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8.1 Winch

Model: Warn Zeon 10-S

Mounting Location: Front bumper (verified compatible)

Pulling Capacity: 10,000 lbs (4,536 kg)

Motor: 12V DC series wound

Product Image:

Warn Zeon 10-S Winch

Electrical Specifications

  • Peak Amperage Draw: 409A (at full load/stall - brief periods only)1
  • Typical Operating Draw: 80-250A (most recovery operations)
  • Main Power Source: AUX battery (passenger rear wheel well - direct connection, no fuse/breaker)
  • See AUX Battery Distribution for wire specs (gauge, length, routing, voltage drop calculations)
  • System Voltage: 13.8V (alternator charging - engine running during winch operations)
  • Protection: None - direct connection (see justification below)

Circuit Protection

No external circuit breaker — per the WARN ZEON 10-S installation manual. Protection: integrated thermal cutoff, contactor isolation (emergency shutoff: disconnect at battery terminal), and 1/0 AWG cable (adequate for 409A brief peaks). Automotive practice (SAE J1128) differs from marine (ABYC E-11), which fuses all circuits. See Standards Exceptions.

Contactor/Solenoid

  • Type: Warn Zeon 10-S integrated contactor (included with winch)
  • Location: Mounted on winch motor housing
  • Rating: Rated for full stall current (≥409A switching)
  • Function: High-current switching for winch motor direction and power

Control System

Dual Control Setup: Dash rocker switch + handheld remote (both work simultaneously)

Dash Rocker Switch:

  • Type: Center-off momentary rocker switch (SPDT or DPDT)
  • Location: Dashboard physical switch panel
  • Function:
  • UP (momentary): Winch OUT (let out cable)
  • CENTER: Off (spring return to center)
  • DOWN (momentary): Winch IN (pull in cable)
  • Power: SafetyHub ATC-1 (15A fuse)
  • Use case: In-cab winch control (self-recovery, convenient operation from driver seat)

Handheld Remote:

  • Type: Warn factory wired remote (included with Zeon 10-S)
  • Function: IN/OUT directional control (same as dash rocker)
  • Connection: Plugs into winch control pack
  • Use case: Outside vehicle spotting (traditional winch operation with visual line of sight)

Control Architecture:

SafetyHub ATC-1 (15A) → Dash Rocker Switch ⟷ Handheld Remote (parallel) → Winch Contactor IN/OUT
                              ↑                      ↑
                           UP = OUT              Remote OUT button
                           DOWN = IN             Remote IN button

Both controls work simultaneously - either dash rocker OR remote can trigger winch IN/OUT

Wiring

Main Power Wiring:

See AUX Battery Distribution for wire specs (gauge, length, routing path).

  • Positive (+): AUX battery+ → winch contactor → winch motor (direct, no breaker)
  • Negative (-): AUX battery- → winch motor ground lug

Control Wiring:

  • Power Source: BODY PDU CB43 (10A fuse) - sourced from Firewall CONSTANT Bus (AUX battery)
  • Dash Switch: CH4X4-TOY-D-WINIO dual-momentary push, Toyota-style (1.54" × 0.83" cutout) - see Dashboard Controls
  • Signal Path: BODY PDU CB43 → CH4X4 switch (push IN or OUT) → HDP24 pins 16/17 → winch contactor IN/OUT triggers
  • Remote: Wired in parallel with dash switch at contactor IN/OUT trigger terminals
  • Wire Gauge: 18 AWG (low-current trigger signals, ~2A max each direction)
  • Routing: BODY PDU (firewall cabin side) → ~3 ft to dash switch → out through HDP24 → engine bay → winch contactor (front bumper)
Circuit Source Protection Wire Gauge Destination Function
Main Power (+) AUX battery+ None (direct) See AUX Battery Distribution for wire specs Winch Contactor → Motor High-current power
Main Power (-) AUX battery- None See AUX Battery Distribution for wire specs Winch Motor Ground High-current return
Trigger IN CH4X4 IN button BODY PDU CB43 (10A) 18 AWG Winch Contactor IN trig Low-current trigger
Trigger OUT CH4X4 OUT button BODY PDU CB43 (10A) 18 AWG Winch Contactor OUT trig Low-current trigger
Remote Control Warn Remote Internal to winch Per Warn specs Winch Control Pack Parallel to dash

Installation

Power Cable Routing:

See AUX Battery Distribution for cable specs and routing path.

  • Route: Passenger rear wheel well → front bumper (~13 ft, exact path TBD - avoid exposed frame rail per offroad protection requirement)
  • Protection: Split loom over entire run
  • Securing: P-clamps every 18" along the chosen path
  • Grommets: Rubber grommets with sealant at body penetrations
  • Heat: Route away from exhaust components (minimum 6" clearance)

Winch Mounting:

  • Zeon 10-S fits front bumper (verified compatible)
  • Factory contactor mounted on winch motor housing
  • Ensure contactor is protected from direct water spray
  • Verify all connections are tight and corrosion-free

Control Switch Location:

  • Dash-mounted center-off momentary rocker switch
  • Easily accessible from driver's seat
  • Clear labeling: UP = OUT, DOWN = IN

Safety Considerations

Winch Safety

  • Never exceed winch rated capacity (10,000 lbs)
  • Always use proper recovery techniques and safety equipment
  • Keep hands and body clear of winch line under tension
  • Use tree savers and recovery equipment rated for load
  • Monitor battery voltage during extended winch operations

Electrical Safety

  • Winch power cables carry extremely high current (up to 409A)
  • Ensure all connections are tight and properly crimped
  • Never disconnect battery while winch is under load
  • Check cable insulation regularly for damage

Outstanding Items

None - all specifications determined.

  1. Model confirmed WARN ZEON 10-S (owner, 2026-05-30) — the earlier "ZEON 10-S" naming was incorrect. WARN's published peak draw for the ZEON 10-S is 409A @ 10,000 lb (pull table: 62/144/215/280/353/409A); the previously documented 450A (≈ ZEON Platinum) was conservative. 1/0 AWG cable and the integrated contactor retain margin above 409A; WARN service battery leads for the 10-S are 2 AWG (our 1/0 AWG is a deliberate upsize). Source: WARN ZEON 10-S (89611) (checked 2026-05-30). ↩