OK Industries
134 Marbledale Road • Tuckahoe, NY 10707
Phone: 914-793-0700 • Fax: 914-793-4527
www.okindustries.com
Manual Wire Wrapping Tools
User’s Guide
G200/R3278
(Lexan
™
)
G100/R3278
(Aluminum)
G100/R3394CT
G100/R3278INS
(Aluminum insulated version)
PN: 21294
REV. D
B
IT
AND
S
LEEVE
I
NSTALLATION
:
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
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!
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 recom-
mended for use with 26
through 30 AWG wire.
Stay With It!
Just keep the OK tool on the terminal
until the wrap is complete. Early
removal can result in spiral and open
wraps.
Pigtail
Insufficient
Turns
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.
4
Wrapping Bits and Sleeves Chart (AWG) Inches
WIRE
GAUGE
REGULAR
MODIFIED
BIT
PART NO.
SLEEVE
PART NO.
MAXIMUM
INSULATION
DIAMETER
INCHES
MINIMUM
TERMINAL
DIAGONAL
INCHES
MAXIMUM
TERMINAL
DIAGONAL
INCHES
TERMINAL
TERMINAL
HOLE
EFFECTIVE
HOLE
DEPTH
RADIUS DIAMETER
INCHES
INCHES
INCHES
18
•
KB18
P194
—
20
•
WB20M P194LN
0.059
20-22
•
KB2075
P2224
—
22
•
WB22MLD P212
0.58
22
•
KB22LT
P2224
—
22
•
KB22
P2224
—
22
•
WB2275M P2224
0.052
22-24
•
KB224LH
P2224
—
22-24
•
KB224-1
P2224
—
22-24
•
KB224
P2224
—
22-24
•
WB224M P2224
0.05
24
•
*KB2444 P3032LN
—
24
•
WB24DH P2224
0.046
24
•
KB24
P2426
—
24
•
*WB24SM P3032LN 0.044
24
•
WB24DHM P2224
0.05
•
WB2426M P2224
0.046
24-26
24-26
•
KB2466
OK8519
—
•
*KB2639
P26LN
—
26
•
KB26
P2426
—
26
26
•
*WB26SM P26LN
0.031
•
WB26M
P2224
0.046
26
26
•
*WB2644M P3032LN
0.046
26
•
WB2669M
P2426
0.041
28
•
WB2870M
P2426
0.034
28-29
•
*WB2829M P3032L
0.036
30
•
*SB30MSH-B P3032
0.027
30
•
*SB30MMK
P3032
0.023
30-32
•
*WB3032M P3032
0.027
* These tools are recommended for .025” square
0.06
0.042
0.042
0.049
0.061
0.054
0.049
0.061
0.054
0.054
0.049
0.024
0.054
0.055
0.024
0.049
0.054
0.054
0.023
0.058
0.023
0.054
0.024
0.053
0.053
0.033
0.031
0.031
0.034
terminals
0.073
0.073
0.073
0.073
0.085
0.073
0.074
0.085
0.073
0.073
0.074
0.043
0.073
0.074
0.043
0.068
0.073
0.065
0.038
0.073
0.038
0.073
0.043
0.068
0.068
0.038
0.035
0.035
0.038
on .100”
1
0.15
1
0.15
1
0.123
1
0.136
1
0.125
0.75
0.117
1
0.132
1
0.117
1
0.111
0.807
0.111
1.25
0.121
1
0.083
1.75
0.117
0.75
0.1
0.75
0.098
1.12
0.118
0.75
0.118
1
0.098
0.75
0.068
1
0.1
0.75
0.075
1
0.118
0.75
0.098
1
0.109
1
0.103
0.75
0.091
0.75
0.064
0.75
0.064
0.75
0.064
centers.
0.075
0.075
0.075
0.075
0.086
0.075
0.075
0.086
0.075
0.075
0.075
0.044
0.075
0.075
0.044
0.069
0.075
0.066
0.04
0.075
0.04
0.075
0.044
0.069
0.07
0.04
0.036
0.036
0.04
Extended Length (5“) Bits and Sleeves Chart
REGULAR
WIRE
MODIFIED
BIT
SIZE
PART NO.
AWG mm.
SLEEVE
PART NO.
MAXIMUM
INSULATION
DIAGONAL
In.
MINIMUM
TERMINAL
DIAGONAL
In.
MAXIMUM
TERMINAL
DIAGONAL
In.
TERMINAL
HOLE
DEPTH
In.
TERMINAL
EFFECTIVE HOLE
RADIUS DIAMETER
In.
In.
22 0.65
24 0.50
26 0.40
•
•
•
PART NO.
KB22-5
KB24-5
KB26-5
P2224-5
P2426-5
P2426-5
—
—
—
0.54
0.55
0.58
.073
.073
.073
.750
.750
.750
.117
.100
.100
.075
.075
.075
Insulated Sleeves (1000V dielectric strength)
WIRE SIZE
22-24 AWG
24-26 AWG
P2224INS (or P2224-5INS for 5” version)
P2426INS (or P2426-5INS for 5” version)
5