Assembly Instructions
HyperGrip® Disposable Plug
April 2022
Do Not Discard, Deliver to Manufacturing.
Contents
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
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)
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
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.
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