The way to keep downtime short is to finish beforehand every job that can be done before the machine stops. The new motor's dimensions are verified, adaptation parts are prepared, the team and lifting equipment are arranged; the downtime is then left only for removal, fitting, alignment and a test run.

DRG-180M-4 18.5 kW 1500 rpm cast iron frame DRG three-phase motor – motor replacement downtime planning

Things to do before the shutdown

  • Compare the shaft height, foot holes, shaft diameter and length, and flange dimensions of the old and new motor.
  • If there is a difference, machine an adapter plate, pulley bush or coupling hub in advance.
  • Determine lifting equipment suited to the motor's weight and the access route.
  • Bring the new motor to site, unpack it and compare its nameplate with the order.
  • Have qualified staff assess the state of the electrical connection in advance.

Work sequence during the shutdown

  1. Power is switched off and locked out.
  2. The pulley or coupling is removed and the old motor is lifted out.
  3. The new motor is put in place and the pulley or coupling is fitted.
  4. Alignment and belt tension are checked.
  5. The connection is made, and the direction of rotation and test run are observed.

Connection and protection settings depend on the motor nameplate, the manufacturer's documentation and the assessment of qualified electrical staff.

Common problems that extend the time

A rusted pulley that will not come off, a shaft diameter mismatch, base holes that do not line up and the lack of crane access are the most frequent causes of delay. Noting these from previous replacements makes the next plan more realistic.

Enter the labour in the cost table

Team hours, crane hire and any out-of-hours work should be calculated as separate rows alongside the motor price. If the new motor is collected by appointment from the DRG warehouse in Buca, Izmir, the shipping cost disappears; otherwise the shipping charge is confirmed in writing before payment.

For dimensional verification you can use the technical drawing page and compare the models you are considering for the replacement in the three-phase motor list in the shop.