Description
Rewind, repair, and rebuild AC/DC electric motors by removing and replacing windings; apply insulation and varnish processes; reassemble, balance, and test motors to meet specifications.
- • Read work orders, schematics, and nameplate data to determine rewind specifications.
- • Inspect and test motors to locate winding or insulation faults using ohmmeters, megohmmeters, and surge testers.
- • Measure voltage, amperage, resistance, rpm, and current draw to diagnose performance issues.
- • Disassemble motors and remove rotors or armatures and end bells using hand and power tools.
- • Document coil data including wire size, turns, pitch, and connections before strip-out.
- • Strip old windings and remove slot wedges and insulation; clean and prepare cores.
- • Perform core loss and lamination short tests; repair or replace damaged iron as required.
- • Cut, form, and install slot liners, phase insulation, and wedges.
- • Wind replacement coils on coil-winding machines to specified dimensions and turns.
- • Form, insert, and connect coils in stator or armature slots per schematics.
- • Braise or solder leads and terminations; sleeve and insulate all joints.
- • Lace and tie windings; apply blocking and bracing to secure coils.
- • Impregnate windings by dip-and-bake or VPI and cure per specifications.
- • Machine, true, and undercut commutators; dress and polish slip rings.
- • Replace bearings, seals, and brushes; lubricate moving parts.
- • Verify and set shaft endplay, bearing fits, and air gap clearances.
- • Dynamically balance rotors and correct unbalance.
- • Reassemble motors and torque fasteners to specification.
- • Perform insulation resistance, hipot, and surge tests; verify polarity and phasing.
- • Test run motors and record no-load current, vibration, temperature, and rpm.
- • Troubleshoot and correct wiring connections, including wye/delta and lead markings.
- • Label and tag leads; provide connection diagrams as required.
- • Maintain inventory of magnet wire, insulation materials, varnish, wedges, bearings, and brushes.
- • Use cranes or hoists to move motors safely; signal operators as needed.
- • Record repairs performed, parts used, test results, and labor time.
- • Maintain rewind tools and equipment; set machine parameters using computer controls as needed.
- • Follow safety procedures, including lockout/tagout and proper handling of solvents and varnishes.
- • Clean housings, shafts, and end bells by scraping, washing, and buffing as required.
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This site includes information from O*NET by the U.S. Department of Labor, Employment and Training Administration (USDOL/ETA), used under the CC BY 4.0 license. Career Clutch has modified some of this information for student readability. USDOL/ETA has not approved, endorsed, or tested these modifications. O*NET® is a trademark of USDOL/ETA.
Last reviewed: Jan 2026
