What Size Wire Is Needed for the Fulton XLT Powered Winch

Updated 12/30/2024 | Published 03/06/2019

Question:

Can 2 gauge wire be used to rewire an old winch? Will the thicker gauge take away power? Thanks!

asked by: Rob

Expert Reply:

The correct gauge of wire that will need to be used to rewire a winch will depend on both the amount of amps the winch draws as well as the distance between the winch and power source. If you can provide me with these two key metrics then I would be glad to provide you with the proper gauge wire that will need to be used.

For example, the Fulton XLT Powered Winch with Rugged Strap 500621 that you referenced has a max amp draw rating of 200 amps. In order to use this winch or one similar with the same amp draw, the distance between the winch and power source should not exceed 25'. If you take a look at the attached photo, you will see the wire gauge recommendation for this winch.

If you take a look at the owner's manual for the winch you have, the same recommendation for wire gauge should be present. However, there is not a standard amp draw rating for all of winches and I don't know how far away the winch you have will be from the power source so I cannot give you an exact yes or no answer unfortunately.

In regards to power restriction, this will not be an issue when using a wire gauge larger than what is recommended but will become an issue when using a wire gauge smaller than what is recommended.

expert reply by: Conner L

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Bruce

12/28/2024

Thanks for the help on the gauge of wire. Next question ... with a 4 gauge wire, length to power supply is 18 ft. What amp fuse or circuit breaker should one use? Would a 30amp or 40amp breaker work?? Thanks for your help Bruce

Kate F.

12/28/2024

@Bruce Hello Bruce, It would depend on the amp draw of what you are wiring. Use a 30-amp breaker if your device draws 24 amps or less, or a 40-amp breaker if your device draws 32 amps or less. If you can let me know exactly what you are wiring, I am happy to be more specific.

Bruce

12/28/2024

@KateF The Fulton XTL 10.0 power winch pulls 200 amps, based on the manual The battery power from the towing vehicle will be about 18 ft to the winch on trailer. I’ll use 4 gauge wire What size breaker do I need? Or do I need a circuit breaker, the manual doesn’t mention one Thanks for your help Bruce

Bruce

12/28/2024

@Bruce Do really need a circuit breaker on the power lead?? According to the manual, it talks to just using one power line from the towing vehicles battery + post. use a shorter line from the vehicles frame in the back. So, they don't mention anything about a circuit breaker. Open to suggestions thanks, Bruce