07_Motor #2 Not at Maximum Displacement

April 2020 – Revision 01

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 Use of this Document
• Purpose
− This document will help guide you through troubleshooting an issue related to Motor #2 not being at maximum displacement.
• Codes associated with Motor #2 not at maximum displacement
− $1027 Motor #2 not at maximum displacement from ET Hystat Troubleshooting Test
− E575 – Unexpected drive motor forward speed detected
− E576 – Unexpected drive motor rearward speed detected
• Machine symptoms associated with Motor #2 not at maximum displacement
− Sluggish or erratic increase in speed.
− Machine has reduced pushing power at lower speeds

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 Troubleshooting Process

• Perform ET Hystat Troubleshooting Test

Step 1 • Confirm that there is an issue with M2 not at max displacement

• ET Transmission Pump & Motor Calibration

Step 2

• Component Troubleshooting
Step 3

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 • Step 1: Perform ET Hystat Troubleshooting Test
− This step will help confirm that the issue is related to Motor #2 not at maximum displacement.
− If you get code $1027 for Motor #2 not at maximum displacement, proceed to Step 2.
− If you get some other code or no code, follow recommended troubleshooting guides detailed in the ET Hystat
test guide or move to next logical troubleshooting steps based on machine conditions.

• Step 2: Perform ET Transmission Pump & Motor Calibration

− This will help rule out that a bad calibration is not the root cause
− If it passes without errors, confirm that the problem is resolved. If not, move to Step 3.
− If calibration does not pass, move to Step 3 unless error code conflicts with M2 not at max displacement.

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 Motor Servo Mechanism Cross Section & Labels
Controller assembly 455-7940
(includes spool, edge filters Control spool
and load shuttle)
Solenoid
threshold
adjustment
screw

Servo piston
Controller solenoid
487-6175 (solenoid assembly)
487-6180 (coil only)

Swash plate /
valve section

Barrel

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 Step 3.1a : Replace Controller Solenoid

• Remove the coil nut from the end of the solenoid pole tube. The nut should be able to
be removed by hand. If you are unable to remove by hand, gently remove with a pair of
pliers.
• Replace the solenoid coil 487-6175.
• The coil nut should be re-installed by hand and tightened to 2.5 to 4.5 Nm. DO NOT
over tighten the coil nut as this could cause the pole tube to seize.
• Once the coil is replaced, you will need to re-run the pump and motor calibration.
− If it fails with the errors 118C or 118B , you will need to follow the threshold
setting process detailed in Step 3.1b of this guide.
− If you pass the pump and motor calibration, you are done with this guide.
− If you do not pass the pump and motor calibration by following the
threshold adjustment process, continue to Step 3 in this guide.

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 Step 3.1b : Threshold Screw Adjustment
• The first step is to check that the solenoid threshold (start to move) setting is correct and has not changed over time:
• This troubleshooting will require that you run a pump and motor calibration. The machine needs to be prepared as such (driveshafts
removed or on stands etc.…).
• Without removing the solenoid or the controller mechanism from the motor, remove the cap off of the end of the solenoid. Under the cap is
an adjustment screw with a 3 mm hex. This is the threshold adjustment screw.
• Based on the code you received when running the pump and motor calibration, follow the procedure below.
• If you ran a pump and motor calibration and got either a 118F or 118B code, you will want to rotate the screw clockwise to lower the
threshold current.
− Start by marking with a pen or scribe the original orientation of the screw. When making any adjustments, keep up with the number of turns in which
direction so that the screw can be returned to the original orientation at the end of this process if needed.
− Start by rotating the screw 1 full turn counterclockwise.
− Re-run the pump and motor calibration.
▪ If it now passes without errors, you are done with this troubleshooting document.
▪ If it fails with the same 118F or 118B code, rotate the screw an additional ½ of a turn. Repeat pump and motor calibration and adjustment process
until it passes without errors.
▪ If you make an adjustment and now get the 1190 or 118B codes when you run the pump and motor calibration, you have gone too far. Back off
the screw slightly (clockwise) from your last adjustment and repeat the calibration until a passing result is achieved.
▪ If you have tried this process and made large adjustments to the adjustment with no success, return the threshold screw to the original
position and continue with this guide.

• If you ran a pump and motor calibration and got either 1190 or 118C codes, you will want to rotate the screw counterclockwise to
increase the threshold current.
− Use same process as above, rotating the screw clockwise to increase threshold current.
− If you have tried this process and made large adjustments to the adjustment with no success, return the threshold screw to the original
position and continue with this guide.
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 Step 3.2: Controller & Servo Inspections & Repair
• Remove the controller assembly (455-7940) from the motor without removing the solenoid.
− Remove the control spool and inspect for damage or contamination on the spool and mating bore. There should be no
evidence of scoring or gaulling on either the spool or bore.
▪ If there is damage, replace the entire controller assembly 455-7940, which will come with a new spool and body.
− Remove the edge filters and load shuttle from controller housing. Inspect for damage or debris blocking filters or effecting
shuttle function.
▪ Clean and re-install or replace entire controller mechanism 455-7940 if damaged. Note plug tightening torque
specifications in diagram.
− When re-installing any parts, clean with contact cleaner before re-installing to ensure the assembly is free from external
contamination. Edge Filters
− If controller mechanism looks OK, clean and re-install.

• Remove cover from opposing end of motor that houses the servo piston. Remove bolt from end of servo shaft
and extract servo piston.
− Inspect servo piston seals. If they are damaged, replace with seals included in the overhaul kit 487-6259 (motor #2) or
455-7956 (motor #2).
− Inspect piston and piston bore. Both parts should be free from gaulling, knicks, scratches etc. If either part is damaged,
replace entire motor.
− If part look good, clean and re-install the servo piston, bolt (200 to 220 Nm) and cover (bolts tightened to 105 to 115 Nm).

• If a repair is made, repeat pump and motor calibration. It may be necessary to repeat the threshold Load shuttle
adjustment in Step 3.1b if the controller mechanism was replaced.
• If no issues are found or a repair is made the pump and motor calibration fails, move to Step 3.3

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 Step 3.3 : Additional Motor Inspections
• Remove the motor from the machine.
• Dis-assemble the motor by splitting the case halves. Inspect the swash plate and barrel to ensure that they can move freely in
the housing. An example of something that would prevent the swash plate from moving freely would be a piece of debris lodged
between the swash plate and housing. Another example would be a piece of debris between the swash plate and cradle.
• If anything abnormal is found, repair if possible, using required serviced parts.
• If nothing is found, replace entire motor.
• Repeat pump and motor calibration after either a repair or replace of the motor.

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