MIL-DTL-781J
4.5 Examinations.
4.5.1 Examination of product. Each sample terminal shall be examined to determine
conformance to dimensions, workmanship, and all other requirements of this specification not
covered by tests.
4.6 Tests.
4.6.1 Distortion. A proof load of 60 percent of the MBS specified on the applicable MS
sheet shall be applied to the terminal-wire rope assembly for sizes up to and including 3/8-inch
diameter. The proof load shall be 40 percent of MBS for sizes 7/16-inch diameter and larger.
After holding for 5 seconds, the load shall be released and the terminal measured for distortion.
Permanent increase of the overall dimensions measured in the direction of application of load
shall not exceed 0.001 inch per inch.
4.6.2 Breaking strength. The wire rope-terminal assembly shall be subjected to the
specified MBS on a tension testing machine. The load shall be applied to the fitting end of the
terminal in a manner similar to that for which it was designed. Prior to application of the load,
the wire rope shall be marked at the point where it enters the swaging end of the terminal. Any
slippage of the wire rope in the fitting, or signs of failure in the terminal shall be cause for
rejection. The test wire rope must not break below the minimum required breaking strength of
the terminal. In order to achieve breaking strength required for terminal, a carbon steel wire rope
should be used.
4.6.3 Hardness. Terminals and ball ends shall be tested in accordance with
ASTM E18 to determine compliance with 3.8.3. Hardness values will be obtained from the area
reserved for swaging. Correction for convex surfaces shall be made when appropriate. Because
of variations caused by surface work hardening, sectionalized hardness testing is permitted to
ascertain conformance when values exceed the allowable limit. The sectioned hardness test must
be performed on a cross-section of the area reserved for swaging.
5. PACKAGING
5.1 Packaging. For acquisition purposes, the packaging requirements shall be as
specified in the contract or order (see 6.2). When packaging of material is to be performed by
DoD or in-house contractor personnel, these personnel need to contact the responsible packaging
activity to ascertain packaging requirements. Packaging requirements are maintained by the
Inventory Control Point's packaging activities within the Military Service or Defense Agency, or
within the military service's system commands. Packaging data retrieval is available from the
managing Military Department's or Defense Agency's automated packaging files, CD-ROM
products, or by contacting the responsible packaging activity.
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