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INCH-POUND

MIL-DTL-781J
10 March 2014
SUPERSEDING
MIL-DTL-781H
1 April 2005
MIL-DTL-781H
w/AMENDMENT 3
17 February 2009

DETAIL SPECIFICATION

TERMINAL, WIRE ROPE SWAGING,

GENERAL SPECIFICATION FOR

This specification is approved for use by all Departments and Agencies of the Department
of Defense.

1. SCOPE

1.1 Scope. This specification covers wire rope terminals designed for attachment to wire
rope by swaging.

1.2 Classification. The terminals will be of the following types, as specified (see 6.2).

1.2.1 Types. The types of terminals are as follows:

Type I - Straight shank terminals

Type II - Ball-end terminals
Other - Eye and fork end strap terminals

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3 and 4 of this
specification. This section does not include documents cited in other sections of this
specification or recommended for additional information or as examples. While every effort has
been made to ensure the completeness of this list, document users are cautioned that they must
meet all specified requirements of the documents cited in sections 3 and 4 of this specification,
whether or not they are listed.

Comments, suggestions, or questions on this document should be addressed to Defense Logistics

Agency - Aviation, ATTN: DLAA-VEB, 8000 Jefferson Davis Highway, Richmond, VA
23297-5616 or emailed to STDZNMGT@dla.mil. Since contact information can change, you
may want to verify the currency of this address information using the ASSIST database at
https://assist.dla.mil/.

AMSC N/A FSC 1640

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2.2 Government documents.

2.2.1 Specifications and standards. The following specifications and standard form a
part of this document to the extent specified herein. Unless otherwise specified, the issues of
these documents are those cited in the solicitation or contract.

FEDERAL SPECIFICATIONS

RR-W-410 - Wire Rope and Strand

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-6117 - Wire Rope Assemblies, Aviation, Swaged Type

MIL-DTL-83420 - Wire Rope, Flexible, for Aircraft Control, General
Specification for

(See supplement 1 for list of specification sheets.)

(Copies of these documents are available online at http://quicksearch.dla.mil)

2.2.2 Other government documents. The following other government documents form a
part of this document to the extent specified herein. Unless otherwise specified, the issues of
these documents are those cited in the solicitation or contract.

STANDARDIZATION DOCUMENTS

SD-6 - Provisions Governing Qualification

(Copies of these documents are available online at http://quicksearch.dla.mil)

2.3 Non-government publications. The following documents form a part of this

document to the extent specified herein. Unless otherwise specified, the issues of these
documents are those cited in the solicitation or contract.

AEROSPACE INDUSTRIES ASSOCIATION

NAS494 - Terminal - Ball Type Cable

NAS1435 - Terminal - Strap, Cable Eye End and Fork End

(Copies of these documents are available online at http://www.aia-aerospace.org/ or from

Aerospace Industries Association, 1000 Wilson Boulevard, Suite 1700, Arlington, VA
22209-3901.)

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AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

ASME B1.1 - Unified Inch Screw Threads (UN and UNR Thread
Form)
ASME B46.1 - Surface Texture (Surface Roughness, Waviness, and
Lay)

(Copies of this document are available from http://www.asme.org/ or from American Society of
Mechanical Engineers, Three Park Avenue, New York, NY 10016-5990.)

AMERICAN SOCIETY FOR QUALITY (ASQ)

ASQ Z1.4 - Sampling Procedures and Tables for Inspection by

Attributes

(Copies of this document are available from http://www.asq.org/ or from American Society of
Quality, 600 North Plankinton Avenue, Milwaukee, WI 53203.)

ASTM INTERNATIONAL

ASTM A967/A967M - Standard Specification for Chemical Passivation

Treatments for Stainless Steel Parts
ASTM E18 - Standard Test Methods for Rockwell Hardness of
Metallic Material

(Copies of these documents are available from http://www.astm.org/ or from ASTM

International, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.)

SAE INTERNATIONAL

SAE AMS2430 - Shot Peening, Automatic

SAE AMS2700 - Passivation of Corrosion Resistant Steels

(Copies of this document are available from http://www.sae.org/ or from SAE International, 400
Commonwealth Drive, Warrendale, PA 15096-0001.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of
a conflict between the text of this document and the references cited herein (except for related
specification sheets), the text of this document takes precedence. Nothing in this document,
however, supersedes applicable laws and regulations unless a specific exemption has been
obtained.

3. REQUIREMENTS

3.1 MS or NAS sheets. The individual item requirements shall be as specified herein
and in accordance with the applicable MS or NAS sheet. In the event of any conflict between the
requirements of this specification and the MS or NAS sheet, the latter shall govern.
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3.2 Qualification. Steel wire rope terminals furnished under this specification shall be
products that are authorized by the qualifying activity for listing on the applicable qualified
products list before contract award (see 4.2 and 6.3). Qualification requirements do not apply to
NAS494 and NAS1435 terminals.

3.3 Material. Unless otherwise specified, all terminals, except NAS1435, shall be made
of corrosion resistant steel, 303Se (UNS S30323) or 304 (UNS S30400). NAS1435 terminals
shall be made of 301(UNS S30100), 302 (UNS S30200), 304 (UNS S30400) or 304L (UNS
S30403). All terminals shall be suitable for swaging onto wire ropes in accordance with the
requirements of 3.3.1.

3.3.1 Tensile strength. Except for NAS494 and NAS1435 terminals, the maximum
tensile strength shall not exceed 125,000 pounds per square inch for sizes under 1/4 inch in
thickness and 115,000 pounds per square inch for sizes 1/4 inch and larger in thickness. Where
applicable, tensile strengths for parts that will be subjected to finish annealing may be higher than
those specified, but must meet the hardness requirements delineated in 3.8.3, after annealing.

3.4 Threads. Threads shall be in accordance with ASME B1.1.

3.5 Design and dimensions.

3.5.1 Type I shank terminals. The design and dimensions of type I terminals shall be in
accordance with MS20658, MS20667, MS20668, MS21259, or MS21260, as specified in the
contract or order (see 6.2).

3.5.2 Type II ball-end terminals. The design and dimensions of type II terminals shall
be in accordance with MS20663, MS20664, or NAS494, as specified in the contract or order
(see 6.2).

3.5.3 Strap, cable eye end and fork end terminals. The design and dimensions of strap,
cable eye end and fork end terminals shall be in accordance with NAS1435, as specified in the
contract or order (see 6.2).

3.6 Protective treatment.

3.6.1 Surface treatment methods. After removal of all oil and grease, terminals shall be
treated by one of the following methods:
a. Nitric passivation per ASTM A967/A967M, Nitric 3 method or SAE AMS2700, Method 1,
type 7.
b. Nitric passivation per ASTM A967/A967M, Nitric 1 method or SAE AMS2700, Method 1,
type 2
c. Citric passivation per ASTM A967/A967M, Citric 1, 2 or 3 method or SAE AMS2700,
Method 2.
d. Glass bead peening per SAE AMS2430.
The method of treatment is at the manufacturer’s option unless specified in the contract (See 6.2.e).

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3.6.2 Washing. Upon completion of any treatment specified in 3.6.1except (d), the
terminals shall be thoroughly rinsed in water and dried.

3.6.3 Retreatment. Retreatment of terminals after swaging is not required.

3.7 Surface roughness. The surface roughness of the machined surface, except in the
threaded area, shall not exceed 125 root mean square (RMS) in accordance with ASME B46.1.

3.8 Performance.

3.8.1 Distortion. Except for NAS494 and NAS1435 terminals, elongation shall not
exceed 0.001 inch per inch in the direction of load application (see 4.6.1) for any measured
dimension resulting after the application of a proof load. The proof load shall be applied for 5
seconds and shall be 60 percent of the minimum breaking strength (MBS) as specified in the
related MS sheet for terminal sizes up to 3/8. Sizes 7/16 and larger shall be tested at a proof load
of 40 percent MBS.

3.8.1.1 Marks from NAS1435 fittings. Marks on MS20663, MS20664, or AIA NAS494
ball end fittings caused by AIA NAS1435 fittings during proof loading are not considered
distortion and shall not be considered as failures of the ball fittings.

3.8.2 Breaking strength. Terminals shall be capable of withstanding a tension load equal
to the MBS specified on the applicable MS or NAS sheet when tested in accordance with 4.6.2.

3.8.3 Hardness. When tested in accordance with paragraph 4.6.3, terminal hardness
readings shall not exceed a Rockwell A-scale value of 62.5 or Rockwell B-scale value of 100.

3.9 Identification of product. Terminals shall be marked for identification in accordance

with the applicable MS or NAS sheet. The maximum depth of marking shall be in accordance
with the applicable MS or NAS sheet, however, on certain curved surfaces, the maximum depth
specified may be exceeded to assure adequate legibility. Unless otherwise specified, the position
of the marking is optional.

3.9.1 Method of marking. Indention as specified on the applicable MS sheets may be

done by stamping, chemical or laser etching, or any other method that will provide a permanent
mark. Method of marking is at the manufacturer’s option.

3.10 Workmanship. Terminals shall be uniform in quality and free from pits, voids,
burrs, sharp edges, rust, laps, cracks, seams and other detrimental defects that would prevent
proper functioning or performance. Slight burrs in the thread-locking slot area that do not
prevent gauging or interfere with installation of the barrel and locking clip are acceptable.

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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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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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6. NOTES

(This section contains information of a general or explanatory nature that may be helpful,
but is not mandatory.)

6.1 Intended use. The corrosion-resistant steel terminals covered by this specification
are intended for swaging to corrosion-resistant steel and galvanized wire rope conforming to
MIL-DTL-83420 or RR-W-410 as applicable. These terminals can also be used in applications
involving corrosive conditions or where non-magnetic properties are essential.

6.1.1 Type I terminals. Type I terminals are the regular terminals in general use on
aircraft wire rope assemblies.

6.1.2 Type II terminals. Type II terminals are designed for use in ordnance and glider
control installations, secondary control systems such as switch or mechanism actuation, trim tab
control, etc., and in attaching wire ropes to quadrants, drums, etc., in the wire rope control
systems of powered aircraft.

6.2 Acquisition requirements. Acquisition documents should specify the following:

a. Title, number, and date of this specification.

b. Type of terminal required (see 1.2).
c. MS or NAS sheet, assembly numbers, or other drawing numbers required (see 3.5.1,
3.5.2, and 3.5.3).
d. Packaging requirements (see 5.1).
e. Specific surface treatment method if required (see 3.6.1).

6.3 Qualification. With respect to products requiring qualification, awards will be made
only for products that are, at the time of award of contract, qualified for inclusion in QPL-781
whether or not such products have actually been so listed by that date. The attention of
contractors is called to these requirements, and manufacturers are urged to arrange to have the
products that they propose to offer to the Federal Government tested for qualification in order
that they may be eligible to be awarded contracts or orders for the products covered by this
specification. Information pertaining to qualification of products may be obtained from Defense
Logistics Agency - Aviation, ATTN: DLAA-VEB, 8000 Jefferson Davis Highway, Richmond,
VA 23297-5616 or STDZNMGT@dla.mil.

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6.4 Subject term (key word) listing.

Ball end
Eye
Fork
Shank ball end
Straight shank terminal
Strap eye
Strap fork

6.5 Amendment notations. The margins of this specification are marked with vertical
lines to indicate where modifications from this amendment were made. This was done as a
convenience only and the Government assumes no liability whatsoever for any inaccuracies in
these notations. Bidders and contractors are cautioned to evaluate the requirements of this
document based on the entire content irrespective of the marginal notations.

Custodians: Preparing Activity:

Army - CR DLA - GS5
Navy - AS
Air Force - 99 (Project 1640-2013-001)
DLA - GS

Review Activities:
Army - AR, GL, MI
Navy - MC
Air Force - 71

NOTE: The activities listed above were interested in this document as of the date of this
document. Since organizations and responsibilities can change, you should verify the currency of
the information above using the ASSIST database at https://assist.dla.mil/.