Application Specification
114-10014
LOC B
1
of 6
E
2006 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
Tyco is a trademark. *Trademark
Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1-800-722-1111
PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at
www.tycoelectronics.com
Size VIII Power Contacts
21 JUN 06 Rev D
All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and
inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2
_
.
Figures and illustrations are for identification only and are not drawn to scale.
1. INTRODUCTION
This specification covers the requirements for the application of Size VIII Power Pin and Socket Contacts.
These contacts have a wire range of 8 thru 18 AWG and are terminated with hand held tooling. Size VIII Power
Contacts may be used in Military Certified 24308 Special Series 109 connectors, such as the AMPLIMITE*,
Drawer, and Metrimate connectors which are designed with power/coax and signal mix cavities.
When corresponding with Tyco Electronics Personnel, use the terminology provided on this specification to
help facilitate your inquiry for information. Basic terms and features of components are provided in Figure 1.
Figure 1
PIN
SOCKET
Wire Barrel
Inspection Hole
Contact Body
Retention
Spring
2. REFERENCE MATERIAL
2.1. Revision Information
This paragraph is reserved for a revision summary of the most recent additions and changes made to this
specification which include the following:
S
Updated document to corporate requirements
S
Changed crimp height dimension for wire size 8 in table in Figure 3
2.2. Customer Service
Reference Product Base Part Number 211159 and Product Code 5064 are representative numbers of Size VIII
Power Connectors. Use of these numbers will identify the product line and expedite your inquiries through a
service network established to help you obtain product and tooling information. Such information can be
obtained through a local Tyco Electronics Representative or, after purchase, by calling the Tooling Assistance
Center or the Product Information Center number at the bottom of this page.
NOTE
Size VIII Power Contacts 114-10014
Rev
D2
of 6
2.3. Drawings
Customer Drawings for specific products are available from the service network. The information contained in
Customer Drawings takes priority if there is a conflict with this specification or with any technical
documentation supplied by Tyco Electronics.
2.4. Specifications
Product Specification 108–10045 provides product performance requirements and test information.
2.5. Instructional Material
The following list of available instruction sheets (408–series) provides assembly procedures for product,
operation, maintenance and repair of tooling.
Document Number Document Title
408–6827 Extraction Tool 58095–1 for AMPLIMITE Connectors
408–7424 Measuring Crimp Height Or Gaging Die Closure
408–7516 Screw Machine Contacts and Application Tooling
408–9310 Extraction Tool 58095–2 For HDI Hybrid Connector Power and Coaxial Contacts
3. REQUIREMENTS
3.1. Storage
The contacts should remain in the shipping containers until ready for use to prevent deformation to the contact.
The contacts should be used on a first–in/first–out basis to avoid storage contamination that could adversely
affect signal transmissions. These contacts have a shelf life of 2 years from date of manufacture.
3.2. Wire Selection and Preparation
A. Wire Type
The contacts will accept copper fused–stranded, or stranded conductor wire within the range of 18 through
8 AWG.
B. Preparation
The wire must be stripped to the dimension provided in Figure 2.
Do not nick, scrape, or cut the wire conductor during the stripping operation.
Locate the contact to be crimped in the appropriate tooling. Crimp the contact according to the instructions
packaged with that tooling.
Figure 2
Strip Length
Conductor
Insulation
9.52 [.375]
NOTE
Size VIII Power Contacts 114-10014
Rev
D 3
of 6
3.3. Crimped Contact Requirements
A. Crimp Length
For optimum crimp effectiveness, the crimp must be within the area shown in Figure 3 and must meet the
crimp dimensions provided. Effective crimp length shall be 3.05 mm [.120 in.] nominal, and is defined as
that portion of the wire barrel, excluding bellmouth(s), fully formed by the crimping tool. Instructions for
adjusting, repairing, and inspecting tools are packaged with the tools.
B. Conductor Location
The wire shall be visible through the wire barrel sight hole after crimping. Care shall be taken not to allow
insulation to be crimped in the wire barrel. See Figure 3.
C. Contact Retention Spring
Contact retention springs shall not be deformed.
D. Crimp Height
See Figure 3 for correct crimp height according to wire size.
Wire Barrel
Inspection
Hole
Effective
Crimp
Length
12.19 + 2.54
[.480 + .100]
Contact
Retention
Spring
Wire Barrel
Insulation
Measuring
Crimp
Height of
Contact
NOTE:
When checking crimp height, always measure the most compressed area of the crimp.
WIRE SIZE
(AWG) SELECTOR
SETTING POSITIONER OR TURRET HEAD
(TYCO ELECTRONICS PART NUMBER) CRIMP HEIGHT
8
7
SP689 (608651-2)
3 18 +0 18/-0 10 [ 125 + 007/- 004]
8
7
SP858
D
(608651-3)
3
.
18 +0
.
18/
-
0
.
10 [
.
125 +
.
007/
-.
004]
10
3
SP689 (608651-2)
2 44 +0 10 [ 096 + 004]
10
3
SP858
D
(608651-3)
2
.
44 +0
.
10 [
.
096 +
.
004]
12
1
SP689 (608651-2)
12
1
SP867
D
(---)
2 13 +0 10 [ 084 + 004]
14
1
SP689 (608651-2)
2
.
13 +0
.
10 [
.
084 +
.
004]
14
1
SP867
D
(---)
16
7
TP731 (608668-2)
1 73 +0 10 [ 068 + 004]
16
7
SP867
D
(---)
1
.
73 +0
.
10 [
.
068 +
.
004]
18
6
TP731 (608668-2)
1 55 +0 10 [ 061 + 004]
18
6
SP867
D
(---)
1
.
55 +0
.
10 [
.
061 +
.
004]
D
Use with long contact only.
Figure 3
Size VIII Power Contacts 114-10014
Rev
D4
of 6
E. Straightness
After crimping the wire to the contact, the contacts shall be chucked in the area shown in Figure 4 and
rotated 360
_
minimum. The point of Total Indicator Reading (TIR) measurement, shall be as shown in
Figure 4. The TIR shall not exceed 0.76 [.030].
There shall be no twist, roll, deformation or other damage to the mating portion of the crimped contact that
will prevent proper mating.
Figure 4
Chucking Area
Dial Indicator Probe
Placed Here for
Measurement of TIR
0.76
[.030]
Max.
Circle
Diameter
Contact and
Circle Diameter
Centerlines
Contact
3.4. Chemical Exposure
Do not store contacts near any chemicals listed below as they may cause stress corrosion cracking in the
contacts.
Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds
Amines Carbonates Nitrites Sulfur Nitrites Tartrates
Where the above environmental conditions exist, phosphor bronze contacts are recommended instead of brass if
available.
3.5. Repair
Contacts are not repairable once a termination has been made. Any defective contact should be removed and
replaced with a new one. If a damaged contact has already been placed in a housing, refer to Section 5
(TOOLING).
4. QUALIFICATIONS
While Size VIII Power Contacts are not UL Listed or CSA International Certified, they are designed to be used
in Military Certified Connectors.
5. TOOLING
Various tools are available for your production needs. The following Figure 5 and table provide tooling
information related to wire size.
The use of Extraction Tools are designed to remove contacts from the connector housings. Extraction tools 58095-1 or
58095-2 may provide your requirements for this process. For more information on extraction tooling or other tooling
information, contact the Tooling Assistance Center number listed at the bottom of page 1.
NOTE
NOTE
Size VIII Power Contacts 114-10014
Rev
D 5
of 6
Hand Crimping Tool
(Typ)
Pneumatic Crimping
Tool (Typ)
Extraction Tool (Typ)
DANIELS TOOLING TYCO ELECTRONICS TOOLING
CONTACT
TYPE WIRE SIZE
(AWG) SELECTOR
SETTING POSITIONER
OR TURRET
HEAD
CRIMPING
TOOLS
POSITIONER
OR TURRET
HEAD
HAND
CRIMPING
TOOL
8
7
SP689 608651-2
8
7
SP858 608651-3
10
3
SP858
M300
-
BT
608651-3
10
3
SP689
M300-BT
(Hand Tool)
or
608651-2
608651 1
12
1
SP689
or
WA27-300-BT-EP
(Pne matic Tool)
608651-2
608651
-
1
Size VIII Power
12
1
SP867
(P
neuma
ti
c
T
oo
l)
---
Contacts
14
1
SP689 608651-2
14
1
SP867 ---
16
7
TP731
FT8
608651-2
16
7
SP867
FT8
(Hand Tool)
or
---
608668 1
18
6
TP731
or
WA27-309EP
(Pne matic Tool)
608651-2
608668
-
1
18
6
SP867
(P
neuma
ti
c
T
oo
l)
---
Figure 5
Size VIII Power Contacts 114-10014
Rev
D6
of 6
6. VISUAL AID
Figure 6 shows a typical application of Size VIII Power Pin and Socket Contacts. This illustration should be
used by production personnel to ensure a correctly applied product. Applications which DO NOT appear
correct should be inspected using the information in the preceding pages of this specification and in the
instructional material shipped with the product or tooling.
FIGURE 6. VISUAL AID
WIRE VISIBLE IN
WIRE INSPECTION HOLE
CRIMP SHALL BE FULLY FORMED
AND CENTRALLY LOCATED
SLIGHT GAP BETWEEN INSULATION
AND WIRE BARREL IS PERMISSIBLE
INSULATION NOT
CRIMPED IN
WIRE BARREL
RETENTION SPRINGS
NOT DEFORMED
CRIMPED SIZE VIII
POWER PIN
CRIMPED SIZE VIII
POWER SOCKET
