What cable size do I actually need?

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I'm sure the question has been asked many times on this sight but for the life of me I couldn't find the info I was looking for when I searched it. Could be because I really really suck at the hole webbernet interweb thingSo heres where I'm at I have a decent size engine drive machine (500 amp) and a couple years ago when I got it I bought cable using the chart in the owners manual. I never thought there would be such a huge difference in those charts. It said that for 200 or 250 amp don't quite recall wich and don't have the manual in front of me. Anyways it said for my total length of 150'. Thats a two 75' leads I dhould use 2/0 cable. well that stuff wasn't cheap and I got what I could afford at the time.Now I'm changing things and putting the welder off the trailer and into the truck but don't what to do for leads I want 100' leads but don't know what size. I thought I needed 2/0 but when talking to some guys at my new job they couldn't believe I am using that heavy of cable. They both used to run 1/0 when they had trucks. So i check more charts and sure enough some say I can and some say I can't.What do you guys think? I really can't afford the 2/0 plus it's a heavy pain in the but. What size and length do you guys have on your truck? And has any one ever bought cable online? And if so was it actually worth it after shipping and everything?Thanks for the help.
Reply:The longer the cable, the more loss you have due to resistance. You combat this by running larger cables. I have a bunch of cables of various lengths I can string together with tweeco connectors to get the length I need. The majority is 2/0 that I picked up used. The last 10-15' however is #2 with the stinger and clamp that came with the machine, so it's more flexible and easier to use. I seldom run 200 amps + however.  If the cables are not getting hot you should be ok. Run the 2/0 when you need a long run and then add say 1/0 for the last 25' or so and then the stinger and clamp leads. If you only need a short length you could then just run say the 1/0 with the end leads, or just the ends if it's right at the machine..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan