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Unread 06-21-2013, 02:07 AM   #1
AZdEvilYJ
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So after my last jeep outing I finally got to use my winch (ENGO9k), but to no avail. With no load, as I spooled in the slack on the cable the wire going to the battery ground were getting insanely hot.

In a rush for time, I removed all the cable from the winch and continued to recover my friend.

As I sit here in my garage I fixed the small ground wire and after a couple sparks at the battery terminal, the winch to begin to power in faster(no more sparks), again with no load, but the ground wire to the battery is still getting very hot....

What is going on here?? The wires are approx. 48" long and maybe 4ga terminal battery cable from the winch to batt.

Thanks,

Greg

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Unread 06-21-2013, 07:17 AM   #2
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Sounds like the ground connection was shaky. There may have been a IR loss (voltage drop) at the ground connection - which is why when you connected the ground directly to the battery it seemed to spin faster.

Hot wires= too much power dissipated in the wire itself. Make the wire significantly shorter and/or increase the diameter of the wire (lower gauge)

Assuming the winch is working correctly and not drawing more current than it should, I would make the ground wire as short as possible- connect it to the bumper or frame as close as possible to the winch.

-Anthony
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Unread 06-21-2013, 11:23 AM   #3
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Strange. I have an Engo 10,000lb winch I only have a problem of the wires getting hot if I put a big load on it for more than 5 minutes without a break.
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Unread 06-21-2013, 12:01 PM   #4
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heat is resistance. be sure you have good connections. maybe the cable is bad or a bad terminal. if the cable is corroded at all you will have resistance. or if it is undersized. check it all.
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Unread 06-21-2013, 12:58 PM   #5
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You have resistance somewhere in the power circuit. Check connections specifically to ground. If it were me I would run new copper wire for the power circuit. Maybe even upside bit a little. Winches typically use aluminum. BOOOO! Copper carries current better.

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Unread 06-21-2013, 09:35 PM   #6
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Mine does the same thing. My ground wire is maybe only 8" long and goes from the winch to the frame right behind the bumper. It's only maybe 10g wire though. Maybe I should up size it? Last time I used it, it got pretty damn warm!

Cheers
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Unread 06-21-2013, 09:36 PM   #7
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Quote:
Originally Posted by Sparrows
Mine does the same thing. My ground wire is maybe only 8" long and goes from the winch to the frame right behind the bumper. It's only maybe 10g wire though. Maybe I should up size it? Last time I used it, it got pretty damn warm!

Cheers
It should be the same size as the positive wire.
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Unread 06-21-2013, 09:52 PM   #8
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Quote:
Originally Posted by Michaelgoesrawr View Post
It should be the same size as the positive wire.
Well there we go then haha! The positive is like 00 battery cable or whatever. A pretty massive difference between the two...add that to the list of little annoying crap to fix.

Cheers
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Unread 06-21-2013, 10:11 PM   #9
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Quote:
Originally Posted by AZdEvilYJ View Post
So after my last jeep outing I finally got to use my winch (ENGO9k), but to no avail. With no load, as I spooled in the slack on the cable the wire going to the battery ground were getting insanely hot.

In a rush for time, I removed all the cable from the winch and continued to recover my friend.

As I sit here in my garage I fixed the small ground wire and after a couple sparks at the battery terminal, the winch to begin to power in faster(no more sparks), again with no load, but the ground wire to the battery is still getting very hot....

What is going on here?? The wires are approx. 48" long and maybe 4ga terminal battery cable from the winch to batt.

Thanks,

Greg
I'd like to see a pic or two of your wiring, we may be able to sort out your issues that way. Didn't you just have alternator issues? What are you referring to as your 'small ground wire' ?
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Unread 06-21-2013, 10:39 PM   #10
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Quote:
Originally Posted by Sparrows

Well there we go then haha! The positive is like 00 battery cable or whatever. A pretty massive difference between the two...add that to the list of little annoying crap to fix.

Cheers
Makes sense. What goes in must come out.
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Unread 06-21-2013, 10:53 PM   #11
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Quote:
Originally Posted by DirtKar
I'd like to see a pic or two of your wiring, we may be able to sort out your issues that way. Didn't you just have alternator issues? What are you referring to as your 'small ground wire' ?
Thanks for all the replies guys!

Ya I did have an alternator problem which i have seemed to solved i hope, after everything I tried/fixed/ replaced it was a faulty breaker... Swapped it out and not an issue since.

As for the winch, there is a small ground that mounts to the body right under the grill (which had some chaffing on it that I fixed), and there is a large cable that runs from the winch to the (-) battery terminal. That is the one getting very hot.

I just got off work so ill post my pics when I get home
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Unread 06-21-2013, 11:08 PM   #12
Siva283
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I wouldn't ground the winch to the frame. Your winch can draw over 600 amps with a heavy load. The factory ground straps are not gonna handle That well. There is a reason the neg and pos are ran straight to vthe battery. All your doing now is heating up the stock ground straps and your not noticing it.

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[QUOTE=Magnum;14117863] I gave the Jeep the required offering of $$, sweat, and blood, and everything works fine now. -- Jim[/QUOTE]

[QUOTE=ldso;16498409]. It started with a $200 axle, and a few thousand dollars later I was done :)[/QUOTE]

[QUOTE=Luuca;16122017]diagnose the real issue before you start going all Obama on it - spending mad cash you'll need for other important things.

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[QUOTE=Overhead;17658665]this is also my second set of RC springs this year. I'd rather spend the money again and get something that will last.[/QUOTE]
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Unread 06-22-2013, 08:54 AM   #13
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Sounds like poor grounds and connections/connectors. I would check them all and look for corrosion under the sheathing.

I think everyone has pretty much said that but that's what came to mind when I read your initial post.

Make sure your negative cable to the battery is grounded to the frame, engine and body. There should be a point on the pass. side of the engine and a ground strap on one of the head bolts.
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Unread 06-22-2013, 01:55 PM   #14
AZdEvilYJ
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Here's how I have it hooked to the battery so I'm sure this is where the problem lies, but how else would I hook it other than this?
So there's a total of 4 cables hooked up there. The two main ground and motor ground, the the alternator upgraded cable and the winch.

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Unread 06-22-2013, 06:19 PM   #15
Siva283
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Part of your prob is that corroded terminal. I have mine hook ed up the same way. With no issues there. Mine will heat up at the terminals on the winch motor only if I run it to long without a break. But yoy really need to clean that bat terminal up

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1995 YJ. 2 inch BDS Spring lift. 1 inch shackle lift. 1.25 inch JKS Body Lift 33x12.5x15's. Engo 10,000 pound winch.

[QUOTE=Magnum;14117863] I gave the Jeep the required offering of $$, sweat, and blood, and everything works fine now. -- Jim[/QUOTE]

[QUOTE=ldso;16498409]. It started with a $200 axle, and a few thousand dollars later I was done :)[/QUOTE]

[QUOTE=Luuca;16122017]diagnose the real issue before you start going all Obama on it - spending mad cash you'll need for other important things.

Ask me how I know...[/QUOTE]

[QUOTE=Overhead;17658665]this is also my second set of RC springs this year. I'd rather spend the money again and get something that will last.[/QUOTE]
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