8.1 Winch¶

Product Image:

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: BODY PDU CB43 (10A)
• 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)

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)

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: Resolved — the winch ground return is the 1/0 AWG (−) conductor of harness H1, routed up the passenger rear sill and forward along the inside floor/side wall (fully inside the body, no exposed… #106 - avoid exposed frame rail per offroad protection requirement)

Outstanding Items¶

Related Documentation¶

• AUX Battery Distribution - Winch power source (passenger rear wheel well)
• Wire Distance Reference - Winch to battery routing distance (13 ft one-way, 26 ft circuit)
• SafetyHub - Winch contactor trigger circuit protection
• Air Compressor - ARB compressor for tire inflation