SURFACE J163

ISSUED
JAN74
VEHICLE
400 Commonwealth Drive, Warrendale, PA 15096-0001
RECOMMENDED Issued 1974-01
PRACTICE
Submitted for recognition as an American National Standard

LOW TENSION WIRING AND CABLE TERMINALS AND SPLICE CLIPS

Foreword—This Document has not changed other than to put it into the new SAE Technical Standards Board
Format.

1. Scope—The SAE Recommended Practice covers the application requirements for terminals and splice clips
attached to stranded low tension wiring and cable as shown in J878 and J558. In addition, it covers maximum
voltage drop limits for friction type connections.

2. References

2.1 Related Publications

2.1.1 SAE PUBLICATIONS—Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.

SAE J558—Low Tension Cable

SAE J878—Low Tension Cable Thermosetting Insulation

3. Use Of Terminals—Friction (quick disconnect) type brass connections should be used only where the
maximum temperature (environmental ambient plus rise due to current), measured at the center of the
terminal surface, does not exceed the capabilities of the physical properties of the material. Maximum
temperatures for terminal materials other than brass should also be determined prior to using so as to be
compatible with the physical properties of these materials.

Electrical connections and splices of standard types must be protected, as application dictates, from moisture,
salt, soil accumulation, acid, or corrosive vapor which will deteriorate the connection beyond the limits of this
recommended practice.

4. Performance Requirements (Electrical)—Terminals or splice clips shall be attached to wire or cable in such
a manner that, following the humidity test, the voltage drop across the attachment shall not exceed the values
in Table 1. Friction connections (terminal to terminal) shall be such that following four repeated insertions and
the humidity test, the voltage drop across the connection shall not exceed the values in Table 2. For a terminal
to be acceptable, all specimens tested must meet the requirements.

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.

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Copyright 1974 Society of Automotive Engineers, Inc.

All rights reserved. Printed in U.S.A.
 SAE J163 Issued JAN74

TABLE 1—WIRE TO TERMINAL OR WIRE TO WIRE (SPLICE CLIP METHOD) VOLTAGE DROP
(AFTER HUMIDITY TEST)
Drop, mV

Wire/Cable Uninsulated Preinsulated

(SAE Gage) Test Current, A Terminal Terminal
20 5 3 3.5
18 10 5 5.5
16 15 8 9
14 20 10 11
12 30 15 17
10 40 20 22
8 50 25 --
6 60 15 --
4 70 18 --
2 80 20 --
0 90 23 --
00 100 25 --

TABLE 2—FRICTION VOLTAGE DROP (AFTER HUMIDITY TEST AND FOUR INSERTIONS)
Wire/Cable (SAE Gage) Test Current, A Drop, mV
20 5 7.5
18 10 15
16 15 22.5
14 20 30
12 30 45
10 40 60
8 50 75

5. Test Procedure—Tests shall be conducted at 73 ± 5 °F (23 ± 3 °C). Test samples shall consist of terminals or
splice clips attached to 12 in (305 mm) of wire. It is suggested that at least 10 specimens of each wire size be
subjected to each test.

6. Voltage Drop Test—Measurements shall be made after the temperature of the specimen has stabilized (2 h
under test load).

Measurements across a wire to terminal attachment shall be made between the center of the conductor grip
and a point on the cable core 3 in (76.2 mm) behind the conductor grip. Probe point on the cable core shall be
stripped and solder dapped. For preinsulated terminals, the measurements shall be made between a point in
front of the conductor grip within 1/16 in (1.6 mm) of the end of the insulation and a point on the cable core 3 in
(76.2 mm) behind the conductor grip. The voltage drop across the attachment is defined as the difference
between this reading and the voltage drop through the 3 in (76.2 mm) of wire.

Measurements across a splice clip connection shall be made between points on cable cores 3 in (76.2 mm)
behind the center of the conductor grip crimp. Probe points on the cable core shall be stripped and solder
dapped. The voltage drop across the splice is defined as the difference between this reading and the voltage
drop through the 6 in (152 mm) of wire. Measurements shall be made across each combination of conductor
pairs in the splice. The current value shall be selected according to the smaller gage cable in the cable pair
being measured.

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 SAE J163 Issued JAN74

Measurements across a friction connection shall be made between the centers of the conductor grips of two
joined line connector type terminals and from the center of the conductor grip of a line terminal to a similar
point on a joined fixed terminal.

For preinsulated terminals, the voltage drop across the wire to terminal attachment plus the 3 in (76.2 mm) of
cable shall be determined first per the above procedure. Then the terminals shall be connected and
measurements across the connection shall be made from the stripped solder dapped points on the cable cores
of two joined line connector type terminals and from the same point on the cable core to a point on a joined
fixed terminal equivalent to that used for uninsulated terminals. The voltage drop across the friction connection
is defined as the difference between this reading and the previous measurement(s) for the same specimen(s)
(wire drop plus attachment drop).

7. Humidity Test—The humidity test shall consist of 100 h at 95 to 100% relative humidity at 100 ± 5 °F (38 ±
3 °C). (Demineralized water shall be used.) Specimens shall be prepared as follows:

1. Mounted at least 1 in (25.4 mm) apart on test boards.

2. Placed in the humidity cabinet with the axis of each specimen in a horizontal plane and such that it has
all surfaces of the terminal completely exposed and not in contact with other objects.
3. Removed from the cabinet after the prescribed exposure period and allowed to dry 24 h at room
condition before final MVD test.

PREPARED BY THE SAE ELECTRICAL EQUIPMENT COMMITTEE

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 SAE J163 Issued JAN74

Rationale—Not applicable.

Relationship of SAE Standard to ISO Standard—Not applicable.

Application—The SAE Recommended Practice covers the application requirements for terminals and splice
clips attached to stranded low tension wiring and cable as shown in J878 and J558. In addition, it covers
maximum voltage drop limits for friction type connections.

Reference Section

J558—Low Tension Cable

J878—Low Tension Cable Thermosetting Insulation

Developed by the SAE Electrical Equipment Committee