REV.

SURFACE ® J378
OCT2004

VEHICLE Issued 1969-01

RECOMMENDED Revised 2004-10

PRACTICE
Superseding J378 JAN1988

(R) Marine Propulsion System Wiring

1. Scope

This SAE Recommended Practice covers the requirements for all marine inboard engine wiring, wiring
assemblies, wiring components, and wiring connectors connected to microprocessors associated with the
operation of the propulsion system.

EXCEPTION—Outboard engines and engines in Personal Water Craft (PWC).

NOTE—See ABYC E11 for additional requirements related to electrical installations on small craft.

1.1 Purpose

The purpose of this document is to insure that electrical and electronic wiring and wiring components
used in a marine propulsion system meet the necessary safety and performance requirements based
upon the marine mechanical and electrical environment. The recommendations include methods that may
be employed by manufacturers to minimize the possibility that engine wiring may be a source of ignition
of explosive or flammable vapors and provide manufacturers installing engine electrical systems sufficient
information to design and develop engine wiring harnesses for marine usage.

1.2 General

Normally, marine engines are installed in enclosed compartments which are difficult to ventilate well
enough to purge quickly any explosive mixtures of flammable gases, particularly if a continuous fuel leak
is present. For this reason, it is essential that precautions be taken to minimize all sources of possible
ignition of explosive fuel air mixtures that may be present.

Wiring can become a potential source of fuel vapor ignition in numerous ways, including damage to
insulation covering, loose connections, accidental shorting at terminals, fatigue failures, etc. These
occurrences can be as much a matter of installation as of design.

Performance tests to determine the necessary external ignition-protection of complete wiring harnesses
are not practical. Protection can be afforded by proper selection of components and installation practices
in accordance with the following recommendations. For inboard and stern drive engines, the minimum
federal requirements for electrical wiring are covered by Title 33 Code of Federal Regulations Part 183
Sections 183.410 to 183.460.

SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is
entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.”
SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.
Copyright © 2004 SAE International
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written permission of SAE.
TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada)
Tel: 724-776-4970 (outside USA)
Fax: 724-776-0790
Email: [email protected]
SAE WEB ADDRESS: http://www.sae.org
 SAE J378 Revised OCT2004

2. References

2.1 Applicable Publications

The following publications form a part of this specification to the extent specified herein. Unless
otherwise indicated, the latest version of SAE publications shall apply.

2.1.1 SAE PUBLICATIONS

Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001, http://www.sae.org

SAE J858—Electrical Terminals—Blade Type

SAE J1127—Battery Cable
SAE J1128—Low-Tension Primary Cable
SAE J1191—High Tension Ignition Cable Assemblies—Marine
SAE J2030—Heavy-Duty Electrical Connector Performance Standard
SAE J2202—Heavy-Duty Wiring Systems for On-Highway Trucks

2.1.2 FEDERAL PUBLICATIONS

Available from the Superintendent of Documents, U. S. Government Printing Office, Mail Stop: SSOP,
Washington, DC 20402-9320. Web: http://www.access.gpo.gov/nara/cfr/waisidx_99/33cfr183_99.html

Title 33 Code of Federal Regulations Part 183—Boats and Associated Equipment

2.1.3 ASTM PUBLICATIONS

Available from the American Society for Testing and Materials, 100 Barr Harbor Drive, West
Conshohocken, PA 19428-2959. Order online at http://www.astm.org

ASTM D 412—Test Methods for Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic
Elastomers-Tension
ASTM D 573—Test Method for Rubber—Deterioration in an Air Oven
ASTM D 471—Standard Test Method for Rubber Property—Effect of Liquids

2.1.4 ABYC PUBLICATION

ABYC documents can be ordered online at http://www.abycinc.org

ABYC E11—AC and DC Electrical Systems on Boats

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 SAE J378 Revised OCT2004

3. Definitions

3.1 Butt Splice

A splice in which the wire ends are positioned in the connection butt to butt.

3.2 Low Voltage Caps

An insulating shield to protect against accidental shorting of terminal or terminations in low-tension

circuits.

3.3 Connector

An insulated device that holds a terminal(s) for electrically interconnecting one or more wires. Connectors
shall conform to SAE J2030.

3.4 End Cap Splice

A splice in which all wires enter at the same end.

3.5 Engine Wiring

Any insulated electrical wiring of a marine engine necessary for operation, monitoring, and/or control.

3.6 Low Tension Wiring

Wiring used in a less that 50 V application.

3.7 Personal Water Craft (PWC)

A vessel that uses an inboard engine powering a water jet pump as its primary source of motive power
and which is designed to be operated by a person sitting, standing, or kneeling on the vessel rather than
the conventional manner of sitting or standing inside the vessel.

3.8 Sonic-Weld Splice

A weld produced by the introduction of high-frequency mechanical vibration between two components
until a metallurgic bond is formed at the weld interface.

3.9 Terminal

A metal fitting attached to the end of a wire to facilitate making electrical connections.

3.10 Tee Connection

A form of a splice in which there are 3 to 4 connection points, each 90 degrees to each other.

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 SAE J378 Revised OCT2004

3.11 Wire

The combination of a conductor surrounded by insulation.

4. Low Tension Wiring

The temperature rating of the wire insulation shall be determined by an accelerated aging test conducted
in accordance with ASTM D 573, except samples of insulation are to be removed from the finished wire
and aged 168 hours. The test temperature shall be 30 °C (86 °F) above the intended rated temperature.
Tensile strength after aging shall not be less than 80% of the original tensile strength. The elongation
after aging shall be at least 50% of the original elongation. Except for intermittent higher currents, each
circuit must not carry a current greater than specified in Figure 1 for the wire gauge and temperature
rating. Resistance conductors that control circuit amperage and cranking motor circuit conductors are
exempt from the requirements of Figure 1.

Wiring longer than 455 mm (18 in), not grouped together and protected, shall be no less than 1 mm2
(metric wire) or AWG 16 gauge (US inch dimensioned wire).

The wiring assembly shall be supported at intervals not greater than 455 mm (18 in) shall be located so
as to be protected from moving parts, and spaced or shielded from high temperature surfaces so that the
wire insulation or sheath will not exceed its temperature rating. Wiring passing through holes shall be
provided with grommets, bushings or other means to protect against abrasion. Wiring shall be routed
above anticipated levels of bilge water or away from areas where water may accumulate, except wiring
for submerged equipment such as bilge pumps. For additional cable specification, see SAE J1127 and
SAE J1128.

Except where otherwise protected or not in contact with metal surfaces, the wiring circuits shall be
grouped together and protected by non-metallic tape or braid covering which shall be capable of
withstanding the abrasion test covered in Section 5.

5. Abrasion Test for Non-metallic Tape or Braid Covering

5.1 Principle

Three individual samples of identical construction shall be selected from a test lot. These samples shall
be constructed the same as for all other sizes to be qualified by this test sample. The samples to be
qualified by this test lot shall not have a cover thickness less than those of the test lot. After 1000 test
cycles, each sample in the test lot shall not have any conductor material exposed.

5.2 Procedure

The test samples shall be preconditioned for at least 24 h at 23 °C ± 2 °C (73 °F ± 3.6 °F) and (50% ±
5%) relative humidity. Testing shall be performed at the previous temperature with an unused abrasive
surface for each sample.

The abrasive surface shall be 25 x 76 mm ± 5 mm (1 x 3 in ± 0.2 in) 240 grit, medium grade, AIO3 emery
cloth firmly affixed to a hard surface which will cycle back and forth 76 mm ± 5 mm (3 in ± 0.2 in) in each
direction.

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 SAE J378 Revised OCT2004

FIGURE 1—ALLOWABLE AMPERAGE OF CONDUCTORS FOR SYSTEMS UNDER 50 VOLTS

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 SAE J378 Revised OCT2004

One test cycle equals 360 degrees rotation of the outside diameter and one back and forth movement of
the abrasive surface.

A constant normal force of 45 N ± 0.5 N (10 lb ± 2 oz) shall be applied to the abrasive surface (see
Figure 2).

FIGURE 2—TYPICAL ABRASION TEST FIXTURE

6. Wire Termination Requirements

6.1 All terminal-to-wire and splice connections must pass the pull-off forces as listed in Table 1. These
forces are the total separating forces, which includes the weight of the connecting wire when tested
in a vertical position.

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 SAE J378 Revised OCT2004

TABLE 1—MINIMUM PULL-OFF FORCE VALUES

1 Min 1 Min 1 s Alternate Quality 1 s Alternate

Wire Size Wire Size Design Test Design Test Control Test Quality Control Test
METRIC ENGLISH Tension Force Tension Force Tension Force Tension Force
2
(mm ) (AWG) N lb N lb
(0.8) 18 44 10 80 18
(1) 16 66 15 124 28
(2) 14 133 30 155 35
(3) 12 155 35 177 40
(5) 10 177 40 200 45
(8) 8 200 45 222 50
(13) 6 222 50 355 80
(19) 4 311 70 444 100
(32) 2 400 90 600 135
(40) 1 444 100 666 150
(50) 0 556 125 778 175
(62) 00 667 150 1000 225
(81) 000 778 175 1155 260
(103) 0000 1000 225 1465 330

6.2 Procedure

The method of setting up the specimens in the pull off test fixture will vary according to the type of
terminal or splice being tested. The test fixture shall be designed to hold one end of the terminal or wire
stationary while the pull force is applied to the other end. Adapters may be required to allow a common
test fixture to be used to test the various types of terminals and splices. In general, each type shall be
secured in a position with the necessary adapters to hold the terminal or splice and keep the direction of
pull along the axis of the wire. The force shall then be applied gradually so there is no sudden application,
jerking, or swinging. Figure 3A illustrates the intention of the pull test set up on some types of terminals
and splices. End cap type splices, however, shall have their wires pulled first in opposite directions, then
with the end cap held securely, the wires shall be pulled individually away from the cap along the axis of
the wire. If the cap contains wires of different sizes, test the smaller wire first. Tee connections and butt
splices that contain more than one wire at either end shall be pulled parallel to the main wire then
perpendicular to it.

Some types of terminals may be tested in pairs, such as, ring and lug types bolted back to back and knife
disconnects mated together, provided the terminal wire barrels are kept parallel to each other and to the
axis of the wire (See Figures 3A and 3B).

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 SAE J378 Revised OCT2004

FIGURE 3A—EXAMPLES OF SOME TERMINAL PULL-OFF METHODS

FIGURE 3B—PAIRING OF TERMINALS

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 SAE J378 Revised OCT2004

7. Connector Moisture Resistance Requirements

7.1 Connectors used on or connected to microprocessors associated with marine propulsion systems
shall pass the water immersion and fluid immersion tests.

7.2 Water Immersion

7.2.1 PRECONDITIONING

The wired, or mated, connectors shall be placed in an oven at 125 °C ± 3 °C (257 °F ± 5 °F) for 1 h.

7.2.2 PROCEDURE

Remove the samples from the preconditioning oven and immediately immerse the samples in a 5% by
weight salt water solution containing 0.1 g/L wetting solution to a depth of one meter for 4 h at 23 °C ±
3 °C (73 °F ± 5 °F).

7.2.3 PASS/FAIL CRITERIA

7.2.3.1 Weatherproof Connectors

Continuity with one probe in the test solution and one probe attached to the conductor shall constitute
failure.

7.2.3.2 Exposed Connectors

Any visual evidence of water on the conductor after complete removal of the cover shall constitute failure.

7.3 Fluid Immersion Test

7.3.1 PROCEDURE

Submerge a sample of wired and mated connector to each listed fluid at 85 °C ± 3 °C (185 °F ± 5 °F) for
5 min, then allow to air dry for 24 h. This completes one cycle. Each sample is to be subjected to a total
of 5 cycles. An untested sample is required to pass this test in each fluid.

The fluids are:

a. Gasoline: ASTM D 471, Reference fuel B

b. Power Steering Fluid: ASTM D 471, IRM903
c. Engine Coolant: 50% distilled water and 50% ethylene glycol mixture

7.3.2 PASS/FAIL CRITERIA

Visual swelling, cracking or continuity with one probe in the solution and one probe connected to the
conductor shall constitute failure.

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 SAE J378 Revised OCT2004

8. Terminal and Multi-Connector Plug Separation Requirements

8.1 Each single friction terminal, spring type terminal and non-locking multi-conductor plug that is
outside of the electrical junction box must not separate when subjected to a 26.7 N (6 lb) tensile
force for 1 min along the axial direction of the terminal or connector blade terminals, when used,
shall conform to SAE J858. This force includes the weight of the connecting wires when tested in a
vertical position. Condition the terminals or connectors prior to testing by connecting and
disconnecting them six times, unless the terminals or connectors are specifically designed not to be
disconnected and installed in the boat in such a way that they would not require disconnection for
normal access, servicing, or maintenance.

8.2 Procedure

Mated terminals and connectors shall be installed in a test fixture (Figure 4) such that one of the halves of
the terminal or connector is held secure and stationary while the other half is subjected to the 26.7 N
(6 lb) tensile force. The force shall be applied gradually so there is no sudden application, jerking, or
swinging. Different adapters will be required to hold the various types of terminals and connector types.

FIGURE 4—SEPARATION TEST FIXTURE

9. Low Voltage Caps

9.1 Cap material shall be aged for 168 h. at a temperature of 90 °C ± 2 °C (194 °F ± 4 °F) in an oven
and allowed to cool to room temperature. The tensile strength after aging shall not be less than
80% of the original tensile strength. The elongation after aging shall be at least 50% of the original
elongation. Tests shall be conducted as per ASTM D 412.

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 SAE J378 Revised OCT2004

9.2 Cap material shall be submerged in each of the following liquids for a period of 5 h at 23 °C ± 3 °C
(73 °F ± 6 °F). Tests may be in any sequence:

a. Gasoline: ASTM D 471, Reference Fuel B

b. Power Steering Fluid: ASTM D 471, IRM903
c. Engine Coolant: 50% distilled water and 50 ethylene glycol mixture

9.2.1 The test specimens shall be removed, blotted dry, and judged with respect to untested
specimens.

9.3 Tested specimens shall not lose more than 40% of their tensile strength or swell by more than 50%
of any dimension as a result of being subjected to the conditions under 9.2, Items (a) (b) (c).

9.4 Dielectric strength of cap material shall be 100 VDC/mil minimum after completion of aging tests
under 9.1 and 9.2.

10. High Tension Wiring

High-tension cable assemblies used in engine ignition systems shall conform to SAE J1191.

Separators, stand-offs, looms, conduit, raceways, or abrasion resistant sleeving shall be used where
necessary to maintain adequate separation between cables and to protect cable insulation from physical
damage. Harness clamps shall be designed with smooth rounded edges to prevent damage from the
clamp to the conductor or insulation. Non-metallic straps or clamps shall be designed to prevent failure if
used in areas of high temperatures, or over engine(s), moving shafts, other machinery or passageways.
High-tension cable to terminal connections shall withstand the tensile forces of 89 N (20 lb) minimum.
The cable with terminals and boot attached shall not disconnect from a spark plug when a 26.7 N (6 lb)
tensile force is applied for 1 min to the lead and pulled parallel to the axis of the spark plug.

11. Color Code

The marking shown in Table 2 is recommended for marine engines and their associated components. As
alternatives, the color code in SAE J1128 Low Tension Wiring, SAE J2202 Truck Wiring or the
manufacturers code may be used. If alternative methods are used, a wiring diagram of the system
indicating the method of identification must be supplied with the craft. Colored sleeves at the terminal
ends of wires may be used in lieu of solid colored wires. The circuit diagram (Figures 5A and 5B) is for
the purpose of clarifying color-coding and not to recommend particular circuiting or components.
Components that may be wired in various ways should be wired with the marking corresponding to the
particular branch of the circuit in which they are used.

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 SAE J378 Revised OCT2004

TABLE 2—MARINE ENGINE WIRING

Color Number Description

Purple 1XX Ignition switch controlled

Black or Yellow 2XX Grounds
(1)
Red 3XX Unprotected battery wires
Red/Purple 4XX Overcurrent protected battery wires
Green or Green/Yellow Stripe 6XX Bonding
Brown and Brown/Stripe 7XX Alternator starter to ignition module
Orange 8XX Alternator DC output and accessory feeds
Light Blue 9XX Oil pressure
Tan 10XX Water temperature
Gray 11XX Tachometer
Green/White 12XX Engine trim in and/or tilt down
Green/Orange 13XX Engine independent trim down
Blue/White 14XX Engine trim out and/or tilt up
Blue/Orange 15XX Engine independent trim up
White 16XX Must not be used in under 50 V wiring
Yellow/Red 17XX Starting circuit
Yellow/Black 18XX Choke
Black/Yellow 19XX Ignition stop
Brown/White 20XX Trim position sender
Manufacturer’s Discretion Ignition triggering and color/stripe for functions not
designated
1. Red/Purple may be used for overcurrent protected wires.

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 SAE J378 Revised OCT2004

FIGURE 5A—CIRCUIT DIAGRAM (ENGINE)

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 SAE J378 Revised OCT2004

FIGURE 5B—CIRCUIT DIAGRAM (INSTRUMENTATION)

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 SAE J378 Revised OCT2004

12. Notes

12.1 Marginal Indicia

The change bar (|) located in the left margin is for the convenience of the user in locating areas where
technical revisions have been made to the previous issue of the report. An (R) symbol to the left of the
document title indicates a complete revision of the report.

12.2 Keywords

Connectors, low tension wiring, low voltage caps, terminals

PREPARED BY THE SAE MARINE TECHNICAL COMMITTEE

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 SAE J378 Revised OCT2004

Rationale

The title and scope of this document have been revised to reflect the requirements necessary to upgrade
marine wiring to accommodate the use of microprocessors in the marine industry.

Non-Wicking wire, water and fluid immersion test have been added to improve the integrity of wire
termination points. An abrasion test has been added to qualify the “severe abrasion resistance”
requirements for non-metallic tape or braid coving in the low tension wiring section.

Rationale for revisions:

Section Changes
1.0 Clarify definition of PWC to match Definitions Section
1.2 Correct error in reference to the Federal Register and added text for clarity
2.1 Several changes to update contact information and add WEB addresses.
3.2 Change 3.2 to match section 9
4.0 Clarify definition of wire gauge
5.2 Revise dimention so metric and English units are closer when converted.
7.2.1, 7.2.2, 7.3.1 Revise tolerances so units are closer when converted
7.3, 9.2 Clarify materials used in testing
11.0 Remove obsolete standard
Reference Section Add ASTM D 471 reference
Added Keywords

Relationship of SAE Standard to ISO Standard

Not applicable.

Application

This SAE Recommended Practice covers the requirements for all marine inboard engines wiring
assemblies and components.

Reference Section

SAE J858—Electrical Terminals—Blade Type

SAE J1127—Battery Cable

SAE J1128—Low-Tension Primary Cable

SAE J1191—High Tension Ignition Cable Assemblies—Marine

SAE J2030—Heavy-Duty Electrical Connector Performance Standard

SAE J2202—Heavy-Duty Wiring Systems for On-Highway Trucks

ABYC E11—AC and DC Electrical Systems on Boats

 SAE J378 Revised OCT2004

ASTM D 412—Test Methods for Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic
Elastomers-Tension

ASTM D 471—Standard Test Method for Rubber Property—Effect of Liquids

ASTM D 573—Test Method for Rubber—Deterioration in an Air Oven

Title 33 Code of Federal Regulations Part 183—Boats and Associated Equipment

Developed by the SAE Marine Technical Committee