9/27/01 AC 43.

13-1B CHG 1

SECTION 16. WIRE MARKING

11-205. GENERAL. The proper identifica­ 11-208. PLACEMENT OF IDENTIFI-

tion of electrical wires and cables with their CATION MARKINGS. Identification
circuits and voltages is necessary to provide markings should be placed at each end of the
safety of operation, safety to maintenance per­ wire and at 15-inch maximum intervals along
sonnel, and ease of maintenance. the length of the wire. Wires less than 3 inches
long need not be identified. Wires 3 to
a. Each wire and cable should be marked 7 inches in length should be identified ap­
with a part number. It is common practice for proximately at the center. Added identification
wire manufacturers to follow the wire material marker sleeves should be so located that ties,
part number with the five digit/letter C.A.G.E. clamps, or supporting devices need not be re­
code identifying the wire manufacturer. Ex­ moved in order to read the identification.
isting installed wire that needs replacement can
thereby be identified as to its performance ca­ The wire identification code must be printed to
pabilities, and the inadvertent use of a lower read horizontally (from left to right) or verti­
performance and unsuitable replacement wire cally (from top to bottom). The two methods
avoided. of marking wire or cable are as follows:

b. The method of identification should a. Direct marking is accomplished by

not impair the characteristics of the wiring. printing the cable’s outer covering. (See fig­
ure 11-23.)
CAUTION: Do not use metallic bands
in place of insulating sleeves. Exercise b. Indirect marking is accomplished by
care when marking coaxial or data printing a heat-shrinkable sleeve and installing
bus cable, as deforming the cable may the printed sleeve on the wire or cables outer
change its electrical characteristics. covering. Indirect-marked wire or cable
should be identified with printed sleeves at
11-206. WIRE IDENTIFICATION. To fa­ each end and at intervals not longer than 6 feet.
cilitate installation and maintenance, original The individual wires inside a cable should be
wire-marking identification is to be retained. identified within 3 inches of their termination.
The wire identification marks should consist of (See figure 11-24.)
a combination of letters and numbers that
identify the wire, the circuit it belongs to, its 11-209. TYPES OF WIRE MARKINGS.
gauge size, and any other information to relate The preferred method is to mark directly on
the wire to a wiring diagram. All markings the wire. A successful requirement qualifica­
should be legible in size, type, and color. tion should produce markings that meet the
marking characteristics specified in MIL-W­
11-207. IDENTIFICATION AND IN- 5088 or AS50881A without causing insulation
FORMATION RELATED TO THE WIRE degradation. Teflon coated wires, shielded
AND WIRING DIAGRAMS. The wire wiring, multi-conductor cable, and thermocou­
identification marking should consist of simi­ ple wires usually require special sleeves to
lar information to relate the wire to a wiring carry identification marks. There are some
diagram. wire marking machines in the market that can
be used to stamp directly on the type wires
mentioned above. Whatever method of mark­
ing is used, the marking should be legible and

Par 11-205 Page 11-83

AC 43.13-1B CHG 1 9/27/01

the color should contrast with the wire insula- tion or sleeve.

3” 15” 15” 3”
H215A20 H215A20 H215A20

(b) Single wire without sleeve

FIGURE 11-23. Spacing of printed identification marks (direct marking).

a. Extreme care must, therefore, be taken

during circuit identification by a hot stamp
machine on insulation wall 10 mils or thinner.

b. Alternative identification methods

such as “Laser Printing”, “Ink Jet”, and “Dot
Matrix” are preferred. When such modern
equipment is not available, the use of stamped
identification sleeving should be considered on
insulation wall thickness of 10 mils or less.

11-210. HOT STAMP MARKING. Due to

widespread use of hot stamp wire marking,
personnel should refer to SAE ARP5369,
Guidelines for Wire Identification Marking
using the Hot Stamp Process, for guidance on
minimizing insulation damage. Hot stamp
process uses a heated typeface to transfer pig­
ment from a ribbon or foil to the surface of
wires or cables. The traditional method im­
prints hot ink marks onto the wire. Exercise
caution when using this method, as it has been
FIGURE 11-24. Spacing of printed identification marks shown to damage insulation when incorrectly
(indirect marking). applied. Typeset characters, similar to that
used in printing presses but shaped to the

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9/27/01 AC 43.13-1B CHG 1

contour of the wire, are heated to the desired pending on equipment configuration, dot ma­
temperature. Wire is pulled through a channel trix can mark wire from 0.037 to 0.5-inch out­
directly underneath the characters. The heat of side diameter. Multi-conductor cable can also
the type set characters transfers the ink from be marked.
the marking foil onto the wire.
11-212. INK JET MARKING. This is a
a. Good marking is obtained only by the “non-impact” marking method wherein ink
proper combination of temperature, pressure, droplets are electrically charged and then di­
and dwelling. Hot stamp will mark wire with rected onto the moving wire to form the char­
an outside diameter of 0.038 to 0.25-inch. acters. Two basic ink types are available:
thermal cure and UV cure.
b. Before producing hot stamp wire, it
must be assured that the marking machine is a. Thermal cure inks must generally be
properly adjusted to provide the best wire heated in an oven for a length of time after
marking with the least wire insulation deterio­ marking to obtain their durability. UV cure
ration. The marking should never create an inks are cured in line much like dot matrix.
indent greater than 10 percent of the insulation
wall. b. Ink jet marks the wire on the fly and
makes a reasonably durable and legible mark
CAUTION: The traditional Hot without damaging the insulation. Ink jets
Stamp method is not recommended normally mark wire from 0.030 to 0.25-inch
for use on wire with outside diameters outside diameter. Multiconductor cable can
of less than 0.035. (REF. SAE also be marked.
ARP5369). Stamping dies may cause
fracture of the insulation wall and 11-213. LASER MARKING. Of the variety
penetration to the conductor of these of laser marking machines, UV lasers are
materials. When various fluids wet proving to be the best. This method marks
these opening in service, arcing and into the surface of the wire’s insulation without
surface tracking damage wire bun- degradation to its performance. One common
dles. Later in service, when various type of UV laser is referred to as an excimer
fluids have wet these openings, serious laser marker. UV laser produces the most du­
arcing and surface tracking will have rable marks because it marks into the insula­
damaged wire bundles. tion instead of on the surface. However, exci­
mer laser will only mark insulation that con­
11-211. DOT MATRIX MARKING. The tain appropriate percentages of titanium diox­
dot matrix marking is imprinted onto the wire ide (TiO2). The wire can be marked on the fly.
or cable very similar to that of a dot matrix UV can mark from 0.030 to 0.25-inch outside
computer printer. The wire must go through a diameter. The UV laser makes only gray
cleaning process to make sure it is clean and marks and they appear more legible on white
dry for the ink to adhere. Wires marked with or pastel-colored insulation.
dot matrix equipment require a cure consisting
of an UV curing process, which is normally 11-214. IDENTIFICATION SLEEVES.
applied by the marking equipment. This cure Flexible sleeving, either clear or opaque, is
should normally be complete 16 to 24 hours satisfactory for general use. When color-coded
after marking. Dot matrix makes a legible or striped component wire is used as part of a
mark without damaging the insulation. De cable, the identification sleeve should

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AC 43.13-1B CHG 1 9/27/01

specify which color is associated with each 11-216. OPERATING CONDITIONS. For
wire identification code. Identification sleeves sleeving exposed to high temperatures (over
are normally used for identifying the following 400 °F), materials such as silicone fiberglass
types of wire or cable: should be used.

a. Unjacketed shielded wire. 11-217. INSTALLATION OF PRINTED

SLEEVES. Polyolefin sleeving should be
b. Thermocouple wire identification is used in areas where resistance to solvent and
normally accomplished by means of identifi­ synthetic hydraulic fluids is necessary. Sleeves
cation sleeves. As the thermocouple wire is may be secured in place with cable ties or by
usually of the duplex type (two insulated wires heat shrinking. The identification sleeving for
within the same casing), each wire at the ter­ various sizes of wire is shown in table 11-17.
mination point bears the full name of the con­
ductor. Thermocouple conductors are alumel, Table 11-17. Recommended size of identification
chromel, iron, constantan, and copper sleeving.
constantan. Wire Size Sleeving Size
AN AL No. Nominal ID
c. Coaxial cable should not be hot (inches)
stamped directly. When marking coaxial ca­ #24 12 .085
ble, care should be taken not to deform the ca­ #22 11 .095
ble as this may change the electrical charac­ #20 10 .106
#18 9 .118
teristics of the cable. When cables cannot be #16 8 .113
printed directly, they should be identified by #14 7 .148
printing the identification code (and individual #12 6 .166
wire color, where applicable) on a nonmetallic #10 4 .208
#8 #8 2 .263
material placed externally to the outer covering #6 #6 0 .330
at the terminating end and at each junction or #4 #4 3/8 inch .375
pressure bulkhead. Cables not enclosed in #2 #2 1/2 inch .500
conduit or a common jacket should be identi­ #1 #1 1/2 inch .500
#0 #0 5/8 inch .625
fied with printed sleeves at each end and at
#00 #00 5/8 inch .625
intervals not longer than 3 feet. Individual #000 #000 3/4 inch .750
wires within a cable should be identified #0000 #0000 3/4 inch .750
within 3 inches from their termination.
11-218. IDENTIFICATION OF WIRE
d. Multiconductor cable normally use BUNDLES AND HARNESSES. The identi­
identification sleeves for identifying un­ fication of wire bundles and harnesses is be­
shielded, unjacketed cable. coming a common practice and may be ac­
complished by the use of a marked sleeve tied
e. High-temperature wire with insulation in place or by the use of pressure-sensitive tape
is difficult to mark (such as Teflon and fiber­ as indicated in figure 11-25.
glass).

11-215. IDENTIFICATION TAPE. Identi­

fication tape can be used in place of sleeving,
in most cases (i.e. polyvinylfluoride).

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9/27/01 AC 43.13-1B CHG 1

FIGURE 11-25. Identification of wire bundles and har­

nesses.

a. Wires for which identifications are FIGURE 11-26. Standard sleeves (135 ºC).
reassigned after installation, may be remarked
on sleeves at the termination of each wire
segment. It may be necessary to reidentify
such wires throughout their lengths to facili­
tate ease of maintenance.

b. For high-density harnessed, shielded,

and jacketed multiconductor cables and when
using nonsignificant wire identification, color
coding or its alphanumeric equivalent may be
interchanged within the same harnesses. The
alphanumeric equivalent of the color code
should be as set forth in MIL-STD-681.
FIGURE 11-27. Installation of heat-shrinkable insula­
11-219. TERMINAL MARKING tion sleeves.
SLEEVE AND TAGS. Typical cable mark­
ers are flat, nonheat-shrinkable tags. Heat- 11-220. SLEEVES AND CABLE
shrinkable marking sleeves are available for MARKERS SELECTION. Sleeves and ca­
marking wires and cables, and should be in­ ble markers must be selected by cable size and
serted over the proper wire or cable and heat- operating conditions. (See tables 11-18
shrunk using the proper manufacturer recom­ through 11-21).
mended heating tool. (See figures 11-26
and 11-27.) a. Markers are printed using a typewriter
with a modified roller. Blank markers on a
bandolier are fed into the typewriter, where
they are marked in any desired combination of
characters. The typed markers, still on ban-

Par 11-221 Pages 11-87

AC 43.13-1B CHG 1 9/27/01

doliers, are heated in an infrared heating tool

that processes the markers for permanency. (2) Cut the marking plate from the
The typed and heat-treated markers remain on bandolier. (See figure 11-28.)
the bandolier until ready for installation.
(3) Thread the tie-down straps through
b. Markers are normally installed using holes in marking plate and around cable.
the following procedure: Thread tip of tie-down strap through slot in
head. (See figure 11-29.) Pull tip until strap
is snug around cable.

FIGURE 11-29. Tie-down strap installation.

FIGURE 11-28. Cable markers.

(1) Select the smallest tie-down strap
that will accommodate the outside diameter of
the cable. (See table 11-22.)

TABLE 11-18. Selection table for standard sleeves.

Wire or Cable Markable Installed Installed As-supplied
Diameter Range. Length * Sleeve Wall Inside
(inches) Length Thickness Diameter
Min Max (inches) (nom) (max inches) (min inches)
(inches)
0.050 0.080 18 1.5 0.026 0.093
0.075 0.110 18 1.5 0.026 0.125
0.100 0.150 18 1.5 0.028 0.187
0.135 0.215 18 1.5 0.028 0.250
0.200 0.300 18 1.5 0.028 0.375
0.135 0.300 18 1.5 0.028 0.375
0.260 0.450 18 1.5 0.028 0.475
* Based on 12 characters per inch

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9/27/01 AC 43.13-1B CHG 1

TABLE 11-19. Selection table for thin-wall sleeves.

Wire or Cable Markable Installed Installed Wall As-supplied
Diameter Range Length * Sleeve Thickness Inside
(inches) (inches) Length (nom) (max inches) Diameter
Min. Max. (inches) (min inches)
0.035 0.080 22 1.75 0.020 0.093
0.075 0.110 22 1.75 0.020 0.125
0.100 0.150 21 1.75 0.021 0.187
0.135 0.225 21 1.75 0.021 0.250
* Based on 12 characters per inch

TABLE 11-20. Selection table for high-temperature sleeves.

Wire or Cable Markable Installed Installed As-supplied
Diameter Range Length * Sleeve Wall Inside
(inches) Length Thickness Diameter (min
Min. Max. (inches) (nom) (max inches) inches)
(inches)
0.035 0.080 18 1.5 0.019 0.093
0.075 0.110 18 1.5 0.016 0.125
0.100 0.150 18 1.5 0.018 0.187
0.135 0.215 18 1.5 0.018 0.250
0.200 0.300 18 1.5 0.018 0.375
0.260 0.450 18 1.5 0.018 0.475
* Based on 12 characters per inch

TABLE 11-21. Selection table for cable markers.

Cable Diameter Type of Cable Marker Number of Number Marker
Range Attachment of Lines Thickness
(inches) Holes of Type (nom)
(inches)
0.25-0.50 Standard, 135 °C 4 2 0.025
0.25-0.50 High Temperature, 4 2 0.020
200 °C
0.25-0.50 Nuclear, 135 °C 4 2 0.025
0.50-up Standard, 135 °C 4 3 0.025
0.50-up Standard, 135 °C 6 3 0.025
0.50-up High Temperature, 4 3 0.020
200 °C
0.50-up High Temperature, 6 3 0.020
200 °C
0.50-up Nuclear, 135 °C 4 3 0.025
0.50-up Nuclear, 135 °C 6 3 0.025

TABLE 11-22. Plastic tie-down straps (MS3367, Type I, Class 1).

Cable Diameter Tie-down Strap Strap Identification * Installation Tool Tension Setting
(inches) MS3367­
Min Max
1/16 5/8 4-9 Miniature (MIN) MS90387-1 2
1/16 1¼ 5-9 Intermediate (INT) MS90387-1 4
1/16 4 2-9 Standard (STD) MS90387-1 6
3/16 8 6-9 Heavy (HVY) MS90387-2 6
* The specified tool tension settings are for typical cable application. Settings less than or greater than those specified may be required
for special applications.

Par 11-221 Pages 11-89

AC 43.13-1B CHG 1 9/27/01

(4) Select the applicable installation

tool and move the tension setting to the cor­
rect position. (See figure 11-30.)

(5) Slide tip of strap into opening in

the installation tool nose piece. (See fig­
ure 11-30.)

(6) Keeping tool against head of tie-

down strap, ensure gripper engages tie-down FIGURE 11-32. Temporary wire identification marker.
strap, and squeeze trigger of installation tool
until strap installation is completed as shown a. With a pen or a typewriter, write
in figure 11-31. wire number on good quality white split in­
sulation sleeve.

b. Trim excess white insulation sleeve,

leaving just enough for one wrap around wire
to be marked, with number fully visible.

c. Position marked white insulation

sleeve on wire so that shielding, ties, clamps,
or supporting devices need not be removed to
read the number.

d. Obtain clear plastic sleeve that is

FIGURE 11-30. Tie-down strap installation tool. long enough to extend 1/4 inch past white in­
sulation sleeve marker edges and wide enough
to overlap itself when wrapped around white
insulation and wire.

e. Slit clear sleeve lengthwise and place

around marker and wire.

FIGURE 11-31. Completed installation. f. Secure each end of clear sleeve with
lacing tape spot tie to prevent loosening of
sleeve.

11-222. MARKER SLEEVE INSTLA-

11-221. TEMPORARY WIRE AND TION AFTER PRINTING. The following
CABLE MARKING PROCEDURE. A general procedures apply:
temporary wire marking procedure follows
but should be used only with caution and with a. Hold marker, printed side up, and
plans for future permanence. (See fig­ press end of wire on lip of sleeve to open
ure 11-32.) sleeve. (See figure 11-33.)

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9/27/01 AC 43.13-1B CHG 1

FIGURE 11-33. Inserting wire into marker.

b. If wire has been stripped, use a scrap

piece of unstripped wire to open the end of the
marker.

c. Push sleeve onto wire with a gentle

twisting motion.

d. Shrink marker sleeve, using heat gun

with shrink tubing attachment. (See fig­
ure 11-34.)

FIGURE 11-34. Shrinking marker on wire.

11-229. [RESERVED.]
11-223.

Par 11-221 Pages 11-90a (and 11-90b)