MIL-DTL-9419G
4.7.5 Strength of actuating lever pivot, lever stop and cap (see 3.5.3). Switches shall be electrically
and mechanically operable after the following test and there shall be no breakage of the cap or body,
loosening or rotation of terminals or other damage to the switch:
a. A minimum of 10 inch-pounds of torque shall be applied to the cap around the major axis of the
switch.
b. A 90-pound load minimum shall be applied to the outer edge of the cap at an angle of 45
degrees to the major axis of the switch in each of the four directions of travel.
c. A 90-pound load minimum shall be applied to the top of the cap coaxial with the major axis of the
switch toward the actuating lever pivot.
d. A 2-pound load minimum shall be dropped from a minimum height of 8 inches and shall strike
the cap. The switch shall be mounted with its major axis at an angle of 30 degrees from vertical
(see figure 1).
4.7.6 Strength of terminals (see 3.5.4). A load of 30 pounds shall be applied to each terminal,
perpendicular to each terminal, perpendicular to the mounting plane of the switch, for one minute. Upon
completion of the test, switches shall be electrically and mechanically operable.
4.7.7 Electrical overload (see 3.5.5). Each switch to be tested for electrical endurance shall first be
tested for overload cycling at room ambient conditions using the same voltage, electrical frequency, and
the same pairs of contacts that will subsequently be used for the electrical endurance test. The switches
shall close and open the overload current of a circuit equal to 150 percent of the load rating at the
particular voltage and electrical frequency (see 3.1). The cycling rate shall be 5 to 6 cycles of operation
per minute. 100 cycles of operation shall be performed. The duty cycle shall be approximately 50
percent on, and 50 percent off.
4.7.8 Electrical endurance (see 3.5.6). For dc inductive loads, Inductive dc loads shall use inductors which
4.7.8.1 Normal. The switches shall be operated to make and free break the inductive load specified,
(see 3.1) for 250,000 cycles at a rate of between 28 and 32 operations per minute. The maximum ratio of
the "time on" to "time off" shall be 1:3. Operating force following endurance testing shall be between 12
and 50 ounces. The actuation lever travel shall be within limits except that the .25 degree differential may
not be measurable due to the degradation of the snap feel. The following conditions shall apply, switches
shall be continuously monitored and recorded to determine whether any contact has failed to open or
close its individual circuit in the proper sequence. The monitoring circuit shall not shunt inductive
components of inductive loads or switch contacts.
4.7.8.2 High speed. Switches shall be operated to make and free break the inductive load specified
herein for 1,000 cycles at a rate of between 60 and 80 operations per minute. At all times during and at
completion of the endurance test, switches shall be capable of making and free breaking the inductive
circuit and returning to center off by its own action. Following the test the operating force and the
actuation lever travel shall be within limits except that the .25 degree differential may not be measurable
due to the degradation of the snap feel.
4.7.9 Temperature rise (see 3.5.7). Switches shall be equipped with suitable thermocouples and leads
which shall be in accordance with SAE-AS50881. While carrying the inductive current specified herein,
the temperature shall not rise more than 30°C for one hour, thermocouples shall not be placed on the
common terminal.
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