minimum.

When things go wrong, you can count on Mader Electric to be there when you
need us, but an effective, multi-stage maintenance plan allows you to keep most
of your industrial pump repair in-house. We understand that unexpected repairs
can be devastating to the bottom line of your operations, and encourage you to
take a proactive approach to avoid as much failure as possible.

7260 15th St E Sarasota, FL 34243 | (855) 430-7984 | www.maderelectricinc.com

 MOTORS
Chapter 3:
What Causes a Motor to Malfunction or Fail?
A working motor is crucial to a factory’s operation. When a motor malfunctions or
fails, it can cause major delays. To help avoid this, it is important that all motors
are inspected and maintained regularly to ensure that they are working properly.
If motor failure does occur, there are a few likely causes.

Low Insulation Resistance

When a motor is first installed
it typically has a resistance
level of over one thousand
megaohms. However as time
goes on, this resistance level
can begin to gradually
decrease. This results in poor
insulation performance, which
can eventually lead to motor
failure.

Overheating
Too much heat within the
motor can quickly lead to the deterioration of the
motor winding insulation. This can be caused by operating the motor in a high
heat environment or when the motor is started at a higher temperature than its
design temperature. Overheating can also occur if the motor operates in an
area without a proper cooling system in place.

7260 15th St E Sarasota, FL 34243 | (855) 430-7984 | www.maderelectricinc.com

 MOTORS
Electrical Overload
If for any reason the motor begins to draw in too much current for what its
capacity can handle, it can suffer from electrical overload. This can cause
serious issues within the motor. Fortunately, there are devices available which
will prevent excess currents from flowing into the motor.

Moisture
Moisture can wreak havoc on a
motor. Over time it can lead to the
corrosion of rotors, motor shafts
and bearings.

Dirt
When dirt is able to access the
inner workings of the motor, serious
damage can occur. If it gets onto
the motor winding, the insulating
value could be effected. Also, dirt
can build up around and block the
cooling fan, which can cause the
motor to overheat.

Vibration
It is difficult for any electrical component to stand up against vibration and this
stands true for motors as well. Vibration can lead to a number of issues within
the motor, which can cause it to malfunction. This can be due to several
reasons, but the main two are misalignment of the motor when it was first
installed and internal corrosion.

Motor failure can occur, but with the proper safeguards in place and with regular
maintenance you can help prevent it.

7260 15th St E Sarasota, FL 34243 | (855) 430-7984 | www.maderelectricinc.com

 MOTORS
Chapter 4:
What Can I do to Prevent my Motor From
Needing Repair?
Industrial electric motors are some of the most heavy duty units in the industry.
They are built to run at continuous levels with varied RPM’s, yet require very little
maintenance. Therein lies the key to prevent your motor from needing repair.
Motor repair can be expensive and time consuming, but incorporating some
preventative maintenance will keep your motor running for the long haul.

Cooling
Make sure that nothing is surround-
ing the area around the motor that
may prevent it from cooling itself.
Overheated motors are one of the
main causes of motor failure, so keep
the space around your motor free of
boxes, debris and other items that
may inhibit cooling.

Cleaning
Once again, keep the motor cooling ports or cooling fins clean, to allow airflow
into the motor. Dust, dirt, cobwebs and the like, can fill the cooling ports in a
motor causing it to overheat. Even something simple like a piece of paper or a
cloth draped over the motor may cause overheating. A simple brushing and
removing any foreign objects, done monthly, will eliminate this problem.

Lubrication
Many electric motors have sealed bearings which cannot be effectively lubricat-
ed. But if your motors have oil ports, they will need to be lubricated on a month-
ly basis. A few drops of bearing oil down into the petcock will keep your motor
running smooth. And while you’re at it, lube up the conveyor system at the axles,
if applicable. The easier your electric motor runs, the longer it will last.
7260 15th St E Sarasota, FL 34243 | (855) 430-7984 | www.maderelectricinc.com
 MOTORS
Chapter 5:
How to Repair a Motor or Pump in Florida
Even with routine maintenance and preventative care, you may inevitably
encounter an issue that requires repair of your pump or motor. You can avoid
replacement costs with in­-house motor and pump repair at Mader Electric, Inc.
With the proper tools, electric motors remain relatively easy to restore. Use the
following tips to get your motor running at full capacity. Alternatively, rely on
Mader Electric experts to provide affordable parts and services.

Testing
Disconnect all power
cords before testing
motors with a megger.
Readings at 0 or infinite
indicate a short affecting
one or more motor com-
ponents. Record motor
type, sizeand power
rating to find an identical
replacement.

Motor Gear
Repair
Inspect plastic/metal motor gears for noticeable chips and cracks. Reduction
and worm gears should be tightened together and replaced in pairs. Replace
broken gears, reassemble and perform final testing.

Motor Drive Repair

Adjust the setscrew where the shaft connects to the pulley. Tighten/loosen the
drive belt for optimal rotation. Replace worn or hardened belts and reassemble.

7260 15th St E Sarasota, FL 34243 | (855) 430-7984 | www.maderelectricinc.com

 MOTORS
Motor Fan Replacement
Access motor fan blades and inspect for damages that may cause uneven spin.
Prevent motor damage by replacing blades immediately.

Professional Motor Repair in Sarasota

Rely on Mader Electric's professional to perform fast, cost-­efficient motor and
pump repairs. We apply years of industry expertise to repair motors and vertical,
turbine, submersible pumps up to 4000hp.

All services work to keep your factory production on track. Contact us to reach a
company associate and learn about our state­of­the ­art training center and
custom class selection. We’ll schedule a convenient appointment to solve all
your factory needs.

7260 15th St E Sarasota, FL 34243 | (855) 430-7984 | www.maderelectricinc.com