MIL-DTL-642E
In the event that no production occurred during the reporting period, a report shall be submitted certifying
that the company still has the capabilities and facilities necessary to produce the item. If during 2
consecutive reporting periods there has been no production, the manufacturer may be required, at the
discretion of the qualifying activity, to submit a representative product of each type to testing in
accordance with the qualification inspection requirements.
4.4.5 Extension of qualification. Plugs of the same type shall be qualified for any permissible color other
than that tested during qualification inspection, provided that the material and design and construction
used are identical. Plugs shall be qualified for types with both plastic shells and metal shells by
submitting a sample of six plugs fabricated with plastic shells and six plugs of the same type fabricated
with metal shells. Plug type PJ-054 and PJ-540 shall both be qualified upon satisfactory completion of
qualification inspection of either type.
TABLE I. Qualification inspection.
Inspection
Requirement paragraph
Test paragraph
Group I (all sample units)
Visual and mechanical examination 1/ - - - - - - -
Torque (when applicable) - - - - - - - - - - - - - - -
Dielectric withstanding voltage- - - - - - - - - - - - -
Contact resistance- - - - - - - - - - - - - - - - - - - - -
Insulation resistance- - - - - - - - - - - - - - - - - - - -
Insertion and withdrawal forces- - - - - - - - - - - -
Strain relief - - - - - - - - - - - - - - - - - - - - - - - - - -
Longitudinal pull- - - - - - - - - - - - - - - - - - - - - - -
Static load- - - - - - - - - - - - - - - - - - - - - - - - - - -
Group II (6 sample units)
Moisture resistance- - - - - - - - - - - - - - - - - - - -
Group III (6 sample units)
Thermal shock - - - - - - - - - - - - - - - - - - - - - - -
Vibration, high frequency- - - - - - - - - - - - - - - -
Shock (specified pulse) - - - - - - - - - - - - - - - - - -
Salt spray (corrosion)- - - - - - - - - - - - - - - - - - -
Stack assembly strength - - - - - - - - - - - - - - - - -
Controlled drop - - - - - - - - - - - - - - - - - - - - - - -
1/ Marking will be considered defective only if it is illegible at the completion of any of the required
tests.
4.5 Quality conformance inspection.
4.5.1 Inspection of product for delivery. Inspection of product for delivery shall consist of groups A and B
inspections.
4.5.1.1 Inspection lot. An inspection lot shall consist of all plugs of the same basic type, produced under
essentially the same conditions, and offered for inspection at one time. An inspection lot may include
plugs of the same basic type having shells of different colors, provided that the plugs are otherwise
mechanically and dimensionally identical.
4.5.1.2 Group A inspection. Group A inspection shall consist of visual and mechanical examination
(see 4.6.1).
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