Smiths Interconnect Hypergrip Disposable Plug Instruction Manual

HyperGrip Disposable Plug

Product Information: Disposable HG Plug Kits

The Disposable HG Plug Kits come in four variants – Disposable
HG Plug, Disposable HG2 Plug Full Kit, Disposable HG4 Plug Full
Kit, and Disposable HG2 Plug Kit without Strain Relief Boot. These
kits are designed for crimp termination of cables and provide
additional cable retention force and strain relief. The product
also comes with optional features such as cable clamp and potting
compound for Ingress Protection rating IPx4.

Product Usage Instructions:

1. Step 1: Slide the strain relief boot (Full Kit) and cable clamp
   (not included*) onto the cable as depicted in the manual. Note that
   components depicted in images are representative of Disposable HG2
   Plug, and assembly of Disposable HG4 Plug follows the same
   process.
2. Step 2: Trim and strip the cable to length. Trim 18.0-19.0 mm
   of cable jacket (Disposable HG2) or 19.0-20.0 mm of cable jacket
   (Disposable HG4).
3. Step 3: Strip wire to expose 5.0 mm of conductor (Disposable
   HG2) or 4.0 mm of conductor (Disposable HG4).
4. Step 4: Insert the conductor into the contact crimp
   barrel.
5. Step 5: Insert the contact into position as shown in the manual
   and crimp it using the Positioner T1914.
6. Step 6: Insert the contact into the plug insulator.
7. Step 7: Push in the contact with Insertion Tool #T2080.
8. Step 8 (Optional): Install a suitable cable clamp to provide
   additional cable retention force and strain relief. The cable clamp
   band width should be 3 mm (MAX). Position and tighten the cable
   clamp 8 mm from the back of the insulator as shown in the
   manual.
9. Step 9 (Optional): Fill the 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 for Ingress
   Protection rating IPx4.
10. 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.
11. Step 11 (Full Kit): Slide the strain relief boot along the
    cable and press it onto the insulator.
12. Step 12 (Full Kit): Align the grip pad to the insulator
    key.
13. Step 13: Install the O-ring (recommended for IPx4 sealing when
    mate to receptacle). Rest the plug assembly in an appropriate
    position and let the potting compound cure before usage.

Assembly Instructions
HyperGrip® Disposable Plug
April 2022
Do Not Discard, Deliver to Manufacturing. No Descartar, Entregar A Fabricación. Instructions De Montage, Ne Pas Jeter.
Bitte nicht wegwerfen, bitte an die produktion weiter liefern. 1

Assembly Instructions
Disposable HG Plug Kits

Disposable HG Plug Disposable HG2 Plug Full Kit Disposable HG4 Plug Full Kit Disposable HG2 Plug Kit without Strain Relief Boot Disposable HG4 Plug Kit without Strain Relief Boot

800-1012659-0XX 800-1005739-0XX 800-1012659-1XX
800-1005739-1XX

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

Note: Components depicted in images are representative of Disposable HG2 Plug; Assembly of Disposable HG4 Plug follows the same process
2

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)
Step 3:
Strip wire to expose 5.0 mm of conductor (Disposable HG2) Strip wire to expose 4.0 mm of conductor (Disposable HG4)
Step 4:
Insert conductor into contact crimp barrel
Step 5:
Insert contact into position as shown Crimp the contact

Positioner T1914
3

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

Cable Clamp Position Cable Clamp

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
4

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

Apply silicone/epoxy around the ridges

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

Grip Pad

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

Insulator Key O-ring

5

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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.