SEMI-AUTOMATIC BENCH TOP CRIMPING
A COMPREHENSIVE GUIDEUNDERSTANDING YOUR TERMINATIONSOLUTION OPTIONS
Selecting the right terminator platform for your wire harness needs starts with understanding how muchforce you require to crimp. Small wire sizes require less crimp force, but benefit largely from wire guides,
and crimp quality monitoring to help maintain proper termination.
Conversely, larger wire sizes require more crimp force and in some cases the need to processloose-piece terminals.
Once you know what you plan to crimp our expert sales and engineering teams can guide you to the rightsolution based on your specific crimp requirements and cost considerations.
Recommended Terminator Type By Wire Size
Applicator Platform & Description

3K/40

5K/40

GIIGII+HF/HV

Up to
2.5 mm2

Up to6 mm2

Up to6 mm2

Up to16 mm2-

Mini Applicator Loose Piece (Up to 8 mm2)

-

-

Loose
piece up to6 mm2

Loose
piece up to16 mm2-

Mid-Size Applicator (6 mm2 - 25 mm2)---

Up to16 mm2Side feedup to120 mm2

Mid-Size Wire Applicator Loose Piece(8 mm2 - 16 mm2)

---

Loose
piece up to16 mm2-Large Size Wire Applicator (25 mm2 - 50 mm2)----

Side feed
up to120 mm2Large Wire Modular Die Holder(16 mm2 - 120 mm2)

----

Loose
piece up to120 mm2Up to
2.5 mm2

Up to6 mm2

Up to6 mm2

-

-

-

For splices
up to6 mm2

For splices
up to6 mm2

-

----

For splices
up to16 mm2----

For splices
up to16 mm2--

Inverted
splice up to6 mm2

-

-

-

OCEAN 2.0 Applicator (Up to 6 mm2)

Feed options: S (Side Feed), E (End Feed)
Crimp form: F (F crimp), O (O crimp), OV (Overlap crimp)

Feed options: LP (Loose Piece)

Feed options: SF (Side Feed), EF (End Feed)

Feed options: LP (Loose Piece)

Feed options: SF (Side Feed), EF (End Feed)

Feed options: LP (Loose Piece)

Splice Applicators
OCEAN 2.0 Applicator (Up to 12,000 CMA)
Feed options: S (Side Feed), E (End Feed)
Crimp form: F (F crimp)

Standard Splice Applicator (Up to 12,000 CMA)

Feed options: SF & EF
Splice Type: Butt (Thru-splice) & Pigtail, but according toterminal features. Terminal determinate crimp style.

Mini Applicator Splice (Up to 22,000 CMA)
Feed options: E (End Feed)
Splice Type: Butt (Thru-splice), Pigtail

Mid-Size Wire Applicator (Up to 12,000 CMA)
Feed options: S (Side Feed)
Splice Type: Butt (Thru-splice), Pigtail

Inverted Splice Applicator (Up to 12,000 CMA)
Feed options: E (End Feed)
Splice Type: Butt (Thru-splice), Pigtail

2

TE CONNECTIVITY / APPLICATION TOOLING / SEMI-AUTOMATIC BENCH TOP CRIMPING

UNDERSTANDING YOUR TERMINATIONSOLUTION OPTIONS
5K Terminators• Capable of 5,000 lbs of crimp force• Priced competitively• 40 mm stroke available• Available with and without crimp quality monitoring (CQM II)

GII Terminator• Capable of 5,000 lbs of crimp force• Improved interior lighting compared to 3K/5K platform• 40 mm stroke only
• Available with and without CQM II module• Split-cycle comes standard (helping to position for data connectivitysub-assemblies)

HF-20T Terminator• Capable of 40,000 lbs of crimp force• 44 mm stroke only
• Capable of processing up to 120 mm2 wire
• No CQM II module

HV-20T Terminator• Capable of 40,000 lbs of crimp force• 44 mm stroke only
• Includes CQM II module• Capable of processing up to 120 mm2 wire

TE CONNECTIVITY / APPLICATION TOOLING / SEMI-AUTOMATIC BENCH TOP CRIMPING

3

AMP 5K/40 TERMINATORS
Dimensions (without terminal reel and reel support)
Weight:77.3 kg [170.4 lb.]

Height:

585 mm [23 in.] without reel supports

Width:

536 mm [21.1 in.]

Depth:

521 mm [20.5 in.]Features
AMP 5K/40 terminators use a DC motor with gearbox drive.
The result is a small-footprint design that is fast and quiet.
Cycle time is less than 0.4 seconds with an operation soundlevel of 76 dB(A).

Specifications

Standard features such as tool-less precision crimp heightadjust, CQM capability, batch counter and an work light are
integral parts of serial equipment. By offering options the AMP
5K/40 terminator can be tailored to the specific application
requirements withou inflating the price for unwanted features.

Customer Manual: 409-10204

The AMP 5K/40 terminator is CE approved.

Crimp Force:				

AMP 5K/40 max. 2.268 kg [5,000 lb.]
capable of crimping 0.03–6 mm2[32-10 AWG]

Standard Equipment (5K/40 models only)• Tool-less precision crimp height adjustment• Manual shut height adjustment• Batch counter

Electrical:

100-240 V, 50/60 Hz, single-phase• Work light		

Operating current is 3 amps

• Tool-less removal/exchange of applicators*Note: Customer must supply power cord and final connection• Jog capability• Assembled with metric hardware

Air:						620-760 kPa [90-100 psi], 2.83 l/s (6 cfm)
(Please refer to application logs for specificair requirements)

Optional Equipment (5K/40 models only)• Pneumatic feed
• Crimp Quality Monitor (CQM II)• Oiler kit

DescriptionStrokeBaseplate

Part #AMP 5K/40 CE Terminator

40 mm

AMP Style2161500-1

AMP 5K/40 CE Terminator (W/ CQM II)

40 mm

AMP Style2161500-2

AMP 5K/40 CE (W/ Strip Module)

40 mm

AMP Style2161700-4

AMP 5K/40 CE (W/ Strip Module and CQM II)

40 mm

AMP Style2161700-5

4

TE CONNECTIVITY / APPLICATION TOOLING / SEMI-AUTOMATIC BENCH TOP CRIMPING

AMP-O-LECTRIC GII TERMINATOR
Safety First
Improved guarding on the GII terminator provides open accessfor quick and smooth installation of both end-feed andside-feed applicator styles and meets applicable CE anddomestic safety requirements.

Engineered with the Operator in Mind
The GII is one of the quietest terminators on the market.
It features improved access to, and significantly updated
lighting in the under cabinet and target areas, and includes avariable speed option which gives the operator more flexibility
for those tricky applications that benefit from slower ram andfeed speeds. And, with its tool-less changeover capability,
setup is both quick and easy.

Precision Matters
Specifications
Customer Manual: 409-32035
Crimp Force:				

2,268 kg [5,000 lb.] maximum crimp force
capable of crimping 0.03–6.0 mm2[32-10 AWG]

Air:						Pneumatic 620-760 kPa [90-100 psi] formodels with air feed applicators and/or
stripper module.

Electrical:		

100-240 VAC, ± 10% AC, 50/60 Hz, Single
phase. Operating current is 3 amps

All GII terminators include precision adjustment for crimp
height — an important feature, which, in combination with theoptional Crimp Quality Monitor (CQM II), enables repeatable,
tight crimp tolerances required for today’s demands for higher
levels of quality. By simply resetting a dial, the operator canadjust crimp height in 0.013 mm [.0005”] increments over a0.457 mm [.018”] range.

Complete Control
Our user-friendly LCD control panel includes simple buttons
for: adjusting ram speed, jogging the motor forward orreverse, split-cycle operation, work lighting, air feed, and batchcounter reset. For improved quality, the controls also detect
and report errors in the machine and stop cycling when a bad
crimp is detected by the CQM II.

*Note: Customer must supply power cord and final connection

Dimensions (without terminal reel and reel support)
Weight:		

104 kg [230 lb.]

Height:		520.7 mm [20.5”]

Width:		

546.1 mm [21.5”]

Depth:		

553.7 mm [21.8”]

Description

StrokeBaseplatePart #GII CE Terminator (W/Stripping Module)

40 mm

AMP Style2217001-3

GII CE Thru-Splice Terminator

40 mm

Thru-Splice

2217002-1

GII CE Thru-Splice Terminator (W/CQM II)

40 mm

Thru-Splice

2217002-2

TE CONNECTIVITY / APPLICATION TOOLING / SEMI-AUTOMATIC BENCH TOP CRIMPING5HF-20T & HV-20T TERMINATORSEngineered for High Voltage Applications
The HF-20T and HV-20T are robust, compact, high force bench
top machines capable of terminating cables up to 120 mm2.
Both models are eccentric presses capable of reaching 178 kN(20 tons) of crimp force, with fast, repeatable accuracy. The
HV-20 model comes with a CQM II digital interface for crimp
force monitoring, variable speed and an integrated vacuum
system to keep sensitive connections clean and clear of debris
commonly associated with high voltage cable processing.

Flexible DesignTo best fit the application process, the flexible design ofthe high force machines accommodate multiple processingorientations. The adjustable die holder platform can be easily
rotated to handle processing from the left, front or rightside of the unit. Side feed guarding is also available for allmodels to accommodate both loose piece and reeled terminal
applications.

Specifications
Crimp Force: 18,144 kg [40,000 lb.] max

Safe, Easy Operation

Air:

Pneumatic 620-760 kPa [90-100 psi]Electrical:

208-240 VAC, 50/60 Hz, Three-Phase Operating
current is 4kW

Dimensions (without terminal reel and reel support)
Weight:637 kg [1,404 lb.]

Height:

974 mm [38”]Width:

777 mm [30.5”]

Depth:

552 mm [22”]Ordering Information
Description

w/Loose Piece
Guarding

HF-20T, High Force Terminator, 400V

2335500-1

HF-20T, High Force Terminator, 200V

2335500-2

HV-20T, High Voltage Terminator, 400V

2348822-1

HV-20T, High Voltage Terminator, 200V

2348822-2

6Both models offer a simple push button design with multiple
interlock features to confirm operator safety throughout thecrimping process.

The HV-20T and HF-20T
bench top terminators
combine sophisticatedcontrols, a traceability system
and multiple ethernet andUSB ports to make themIndustry 4.0. ready.

TE CONNECTIVITY / APPLICATION TOOLING / SEMI-AUTOMATIC BENCH TOP CRIMPINGPIGTAIL SPLICE STANDARD AND INVERTEDTERMINATORS
Multiple Versions Available
TE standard splice terminators are offered in multiple
versions, for both pigtail or thru-splices (with front andrear operator access), and can come with or without crimp
quality monitoring (CQM II). When equipped with the CQM
II, force and position can be measured during every crimp
cycle, providing real-time monitoring of crimp height, thefundamental crimp characteristic, and the shape of the work
curve for every termination. Standard Splice terminators do
not accept heavy-duty mini (HDM), heavy-duty industrial (HDI)and OCEAN applicators.

Crimp Force: 2,268 kg [5,000 lb.] max
Air:

Electrical:

Pneumatic 620-760 kPa [90-100 psi] for models
w/air-feed applicators (Please refer to application
logs for specific air requirements)
208-240 VAC, 50/60 Hz, Single Phase Operating
current is 5 amps*Note: Customer must supply power cord and final connection

Dimensions (without terminal reel and reel support)
Weight:77.3 kg [170.4 lb.]

Height:

585 mm [23 in.] without reel supports

Width:

536 mm [21.1 in.]

Depth:

521 mm [20.5 in.]

Ordering Information
Description
Standard
SpliceSpecifications

If better access to present wires to the crimping area isneeded, the Inverted Splice Terminator (IST) provides more
flexibility when terminating leads from completed motor
assemblies. When using the pig-tail applicator, operators cancut excess wire using the integrated shear in the applicator,
thereby keeping leads as small as possible (short break out).
Shorter leads provide added flexibility to post-process magnet
wire applications. Operators can more easily tuck in or heat
shrink terminated lead ends, allowing for potentially smaller
motor housings.

Part #GII CE Thru-Splice Terminator

2217002-1

GII CE Thru-Splice Terminator (w/CQM II)

2217002-2

TE CONNECTIVITY / APPLICATION TOOLING / SEMI-AUTOMATIC BENCH TOP CRIMPING

7

TERMINATOR OPTIONS

Optional Stripping Module

Capacitive Start SensorA retrofittable capacitive start sensor is available for 5K/40
terminators with stripping modules.

Description

Part #

Capacitive start sensor

2844876-2

Short Strip Blades
Short strip blades for stripping down to 1.5 mm strip length areavailable for 5K/40 terminators with stripping modules.

Description

Part #

Short strip blades

2217860-1• For end- and side-feed applicators• 3 modes of operation (Crimp only, strip only, orstrip & crimp)• Foot-switch or sensor activatedGuard Insert Part Numbers
Description

Part #• Fast applicator changeover and easy adjustments

Dimensions
AB

Standard (away fromthe applicator)

354529-2

7.80 mm[.307 in ]6.35 mm[.250 in.]Standard (close to theapplicator) shippedwith the machine

1-679532-0

6.22 mm[.245 in.]5.08 mm[.200 in.]

Near tape679994-2

6.35 mm[.250 in.]

6.35 mm[.250 in.]

Away from tape679995-2

8.74 mm[.344 in.]

6.35 mm[.250 in.]

• Step mode for fast set-up• Air blast ejects slugs into a collecting tray
• Compatible with crimp quality monitor

Base Plate• The base plate with stripping unit as an option provides themounting surface on which the applicator is installed• The applicator can be installed and removed with a longallen key
Tape Guard Insert

Standard Guard Insert

Note: Some applications require the installation of an
oversized guard kit 1976900-1. These applications are primarily
ones that use two-inch stroke air-feed cylinders.

8TE CONNECTIVITY / APPLICATION TOOLING / SEMI-AUTOMATIC BENCH TOP CRIMPINGTERMINATOR OPTIONS
Crimp Height Adjustment Using Precision
Adjustment Mechanism

Applicator Gauge• Uses detent stops in themechanism to adjust crimp height

Suitable instrument to provide
correct positioning of all TE
applicators.

• Indexing the mechanism can bedone in either direction

Compatible with most crimping
presses that use quick changes style
applicators.

• Allows users to change the crimp
height in increments of approx.
0.013 mm [.0005 in.] per step

Alignment Gauge
528440-5

Airfeed Valve Assembly
Description

TypePart #Air feed valve kit for 3K & 5K

Standard

2161209-1

Air feed valve kit for GII

Standard

2217339-1

PurposeRequired to run air feed
applicators equipped withdual-acting cylinders

Control Panels
5K

Decrease Speed
Decreases the motor speed for normal cycle operation and for jogging.

Increase Speed
Increases the motor speed for normal cycle operation and for jogging.

Error Reset
Clears the displayed error code.

Count Reset
Clears the batch count to 0.

Jog & Jog Reverse
Causes the DC motor to rotate forward or backward at the jog speed set by theincrease/decrease speed. Reverse is only available on GII & GII+ models.

Full Cycle
Terminator rotates one full cycle when the footswitch is pressed. The LED light willremain on when in this mode of operation. GII & GII+ models only.

Split Cycle
The terminator rotates to the down position on the first press of the footswitch, thencompletes the cycle on the second press of the footswitch. The LED light will remainon when in this mode of operation. GII & GII+ models only.
Split cycle is required for some closed barrel terminals and data connectivity
applications.

TE CONNECTIVITY / APPLICATION TOOLING / SEMI-AUTOMATIC BENCH TOP CRIMPING

9TERMINATOR OPTIONS
Crimp Quality Monitor (CQM II)
When used on TE terminators the CQM II provides acomplete crimp detection analysis. It checks every crimp as
it is produced, measuring crimp height of each terminationand evaluating the quality of each crimp. If a crimp hasquestionable characteristics, visual and audible alarms alert
the operator. The CQM II includes data ports for printing andnetworking.
CQM II offers five different crimp analysis methods.
• Crimp height• Work index• Peak force• Fast Fourier Transform (FFT)• Point-to-pointFeatures• Best measurement to check compliancewith crimp design• Real time measurement during crimp cycle• Inspects 100% of terminations• Crimp height measurement accuracy: +/-0.012 mm• Data can be saved to a USB flash drive• 5 unique analysis methods capable of detecting mostcrimp faults

Operation Setup of CQM• Simple set-up and operation through task-bar selections• The system walks the user through all necessary tasks
required to start production

Ordering Information for CQM II Kits
Description

Part #AMP 5K/40 Terminator

2161670-1

AMP 5K/40 Terminator (w/ Stripping Module)

2161670-2

GII Terminator

2217288-1

GII Terminator (w/ Stripping Module)

2217288-2

10

TE CONNECTIVITY / APPLICATION TOOLING / SEMI-AUTOMATIC BENCH TOP CRIMPING

FIELD SERVICE SUPPORTSERVICES
Standard Service• Includes troubleshooting andmaking repairs

Equipment Installation• Providing installation, set-up andtraining at time of equipment
deliveryTraining• Basic crimp theory• Hand tool, applicator andequipment set-up,
operation and maintenancePreventive Maintenance and/or Inspection Certification• Provides service for periodicvisits to perform preventive
maintenance and/or inspection
certification service on hand tools,
applicators and bench equipment.
Inspection of the finished productis made to confirm it meetsTE application specifications.
Documentation is available uponrequest for traceability to support
your facilities’ quality system
requirements.

CONNECT WITH US
WE MAKE IT EASY TO CONNECT WITH OUR EXPERTS AND ARE READY TO PROVIDE ALL THE SUPPORT YOU NEED.
VISIT TOOLING.TE.COM

te.com

BROCHURE

TE, TE Connectivity, TE connectivity (logo), OCEAN, AMP, and AMP-O-LECTRIC are trademarks. All other logos,

Contact us today to learn moreproducts and/or company names referred to herein might be trademarks of their respective owners.

E-mail (Americas): toolingsales@te.com

The information given herein, including drawings, illustrations and schematics which are intended for illustration

Phone (Americas): 800-722-1111 or
717-986-3434

purposes only, is believed to be reliable. However, TE Connectivity makes no warranties as to its accuracy or

Phone (EMEA):+49-6251-133-3936

set forth in TE Connectivity‘s Standard Terms and Conditions of Sale for this product and in no case will

Phone (APAC):+86 21 3325 9030TE Connectivity be liable for any incidental, indirect or consequential damages arising out of the sale, resale, use

For field service inquiries go towww.te.com/fieldservice

completeness and disclaims any liability in connection with its use. TE Connectivity‘s obligations shall only be asor misuse of the product. Users of TE Connectivity products should make their own evaluation to determine thesuitability of each such product for the specific application.
© 2024

TE Connectivity Ltd. family of companies

2338133-1

Published

All Rights Reserved.

6/24

TE CONNECTIVITY / APPLICATION TOOLING / SEMI-AUTOMATIC BENCH TOP CRIMPING