1、_ 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 there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2011 SAE International All rights reserved. No part of this p
3、ublication 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: +1 724-776-497
4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedbackon this Technical Report, please visit http:/www.sae.org/technical/standards/J378_201110SURFACEVEHICLERECOMMENDEDPRACTICEJ378 OCT2011 Issued 1969-01 Revised 201
5、1-10Superseding J378 OCT2004 Marine Propulsion System Wiring RATIONALE Remove the schematic diagram examples shown in Figure 5, and the reference to J 2202 in the reference section. Also removed SAE J1128 as an alternate reference in section 11. They represent older practices, and are only shown as
6、examples for the purpose of clarifying color coding and were not meant to be recommendations of circuiting or component use. The industry has a well established practice of providing good wiring diagrams so the figure is unnecessary. Review and revise the color code chart to be consistent with curre
7、nt practice. Clarify scope to exclude high voltage DC Hybrid systems which are covered by specific standards. 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
8、associated with the operation of the propulsion system, operating at 50 V or less. EXCEPTIONOutboard 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 in
9、sure 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 minimiz
10、e 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 i
11、n 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 fue
12、l 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 desig
13、n. SAE J378 Revised OCT2011 Page 2 of 12 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.
14、 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. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this specification to the extent spe
15、cified herein. Unless otherwise indicated, the latest issue of SAE publications shall apply. 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.SAE J858 Elect
16、rical Terminals - Blade Type SAE J1127 Low Voltage Battery Cable SAE J1128 Low Voltage Primary Cable SAE J1191 High Tension Ignition Cable Assemblies - Marine SAE J2030 Heavy-Duty Electrical Connector Performance Standard 2.1.2 Federal Publications Available from the Superintendent of Documents, U.
17、S. Government Printing Office, Mail Stop: SSOP, Washington, DC 20402-9320. Web: http:/www.access.gpo.gov/nara/cfr/waisidx_99/33cfr183_99.htmlTitle 33 Code of Federal Regulations Part 183Boats and Associated Equipment 2.1.3 ASTM Publications Available from ASTM International, 100 Barr Harbor Drive, P
18、.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org.ASTM D 412 Test Methods for Vulcanized Rubber and Thermoplastic Rubbers and Thermoplastic Elastomers-Tension ASTM D 573 Test Method for RubberDeterioration in an Air Oven ASTM D 471 Standard Test Method for Rubber Proper
19、tyEffect 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 SAE J378 Revised OCT2011 Page 3 of 12 3. DEFINITIONS 3.1 BUTT SPLICE A splice in which the wire ends are positioned in the connection butt to butt.
20、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 SPLI
21、CE 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 than 50 V application. 3.7 PERSONAL WATER CRAFT (PWC) A vessel that uses an inb
22、oard 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 introdu
23、ction 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 conne
24、ction points, each 90 degrees to each other. 3.11 WIRE The combination of a conductor surrounded by insulation. SAE J378 Revised OCT2011 Page 4 of 12 4. LOW TENSION WIRING The temperature rating of the wire insulation shall be determined by an accelerated aging test conducted in accordance with ASTM
25、 D 573, except samples of insulation are to be removed from the finished wire and aged 168 h. 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
26、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 f
27、rom 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
28、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 route
29、d 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 circ
30、uits 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 select
31、ed 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 havea cover thickness less than those of the test lot. After 1000 test cycles, each sample in the test lot shall not have
32、 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
33、x 76 mm 5 mm (1 x 3 in 0.2 in) 240 grit, medium grade, AIO3emery 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. SAE J378 Revised OCT2011 Page 5 of 12 FIGURE 1 - ALLOWABLE AMPERAGE OF CONDUCTORS FOR SYSTEMS UNDER 50 VOLTS SAE J378 Re
34、vised OCT2011 Page 6 of 12 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
35、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. SAE J378 Revised OCT2011 Page 7 of 1
36、2 TABLE 1 - MINIMUM PULL-OFF FORCE VALUES Wire Size METRIC(mm2)Wire Size ENGLISH(AWG) 1 Min Design Test Tension ForceN1 Min Design Test Tension Forcelb1 s Alternate Quality Control Test Tension Force N1 s Alternate Quality Control Test Tension Forcelb(0.8) 18 44 10 80 18 (1) 16 66 15 124 28(2) 14 13
37、3 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 3306.2 Procedure The method of setting up th
38、e specimens in the pull off test fixture will vary according to the type of terminal or splice beingtested. The test fixture shall be designed to hold one end of the terminal or wire stationary while the pull force is applied tothe other end. Adapters may be required to allow a common test fixture t
39、o 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 app
40、lication, 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 a
41、way 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 te
42、sted 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). SAE J378 Revised OCT2011 Page 8 of 12 FIGURE 3A - EXAMPLES OF SOME TERMINAL PUL
43、L-OFF METHODS FIGURE 3B - PAIRING OF TERMINALS SAE J378 Revised OCT2011 Page 9 of 12 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 Imme
44、rsion 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
45、 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
46、 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
47、 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, crackin
48、g or continuity with one probe in the solution and one probe connected to the conductor shall constitute failure. SAE J378 Revised OCT2011 Page 10 of 12 8. TERMINAL AND MULTI-CONNECTOR PLUG SEPARATION REQUIREMENTS 8.1 Each single friction terminal, spring type terminal and non-locking multi-conducto
49、r 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 conne
