MIL-DTL-781J
4. VERIFICATION
4.1 Classification of inspections. The inspection requirements specified herein are
classified as follows:
a. Qualification inspection (see 4.2).
b. Conformance inspection (see 4.3).
4.2 Qualification inspections. The qualification inspections shall consist of all the tests
and examinations of this specification.
4.2.1 Sampling instructions. Qualification test samples shall consist of a minimum of
four terminals of the type and size upon which qualification is desired. Either the left-hand or
right-hand threaded fitting may be submitted for qualification approval, wherein qualification of
one would automatically mean approval of the other without additional tests
4.2.2 Maintenance of qualification. At specified intervals determined by the qualifying
activity, the manufacturer must be able to demonstrate that the company still has the capabilities
and facilities necessary to produce the QPL items in accordance with this specification and in
accordance with the provisions governing qualification specified in SD-6.
4.3 Conformance inspection. The conformance inspection shall consist of:
a. Examination of product (see 4.5.1).
b. Hardness (see 4.6.3).
c. Breaking strength (see 4.6.2).
4.3.1 Lot. A lot shall consist of finished terminals of the same material, size, and part
number produced consecutively by the same machine or series of progressive processing
machines submitted for inspection at the same time under one contract or order. Lots shall be
segregated and marked to identify them with their respective random samples designated for
testing.
4.3.2 Sampling. ASQ Z1.4 shall be used as a guide in the development of contractors'
statistical techniques to assure the components meet all requirements specified herein.
4.4 Test preparations. Sample terminals to be tested for distortion and breaking strength
shall be swaged, in accordance with MIL-DTL-6117, to 2-foot lengths (minimum) of the
appropriate size wire rope conforming to MIL-DTL-83420 for sizes of wire rope up to and
including 3/8-inch diameter or to RR-W-410 for 6 x 19 independent wire rope core (IWRC)
construction, 7/16-inch diameter and larger as applicable. The swaged terminals shall be
examined for cracks and splits and dimensions accurately measured and noted.
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