ok industries manual wire wrapping tools users guide g200/r3278 (lexan ? ) g100/r3278ins g100/r3278 (aluminum) (aluminum insulated version) g100/r3394ct pn: 21294 rev . d 134 marbledale road ?tuckahoe, ny 10707 phone: 914-793-0700 ?fax: 914--93--527 www.okindustries.com
b it and s leeve i nst alla tion : 1. remove the tool from the box. 2. install a bit and sleeve. follow installation instructions below. (bits and sleeves are sold separately. see page 5 for bit and sleeve selection). * loosen nose piece (nut). * insert the bit into the nose piece * rotate until the bit is seated on the driver. * place sleeve over the bit and slide the sleeve into the nose piece. rotate the sleeve as you are sliding the sleeve into the nose piece until the sleeve has engaged with the collet pin, the sleeve will then slide further into the nose piece. the sleeve is now seated. 2
* while squeezing the trigger, tighten the nose piece. this will insure proper orientation of the bit and sleeve and will minimize drag on the trigger. * the tool is now ready for use. to make a wire wrapped connection follow the instructions and helpful hints on the pages ahead. 3
4 how to make a wire wrapped connection: step 1: select the proper bit and sleeve for the wire being used step 2 insert the wire into the wire slot step 3 anchor the wire step 4 insert the terminal step 5 finished connection some hints on making wrapped connections easy does it! do not pr ess too har d. let the ok tools do the work. excessive pr essur e can lead to over wrapping. backfor ce "bf" to pr event over wrapping is available on most power tools and is r ecom - mended for use with 26 thr ough 30 a wg wir e. feed wire correctly! its easy to feed wire into the slot in the ok bit correctly. be sure the stripped end of the wire is ushed--n all the way. stay w ith it! just keep the ok tool on the terminal until the wrap is complete. early removal can result in spiral and open wraps. use the cor r ect bit and sleeve! wire wrapping is a precision technique and the wrong bit and sleeve just can- not do the job. improper selection can cause problems ranging from igtails to loose wraps. over wrap open wrap spiral w rap insufficient turns pigtail
5 wrapping bits and sleeves chart (awg) inches maximum minimum maximum terminal terminal regular insulation terminal terminal hole effective hole w ire modified bit sleeve diameter diagonal diagonal depth radius diameter g auge part no. part no. inches inches inches inches inches inches 18 ? kb18 p194 0.06 0.073 1 0.15 0.075 20 ? wb20m p194ln 0.059 0.042 0.073 1 0.15 0.075 20-22 ? kb2075 p2224 0.042 0.073 1 0.123 0.075 22 ? wb22mld p212 0.58 0.049 0.073 1 0.136 0.075 22 ? kb22lt p2224 0.061 0.085 1 0.125 0.086 22 ? kb22 p2224 0.054 0.073 0.75 0.117 0.075 22 ? wb2275m p2224 0.052 0.049 0.074 1 0.132 0.075 22-24 ? kb224lh p2224 0.061 0.085 1 0.117 0.086 22-24 ? kb224-1 p2224 0.054 0.073 1 0.111 0.075 22-24 ? kb224 p2224 0.054 0.073 0.807 0.111 0.075 22-24 ? wb224m p2224 0.05 0.049 0.074 1.25 0.121 0.075 24 ? *kb2444 p3032ln 0.024 0.043 1 0.083 0.044 24 ? wb24dh p2224 0.046 0.054 0.073 1.75 0.117 0.075 24 ? kb24 p2426 0.055 0.074 0.75 0.1 0.075 24 ? *wb24sm p3032ln 0.044 0.024 0.043 0.75 0.098 0.044 24 ? wb24dhm p2224 0.05 0.049 0.068 1.12 0.118 0.069 24-26 ? wb2426m p2224 0.046 0.054 0.073 0.75 0.118 0.075 24-26 ? kb2466 ok8519 0.054 0.065 1 0.098 0.066 26 ? *kb2639 p26ln 0.023 0.038 0.75 0.068 0.04 26 ? kb26 p2426 0.058 0.073 1 0.1 0.075 26 ? *wb26sm p26ln 0.031 0.023 0.038 0.75 0.075 0.04 26 ? wb26m p2224 0.046 0.054 0.073 1 0.118 0.075 26 ? *wb2644m p3032ln 0.046 0.024 0.043 0.75 0.098 0.044 26 ? wb2669m p2426 0.041 0.053 0.068 1 0.109 0.069 28 ? wb2870m p2426 0.034 0.053 0.068 1 0.103 0.07 28-29 ? *wb2829m p3032l 0.036 0.033 0.038 0.75 0.091 0.04 30 ? *sb30msh-b p3032 0.027 0.031 0.035 0.75 0.064 0.036 30 ? *sb30mmk p3032 0.023 0.031 0.035 0.75 0.064 0.036 30-32 ? *wb3032m p3032 0.027 0.034 0.038 0.75 0.064 0.04 * these tools ar e r ecommended for .025squar e terminals on .100centers. extended length (5 bits and sleeves chart maximum minimum maximum terminal terminal wire regular insulation terminal terminal hole effective hole size modified bit sleeve diagonal diagonal diagonal depth radius diameter awg mm. part no. part no. in. in. in. in. in. in. 22 0.65 ? kb22-5 p2224-5 0.54 .073 .750 .117 .075 24 0.50 ? kb24-5 p2426-5 0.55 .073 .750 .100 .075 26 0.40 ? kb26-5 p2426-5 0.58 .073 .750 .100 .075 insulated sleeves (1000v dielectric str ength) wire size part no. 22-24 awg p2224ins (or p2224-5ins for 5 version) 24-26 awg p2426ins (or p2426-5ins for 5 version)
maintenance procedure: manual wire wrapping tools periodic maintenance: the only required maintenance is periodic greasing of the gear assembly. the interval is dependent on use. for reference we suggest every 50,000 wraps or every 6 months which ever comes first. tools required: 1. philips head screwdriver. 2. synthetic grease (such as: chemplex 940 from nfo technologies). disassembly: 1. using a philips head screwdriver, remove the 5 screws that hold the housing together. note the type and location of the screws. 2. turn the gun over and lay it down on a flat surface so the nose piece is facing left. separate the housings and remove the collet and nose piece. note: use a flat head screwdriver to separate the hous- ings. 6
3. apply grease to the bevel, spur and face gear. reassembly: 1. prior to closing the unit the bit index must be checked. 2. load a bit into the barrel assembly. 3. the wire slot on the bit should be in the 12 olock position. if the wir e slot is not in the 12 olock position then pr oceed to step 4. if the wir e slot is in the 12 olock position then pr oceed to step 5. 4. lift the barrel assembly from the gun assembly and rotate the bit until the wire slot is in the 12 olock position. reinstall the barrel assembly into the gun housing. insure the barrel-locating pin is seated into its locating hole in the housing and that the bit is still in the 12 olock position. 5. reinstall top housing and install the bottom 6-32x5/8 screw. install collet and nose piece, insuring that the colet-locating pin is seated in the locating hole in the housing. install remaining screws. 7
spare parts item gun type part # description 1 g100/r3278 21612 frame pair g200/r3278 10441 frame pair g100/r3278ins 21424 frame pair 2 g100/r3278 11589 trigger asm. g200/r3278 10938 trigger asm. g100/r3278ins 21333 trigger asm. 3 all gun types 21671 gear-barrel asm. kit 4 all gun types 10344 collet nut 8
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