Bend cable, then push into swaging position 1 2 Before Swaging After Swaging Cable size (inches) 1/16 3/32 1/8 5/32 3/16 7/32 1/4 9/32 5/16 3/8 7 x 7 7 x 7 7 x 19 7 x 19 7 x 19 7 x 19 7 x 19 7 x 19 7 x 19 7 x 19 0.160 0.218 0.250 0.297 0.359 0.427 0.494 0.563 0.635 0.703 0.078 0.109 0.141 0.172 0.203 0.234 0.265 0.297 0.328 0.390 1.042 1.261 1.511 1.761 2.011 2.261 2.511 2.761 3.011 3.510 0.969 1.188 1.438 1.688 1.938 2.188 2.438 2.688 2.938 3.438 480 920 2,000 2,800 4,200 5,600 7,000 8,000 9,800 14,400 0.138 0.190 0.219 0.250 0.313 0.375 0.438 0.500 0.563 0.625 Wire strands Outside  diameter Bore diameter Bore length Swaging length Minimum breaking strength (pounds) Shank diameter * *Use gauges in kit for checking diameters. Figure 2-70.  Straight shank terminal dimensions. Figure 2-68.  Insertion of cable into terminal. Figure 2-69.  Gauging terminal shank dimension after swaging. 2-42 This load should be held for at least 3 minutes. Any testing  of this type can be dangerous. Suitable guards should be  placed over the cable during the test to prevent injury to  Aircraft cable systems are subject to a variety of environmental  conditions and deterioration. Wire or strand breakage is easy  to recognize visually. Other kinds of deterioration, such as  wear, corrosion, and distortion, are not easily seen. Special  attention should be given to areas where cables pass through  battery compartments, lavatories, and wheel wells. These are  prime areas for corrosion. Special attention should be given to  critical fatigue areas. Those areas are defined as anywhere the  cable runs over, under, or around a pulley, sleeve, or through  a fairlead; or any section where the cable is flexed, rubbed,  or within 1 foot of a swaged-on fitting. Close inspection in  these critical fatigue areas can be performed by rubbing a rag  along the cable. If there are any broken strands, the rag snags  on the cable. A more detailed inspection can be performed  in areas that may be corroded or indicate a fatigue failure by  loosing or removing the cable and bending it. This technique  personnel in the event of cable failure. If a proper test fixture  is not available, the load test should be contracted out and  performed by a properly equipped facility. •  Inspect the terminal after swaging to determine that it  is free of die marks and splits and is not out of round.  Check the cable for slippage at the masking tape and  for cut and broken wire strands. •  Using a go/no-go gauge supplied by the swaging  tool manufacturer or a micrometer and swaging  chart, check the terminal shank diameter for proper  dimension.  [Figures 2-69  and  2-70] •  Test the cable by proof-loading locally fabricated  splices and newly installed swage terminal cable  fittings for proper strength before installation. This  is conducted by slowly applying a test load equal to  60 percent of the rated breaking strength of the cable  listed in  Figure 2-71 . Cable Inspection