WIRING GUIDE – PRIMARY WIRE & BATTERY CABLE

TECHNICAL DATA
Using an automotive wiring guide is TOTAL APPROX.
critical to help determine the correct CIRCUIT
wire or cable gauge for 12-volt AMPERES WIRE GAUGE (FOR LENGTH IN FEET)
systems. The selection of the correct 12V 3 5 7 10 15 20 25 30 40 50 75 100
gauge for automotive or other low 1 18 18 18 18 18 18 18 18 18 18 18 18
voltage applications is extremely 1.5 18 18 18 18 18 18 18 18 18 18 18 18
important to maximize safety and 2 18 18 18 18 18 18 18 18 18 18 16 16
performance. Voltage drop or a loss 3 18 18 18 18 18 18 18 18 18 18 14 14
of candlepower can occur if an
4 18 18 18 18 18 18 18 18 16 16 12 12
insufficient gauge is used.
5 18 18 18 18 18 18 18 18 16 14 12 12
Always consider the total amperage 6 18 18 18 18 18 18 16 16 16 14 12 10
and length of wire in each circuit
7 18 18 18 18 18 18 16 16 14 14 10 10
when selecting an adequate gauge.

PAGES 87 THRU 90
8 18 18 18 18 18 16 16 16 14 12 10 10
Allow for the return circuit, including
the grounded return, when estimating 10 18 18 18 18 16 16 16 14 12 12 10 10
the length. 11 18 18 18 18 16 16 14 14 12 12 10 8
12 18 18 18 18 16 16 14 14 12 12 10 8
15 18 18 18 18 14 14 12 12 12 10 8 8
18 16 16 16 16 14 14 12 12 10 10 8 8
USING THE CHART 20 16 16 16 16 14 12 10 10 10 10 8 6
1. Measure the length of wire in the 22 14 14 14 14 12 12 10 10 10 8 6 6
circuit including the ground return. 24 14 14 14 14 12 12 10 10 10 8 6 6
A two-wire circuit will be the total 30 12 12 12 12 10 10 10 10 10 6 4 4
lengths of both the wires. Account 40 10 18 18 18 18 18 18 18 6 6 4 2
for both vehicles on auto and trailer
50 8 8 8 8 8 8 8 8 6 6 2 2
applications.
100 4 4 4 4 4 4 4 4 4 2 1 1/0
2. Find the total amperes, watts, or 150 2 2 2 2 2 2 2 2 2 1 2/0 2/0
candlepower and choose the nearest
200 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 1/0 4/0 4/0
number in Circuit Amperes column.
3. Look across for proper footage to
find nearest wire gauge.

Note:
18-gauge applications outside of the shaded
area could be 20-gauge for electrical TYPICAL AMPERAGE GUIDE
purposes. However, it is recommended to
use 18-gauge for the tensile strength of the EQUIPMENT AVG. AMPS*
wire. Chart is based on maximum 10% Power Antenna 6 to 10
voltage drop @ 100°F (in free air).
Electric Wiper 3 to 6
Electric Clock and Light 0.3
Radio/CD Player 2 to 5
Cigarette Lighter/Power Outlet 10 to 12
Gauges 0.7 to 1
Dome Light 1
Power Sunroof 20 to 25
Dash lights 1.5 to 3
Trunk Lights 0.5
License Lights 0.5
Power to Trailer Hitch if Equipped 20 to 30
Stop Lights (2) 3.5 to 4
Tail Lights (2) 0.5
Reverse Lights (2) 3.5 to 4
Rear Window Defogger 20 to 25
Power Door Locks 3 to 5
Power Seats 25 to 50
Power Windows 2 to 20
Headlight Dimmer 2.2
Anti-lock Brake Module 2 to 6
Starter Motor 75 to 300
Starter Solenoid 12 to 20
Side Marker Lights (2) 1.3
Parking Lights (2) 1.3
Headlights - Low Beams 8 to 9
Headlights - High Beams 13 to 15
Fog Lights 8 to 9
Horns (2) 18 to 20
Alarm System 18 to 20
Ignition 1.5 to 3.5
Heater/Defroster 6 to 10
Air Conditioner 13 to 20
*Based on a typical 12-volt system.

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 MARINE WIRE & CABLE COLOR CODING
TECHNICAL DATA

Color Item Use

Red DC positive conductor Positive mains
Black or yellow DC negative conductor Return, negative mains
Green or green w/ DC grounding conductor Bonding system
yellow stripe Bonding wires (if insulated)
Light blue Oil pressure Oil pressure sender to gauge
Dark blue Cabin & instrument lights Fuse or switch to lights
Brown Generator charge light Generator armature to regulator
Alternator charge light Generator, terminal/alternator,
PAGES 87 THRU 90

auxiliary terminal to light regulator

Pumps Fuse or switch to pumps
Gray Navigation lights Fuse or switch to lights
Tachometer Tachometer sender to gauge
Orange Accessory feed Ammeter to alternator of generator output
and accessory fuses or switches
Pink Fuel gauge Fuel gauge sender to gauge
Purple Ignition Ignition switch to coil & electrical instruments
Brown w/yellow stripe Bilge blowers Fuse or switch to blower
Yellow w/red stripe Starting circuit Starting switch to solenoid
Tan Water temperature Water temperature sender to gauge
Green/stripe (G/x) Tilt down and/or trim in Tilt and/or trim circuits
(except G/Y)
Blue/stripe (Bl/x) Tilt up and/or trim out Tilt and/or trim circuits
NOTE: If yellow is used for DC negative, blower must be brown with yellow stripe.

88
TRAILER WIRING RECOMMENDATIONS

TECHNICAL DATA
PAGES 87 THRU 90
TRACTOR TRAILER WIRING RECOMMENDATIONS (RCCC & A.T.A.)

89
 MODERN METRIC CONVERSION FACTORS
TECHNICAL DATA

Symbol When You Multiply By To Find Symbol Symbol When You Multiply By To Find Symbol
Know... Know...

LENGTH LENGTH
in inches 25.4 millimeters mm mm millimeters 0.039 inches in
ft feet 0.305 meters m m meters 3.28 feet ft
yd yards 0.914 meters m m meters 1.09 yards yd
mi miles 1.61 kilometers km km kilometers 0.621 miles mi

AREA AREA
in2 square inches 645.2 square millimeters mm2 mm2 square millimeters 0.0016 square inches in2
ft2 square feet 0.093 square meters m2 m2 square meters 10.764 square feet ft2
PAGES 87 THRU 90

yd2 square yards 0.836 square meters m2 m2 square meters 1.195 square yards ac
ac acres 0.405 hectares ha ha hectares 2.47 acres mi2
mi2 square miles 2.59 square kilometers km2 km2 square kilometers 0.386 square miles

VOLUME VOLUME
fl oz fluid ounces 29.57 milliliters ml ml milliliters 0.034 fluid ounces fl oz
gal gallons 3.785 liters l l liters 0.264 gallons gal
ft3 cubic feet 0.028 cubic meters m3 m3 cubic meters 35.71 cubic feet ft3
yd3 cubic yards 0.765 cubic meters m3 m3 cubic meters 1.307 cubic yard yd3
NOTE: Volumes greater than 1000 l shall be shown in m3

MASS MASS
oz ounces 28.35 grams g g grams 0.035 ounces oz
lb pounds 0.454 kilograms kg kg kilograms 2.202 pounds lb
T short tons (2000 lb) 0.907 megagrams Mg Mg megagrams 1.103 short tons (2000 lb) T

TEMPERATURE (exact) TEMPERATURE (exact)

Fahrenheit 5(F-32)/9 or Celsius Celsius Fahrenheit
°F °C °C 1.8°C +32 °F
temperature (F-32)/1.8 temperature temperature temperature

ILLUMINATION ILLUMINATION
fc foot-candles 10.76 lux lx lx lux 0.0929 foot-candles fc
fl foot-Lamberts 3.426 candela/m2 cd/m2 cd/m2 candela/m2 0.2919 foot-Lamberts fl

FORCE and PRESSURE or STRESS FORCE and PRESSURE or STRESS

lbg poundforce 4.45 newtons N N newtons 0.225 poundforce lbf
psi pounds per square inch 6.89 kilopascals kPa kPa kilopascals 0.145 pounds per square inch psi

ELECTRICAL ELECTRICAL
Ohms/Kilofeet 3.2808 Ohms/Kilometer Ohms/Kilometer 0.3048 Ohms/Kilofeet
Insulation Resistance: Insulation Resistance:
Megohms–Kilofeet 0.3048 Megohms–Kilometer Megohms–Kilometer 3.2808 Megohms–Kilofeet

90
GLOSSARY

GLOSSARY
A Common abbreviation for ampere.
ABRASION RESISTANT Ability to resist surface wear.
ABS Anti-lock Brake System.
ABYC American Boat and Yacht Council.
AC Alternating Current.
ACID-RESISTANT Ability to resist acid corrosion.

PAGES 91 THRU 94
Al Period Table of Elements abbreviation for Aluminum.
ALLOY A substance having metallic properties and being composed of an elemental metal and one or
more chemical elements.
AMP Common abbreviation for ampere.
AMPACITY The RMS current which a device can carry within specified temperature limitations in a specified
environment: dependent upon temperature rating, power loss or heat dissipation.
AMPERE The SI unit used to measure electric current. Electric current through any given cross-section (such
as a cross-section of a wire) may be measured as the amount of electrical charge moving through
that cross-section in one second. One ampere is equal to a flow of one coulomb per second, or a
flow of 6.28 × 1018 electrons per second.
ANNEALED An object that is free from internal stress by heating and gradually cooling.
ANTIMONIAL LEAD A lead alloy that contains antimony.
ANTIMONY A brittle, lustrous, white metallic element occurring in nature free or combined, used chiefly in
alloys.
APPROVED Formally confirmed or sanctioned.
ASTM American Society for Testing and Materials.
AUXILIARY A secondary or supplementary wire.
AWG American Wire Gauge. A wire diameter specification. The lower the AWG number the larger the
wire diameter.
AWM Appliance Wiring Material.
BARE CONDUCTOR A conductor having no insulation or jacket.
BUNCH STRANDING Conductors twisted together with the same lay and direction without regard to geometric pattern.
°C Common abbreviation for Celsius.
CABLE A conductor or group of conductors for transmitting electric power or telecommunication signals
from one place to another.
CABLE ASSEMBLY A string of cables and/or wires which transmit informational signals or operating currents. The
cables are bound together by clamps, cable ties, lacing, sleeves, electrical tape, conduit, or a
combination there of.
CAPACITY A measurement of the ability to store electrical charge.
CCA Copper Clad Aluminum.
CERTIFICATE OF COMPLIANCE A document certified by a competent authority that the supplied good or service meets the
required specification. Also called certificate of conformance, certificate of conformity.
CIRCULAR MILS A unit of area equal to the area of a circle with a diameter of one mil (one thousandth of an inch).
CLADDING The bonding together of dissimilar metals often achieved by extruding two metals through a die as
well as pressing or rolling sheets together under high pressure
COAST GUARD APPROVED Meets or exceeds operating equipment requirements as set by the Coast Guard.
COLD TEST A type of test performed using colder than average temperatures to determine certain
characteristics of an object or material.
COMEX Primary market for trading metals such as gold, copper, silver and aluminum.
COMPLIANT Conforming to requirements.
CONDUCTANCE Measure of how well a material will conduct electricity. Measured in siemens.
CONDUCTIVITY The ability of a material to allow electrons to flow, measured by the current per unit of voltage
applied.
CONDUCTOR A material suitable for carrying an electric current.
CONNECTOR A metallic device of suitable electric conductance and mechanical strength, used to splice the ends
of two or more cable conductors, or as a terminal connector on a single conductor.
COPPER-CLAD ALUMINUM Aluminum and copper bonded together by extruding two metals through a die or pressing or
rolling sheets together under high pressure.
CORE The center of an object.
CORROSION The disintegration of an engineered material into its constituent atoms due to chemical reactions
with its surroundings.
CORRUGATED Shaped into folds or parallel and alternating ridges and grooves.
CRIMP A connection typically used to terminate stranded wire. Attached by inserting the stripped end of
stranded wire into a portion of the terminal, which is then mechanically deformed/compressed
tightly around the wire.
CROSS-LINK A special purpose high temperature automotive wire with cross-linked polyethylene (XLPE)
insulation. Typically used in high heat applications such as the engine compartment.

91
 GLOSSARY
GLOSSARY

CSA Canadian Standards Association. Similar to UL in the United States.

Cu Abbreviation for Copper in accordance with the Periodic Table of Elements.
CURRENT The rate of transfer of electricity. The unit of current is the ampere, rate of one coulomb per
second.
DC Direct current. Electrical current whose electrons flow in one direction only. It may be constant or
pulsating as long as their movement is in the same direction.
DIAMETER A straight line passing through the center of a circle or sphere and meeting the circumference or
PAGES 91 THRU 94

surface at each end.

DIE A metal block that is used for forming materials.
DIE CAST A metal casting process that is characterized by forcing molten metal under high pressure into a
mold cavity. The mold cavity is created using two hardened steel dies which have been machined
into shape and work similarly to an injection mold during the process.
DIELECTRIC An electrical insulator that can be polarized by an applied electric field.
DOT Department of Transportation.
DRAWING A technical drawing used to fully and clearly define requirements for engineered items.
DRAWING, WIRE A metal working process used to reduce the cross-section of a wire by pulling the wire through a
single, or series of drawing dies. Although similar in process, drawing is different from extrusion,
because in drawing the wire is pulled, rather than pushed, through a die.
DUAL EXTRUSION involves combining two or more extruders to produce wire with two or more colors.
ELASTOMER Any material that will return to its original dimensions after being stretched or distorted.
ELECTRO-TINNED To plate or coat (a base metal) with tin by electrolysis.
ELECTROLYSIS Is a process by which electrical energy is used to produce a chemical change.
EPDM (Ethylene Propylene Diene Monomer (M-class) rubber) A type of synthetic rubber.
EXTRUSION The act or process of shaping by forcing through a die.
°F Common abbreviation for Fahrenheit.
FERROUS Composed of and/or containing iron. A ferrous metal exhibits magnetic characteristics.
FILLER Something added to augment weight or size or fill space.
FLAME RETARDANT Chemicals used in thermoplastics, thermosets, textiles and coatings that inhibit or resist
the spread of fire.
FLANGE Disc shaped collar on the end of a spool or reel to prevent wire from sliding off barrel.
FLEXIBILITY The distance of motion.
FLEXIBLE Capable of being bent, usually without breaking. Susceptible of modification or adaptation. Pliable.
GAUGE A standard of measure or measurement.
GOLD-PLATED A base metal coated with gold through an electroplating process.
GPT General Purpose Thermoplastic.
GRAVITY CAST A manufacturing process utilizing the force of gravity instead of high pressure to fill a permanent
mold, or die, with molten material. The molten material is then allowed to solidify within that
mold, and is then ejected or broken out to make a fabricated part.
GROUND A voltage reference point that is the same as earth or chassis ground.
GXL General purpose Cross-linked polyethylene insulated wire. Intended for use in engine
compartments where higher heat resistance is required.
ID Inside Diameter.
INSULATION A material having good dielectric properties which is used to separate close electrical components,
such as cable conductors and circuit components.
ISO International Organization for Standardization.
JACKET Pertaining to wire and cable, the outer sheath which protects against he environment and may also
provide additional insulation.
LAY The length measured along the axis of a wire or cable required for a single strand (in stranded
wire) or conductor (in cable) to make one complete turn about the axis of the conductor or cable.
LAY DIRECTION The twist in the cables as indicated by the top strands while looking along the axis of the cable
away from the observer. Described as right-hand or left hand.
LME London Metal Exchange.
MC Master Carton.
MIL Military specification.
MTW Machine Tool Wire.
NAFTA North American Free Trade Agreement.
NATIONAL ELECTRICAL CODE A U.S. consensus standard published by the National Fire Protection Association (NFPA) and
(NEC) incorporated in OSHA regulations.
NEGATIVE A polarity of electrical charge.
NEUTRALIZE A chemical reaction in which an acid and a base react to form a salt. Water is frequently, but not
necessarily, produced as well.
NM-B A UL Cable type, non metallic–sheathed cable.

92
GLOSSARY

GLOSSARY
NOMINAL Name or identifying value of a measurable property by which a conductor or component or
property of a conductor is identified, and to which tolerances are applied.
NON-FERROUS Indicates metals other than iron and alloys that do not contain an appreciable amount of iron.
OD Outside diameter.
OE Original Equipment.
OEM Original Equipment Manufacturer.
OHM The electrical unit of resistance.

PAGES 91 THRU 94
OSHA U.S. Occupational Safety and Health Administration.
Pb Abbreviation for Lead in accordance with the Periodic Table of Elements.
PIES Product Information Exchange Standard.
PLASTICIZER A chemical agent added to plastics to make them softer and more pliable.
POLARITY Present in every electrical circuit. Electrons flow from the negative pole to the positive pole. In a
direct current (DC) circuit, one pole is always negative, the other pole is always positive and the
electrons flow in one direction only. In an alternating current (AC) circuit the two poles alternate
between negative and positive and the direction of the electron flow continually reverses.
POLYETHYLENE (PE) A thermoplastic material having excellent electrical and physical properties.
POLYMER A substance made of many repeating chemical units or molecules. The term polymer is often used
in place ov plastic, rubber, or elastomer.
POLYPROPYLENE (PPE) A thermoplastic similar to polyethylene but stiffer and having a higher softening point
(temperature).
POSITIVE A polarity of electrical charge.
POLYVINYL CHLORIDE (PVC) A general-purpose thermoplastic used for low voltage wire and cable insulation, and for jackets.
REEL DRUM DIAMETER Diameter of the drum (or hub) of the reel.
REEL FLANGE DIAMETER Diameter of the reel flanges.
(REEL HEIGHT)
REEL TRAVERSE Width of space between reel flanges.
REEL WIDTH Overall width of reel.
RESISTANT Impervious to the action of corrosive substances.
Root Mean Square (RMS) The effective value of an alternating current or voltage.
RoHS Restriction of Hazardous Substances.
ROPE LAY CONDUCTOR A conductor composed of a central core surrounded bo one or more layers of helically laid groups
of wires used in portable cables.
SAE Society of Automotive Engineers.
SGT Starter or Ground, general purpose, thermoplastic insulated cable.
SGX Starter or Ground, general purpose, Cross-linked polyethylene insulated cable.
SINTERED METAL Metal created from powder. Advantages include very high levels of purity and controlled,
uniformed porosity.
SLEEVING An extruded tube.
SOLDER A fusible metal alloy used to join together metal workpieces and having a melting point below that
of the workpiece(s).
SPECIFIC GRAVITY The ratio of the density (mass per unit volume) of a material to that of water.
SPLICE The physical connection of two or more conductors to provide electrical continuity.
STANDARD Something established by authority, custom, or general consent as a model or example.
Something set up and established by authority as a rule for the measure of quantity, weight,
extent, value, or quality.
STRANDED CONDUCTOR A conductor composed of a group of wires, usually twisted, or of any combination of such groups
of wire.
SXL Special purpose, Cross-linked polyethylene insulated wire. Used in engine compartments where
higher heat resistance is required.
TEMPERATURE RATING A measure of the highest (or occasionally lowest) temperature at which it is safe to use a product
for a particular purpose. For example, temperature ratings are often quoted for electrical insulators,
specifying the maximum temperature at which they provide adequate protection against electrical
breakdown.
TEMPERED STEEL A heat treatment technique that is done to "toughen" the metal by transforming brittle martensite
or bainite into a combination of ferrite and cementite or sometimes Tempered martensite.
Tempering is accomplished by a controlled reheating of the work piece to a temperature below its
lower critical temperature.
TENSILE STRENGTH The maximum load per unit of original cross-sectional area that a conductor attains when tested in
tension to rupture.
TERMINAL A device for joining electrical circuits together.
TEW Thermoplastic Equipment Wire. Canadian Standards Association type appliance wires. Solid or
stranded single conductor, plastic insulated, 105°C, 600V.
THERMOPLASTIC A material that can be softened repeatedly by heating and hardened by cooling through a
temperature range characteristic of the plastic, and that in the softened state can be shaped by
molding or extrusion.

93
 GLOSSARY
GLOSSARY

THERMOSET A material that has been vulcanized by heat or by other means and is substantially infusible and
insoluble.
THERMOSETTING INSULATION A polymer material that irreversibly cures. The cure may be done through heat (generally above
200 °C (392 °F)), through a chemical reaction, or irradiation such as electron beam processing.
Thermoset materials are usually liquid or malleable prior to curing and designed to be molded into
their final form, or used as adhesives.
THHN 600 volt 90°C nylon jacketed building wire.
PAGES 91 THRU 94

TIN-PLATED The resulting product of a process of thinly coating sheets of wrought iron or steel with tin. Often
to prevent rust and corrosion.
TINNED COPPER Tin coating added to copper to aid in soldering and inhibit corrosion.
TPE Thermoplastic Elastomer.
TRAVERSE The length of the barrel of a reel or spool from flange to flange.
TWP Thin-wall PVC Wire.
TXL Thin-wall cross-link polyethylene insulated wire. Used in automotive applications where small
diameter and minimal weight is desirable.
UL Underwriters Laboratory. A non-profit independent organization, which operates a listing service
for electrical and electronic materials and equipment. (Canadian counterpart is CSA).
UNILAY A conductor with more than one layer of helically laid wires with the direction of lay and length of
lay the same for all layers.
UNIVERSAL Adapted or adjustable to many sizes or mechanical uses. Can be used in both positive and
negative applications.
UV RESISTANT Being resistant to ultra violet (UV) light or sunlight. UV light, or sunlight, will cause non-resistant
materials and surfaces to fade or discolor.
VINYL Any of various compounds containing the vinyl radical, typically highly reactive, easily
polymerized, and used as basic materials for plastics.
VOLT The International System unit of electric potential and electromotive force, equal to the difference
of electric potential between two points on a conducting wire carrying a constant current of one
ampere when the power dissipated between the points is one watt.
VOLTAGE Electromotive force or potential difference, usually expressed in volts.
VOLTAGE DROP A voltage loss occurring between any two points in a power circuit.
VULCANIZED To improve the strength, resiliency, and freedom from stickiness and odor of (rubber, for example)
by combining with sulfur or other additives in the presence of heat and pressure.
VW-1 The flammability rating established by Underwriters Laboratories for wires and cables that pass a
specially designed vertical flame test, formerly designated FR-1, Similar to CSA designation FT1.
WIRE A usually pliable metallic strand or rod made in many lengths and diameters, sometimes clad and
often electrically insulated, used chiefly for structural support or to conduct electricity.
XLPE Cross-linked polyethylene.
ZINC-PLATED The product of a electroplating, the practice of putting an object in a solution and using electricity
to coat it. Zinc plating is commonly used on steel to provide corrosion resistance.

94