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Old 12-29-2018, 07:16 PM   #61
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I've rolled it a bit.
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Old 01-08-2019, 12:57 AM   #62
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I got the winch to work properly once I rolled it out about 15 feet. Not sure why that made the difference, but it is now locking and unlocking the way it should.


Question about wire gauges: I assume the diameter of a given gauge (e.g.: 18 or 2/0) corresponds to the diameter of the copper filament itself, NOT including any of the insulation?
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Old 01-08-2019, 02:06 AM   #63
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It may be worth while taking the gearbox off and making sure that the lever and clutch assembly is lubed. Instruction manual has how to do this.

And yes wiring gauge is talking about the copper part of The wire.

I use 2/0 for defender installs
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Old 01-08-2019, 02:36 AM   #64
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Quote:
Originally Posted by RBBailey View Post
Question about wire gauges: I assume the diameter of a given gauge (e.g.: 18 or 2/0) corresponds to the diameter of the copper filament itself, NOT including any of the insulation?
Correct. Make sure you're using 100% copper wire; some of the cheap wire out there (e.g.., most jumper cables) are copper-clad-aluminum (CCA) and have much higher resistance.

Figure out how much cable you're using, both ways (add up the length of the two wires). Decide how much of the rated pull you want the winch to deliver; ideally, you'll have a chart for the winch that shows the ampere draw for that pulling force. That, and the voltage drop you're willing to tolerate, with determine the maximum voltage drop in the cable, according to Ohm's Law: Resistance = (voltage drop)/(current). IMO 1 volt is a good voltage drop. Divide the resistance by the total length of cable gives you the maximum resistance per foot; look up the needed wire size on a table for copper wire.

Based on that. IMO 1/0 is a good size to use in many cases; you can always go bigger if you want to spend the money and want to put up with dealing with the larger size.
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Old 01-08-2019, 11:35 AM   #65
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Pretty sure I had a nice chart someplace that showed the voltage drop over distance for a given gauge of wire when I made my glow plug harness. Thanks.
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Old 01-08-2019, 11:36 AM   #66
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I think I used 13feet of each color to run it on top of the frame rail to the battery box
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Old 01-08-2019, 11:40 AM   #67
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Was that going the driver's side?

I'm going to lay under there this week sometime and run a test line to get the right length. Going over the wheel well is one option, drivers side frame another, or pass frame, then over the gearbox is another. The third option is where several of my wires are already running.
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Old 01-08-2019, 12:53 PM   #68
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My truck is rhd so yes to the driver side. Just take the shortest route, over the gearbox seems dangerous?
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Old 01-09-2019, 12:56 PM   #69
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Quote:
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I use 2/0 for defender installs
2/0 is what came with the winch. At least, it measures out at almost exactly 0.36 inches. I had envisioned that I was needing a thicker cable, but really I just need longer versions of what I have. I suppose it never hurts to go larger. I'm pretty sure that the cable that is on my old 6000lbs Warn winch is 3/0.
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Old 01-09-2019, 01:22 PM   #70
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Main reason I i didn't go larger is that the 3/0 and above is massive and really really expensive.

Warn sells a rear winch wiring kit for the 6-9.5k winches that uses AWG 2 not 00 or 2/0. Its 20 feet long!

after finding that out, I felt pretty good about using 2/0 for a 13ft dual home run.
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