traveller winch solenoid

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• User manual

TravellerX 10,000 Winch Manual

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Performance Specifications

Product overview, installation, replacing the cable, maintenance.

• Motor does not turn on
• Motor runs but cable drum does not turn
• Motor runs slowly or without normal power
• Motor overheating
• Motor runs only in one direction
• Winch braking malfunction

WINCH ASSEMBLY

Winch part list, safety precautions, line speed and motor current(first layer), line pull and cable capacity.

• Download manual
• 1 Performance Specifications
• 2 Product Overview
• 3 INSTALLATION
• 4 OPERATION
• 5 REPLACING THE CABLE
• 6 MAINTENANCE
• 7.1 Motor does not turn on
• 7.2 Motor runs but cable drum does not turn
• 7.3 Motor runs slowly or without normal power
• 7.4 Motor overheating
• 7.5 Motor runs only in one direction
• 7.6 Winch braking malfunction
• 8 WINCH ASSEMBLY
• 9 WINCH PART LIST
• 10 SAFETY PRECAUTIONS
• 11 Line speed and Motor current(First layer)
• 12 Line Pull And Cable Capacity
• 13.1 Download manual

Max Line Pull 10000lbs.(4536kgs)

Gear reduction ratio 253:1

Motor Series wound DC12V motor with 2.8hp output

Overall Dimensions 22.9in.( 582mm) L × 6.9in.( 175mm) W × 8.94in.( 227mm) H

Drum size 2.48in.( 63mm) D × 8.54in.( 217mm) L

Remote Controller Max control distance 30m

Rope 82ft.(25.0m) L of 25/64in.(10mm) D

Net weight 69.7lbs.(31.6kgs)

This winch is equipped with a series wound motor and is designed for intermittent duty general use. This winch is not to be used for industrial lifting or moving people.

Improper operation could damage the winch and void the warranty.

Free spool clutch is operated by a pull and turn knob, which disengages the gearbox, allowing the cable to be released.

Correct installation of the winch is required for proper operation.

• Mount the winch on the vehicle or other fixed installation by using a screw (M10 × 1.5 × 35mm), M10 nut, ∅10 flat washer and ∅10 spring washer (four sets).

Improper mounting could damage the winch and void the warranty. Connect the red wire to the positive terminal and the black wire to the negative terminal of the battery.(See Fig. 1).

• Check the rotation direction of the drum. Pull and turn the clutch knob to the "OUT" position (drum should turn freely by hand). Pull out some cable from the drum, and then turn the clutch knob to the "IN" position. Press the "OUT" button on the switch; if the cable is releasing then it is properly connected. Otherwise reverse the wire connections to the motor, and repeat the above-mentioned operation.
• Pull and turn the clutch knob, so the drum can turn freely by hand.
• Use hand saver bar to hitch the hook of the cable assembly and pull cable to the load. Attach the cable hook to the load.

Never operate the clutch while drum is turning. Do not readjust clutch knob as it has been adjusted and permanently locked in place with a thread-locking compound in the factory.

• Press the "IN" button on the switch to re-spool the cable. Press the "OUT" button to reverse directions. Wait until the motor stops before reversing directions.
• Re-spool the cable after completing the operation.
• Engage the clutch by turning the clutch knob to the "IN" position.
• When inserting the cable into the drum, insert it into the correct end of the hole provided. Tighten the screws.
• Operate the winch an re-spool the cable around the drum tightly.
• Periodically check tightness of mounting bolts and electrical connections. Remove all the dirt or corrosion and always keep clean.
• Do not attempt to disassemble the gearbox. Repairs should be done by the manufacturer or authorized repair center.
• The gearbox has been lubricated using high temperature lithium grease in the factory. No internal lubrication is required except when being repaired.
• When the transmitter is replaced, the same type of transmitter is required for pairing. The pairing method is as follows:

Press the power button →Press IN and OUT button at the same time (the red light was flashing) →Turn on receiver for 1-2s (the relay makes a sound of absorption)

TROUBLE SHOOTING

• Never lift people or hoist loads over people. Do not lift items vertically, this winch is designed for horizontal use only.
• Never overload. Be sure all equipment used meets the winch's maximum line pull rating. When double-lining, pulley blocks should be rated for a minimum of two times the winch's line pull rating.
• Do not attempt prolonged pulls with heavy loads. The electric winch is designed for intermittent use only, and should not be used in a constant duty application. Never pull for more than one minute or exceed the rated load. If the winch motor becomes hot to the touch, stop the winch and allow it to cool down for several minutes.
• Never operate winch with less than 5 turns of cable around the winch drum since the cable end may not withstand full load.
• Avoid continuous pulls from extreme angles because this will cause the cable to gather on one end of the drum and damage the cable. Be aware that the winch's line pull capacity is the max line pull of the first layer. Never operate winch pulling a load that exceeds the rated capacity.
• Never hook the cable back to itself because it could damage the cable.
• Be sure the winch is mounted securely on the vehicle or bracket before operation.
• Before moving a load, inspect the cable. Prevent kinks and uneven cable layer before they occur. Apply proper tension to loads under 100lbs.
• Do not move your vehicle to assist the winch in pulling the load. It will be easy to overload, and cause cable damage. Be aware of the danger zone. Keep away from the danger zone during the operation. The danger zone is the area of the winch drum, the fairlead (if fitted), the cable, the pulley block (if used), the hook, and the motor.
• Never approach or span the cable when the winch is under load.
• When using the winch to move a load, place the vehicle transmission in neutral, set vehicle brake, and chock all wheels. The vehicle engine should be running during winch operation so that battery has fully electricity. Never use the winch when there is a lack of voltage.
• Never disconnect free spool cultch when there is a load on the winch.
• Always stand clear of the cable, hook and winch. You should disconnect the clutch first, then use the hand saver bar to hitch the hook to pull the cable.
• Inspect winch, cable, hooks and other accessories frequently. A frayed cable with broken strands should be replaced immediately. Use heavy leather gloves when handling the cable. Do not let the cable slide through your hands. Inspect the cable before use. Mashed, pinched, frayed or kinked areas severely reduce the load-carrying capability. Replacement cables must be re-spooled under 100lbs.
• To keep stated tensile, re-spool the cable around the drum tightly after operation.
• Do not operate winch when under the influence of drugs, alcohol or medication. Always stay alert during operation.
• Wear eye protection and personal protective equipment while operating winch.
• For loads over 50% of rated line pull, the use of the pulley block/snatch block to double the cable is recommended.
• Do not operate around potentially flammable liquids, gases, or debris. Sparks may occur, resulting in the ignition of fire.

Distributed By: TRACTOR SUPPLY COMPANY 5401 VIRGINIA WAY, BRENTWOOD, TN37027

For customer support, call: 1-888-376-9601

www.TractorSupply.com

Here you can download full pdf version of manual, it may contain additional safety instructions, warranty information, FCC rules, etc.

Download TravellerX 10,000 Winch Manual

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Warn Winch Solenoid Just Clicks – What Does That Mean?

There are a lot of electrical components in a winch. Each of these components make is essential to a smooth operation. However, there are other parts that are more vital – they provide more than smoothness and efficiency in the the function of the winch.

Such parts include (but are not limited to) the motor, the drum, and of course the solenoids. These are parts are more essential in that the winch wouldn’t really work wihout these parts.

The motor, for example, provides the power of pulling to the winch. Without it, the winch wouldn’t do any pulling anytime soon. Without the drum, the motor can’t do any pulling without damaging itself and the winch cable. And without the Warn solenoids… well, what does the Warn solenoid do, really?

Let’s find out!

At a Glance

What are Warn Winch Solenoids?

Winch solenoids are electromagnetic switches. How are they different from the winch switch? The solenoids are used to activate the winch motor by delivering the exact amount of current. It controls the current that flows into the motor to avoid damaging it.

This means that if just one of the four solenoids (the number of solenoids in winches vary from models to models) in your winch is faulty, your winch might suffer some motor damage.

The winch switch sends current from the battery to the solenoid. The solenoid redirects this current to the motor. The motor then turns the winch drum. There are dedicated solenoids for each turning of the motor. In high quality winches, two solenoids are used for reverse and another pair for forward.

You can tell that the solenoids are working by the clicking sounds they make. But what if you can hear that tell-tale clicking sound but the winch drum is not working?

Warn Winch Solenoid Just Clicks

There are a few possibilities when your Warn winch solenoids just click but the motor doesn’t work.

Within each solenoid are little materials called contacts. The solenoid bump these contacts together in order to deliver the correct current to the motor. These contacts bumping into each other are what causes the clicking sound you hear.

If you hear the Warn winch solenoid clicking, it means that it working properly. The problem, then, could be any of the following:

• Dirty or pitted contacts – dirty or pitted contacts may cause them to lose their ability to deliver current.
• Bad connection – a bad connection between the solenoid and the motor may mean that the solenoid can’t deliver the current to the motor.
• Faulty wiring – if the wiring has rusts or is damaged, the solenoid’s capacity to deliver current to the motor is compromised.

Checking Your Warn Winch Solenoids

• Check all of the connections from the winch solenoid to the motor. Look out for damages in the wiring and make sure that the terminals are clean and properly connected.
• If there are damages to the wiring, replace or repair the wires. If the terminals are corroded, clean them with a wire brush or replace them entirely. If one of the terminal connections is loose, rectify it.
• Disconnect the cables from the solenoid so you can unscrew the solenoid cover. Examine each connection in the solenoid. Make sure they are secure.
• Once every connection is in the ebst condition, try switching the winch again. See if you are getting power to the motor using a voltmeter. The motor should have a 12 volts reading.
• If there is no power getting to the motor, examine each connection to the solenoids. As was mentioned above, there are more than one solenoids on a winch. Check all of them.
• Check the motor again. All three motor terminals should have a 12V reading when activated.
• If it still does not work, the problem may be the motor is broken. You know that the winch solenoids are working if they are making the clicking sounds. This means that everything from the battery to the winch switch to the solenoids are in working condition.

If the motor seems to be the problem, you can try repairing it yourself or get a professional to repair ir for you. Another option is to buy a replacement. It is not advisable for you to repair the motor by yourself if you don’t have any experience. You might just do more damage.

To totally confirm whether the motor is the problem, you can try bypassing the winch solenoid.

Bypassing Warn Winch Solenoids

Here is how you can test and bypass a Warn winch motor.

• Put the winch in freespool mode
• Disconnect the positive connection from the battery. The ground conenction should be left alone.
• Disconnect the three cables on the three posts on the motor. Make sure you label the cables so you can reconnect them to the right posts later on.
• Each of the three posts on the motor has a label, “A”, “F1”, and “F2”. Using a small jumper wire (8 ga works fine), connect the “A” post to the “F1” post. Then connect the battery to the “F2” post. The motor should turn in one direction.
• Then try connecting “A” to “F2” and connect the battery to “F1”. The motor should turn the opposite direction now.

If you follow these steps, you can know whether your Warn motor is operational or not.

Learn to Diagnose Your Winch Problems

It is important, as a Warn winch owner, to learn to diagnose its potential problems if it is not working properly. Warn is one of the most expensive winch brands. And repairs may cost you a fortune if warranty does not cover your problem.

However, if you tamper with your Warn winch and damage it even more, it would cost you a lot more. So if your Warn winch solenoid just clicks, make sure you follow these  instructions to the letter. You don’t want to make a mistake.

We offer tons of winch-related advice and instructions. Here are a few you might be interested in:

• How to Bench Test Your Winch
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Zvenigorod's most famous sight is the Savvino-Storozhevsky Monastery, which was founded in 1398 by the monk Savva from the Troitse-Sergieva Lavra, at the invitation and with the support of Prince Yury Dmitrievich of Zvenigorod. Savva was later canonised as St Sabbas (Savva) of Storozhev. The monastery late flourished under the reign of Tsar Alexis, who chose the monastery as his family church and often went on pilgrimage there and made lots of donations to it. Most of the monastery’s buildings date from this time. The monastery is heavily fortified with thick walls and six towers, the most impressive of which is the Krasny Tower which also serves as the eastern entrance. The monastery was closed in 1918 and only reopened in 1995. In 1998 Patriarch Alexius II took part in a service to return the relics of St Sabbas to the monastery. Today the monastery has the status of a stauropegic monastery, which is second in status to a lavra. In addition to being a working monastery, it also holds the Zvenigorod Historical, Architectural and Art Museum.

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Located near the main entrance is the monastery's belfry which is perhaps the calling card of the monastery due to its uniqueness. It was built in the 1650s and the St Sergius of Radonezh’s Church was opened on the middle tier in the mid-17th century, although it was originally dedicated to the Trinity. The belfry's 35-tonne Great Bladgovestny Bell fell in 1941 and was only restored and returned in 2003. Attached to the belfry is a large refectory and the Transfiguration Church, both of which were built on the orders of Tsar Alexis in the 1650s.  

To the left of the belfry is another, smaller, refectory which is attached to the Trinity Gate-Church, which was also constructed in the 1650s on the orders of Tsar Alexis who made it his own family church. The church is elaborately decorated with colourful trims and underneath the archway is a beautiful 19th century fresco.

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Under the reign of Tsar Alexis the cathedral was decorated with frescoes by Stepan Ryazanets, some of which remain today. Tsar Alexis also presented the cathedral with a five-tier iconostasis, the top row of icons have been preserved.

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At present the Tsaritsa's Chambers houses the Zvenigorod Historical, Architectural and Art Museum. Among its displays is an accurate recreation of the interior of a noble lady's chambers including furniture, decorations and a decorated tiled oven, and an exhibition on the history of Zvenigorod and the monastery.

Palace of Tsar Alexis

The Palace of Tsar Alexis was built in the 1650s and is now one of the best surviving examples of non-religious architecture of that era. It was built especially for Tsar Alexis who often visited the monastery on religious pilgrimages. Its most striking feature is its pretty row of nine chimney spouts which resemble towers.

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• Replacement Parts
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WARN NEW U.S.A. WINCH SOLENOID WARN 12 VOLT HEAVY DUTY 28396 72631

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• If any of the products or content related to this discount are returned, your refund will equal the amount you paid for the product or content, subject to applicable refund policies.

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From the manufacturer

WHEN YOU GO WITH WARN, YOU GO PREPARED

We’re the industry leader for a reason. Since 1948 Warn Industries has built its reputation on manufacturing the very best winches, bumpers, and accessories that are designed, engineered and tested for reliability, durability and, of course, for the love of off-roading. When you go prepared, you get to keep going.

WHEREVER THE TRAIL

Product description.

The WARN 72631 Solenoid Replacement is a service replacement part with an upright terminal. This is a genuine WARN service replacement solenoid so don't be fooled by cheap knock-offs. This is the top of line product for numerous WARN Winch Models, Including: M6000, M8000, M8000S, XD9000, XD9000i, 9.5ti, VR 8000, 10000, 12000, 16.5ti, 16.5ti-S. It replaces 28396.

Product information

Technical details, additional information, looking for specific info, customer reviews.

Customer Reviews, including Product Star Ratings help customers to learn more about the product and decide whether it is the right product for them.

To calculate the overall star rating and percentage breakdown by star, we don’t use a simple average. Instead, our system considers things like how recent a review is and if the reviewer bought the item on Amazon. It also analyzed reviews to verify trustworthiness.

Customers say

Customers like the value of the electronic switch, saying it works great for a great price. They also mention that it's a good product. However, some customers have reported issues with the warnings and packaging on the switch. Opinions are mixed on performance, quality, fit, and description.

AI-generated from the text of customer reviews

Customers appreciate the value of the electronic switch. They mention that it works great for a great price and is a perfect fit.

"...These value priced Chinese solenoids worked perfectly (no grounding problems and wired exactly like the original design)...." Read more

"...Fast free shipping and fair prices . I strongly recommend anyone buy from them instead of these cheap knock-offs." Read more

"...I can say, just a typical solenoid, good fit, works as should, price was fair , did what it should" Read more

" great value " Read more

Customers find the electronic switch easy to install. They say it's heavy duty, easy to work with, and requires no modifications.

"...replacement for the four solenoids in my 1970’s Warm 8274, Easy to install because all wiring and jumpers are the same as original...." Read more

"...Good apm rating, heavy duty and easy to work with . I had to make some new cables and fully modify the motor driver unit but these worked fine." Read more

"Genuine OEM part marked Warn in sealed plastic bags. Easy install and worked perfectly as new in a 16.5 winch which would only power out...." Read more

"They required no modifications , bolted right in." Read more

Customers are mixed about the performance of the electronic switch. Some mention that it works well enough with no issues, while others say that it failed on every slight load and burnt up their motor. Some customers also say that the relay failed after the second use and one of the four solenoids didn't work out of the box.

"This solenoid worked perfectly on my 22 JLURXR with Warn winch I installed so I could hook up my #4 aux switch to power it on and not have it..." Read more

"When it worked, it worked well . As soon as it was placed under a heavy load, the solenoid got extremely hot (too hot to touch) and simply failed...." Read more

"Did better than the ones i bought from BR electrical. Those failed on ever slight load ...." Read more

"Glad i bought them my winch has all the power now!!! Works like new " Read more

Customers are mixed about the quality of the electronic switch. Some mention it's a quality replacement, heavy duty, and reliable, while others say it'd be better off buying a knock off. Some customers also report that the product arrived damaged or with brittle plastic.

" Quality replacement . Including nuts would be good." Read more

"...second picture of the seller‘s add. I believe these are possibly knock offs , unfortunately I am under the gun and need to fix my M 8000 ASAP..." Read more

"These seem well made but were not a direct replacement for my XD9000i winch; modification was required...." Read more

"...An easy and simple replacement that keeps my Warn winch in service." Read more

Customers are mixed about the fit of the electronic switch. Some mention that it fits perfectly, while others say that it does not fit, the baseplate is too large to fit, and it requires modification to fit into Warn winches. Some customers also mention that the base plates were not the same size and they had to grind them down to size.

"...tab (shown on left and right sides of the picture) that is too wide for my winch which uses an 8mm channel where the solenoids slide into place...." Read more

"...There are exact replacements and fit perfectly in my X8000i . I highly recommend these to anyone rebuilding their Warn winch." Read more

"The baseplate is too large to fit into a 9000i warn winch. You can grind or shear off a little of the plate to make it fit..." Read more

"Not much I can say, just a typical solenoid, good fit , works as should, price was fair, did what it should" Read more

Customers are mixed about the description of the electronic switch. Some mention that it has WARN labeling, and the logo is printed on the plastic housing. However, others say that the description is wrong, misleading, and incomplete. They also mention that there's no info sheet or wiring diagram included.

"...There's no info sheet or wiring diagram included- so it's all seat of the pants troubleshooting. Once I figured that out they work great." Read more

"When ordering this item be aware the description is wrong . 2 NEW U.S.A. WINCH SOLENOID WARN 12 VOLT HEAVY DUTY 28396 72631..." Read more

"...They come in a Warn bag and have the Warn logo printed on the plastic housing ...." Read more

"...bag has a warn pry number on it but the solenoid itself is does not have any part numbers or the warn logo...." Read more

Customers are dissatisfied with the warn brand. They mention that the solenoids are not Warn brand, they didn't come in a Warn bag, and they are not as advertised.

"These are NOT Warn parts , they are in a generic bag with no markings whatsoever on the part. Paid extra thinking I was getting a oem part." Read more

"Junk, not a warn product . Just another start solenoid in a regular plastic bag! The stamping I S gives it away...." Read more

"This is not a warn solenoid . The plastic bag has a warn pry number on it but the solenoid itself is does not have any part numbers or the warn logo...." Read more

"This is not a warn solenoid ...." Read more

Customers are dissatisfied with the heat produced by the electronic switch. They mention that it overheats and burns up under heavy load. Some customers also report that the solenoid gets extremely hot, making it too hot to touch.

"...As soon as it was placed under a heavy load, the solenoid got extremely hot (too hot to touch) and simply failed...." Read more

"I have tried 3 of these as a shut off switch for my winch. they burn up instantly ...." Read more

"...Installed new winch and used the solenoid. Worked for one day but ran extremely hot ...." Read more

"...Buyer beware. 2 of mine failed and burnt up my motor when they did." Read more

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