Winch Cables

[Jock The Rock]

Gday

Almost got my winch back together. Just have to run new wiring from the battery, pick up the motor and get some new wire rope.

Now with the wiring, will 200 A be big enough?

Also could someone please post up a picture of where the positive and negative go on the actual winch (Warn, I imagine there all roughly the same). I havent actually pulled the winch off the Landy. JC did it an I cant remember :(

And its just a simple case of positive on positive and negative on negative when I hook it up to the spare battery right?

Thanks

https://www.aulro.com/afvb/images/imported/2009/01/171.jpg

[Bushie]

I think most winches are capable of pulling 400+amps especially if close to stall, I know the cables for my winch are significantly heavier than those going to the starter (but maybe I just went for a bit of overkill).


Martyn

[Jock The Rock]

I think most winches are capable of pulling 400+amps especially if close to stall, I know the cables for my winch are significantly heavier than those going to the starter (but maybe I just went for a bit of overkill).


Martyn

Thanks lucky I didnt get that other wire then

Yeh had a talk to a mate of mine whos dad is an electrician so hopefully might be picking some up for free :)

After that should have the winch mounted up tomorrow then just need the wiring

[Psimpson7]

Jock,

The wires at the winch end will probaly be slightly more complicated than just connecting up the positive and negative.

It sorts of depends on how it was taken apart. The feed wire will go to the solenoid box rather than the motor.

There are 3 positive termianls on most (Warn) winches. The main constant feed wire will go onto the end terminal, and there are 2 positive terminals on the drum end of the winch motor, and these are the controlled feeds for forward and reverse. (these will all come from teh solenoid)

the earth cable will go from the tapped hole in the base of the motor to either the chassis or negative terminal of the battery.

How has the winch been removed (or at least the wiring)?

What solenoids are you using....? The standard Warn ones or Albright type ones.?
Rgds
Pete

[Slunnie]

Gday

Almost got my winch back together. Just have to run new wiring from the battery, pick up the motor and get some new wire rope.

Now with the wiring, will 200 A be big enough?

Also could someone please post up a picture of where the positive and negative go on the actual winch (Warn, I imagine there all roughly the same). I havent actually pulled the winch off the Landy. JC did it an I cant remember :(

And its just a simple case of positive on positive and negative on negative when I hook it up to the spare battery right?

Thanks

https://www.aulro.com/afvb/images/imported/2009/01/171.jpg
Jock if its those little wires coming off your battery in the pic, then there is no way in the world that those wires are good enough. Winch wires are bigger than even what your heavy wires in the pic look like.

[Psimpson7]

Hi Jock,

Slunnies right, I just assumed they were some ancillary power cables.

This is the wire I use:

https://www.aulro.com/afvb/images/imported/2009/01/168.jpg

(Admitedly this is probably overkill, but at least the same side as the battery lead would be wise)

Rgds
Pete

[Jock The Rock]

Jock,

The wires at the winch end will probaly be slightly more complicated than just connecting up the positive and negative.

It sorts of depends on how it was taken apart. The feed wire will go to the solenoid box rather than the motor.

There are 3 positive termianls on most (Warn) winches. The main constant feed wire will go onto the end terminal, and there are 2 positive terminals on the drum end of the winch motor, and these are the controlled feeds for forward and reverse.

the earth cable will go from the tapped hole in the base of the motor to either the chassis or negative terminal of the battery.

How has the winch been removed (or at least the wiring)?

What solenoids are you using....? The standard Warn ones or Albright type ones.?
Rgds
Pete

Im in this pickle because I didnt take the wiring off, JC did when he swapped the bars over and they werent hooked back up because (long story) basically my Warn was on the new bar but wasnt hooked up because I didnt have the dual battery setup in and the winch motor needed serious attention

Im unsure of the solenoids Im running I think they are Warn. Where does the third wire out of the control box go then? Both the third wire and the battery leas go on the terminal on the end of the winch motor

https://www.aulro.com/afvb/images/imported/2009/01/163.jpg

F-1 and F-2 seem pretty simple, F-2 is bottom middle, unfortunately I cant find the marking for F-1 is this the top middle or bottom left?

So the red positive wire from the battery will go to the end terminal on the winch motor?

https://www.aulro.com/afvb/images/imported/2009/01/165.jpg

https://www.aulro.com/afvb/images/imported/2009/01/166.jpg

Is this the tapped hole in the base of the motor your talking about?

https://www.aulro.com/afvb/images/imported/2009/01/167.jpg

Hope you can make sense of what Im saying (Im not sure I do :p) If it all ends up to hard Ill get JC to have a look for me this weekend, Im going 4wding with him.


Jock if its those little wires coming off your battery in the pic, then there is no way in the world that those wires are good enough. Winch wires are bigger than even what your heavy wires in the pic look like.

Na those arent the wires. Ill be looking for them tomorrow, what exactly do I need? Its been suggested I use 6mm wire but how many strand?

[Psimpson7]

Hi Jock,

Re the cable, car battery lead, as per the wires already into the solenoids will be fine I think for what you need.

Regarding the terminals, the hole in the base is the earth (Negative) yes.

F1 and F2 are in and out, there should also be an 'A' post which goes to the positive on the motor.

I will draw a little diagram... hang on...:)

If you have any doubts, ask JC!

[Jock The Rock]

Hi Jock,

Re the cable, car battery lead, as per the wires already into the solenoids will be fine I think for what you need.

Regarding the terminals, the hole in the base is the earth (Negative) yes.

F1 and F2 are in and out, there should also be an 'A' post which goes to the positive on the motor.

I will draw a little diagram... hang on...:)

If you have any doubts, ask JC!

Okey dokey those wires out of the solenoids were ones I pinched out of my old dual battery setup.

These are the old wires:

http://www.aulro.com/afvb/projects-tutorials/69722-warn-winch-rebuild.html

Ill have to get myself a bolt for that earth hole.

Alright starting to understand this, the 'A' wire goes to the positive on the motor. So does this mean two wires are on the positive on the motor? The 'A' wire and the positive from the battery?

Diagram will be good thanks :)

Thanks for helping with this mate, many :beer: when I meet you one day

[Psimpson7]

This picture shows it well

http://www.aulro.com/app/data/500/medium/PC250277.JPG

The one on its own is 'A' The other two are F1 and F2

The positive from the battery goes to the solenoid, and that is then split into the 3 positives that the motor needs. These are continuos (A) and in adn out (f1 and f2)

I am just trying to find a wiring diagram to make it clearer.

Rgds
Pete

ps. no worries!

[Psimpson7]

Heres one that I was trying to draw (but managed to find on the net!)

http://www.devon4x4.com/download-document/35-dc88-contactor-wiring.html

Its not quite the same as yours as you dont have the solid state type solenoid, but the basic principles are correct..

I am just looking for a wiring diagram for the old style solenoids.

I dont want to try and guess which one is F1 and F2 looking at the photos of the solenoids...

[Jock The Rock]

Pretty sure I have this sorted. The positive wire from the battery goes into the control box in the top left hand corner of this photo. I have marking for the 'A' wire coming out of the control box, this goes to the end end of the winch motor. I also have marking for F-2 so that can go on as it is marked on the winch motor. So the last wire left in the control box is F-1 which goes to the motor. And the negative from the battery goes to the threaded hole in the bottom on the motor

https://www.aulro.com/afvb/images/imported/2009/01/163.jpg

[Psimpson7]

yep. Spot on!!:)

When you wire it up and test it, put the winch in freespool, and drag out 20ft of cable. this will mean that if it does something odd you have time to stop it before it motors all the wire in and stalls!

[Jock The Rock]

yep. Spot on!!:)

Thanks mate

Greatly appreciate your help, I owe you a couple

At the moment there is no cable on it, Im having some new stuff made up later this week hopefully. Was tempted by Plasma but was told it wasnt suitable on low mount winches

[Psimpson7]

No worries! Good luck!!:)

Rgds
Pete.

[Jock The Rock]

Ill let you know how I get on once I get these battery cables

Once again thanks :BigThumb:

[Jock The Rock]

Got it all working :)

Spent all morning stuffing around with it. Turned out one of the connections was loose so all fixed now. And got the new cable wound on :D

Thanks

[Psimpson7]

Nice one.

Plasma is ok on low mounts. The main issue is if you are letting yourself down the internal brake can heat the drum up too much

[Jock The Rock]

Nice one.

Plasma is ok on low mounts. The main issue is if you are letting yourself down the internal brake can heat the drum up too much

Yeah the fella JC works with told me the same. Because the drum gets so hot. So I had new wire made up, cost me about $60 in total

Ill post a picture up when I get a chance

[Jock The Rock]

Hey mate heres the photos of it finished and fitted

Thanks for your help

https://www.aulro.com/afvb/images/imported/2009/02/1437.jpg

https://www.aulro.com/afvb/images/imported/2009/02/1435.jpg

https://www.aulro.com/afvb/images/imported/2009/02/1407.jpg

https://www.aulro.com/afvb/images/imported/2009/02/1438.jpg

[foz.in.oz]

Hey mate heres the photos of it finished and fitted

Thanks for your help

https://www.aulro.com/afvb/images/imported/2009/02/1435.jpg


Sparkies out there coreect me if I'm wrong, but I though it was not a good idea to leave winch cables longer than needed and definately not coiled like this. Can lead to overheating of cable. If insulation melts you'll get total battery power direct to earth. :eek::eek:

Just a thought.

[Psimpson7]

Looks good Jock, but as Ray says may be worth shortening that cable if you can.

Rgds
Pete

[Jock The Rock]

Should have thought of that :(

I'll take it in tomorrow to the fella who has the crimping tool and get them shortened

Thanks for the heads up