PN: 21294 REV. F
OK INDUSTRIES
134 Marbledale Road Tuckahoe NY 10707
www.okindustries.com
G 1 0 0 / R 3 2 7 8
OK INDUSTRIES
134 Marbledale Road Tuckahoe NY 10707
www.okindustries.com
Manual Wire Wrapping Tools
User’s Guide
G200/R3278 (Lexan™)
G100/R3278 (Aluminum)
G100/R3278FL (with Flashlight)
G100/R3278INS
(Aluminum insulated version)
G100/R3394CT (Unwrap)
134 Marbledale Road • Tuckahoe, NY 10707
Tel: 914-793-0700 • Fax: 914-793-4527
E-mail: sales@jonard.com
www.jonard.com
2
BIT AND SLEEVE INSTALLATION:
Remove the tool from the box.1.
Install a Bit and Sleeve. Follow installation instructions below.2.
(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.
3
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 page 4.
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
Do not press too hard. Let the OK tools
do the work. Excessive pressure can
lead to overwrapping. Backforce “BF”
to prevent overwrapping is available on
most power tools and is recommended
for use with 26 through 30 AWG wire.
Just keep the OK tool on the terminal
until the wrap is complete. Early
removal can result in spiral and open
wraps.
Feed Wire Correctly!
It’s easy to feed wire into the slot in
the OK bit correctly. Be sure the
stripped end of the wire is “pushed-in”
all the way.
Use the Correct 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 “Pigtails”
to loose wraps.
Easy Does It! Stay With It!
Insufcient
Turns
Overwrap
Open
Wrap
Spiral
Wrap
Pigtail
5
Wrapping Bits and Sleeves Chart (AWG) Inches
Wire
Gauge
AWG
Regular
Modified Bit
Part No.
Sleeve Part
No.
Maximum
Insulation
Diameter
Inches
Minimum
Terminal
Diagonal
Inches
Maximum
Terminal
Diagonal
Inches
Terminal
Hole
Depth
Inches
Effective
Radius
Inches
Terminal
Hole
Diameter
Inches
18 •KB18 P194LN __ 0.06 0.073 1.000 0.15 0.075
20 •WB20M P194LN 0.059 0.042 0.073 1.000 0.15 0.075
20-22 •KB2075 P2224 __ 0.042 0.073 1.000 0.123 0.075
22 •KB22 P2224 __ 0.054 0.073 0.75 0.117 0.075
22 •WB2275M P2224 0.052 0.049 0.074 1.000 0.132 0.075
22-24 •KB224LH P2224 __ 0.061 0.085 1.000 0.117 0.086
22-24 •KB224-1 P2224 __ 0.054 0.073 1.000 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 •WB24DH P2224 0.046 0.054 0.073 1.75 0.117 0.075
24 •KB24 P2224 __ 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
24-26 •WB2426M P2224 0.046 0.054 0.073 0.75 0.118 0.075
26 •KB26 P2426 __ 0.058 0.073 1.000 0.10 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 1.000 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 1.000 0.109 0.069
28 •WB2870M P2426 0.034 0.053 0.068 1.000 0.103 0.07
28 •*WB28SHM P3032 0.03 0.031 0.035 0.75 0.066 0.036
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
30-32 •†WB3032MIL P3032 0.027 0.034 0.038 0.75 0.064 0.04
30-32 •KB3032 P3032 __ 0.034 0.038 0.75 0.064 0.04
*These tools are recommended for .025” square terminals on .100”
† Provides 2.5 turns of insulation centers
Extended Length (5“) Bits and Sleeves Chart
Wire
Gauge
AWG mm.
Regular
Modified Bit
Part No.
Sleeve
Part No.
Maximum
Insulation
Diameter
Inches
Minimum
Terminal
Diagonal
Inches
Maximum
Terminal
Diagonal
Inches
Terminal
Hole
Depth
Inches
Effective
Radius
Inches
Terminal
Hole
Diameter
Inches
22 0.65 •KB22-5 P2224-5 __ 0.054 0.073 0.75 0.117 0.075
24 0.50 •KB24-5 P2426-5 __ 0.055 0.074 0.75 0.100 0.075
26 0.40 •KB26-5 P2426-5 __ 0.058 0.073 0.75 0.100 0.075
Insulated Sleeves (1000V dielectric strength)
WIRE SIZE PART NO.
22-24 AWG P2224INS (or P2224-5INS for 5” version)
24-26 AWG P2426INS (or P2426-5INS for 5” version)
6
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 rst.
Tools Required:
Philips Head Screwdriver.1.
Synthetic Grease (Such as: Chemplex 940 from NFO Technologies).2.
Disassembly:
Using a Philips head screwdriver, remove the 5 screws that hold1.
the housing together. Note the type and location of the screws.
Turn the gun over and lay it down on a at surface so the nose2.
piece is facing left. Separate the housings and remove the collet
and nose piece. Note: Use a at head screwdriver to separate the
housings.
8-32 x 5/8
8-32 x 3/8
NOSE PIECE
6-32 x 5/8
7
GREASE BEVEL, SPUR AND F A CE GEARS
Apply grease3.
to the bevel,
spur and face gear.
Reassembly:
Prior to closing the unit the bit index must be checked.1.
Load a bit into the barrel assembly.2.
The wire slot on the bit should be in the 12 O’clock position. If the3.
wire slot is not in the 12 O’clock position then proceed to step 4. If
the wire slot is in the 12 O’clock position then proceed to step 5.
Lift the barrel assembly from the gun assembly and rotate the4.
bit until the wire slot is in the 12 O’clock 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 O’clock position.
Reinstall top housing and Install the bottom 6-32x5/8 screw.5.
Install collet and nose piece, insuring that the collet-locating pin
is seated in the locating hole in the housing. Install
remaining screws.
WIRE SLOT
8
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