WINCH UNIT INSPECTION


  1. INSPECT WINCH WIRE

    A015E7U

    1. Inspect the wire for the following damage: 1) areas where several strands are severed; 2) areas where the diameter is less than 7.5 mm (0.295 in.); 3) kinks; 4) corrosion; and 5) fraying.

      If the wire is damaged, replace it with a new one.

  2. INSPECT WINCH MOTOR ARMATURE SUB-ASSEMBLY


    1. Inspect the commutator for a shot circuit.


      1. A0158UG

        Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Commutator - Armature core Always 10 kΩ or higher

        If the result is not as specified, replace the armature sub-assembly.

    2. A0155S0

      Using a dial indicator, measure the circle runout of the commutator.

      Standard runout
      0.05 mm (0.0020 in.) or less
      Maximum runout
      0.2 mm (0.008 in.)

      If the circle runout is more than the maximum, correct it with a lathe.

    3. A01587R

      Using a vernier caliper, measure the diameter of the commutator.

      Standard diameter
      43 mm (1.69 in.)
      Minimum diameter
      41 mm (1.61 in.)

      If the diameter of the commutator is less than the minimum, replace the armature.

    4. A015DT3E01

      Check that the undercut depth is clean and free of foreign particles. Then smooth off the edge and measure the undercut depth.

      Standard undercut depth
      0.5 to 0.8 mm (0.020 to 0.031 in.)
      Minimum undercut depth
      0.2 mm (0.008 in.)

      If the undercut depth is less that the minimum, correct it with a hacksaw blade.

  3. INSPECT WINCH MOTOR YOKE SUB-ASSEMBLY


    1. Inspect for an open circuit.


      1. A015C0C

        Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Lead wire - Field coil brush lead Always 10 kΩ or higher

        If the result is not as specified, replace the winch motor yoke sub-assembly.

    2. Inspect the shunt coil for an open circuit.


      1. A015769

        Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Field coil brush lead - Field frame Always Below 1 Ω

        If the result is not as specified, replace the winch motor yoke sub-assembly.

  4. INSPECT WINCH MOTOR BRUSH


    1. A015E28

      Using a vernier caliper, measure the length of the brush.

      Standard length
      22 mm (0.87 in.)
      Minimum length
      15 mm (0.59 in.)

      If the brush length is less than the minimum, replace the brush.

  5. INSPECT WINCH MOTOR BRUSH SPRING


    1. A0159KG

      Using a pull scale, measure the installed load of the brush spring.

      Standard installed load
      16 to 20 N (1.6 to 2.0 kgf 3.6 to 4.4 lbf)

      Tech Tips

      Take the pull scale reading at the very instant the brush spring separates from the brush.

  6. INSPECT WINCH MOTOR BRUSH HOLDER ASSEMBLY


    1. Inspect for an open circuit.


      1. A0157B0

        Measure the resistance according to the value(s) in the table below.

        Standard Resistance
        Tester Connection Condition Specified Condition
        Positive (+) brush holder - Negative (-) brush holder Always Below 1 Ω

        If the result is not specified, replace the brush holder assembly.

  7. INSPECT NO. 1 WINCH MOTOR ARMATURE BEARING


    1. A015DPN

      Turn each bearing by hand while applying inward force.

      If the bearing sticks or resists, replace it.