134 Marbledale Road * Tuckahoe, NY 10707 Tel: 914-793-0700 * Fax: 914-793-4527 E-mail: sales@jonard.com www.jonard.com Manual Wire Wrapping Tools User's Guide G200/R3278 (LexanTM) G100/R3278 (Aluminum) G100/R3278FL (with Flashlight) S Y IE oe N TR kah om US Tuc ies.c ND d str G100/R3278INS (Aluminum insulated version) G100/R3394CT (Unwrap) 7 70 10 8 7 7 70 2 10 3 ES NY e / R TRI kaho om 0 S c .c I Roa du OK ale kin 4 13 0 U Tu ies 1 IND ad str G OK le Ro kindu a .o d .o ble ww w ar M 4 13 PN: 21294 REV. F d ble ww w ar M BIT AND SLEEVE INSTALLATION: 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 page 4. 3 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 Overwrap Open Wrap Spiral Wrap Easy Does It! Stay With It! 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. Insufficient Turns Pigtail Use the Correct Bit and Sleeve! Feed Wire Correctly! Wire wrapping is a precision technique and the wrong bit and sleeve just cannot do the job. Improper selection can cause problems ranging from "Pigtails" to loose wraps. 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. 4 Wrapping Bits and Sleeves Chart (AWG) Inches Regular Wire Gauge AWG Modified * 18 20 * * 20-22 22 22 * * * 22-24 22-24 22-24 22-24 24 * 24 24 24-26 * 26 26 26 26 26 28 28 30 30 30-32 30-32 * 30-32 * * * * * * * * * * * * * * * * 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 KB18 P194LN __ 0.06 0.073 1.000 0.15 0.075 WB20M P194LN 0.059 0.042 0.073 1.000 0.15 0.075 KB2075 P2224 __ 0.042 0.073 1.000 0.123 0.075 KB22 P2224 __ 0.054 0.073 0.75 0.117 0.075 WB2275M P2224 0.052 0.049 0.074 1.000 0.132 0.075 KB224LH P2224 __ 0.061 0.085 1.000 0.117 0.086 KB224-1 P2224 __ 0.054 0.073 1.000 0.111 0.075 KB224 P2224 __ 0.054 0.073 0.807 0.111 0.075 WB224M P2224 0.05 0.049 0.074 1.25 0.121 0.075 WB24DH P2224 0.046 0.054 0.073 1.75 0.117 0.075 KB24 P2224 __ 0.055 0.074 0.75 0.1 0.075 *WB24SM P3032LN 0.044 0.024 0.043 0.75 0.098 0.044 WB2426M P2224 0.046 0.054 0.073 0.75 0.118 0.075 KB26 P2426 __ 0.058 0.073 1.000 0.10 0.075 *WB26SM P26LN 0.031 0.023 0.038 0.75 0.075 0.04 WB26M P2224 0.046 0.054 0.073 1.000 0.118 0.075 *WB2644M P3032LN 0.046 0.024 0.043 0.75 0.098 0.044 WB2669M P2426 0.041 0.053 0.068 1.000 0.109 0.069 WB2870M P2426 0.034 0.053 0.068 1.000 0.103 0.07 *WB28SHM P3032 0.03 0.031 0.035 0.75 0.066 0.036 *SB30MSH-B P3032 0.027 0.031 0.035 0.75 0.064 0.036 *SB30MMK P3032 0.023 0.031 0.035 0.75 0.064 0.036 *WB3032M P3032 0.027 0.034 0.038 0.75 0.064 0.04 WB3032MIL P3032 0.027 0.034 0.038 0.75 0.064 0.04 KB3032 P3032 __ 0.034 0.038 0.75 0.064 0.04 Effective Radius Inches Terminal Hole Diameter Inches *These tools are recommended for .025" square terminals on .100" Provides 2.5 turns of insulation centers Extended Length (5") Bits and Sleeves Chart Regular Wire Gauge AWG mm. 22 0.65 24 0.50 26 0.40 Modified * * * Bit Part No. Sleeve Part No. Maximum Insulation Diameter Inches Minimum Terminal Diagonal Inches Maximum Terminal Diagonal Inches Terminal Hole Depth Inches KB22-5 P2224-5 __ 0.054 0.073 0.75 0.117 0.075 KB24-5 P2426-5 __ 0.055 0.074 0.75 0.100 0.075 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) 5 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. 8-32 x 5/8 NOSE PIECE 8-32 x 3/8 6-32 x 5/8 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 housings. 6 3. Apply grease to the bevel, spur and face gear. GREASE BEVEL, SPUR AND FACE GEARS Reassembly: 1. Prior to closing the unit the bit index must be checked. 2. Load a bit into the barrel assembly. WIRE SLOT 3. The wire slot on the bit should be in the 12 O'clock position. If the 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. 4. Lift the barrel assembly from the gun assembly and rotate the 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. 5. Reinstall top housing and Install the bottom 6-32x5/8 screw. Install collet and nose piece, insuring that the collet-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 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 2 8