Vw H w

Over Heating Warning light

Control switch

DISASSEMBLY

1. Disassemble the parts in the numerical order shown in the figure.

Fig. 10-126

1 Connector Cover

2 Magnet Switch Cover

3 Terminal Plate

4 Field Coil Lead Wire Set Nut

5 Base Set Bolt 6. Lead Wire

7 Magnet Switch

8 Connector

9 Base

2. Disassemble the parts in the numerical order shown in the figure.

Fig. 10-127

1.

Motor Cover

2

0 Ring

3

Brush

4

Commutator End Frame

5

0 Ring

6

End Frame

7

Fig. 10-128

Fig. 10-129

Take off the brushes and remove the screw.

Take off the brushes and remove the screw.

Measure the armature shaft thrust clearance. Thrust clearance:

0.05 - 0.50 mm (0.0020 - 0.0197 in.) Thrust washer thickness: 1.6 mm (0.063 in.)

Fig. 10-130

FiiS

INSPECTION & REPAIR

Armature Shaft

Check for wear or damage.

Fig. 10-131

Fig. 10-131

Bearing

1. Check to see that there is no drag on the bearing when it is turned with force.

2. Replace the bearing.

(1) Remove the bearing with SST. SST [09611-12010]

(2) Install the bearing with a press.

Fig. 10-134

Fig. 10-134

(3) Check the bearing condition.

Fig. 10-135

Fig. 10-135

Commutator

Check for following items and repair or replace.

1. Dirty or burnt surface.

Correct by sandpaper if necessary.

Fig. 10-136

2. Depth of segument mica. Mica depth:

STD 0.7 mm

Fig. 10-137

Fig. 10-137

3. Correct with a hacksaw blade.

After correcting, eliminate chips using sandpaper.

Fig. 10-138

Fig. 10-138

4. Smooth out the edge with a hacksaw blade.

Fig. 10-139

Fig. 10-139

5. Use #400 sandpaper.

Fig. 10-140

6. Measure the runout. Runout:

STD 0.05 mm

Fig. 10-141

Fig. 10-141

7. Surface wear: If below the limit, replace armature.

Outer diameter: STD 43 mm

Fig. 10-142

Fig. 10-142

Armature Coil

1. Ground test

Check commutator and armature coil core. If there is continuity, armature is grounded and must be replaced.

2. Open circuit test

Check for continuity between the segu-ments.

If there is no continuity at any test point, there is an open circuit and armature must be replaced.

Field Coil

1. Open-circuit test

Check for continuity between lead wire and field coil brush soldered connection. If there is no continuity, there is an opencir-cuit in field coil and it should be replaced.

2. Ground test

Check for continuity between field coil end and field frame.

If there is continuity, repair or replace field coil.

Fig. 10-146

Fig. 10-147

Fig. 10-148

Fig. 10-149

Thermo Switch

Check for continuity shown in the figure.

Brush

Measure brush length and replace if below limit.

Brush length: STD 22 mm

Fig. 10-148

Fig. 10-149

Brush Spring

Measure the brush spring load with a pull scale.

If the reading is below standard, replace the spring.

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

Brush Holder

Check insulation between (—) brush holder and (+) brush holder. Repair or replace if continuity is indicated.

Fig. 10-150

Fig. 10-151

Fig. 10-151

Fig, 10-152

Fig. 10-153

Fig. 10-153

Magnetic Switch

1. Push in plunger and release it.

Plunger should return quickly to its original position.

2. Check for continuity.

3. Check for no continuity.

4. Push in the plunger until it stops. Check for continuity

Perform a switch operation test after assembling it to the motor.

ASSEMBLY

1. Assemble the parts in the numerical order shown in the figure.

Fig. 10-154

1. Armature

2 End Frame

4 Commutator End Frame

5. Brush

6 0 Ring

7. Motor Cover

Fig. 10-155

Align yoke dowel with center bearing hole.

Fig. 10-156

Fig. 10-156

Align yoke edge dowel with groove on commutator end frame.

Fig. 10-157

Apply retaining compound to the bolts.

Fig. 10-158

Fig. 10-158

Recheck armature shaft thrust clearance. Thrust clearance:

0.05 - 0.50 mm (0.0020 - 0.0197 in.) Thrust washer thickness: 1.6 mm (0.063 in.)

2. Assemble the parts in the numerical order shown in the figure.

Fig. 10-159

Fig. 10-159

1. Base

2. Connector

3. Lead Wire

4. Magnet Switch

5. Base Set Bolt

6. Field Coil Lead Wire Set Nut

7. Terminal Plate

8 Magnet Switch Cover

9. Connector Cover

10-170

INSTALLATION

Install the parts in the numerical order shown in the figure.

Fig. 10-160

10-170

1. Rear Base Member

2 Winch with Rear Base Member

4 Wiring Harness

5. Connector

6. Negative Battery Terminal

7. Wire

8 Housing Cover

Fig. 10-161

Fig. 10-161

fl^l

Temporarily install the rear base member.

Fig. 10-162

Fig. 10-162

Fig. 10-163

Install the winch mounted on the rear base member through a spacer to the frame.

Fig. 10-163

Install the winch front mounting bolt and temporarily tighten.

Fig. 10-164

Fig. 10-164

Tighten the rear base member mounting bolts. Tightening torque: 5.0 — 8.0 kg-m (37 - 57 ft-lb)

Fig. 10-165

Fig. 10-165

Tighten the winch front mounting bolts.

Tighten the winch front mounting bolts.

Fig. 10-166

Fig. 10-166

Check the clearance between the rear base member and winch rear mount. If there is clearance, insert shims.

Fig. 10-167

Fig. 10-167

Tighten the winch rear mounting bolts.

Tighten the winch rear mounting bolts.

Fig. 10-168

Fig. 10-168

Align the protrusion and groove, and install the motor.

Fig. 10-169

Fig. 10-169

Tighten the motor mounting bolts.

Tightening torque: 1.5 — 2.0 kg-m (11 — 14 ft-lb)

Fig. 10-170

5-10 mm

Tighten the motor mounting bolts.

Tightening torque: 1.5 — 2.0 kg-m (11 — 14 ft-lb)

Fill with about 2 litters of automatic transmission fluid.

Fluid ATF Type F

Fig. 10-171

Fig. 10-171

Insert the cable into the drum hole, install the cable lock plate and tighten the bolts.

Fig. 10-172

Fig. 10-172

Insert the cable into the drum hole, install the cable lock plate and tighten the bolts.

Shift the lever to the lock position.

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