Winch Unit Inspection

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.

Inspect the commutator for a shot circuit.

1. 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.
   

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.)

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

Standard diameter:

43 mm (1.69 in.)

Minimum diameter:

41 mm (1.61 in.)

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.)

Inspect for an open circuit.

1. 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.
   

Inspect the shunt coil for an open circuit.

1. 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.
   

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

Standard length:

22 mm (0.87 in.)

Minimum length:

15 mm (0.59 in.)

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)

HINT:

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

Inspect for an open circuit.

1. 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.
   

Turn each bearing by hand while applying inward force.
If the bearing sticks or resists, replace it.