The Cord-Stripper

Operating Manual
Subject to technical alterations
Contents Page

The Cord Stripper 3

Field of application 3
Functional description 3
Availability 4
Blades
5

Handling Instructions 6
Safety instructions 6
Maintenance 7
Repair 7

Operating Instructions 8

Preparing the conveyor belt 8

Pulling unit and slide unit 8
Preparing and positioning on belt /conveyor 9
Preparing the cutting unit 10
Installing and changing the blades 10
Adjusting the blades 11
Adjusting to the cable pitch 12
Connecting the cutting unit to the puiling unit 13
Stripping the steel cables 14

Technical Data 16

Cutting unit 16
Pulling unit (Standard) 16
Slide unit 16

Spare Parts 18

Cutting Unit 18
Pulling unit 18

Page 2
The Cord Stripper System

Field of application:
The Cord Stripper System has been designed for fast and clean stripping of steel cables
on conveyor belt heads which are to be spliced. This operation can be carried out in the
vulcanizing shop
and on site.
The Cord Stripper System consists of Cutting Unit, Pulling Unit and Slide Unit.
The Cutting Unit* is suitable for cable pitches from 1025 mm and for cable diameters
from 4,9 - 12,5 mm. The rubber cover thickness can be up to 12 mm on the running
side and up to 25 mm on the carrying side. The total belt thickness can be up to 43
mm.
The Cord Stripper System offers the following advantages: no turning of the belt,
because the rubber cover on both carrying side and running side is removed in one
single operation. The steel cables remain embedded in a thin rubber layer ensuring
high adhesion of the core rubber within the splice. Easy handling and tremendous
time saving in comparison to conventional manual stripping methods and therefore
considerable labour reduction.

Functional Description:
The Cutting Unit enables fast stripping of steel cables on conveyor belt heads for
subsequent vulcanization. After an approx. 200 mm wide strip of the rubber cover
has been removed manually across the belt on carrying side and running side,
mechanical stripping of the steel cables can be started on the left hand side of the
belt (in direction of belt end).
The cutting depth can be adjusted according to rubber cover thickness. Especially
designed blades are used far each individual cable diameter. The staggered
arrangement of 2 blades with an adjustable counter pressure roller each ensures
exact guiding of the cutting unit along the steel cables and can be adjusted to a
cable pitch from 10 - 25 mm. The pulling Unit (cable winch) supplies the pulling
strength required for stripping a steel cable of the belt. The Slide Unit serves as an
anchorage for the pulling unit and ensures its stability. The slide unit enables the
pulling unit to be positioned always in a right angle to the cutting unit which is the
optimum angle for stripping. The slide unit is availabe in a length of 3 m and 4 m.
The Cable Stripping System can be operated by just 2 persons.

Page 3
Availability:

The Cord Stripper consists of:

Cutting Unit (incl. basic equipment) (see below)
Pulling Unit
Slide Unit (3 m or 4 m*)
Operating Manual

The System Components can also be supplied individually:

Cutting Unit (incl. basic equipment)

Pulling Unit (Standard 16 A /380 V)
Slide Unit, 3 m long
Slide Unit, 4 m long

The Basic Equipment consists of:

Description:
5 blades for cable dia. 7.2 rnrn (ST 2500/ DIN) - top
5 blades for cable dia. 7,2 rnrn (ST 2500 f DIN) - bottorn
5 blades for cable dia. 9,7 rnm (ST 4500 f DIN) - top
5 blades for cable dia. 9,7 rnrn (ST 4500 I DIN) - bottorn

1 blade holder No. 1 - top - for cable 8.9 rnm

1 balde holder No. 1 - bottorn - for cable 8,9 rnrn
1 blade holder No. 2 - top - for cable 9,0 rnrn
1 blade holder No. 2 - bottorn - for cable 9,0 rnrn
1 pressure roller No. 1 cpl - top - for cable 8,9 rnrn
1 pressure roller No. 2 cpl - bottorn - for cable 9,0 mrn

1 Allan key, size 6

1 Allan key, size 8
1 Allan key, size 14
1 Combination wrench, size 17
2 Setting gauges (for rough adjustment of
cutting unit)

Slide units in other lengths are available on demand!

Page 4
The Cord Stripper

Blades
roller

for

for
for

for

for
for

Page 5
Handling Instructions

Safety Instructions

The cable stripping system may be operated/used only by staff trained in handling and
operation.
Current-carrying / live equipment must always be protected against water and
humidity.
Slide unit and pulling unit must always be firmly secured.
Pulling unit and slide unit should only be transported or lifted with suitable hoists or by
at least 2 persons.
The slide unit must be secured/fastened in such a way that it can not tilt over or move
(fastening brackets/shackles on frame of slide unit.
The pulling unit must be positioned at an angle of 90 to the steel cable bell.
The pulling unit must be secured against rolling off after each change of position by the
locking brake.
The safety bracket must be positioned in the slide until frame always on the right hand
side of the steel pulling rope.
Check steel rope of pulling unit before each operation and replace if damaged.
The pulling rope must not be unwound more than 6 m in order to ensure that the rope is
still wound at least twice around the rope
drum.
The winch is designed exclusively as pulling unit for the cutting unit and must not be
used for any other purpose whatsoever!

(Only for pulling in horizontal direction. Moving of load on slopes and lifting is prohibited.
Unwind or wind up steel rope under pulling tension only!)
When installing or changing the blades suitable protective gloves should be worn
(danger of cutting!).
When stripping the steel cables no person is allowed in a radius of 1,2 times the rope
length!
Maintenance and repair may be carried out to the units by trained specialists only.
Original spare parts should be used only in order to ensure correct function and
maximum safety.

Page 6
Handling Instructions

Maintenance

Cutting Unit:
Used, blunt or worn blades have to be replaced.
In case of contamination the unit has to be cleaned and proper functioning of the
mechanical components should be checked

Pulling Unit:
The gear lubricant oil has to be changed at least every 2 years (1,3 kg mineral oil VG
220).
The roller bearings of motor and transmission should be lubricated with grease such
as Mobilux (M) EP 2 or Alvania (M) R3.

Before each operation observe the following:

Clean contaminated steel rope with a clean cloth - do not lubricate (splice area to be
vulcanised must not be contaminated by grease or chemicals).
If any wires of the steel rope are broken or damaged, the steel rope has to be
replaced immediately (danger of accident!).
If the steel rope diameter is 10 % or more below its nominal diameter, the rope has
to be replaced even when none of the wires are broken or damaged. (The nominal
diameter of the steel rope is 6 mm i.e. at a diameter of 5,4 mm the rope has to be
exchanged).
Proper functioning of the locking brake must be checked at regular intervals.

Slide Unit:
In case of contamination the unit has to be cleaned and the stopping device as well
as the fastening shaekles have to be examined for safe functioning before eaeh
operation.
Check slide unit for deformation / distortion - the safety bracket must be easily
movable over the full length.

Important: Pull out mains plug before starting!

Repairs on the pulling unit may be carried out by a professional electrician only!
Faulty and worn components have to be exchanged immediately by means of
original spare parts.

Page 7
Operating Instructions

Preparing the Conveyor Belt

Secure belt (e.g. fasten belt on conveyor), mark splice geometry and align belt.

Expose steel cables across the belt on the joint marking (remove
rubber on carrying side and running side). A thin rubber layer (approx. 0,3 mm) should
remain on the steel cables (contours of cables should be visible). The top and bottom
cover should be removed in a width of approx. 200 mm.
Cut off rubber edges in the splice area on both sides of the belt.

Note: The length in which the cables have to be exposed depends on splice length
and type of splice (splice geometry according to local standards) .

Carrying
side

Running
Splice length side

For easy installation of the

cutting unit place a support (e.g. a wooden beam
120 x 120 mm x belt width) under the belt end outside the splice area.

Pulling Unit and Slide Unit

Rope drum Pulling Unit

Handle Machine
housing
Pulling
direction
Locking brake

Shackle for anchorage Slide unit

Page 8
Operating Instructions

Preparing and Positioning on Conveyor Belt

Important: Observe safety instructions on page 6 before putting the Cable Stripping
System into operation!

Place the slide unit into required position manually or with a hoist (crane) on
conveyor or in the workshop and secure with shackles and suitable stops against
moving and tilting. The distance between pulling unit and belt head should be
approx. 1,5 - 2 m.

The anchorages have to resist a pulling strength of at least 6 KN each. The slide unit
must be positioned horizontally and in a right angle to the running direction of the
conveyor belt. Place the pulling unit with its rollers into the slide unit manually or with
a hoist. Unlock the stopping device (safety device), insert the pulling unit completely
into the slide unit and secure on the rail with the locking brake. It must be ensured
that the rolls of the pulling unit are fully located in the frame of the slide unit. Move
the safety bracket into the frame of the slide unit, on the rope side of the
winch, at the way in until the stop.

Connect pulling unit to appropriate power supply. Unwinding and rewinding of the
pulling rope is done by means of remote cable control in 2 winding speeds.
Steel cable Belt

Belt fixation
Wooden beam

min. 1.500 mm Splice length

Anchorage
Pulling unit Pulling rope Cutting Unit
Safety bracket

Slide Unit

Page 9
Operating Instructions

Preparing the Cutting Unit

Select suitable blade tor the corresponding steel cable diameter (measure cable
diameter or see chart tor DIN belts on page 5).
Install the corresponding blade with its blade holder and the appropriate pressure
roller:
for cable diameters 8,9 mm:
Blade holder No. 1 and pressure roller No. 1 - top
for cable diameters 9,0 mm:
Blade holder No. 2 and pressure roller No. 2 - top
the bollorn pressure roller is suitable for all cable diameters

Important: Wear protective gloves - Danger of cuttingl

Installing and changing the blades
Proceed as follows:
Upper blade (long sides)
Slacken nut (3) and bolt (4). Move pressure roller unit (5) sideways. Remove bolt (6)
and remove lid (7). Check number of blade holder (9) (see page 4) and exchange if
necessary. Insert blade (8) into blade holder with cutting edge in pulling direction
and press against stop plate (10). Replace Lid (7) and tighten bolt (6).
Move pressure roller unit (5) back and tighten nut (3) and bolt (4) Check blade seat
(must touch stop plate (10)), correct if necessary.
Lower blade (short sides)
Proceed as for upper blade. Moving the pressure roller unit (5) sideways
is not necessary.

Cutting Unit
(Top View)

Page 10
Operating Instructions

Adjusting both Blades

Roughly adjust the blades with the setting gauges as follows:

Move upper pressure roller to upper position with adjusting
screw (2).
Select setting gauge and press down eccentric lever.
Insert setting gauge and move the upper edge of the upper
blade with the adjusting screw (1) until it coincides with the
notch in the setting gauge.
Lower notch: for bottom cover thickness 8 mm
Upper notch: for bottom cover thickness 10 mm
For other bottom cover thicknesses the corresponding
adjustment has to be made (upwards or downwards)

Cutting Unit
Eccentric lever
(side view) (closed)

Eccentric lever
(open)

Notches Setting gauge

Upper edge

Pulling direction

Page 11
Operating Instructions

Adjusting the Cable Pitch

Setting of the cable pitch is done by means of the scale on the side of the cutting
unit.
Measure cable pitch on conveyor belt.
Slacken bolts (11) and (12), adjust to required cable pitch setting and tighten the
bolts.

Cutting Unit
(Front view)

Reading
Point

Scale

Page 12
Operating Instructions

Connecting the Cutting Unit to the Pulling Unit

Completely release the tension of the upper pressure roller with adjusting screw (2).
Open cutting unit with eccentric lever and position upper blade onto the first steel cable
in the already exposed area on the left hand side of the belt - in pulling direction.

Close cutting unit by pressing eccentric lever down.

Important: The upper blade must be situated exactly on the first

steel cable.

Unwind steel rope of pulling unit with shackle to the required length.

Important: When unwinding the steel rope must be tensioned

all the time!

The steel rope can be unwound max. 6 m in order to ensure that the rope is still
wound at least twice around the rope drum.

Cutting Unit
(Side View)

Eccentric lever
(closed)

Eccentric lever
(open)

Steelcord
belt

Pulling direction

Page 13
Operating Instructions

Connect shackle to the cutting unit

Important: The pulling rope must be pulled only in a right angle
to the slide unit (correct position of pulling unit on slide unit if necessary).

Stripping the steel cables

Caution: During the stripping operation no person is allowed

within the dangerous area (pulling rope length x 1,2)!
Pull cutting unit with pulling speed 1.

Important: Check after approx. 150 mm whether there remains

a thin layer of rubber (approx. 0.3 mm) around the steel cable! Control only at a
standstill and when the pulling rope is not tensioned!

Precisely adjust the upper blade with adjusting screw (1) (only when the cutting unit
is at a standstill and the pulling rope not tensioned!).

After the upper blade is precisely adjusted pull the cutting unit to the belt end. During
this operation the upper half of the first steel cable is stripped, while the lower blade
is idle during this first operation.

Move cutting unit with pulling rope back to starting position by hand. When winding
up or unwinding, the pulling rope must be tensioned always.
Position upper blade onto second steel cable; the lower blade is now on the first steel
cable. Tighten adjusting screw (2) until the upper pressure roller is situated on the
stripped cable.
Pull the cutting unit again with pulling unit. The stagged lower blade is now stripping
the first steel cable completely and the upper blade strips the second steel cable on
the carrying side of the belt.
Check after approx. 150 mm whether a correction of the two pressure rollers is
necessary in order to adjust the blade cutting.

Note: By adjusting screw (1) the pressure of the upper pressure roller to the lower
blade is changed at the same time!
Important: The steel cables must be stripped in such a way that a thin layer of
rubber (approx. 0,3 mm) still remains on the cables.

If the blades are precisely set adjusted the cutting unit can now be pulled with
pulling speed 2.
Above procedures have to be repeated until all steel cables are stripped.
Reposition pulling unit ensuring that the pulling angle is always 90.

Important: The stripped steel cables must be laid onto a clean

surface and must not be exposed to dirt or grease. Use clean working gloves only!

Page 14
Operating Instructions

In case of thin cables strip the lower half of the last steel cable by hand using a Don
Carlos knife if necessary. Thin steel cables are usually not rigid enough for mechanical
stripping.
Position the Cord Stripper for stripping the second belt head.
After having stripped all steel cables proceed in accordance with the instructions for
the splicing of steel cable conveyor belt.

Steel cable Cutting Unit

belt

min. 1500 mm Splice length

Pulling Exposed steel

Pulling unit
rope cables
Safety bracket
Anchorage

Slide unit

Page 15
Technical Data

Cutting Unit
Cable pitch: 10 - 25 mm
Cable diameter: 4,9 - 13,2 mm
Weight: approx. 10 kg
Length x Width x Height: approx. 380 x 270 x 450 mm

Pulling Unit (Standard)

Motor: 400 V - 0,61 2,4 kW IP 54
Speed: Motor: 2700 1 630 rpm.
Transmission: 35/8,5 rpm
Rope type: Diameter 6 mm, Standard DIN 3060
Pulling speed: Speed 1: approx. 6 m/min
Speed 2: approx. 20 m/min
Rope length: 7 m (admissible pulling length: 6m)
Winch power: 6 KN (when half the rope is unwound)
Noise emission: < 70 dB (A)
Electric connection: CEE plug 16 A (400 V)
Weight: approx. 80 kg
Length x Width x Height: approx. 650 x 500 x 390 mm

Slide Unit (3 m long)

Weight: approx. 50 kg
Length x Width x Height: approx. 4000 x 510 x 85 mm

Slide Unit (4 m long)

Weight: approx. 50 kg
Length x Width x Height: approx. 4000 x 510 x 85 mm

Page 16
Technical Data

Cutting Unit

Pos. No. Description

1 Upper blade holder cpl. No.1 - for cable 8.9 mm

2 Upper blade holder cpl. No. 2 - for cable 9.0 mm
3 Lower blade holder cpl. No. 1 - for cable 8.9 mm
4 Lower blade holder cpl. No. 2 - for cable 9.0 mm
5 Upper pressure roller cpl. No. 1 - for cable 8.9 mm
6 Upper pressure roller cpl. No. 2 - for cable 9.0 mm
7 Lower pressure roller
8 Rollers cpl., 1 set, cpl. (= 4 piece)
9 Eccentric lever cpl.
10 Rubber handle
11 Main adjusting screw cpl.
12 Pressure roller bracket cpl.
13 Butt plate with angle
14 Pulling fork cpl.
15 Machine handle
16 1 Set setting gauges

Page 17
Technical Data

Pulling rope

Spare parts for Pos. No. 6

(Motor and Transmission) on
request

Pos. No. Description

1 Pulling rope cpl.

2 Rope drum cpl.
3 Sliding hub cpl.
4 Housing / frame cpl.
5 Rollers cpl., 1 set (= 4 piece)
6 Spur wheel back-geared motor
7 Locking brake cpl.
8 Protection hood
9 Control unit cpl. with 7,5 m cable
10 CEE plug 16 A cpl. with 10m cable
11 Rubber handle
12 Safety bracket for slide unit

Page 18