Troubleshooting Common Faults for Bosch Rexroth 2AD Motors
Technical Error and Fault Guides19 August, 2026 | Bosch Rexroth 2AD fault codes, Indramat 2AD fault codes, Bosch Rexroth 2AD motor troubleshooting, Indramat 2AD motor repair, 2AD AC motor diagnostics, 2AD motor overheating, 2AD temperature sensor fault, 2AD NTC thermistor testing, 2AD blower failure, 2AD encoder fault, 2AD motor vibration, 2AD positioning error, 2AD motor feedback troubleshooting, Bosch Rexroth motor repair, Indramat motor replacement, 2AD132 motor, 2AD160 motor, 2AD164 motor
Bosch Rexroth Indramat 2AD Troubleshooting Guide
To receive a quote for repairing or replacing your 2AD motor, contact Wake Industrial by calling 1-919-443-0207, by sending an email to sales@wakeindustrial.com, or by filling out the quote form on this page. Bosch Rexroth Indramat 2AD motors operate as part of a complete drive system that includes a drive controller and machine control. The motor does not generate its own numbered fault codes. Instead, the connected controller displays diagnostic messages when it detects problems involving the motor encoder, encoder connection, winding-temperature sensors, or other monitored drive conditions.
For that reason, a controller code displayed while operating a 2AD motor should be interpreted using the documentation for the installed drive controller. The 2AD motor manual identifies the physical motor conditions that should be inspected after a diagnostic message, abnormal temperature reading, positioning problem, or vibration condition occurs.
Common 2AD 3-Phase Induction Motors
| Product Number | Mounting Style | Cooling Mode | Motor Feedback |
| 2AD160B-B05OB1-BS03-B2N1 | B05 flange mounting | Axial blower, blowing airflow | High-resolution motor encoder |
| 2AD132D-B35OB2-AS06-A2V1 | B35 flange and foot mounting | Axial blower, suction airflow | Digital servo feedback |
| 2AD160C-B35OB1-BS03-B2V1 | B35 flange and foot mounting | Axial blower, blowing airflow | High-resolution motor encoder |
| 2AD164C-B35OB1-BS06-H2N2 | B35 flange and foot mounting | Axial blower, blowing airflow | Digital servo feedback |
| 2AD132C-B05OL1-CS03-D2V1 | B05 flange mounting | Axial blower, blowing airflow | High-resolution motor encoder |
How Bosch Rexroth 2AD Motor Diagnostics Work
A 2AD motor is monitored through the drive controller and machine control. Encoder and thermistor failures may cause diagnostic or fault messages to appear on the controller, but the precise message depends on the controller and its software. The 2AD manual therefore organizes troubleshooting around observable motor conditions rather than universal F-codes. Most 2AD motor problems can be traced to one of five areas:
| Fault Area | Components to Inspect |
| Motor feedback | Motor encoder, encoder connector, encoder cable, shielding, and configured encoder data |
| Temperature monitoring | Active NTC thermistor, spare NTC thermistor, sensor wiring, and controller diagnostics |
| Forced-air cooling | Blower operation, rotation direction, airflow, cooling fins, and accumulated contamination |
| Internal motor mechanics | Bearings, shaft movement, housing condition, and internal mechanical damage |
| Machine connection | Motor mounting, coupling, shaft-mounted components, alignment, and component balance |
Do not assume that a displayed drive-controller code automatically proves the motor has failed. Wiring, controller parameters, cooling conditions, or the mechanical load can produce symptoms that appear to originate inside the motor.
Safety Steps Before Troubleshooting a 2AD Motor
Bring the drive to a controlled stop using the machine controls before beginning inspection. Switch off the power and control voltage to the drive controller, switch off the motor-protection device for the blower, and then turn off the machine’s main disconnect. Secure the machine against unintended movement and unauthorized restarting. Allow the electrical system’s required discharge time to expire before disconnecting cables. The motor and blower assembly must also be secured against falling or moving before mechanical connections are removed.
Do not perform maintenance while the machine is operating or while motor surfaces remain hot. Record the observed condition, operating state, controller message, motor type code, and corrective work performed.
2AD Temperature and Cooling Faults
Motor Housing Becomes Unusually Hot
| Possible Cause | What It Means | Corrective Action |
| Blower failure or heavy contamination | The required cooling air is not moving across the motor surface. | Verify blower operation and airflow. Clean the blower, screen, housing, and cooling fins. A failed blower requires service or replacement. |
| Processing cycle changed | Higher load, speed, acceleration, or duty-cycle demands may exceed the original motor sizing. | Compare the current machine cycle with the original drive design. Stop operation if the motor is overloaded. |
| Motor parameters changed | Incorrect motor or drive parameters can produce excessive loading or unstable operation. | Restore the original parameter values. Recalculate the drive requirements if the application has changed. |
| Worn or damaged motor bearings | Bearing friction can increase motor temperature and may be accompanied by rough rotation or noise. | Compare operating time with the applicable bearing and grease lifetime. With the system safely isolated, rotate the shaft slowly by hand and check for noise, resistance, or uneven movement. |
A 2AD motor must not be operated without its external blower. Cooling air is directed over the motor housing through the blower cowl, and restricted airflow can cause thermal overload even when the electrical system remains functional.
All blower configurations require at least 80 mm of unobstructed space at the blower intake or discharge area. The manual recommends a blowing airflow arrangement where the motor configuration permits it. Blower rotation and airflow direction should be checked before the motor is commissioned.
High Winding Temperature Reading With a Normal Housing Temperature
This condition occurs when the drive controller or control software reports an unusually high winding temperature while the physical motor housing remains at a normal temperature.
| Possible Cause | What It Means | Corrective Action |
| Temperature-sensor wiring error | The NTC circuit may be incorrectly connected. | Check the sensor wiring against the applicable connection diagram. Verify the terminal or connector assignments. |
| Broken sensor cable or conductor | An open circuit can produce an abnormal temperature value at the controller. | Inspect the sensor cable and connections for breaks, loose contacts, or physical damage. |
| Active NTC thermistor failure | The winding sensor may no longer provide the correct resistance value. | Disconnect the sensor circuit from the controller and test its resistance with a multimeter. Include the sensor cable in the measurement. |
| Controller diagnostic problem | The motor sensor may be functional while the controller processes the signal incorrectly. | Check the temperature-monitoring circuit and diagnostic functions of the drive controller or control. |
The 2AD winding contains two permanently installed NTC thermistors, although only one sensor is connected during normal operation. The second thermistor is provided as a spare. Polarity within an NTC wire pair does not affect sensor operation.
2AD Vibration and Mechanical Faults
| Possible Cause | Corrective Action |
| Shaft-mounted machine components are not adequately balanced. | Inspect and balance the connected components. Check the motor shaft and motor assembly for resulting damage. |
| Motor bearings are worn or defective. | Check for rough shaft movement, abnormal bearing noise, excessive play, or evidence that the bearing or grease lifetime has expired. |
| Blower-motor bearings are worn or defective. | Inspect the blower separately and determine whether the vibration originates in the blower assembly rather than the 2AD motor. |
| Motor mounting is loose. | Tighten the motor mounting correctly and inspect the flange, mounting points, and connected machine structure for damage. |
| Drive control is unstable. | Verify the configured motor data, encoder data, and applicable drive-system parameters. |
Persistent bearing noise, rough rotation, increasing vibration, or visible shaft damage should be treated as potential mechanical failure. Continued operation can increase damage to the bearings, encoder, shaft, or connected machine components.
2AD Position and Encoder Faults
| Possible Cause | Corrective Action |
| Encoder cable wiring is incorrect or damaged. | Check the cable and connector wiring against the connection plan. Look for switched encoder signals, damaged pins, broken conductors, or cable damage. |
| Encoder-cable shielding is inadequate. | Inspect the shield connection and increase the effective shield-contact area where necessary. |
| Incorrect encoder parameters are loaded in the drive controller. | Correct the configured encoder data and compare the settings with the commissioning record. |
| The motor-shaft connection to the machine is loose. | Inspect the coupling and other mechanical connections. Do not continue operating damaged components. |
| The motor encoder is defective. | Replace the encoder or motor as required after the cable, connection, shielding, and parameter settings have been eliminated as causes. |
Encoder troubleshooting should begin with the external cable and connections. Replacing the motor or feedback device before checking wiring, shielding, and controller configuration can leave the original problem unresolved.
The encoder interface on the controller and the encoder cable must also be compatible with the feedback option installed in the motor. The complete 2AD type code should be recorded before selecting a cable, encoder, or replacement motor. Contact Wake Industrial for premiere repair and replacement options.
Preventive Checks That Reduce 2AD Faults
| Maintenance Item | Recommended Interval |
| Check blower function and cooling-air circulation. | Follow the machine maintenance plan, but inspect at least every 1,000 operating hours. |
| Check mechanical and electrical connections. | Follow the machine maintenance plan, but inspect at least every 1,000 operating hours. |
| Check the motor for smooth operation, vibration, and bearing noise. | Follow the machine maintenance plan, but inspect at least every 1,000 operating hours. |
| Remove dust, chips, and contamination from the housing, cooling fins, and blower. | Clean according to contamination level, but no later than once per operating year. |
When a 2AD Motor Requires Repair
Professional inspection should be considered when the motor has worn or noisy bearings, rough shaft movement, persistent vibration, encoder failure, internal mechanical damage, or temperature problems that remain after the blower and sensor wiring have been checked. A motor with two failed winding-temperature sensors cannot be returned to normal monitored operation using the built-in spare-sensor arrangement.
Wake Industrial provides repair and replacement support for Bosch Rexroth Indramat 2AD motors and associated drive equipment. Call 1-919-443-0207, send an email to sales@wakeindustrial.com, or submit a quote request with the complete motor type code, controller diagnostic information, and a description of the operating symptoms.
Wake Industrial is sharing information sourced from the original manufacturer's manual. Please be advised that Wake Industrial does not offer troubleshooting assistance through phone or email. For repair, replacement, or refurbishment needs, we invite you to use our quote form or call us at 1-919-443-0207. It is the user's responsibility to exercise independent judgment and caution when implementing these instructions. Wake Industrial shall not be held liable for any direct, indirect, incidental, or consequential damages to products or individuals resulting from the use of this information.
Request a Quote
Cary, NC 27513
