User Manual

3
OK Industries Inc. Tel [phone] Fax [phone] www.okindustries.com
In. .010 .015 .020 .025 .030 .035 .040 .045 .050 .055 .060 .065 .070 .075 .080 .085 .090 .095 .100
mm 0.25 0.38 0.51 0.64 0.76 0.89 1.02 1.14 1.27 1.40 1.52 1.65 1.78 1.91 2.03 2.16 2.29 2.41 2.54
.010 .014 .018 .022 .027 .032 .036 .041 .046 .051 .056 .061 .066 .071 .076 .081 .086 .091 .096 .101
0.25 0.36 0.46 0.56 0.69 0.81 0.91 1.04 1.17 1.30 1.42 1.55 1.68 1.80 1.93 2.06 2.18 2.31 2.44 2.57
.015 .018 .021 .025 .029 .033 .038 .043 .047 .052 .057 .062 .067 .072 .077 .082 .087 .092 .097 .102
0.38 0.46 0.53 0.64 0.74 0.84 0.97 1.09 1.19 1.32 1.45 1.58 1.70 1.83 1.96 2.08 2.21 2.34 2.46 2.59
.020 .022 .025 .028 .032 .036 .040 .045 .049 .053 .058 .063 .068 .073 .078 .083 .088 .093 .098 .103
0.51 0.56 0.64 0.71 0.81 0.91 1.02 1.14 1.25 1.35 1.47 1.60 1.73 1.85 1.98 2.11 2.24 2.36 2.49 2.62
.025 .027 .029 .032 .035 .039 .043 .047 .050 .056 .060 .065 .069 .074 .079 .084 .089 .094 .099 .104
0.64 0.69 0.74 0.81 0.89 0.99 1.09 1.19 1.27 1.42 1.52 1.65 1.75 1.88 2.01 2.13 2.26 2.39 2.52 2.64
.030 .032 .033 .036 .039 .042 .046 .050 .054 .058 .062 .067 .071 .076 .080 .085 .090 .095 .100 .105
0.76 0.81 0.84 0.91 0.99 1.07 1.17 1.27 1.37 1.47 1.58 1.70 1.80 1.93 2.03 2.16 2.29 2.41 2.54 2.67
.035 .036 .038 .040 .043 .046 .049 .052 .056 .060 .064 .069 .073 .078 .082 .087 .091 .096 .101 .106
0.89 0.91 0.97 1.02 1.09 1.17 1.25 1.32 1.42 1.52 1.63 1.75 1.85 1.98 2.08 2.21 2.31 2.44 2.57 2.69
.040 .041 .043 .045 .047 .050 .052 .056 .060 .064 .068 .072 .076 .080 .084 .089 .092 .097 .102 .107
1.02 1.04 1.09 1.14 1.19 1.27 1.32 1.42 1.52 1.63 1.73 1.83 1.93 2.03 2.13 2.26 2.34 2.46 2.59 2.72
.045 .046 .047 .049 .050 .054 .056 .060 .063 .067 .071 .074 .078 .083 .087 .091 .096 .101 .105 .109
1.14 1.17 1.19 1.25 1.27 1.37 1.42 1.52 1.60 1.70 1.80 1.88 1.98 2.11 2.21 2.31 2.44 2.57 2.67 2.77
.050 .051 .052 .053 .056 .058 .060 .064 .067 .071 .074 .078 .082 .086 .090 .094 .098 .103 .107 .111
1.27 1.30 1.32 1.35 1.42 1.47 1.52 1.63 1.70 1.80 1.88 1.98 2.08 2.18 2.29 2.39 2.49 2.62 2.72 2.82
Example: If “E”=.020”. “F”=.060”. The terminal diagonal is .063" as shown on chart.
How to Select Wire
Bare Wire Dia. AWG SWG
Inches mm (USA) (GB)
.0403 1.022 18
.040 1.016 19
.036 0.914 19 20
.032 0.813 20 21
.028 0.711 21 22
.0253 0.643 22
.024 0.61 23
.0226 0.574 23
.022 0.559 24
.0201 0.51 24
.020 0.508 25
.018 0.457 26
.0179 0.455 25
.0164 0.417 27
.0159 0.404 26
.0148 0.376 28
.0142 0.361 27
.0136 0.345 29
.0126 0.320 28
.0124 0.315 30
.0116 0.295 31
.0113 0.287 29
.0108 0.274 32
.0100 0.254 30 33
.0092 0.234 34
.0089 0.226 31
.0084 0.213 35
.008 0.203 32
1. Determine Wire Gauge
2. Select Regular wrap (bare wire only
around terminal) or Modified wrap (first
1
1
/2 turns of insulation around terminal,
balance of turns - bare wire)
3. Determine terminal diagonal using
terminal diagonal chart below
4. Select Bit (and corresponding sleeve) using
charts on page 8 by using wire gauge,
regular/modified wrap then terminal hole
diameter
5. Insure the terminal diagonal fits between
minimum and maximum terminal diagonal
on bit and sleeve chart
Notes:
A. Once bit is selected, the corresponding
sleeve part number is printed along side
B. Bits marked with an asterisk (*) are for use
on .025" (.63mm) square terminals
C. Modified wraps are recommended for wire
diameters 26, 28, 30 AWG (.40, .32, .25mm)
when used on .025" (.63mm) square
terminals
Terminal Diagonal Chart
Wire Size Chart
Some Hints on Making Wrapped Connections
How to Make Wire Wrapped
Connections with OK Tools
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.
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.
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.
Use the Correct Bit and
Sleeve!
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.
Step 1
Bit, Sleeve and
Pre-Stripped Wire
Step 2
Wire Insertion
Step 3
Wire Anchoring
Step 4
Terminal Insertion
Step 5
Finished Connection
Overwrap
Open
Wrap
Spiral
Wrap
Insufficient
Turns
Pigtail
Dimension “E”
Dimension “F”