smiths interconnect HyperGrip Disposable Plug Instruction Manual

October 30, 2023
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Assembly Instructions
HyperGrip® Disposable Plug
April 2022

smiths interconnect HyperGrip Disposable Plug - Cover

Do Not Discard, Deliver to Manufacturing.

HyperGrip Disposable Plug

Disposable HG Plug Kits

Disposable HG Plug

Disposable HG2 Plug Full Kit| 800-1012659-0XX
Disposable HG4 Plug Full Kit| 800-1005739-0XX
Disposable HG2 Plug Kit ithout Strain Relief Boot| 800-1012659-1XX
Disposable HG4 Plug Kit ithout Strain Relief Boot| 800-1005739-1XX

Step 1: Slide strain relief boot (Full Kit), and cable clamp (not included*) onto cable as depicted below

smiths interconnect HyperGrip Disposable Plug - Assembly Instructions
1

Note: Components depicted in images are representative of Disposable HG2 Plug; Assembly of Disposable HG4 Plug follows the same process

Crimp Termination Instructions
Step 2:
Trim and strip cable to length
Trim 18.0-19.0 mm of cable jacket (Disposable HG2)
Trim 19.0-20.0 mm of cable jacket (Disposable HG4)

smiths interconnect HyperGrip Disposable Plug - Assembly Instructions
2

Step 3:
Strip wire to expose 5.0 mm of conductor (Disposable HG2)
Strip wire to expose 4.0 mm of conductor (Disposable HG4)

smiths interconnect HyperGrip Disposable Plug - Assembly Instructions
3

Step 4:
Insert conductor into contact crimp barrel

Step 5:
Insert contact into position as shown
Crimp the contact

Step 6:
Insert contact into plug insulator

Step 7:
Push in contact with Insertion Tool #T2080

Step 8 (Optional):
Suitable cable clamp can be installed to provide additional cable retention force and strain relief Cable clamp band width 3 mm (MAX)
Positioned and tighten cable clamp 8 mm from the back of insulator as shown

Step 9 (Optional):
Fill rear insulator cup with appropriate silicone RTV or epoxy
Fill potting compound until the cup is full, or at least half-full
This step is recommended d for Ingress Protection rating IPx4

Step 10 (Full Kit, Optional):
Apply beads of silicone RTV or epoxy all the way around the ridges
This step is recommended for Ingress
Protection rating IPx4

Step 11 (Full Kit):
Slide strain relief boot along the cable
Press strain relief boot onto insulator

Step 12 (Full Kit):
Align grip pad to insulator key

Step 13:
Install O-ring (recommended for IPx4 sealing when mate to receptacle)
Rest plug assembly in an appropriate position and let potting compound cured before usage

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Copyright© 2022 Smiths Interconnect | All rights reserved | Version 1.0
All of the information included in this document is believed to be accurate at the time of printing.
The information contained within this document is subject at all times to applicable Export Control regulations and legal requirements.

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