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How to Strip the Insulation from Machine Cable

Stripping insulation from machine cables is a common yet crucial task in electrical maintenance, repair, and installation work. Done incorrectly, it can damage the conductor, compromise safety, or lead to poor connections. Follow this step-by-step guide to achieve clean, precise results.

Gather the Right Tools

• Wire strippers: Choose adjustable models with multiple notches to match cable gauge (e.g., 10–22 AWG). Ratcheting strippers offer better control for thick insulation.
• Utility knife: Use a sharp, retractable blade for thick or rigid insulation (e.g., PVC or rubber sheathing on heavy-duty cables).
• Heat gun: Useful for heat-shrinkable or adhesive-backed insulation that resists mechanical stripping.
• Cable cutter: Ensure clean, square cuts before stripping to prevent conductor damage.

Step-by-Step Stripping Process

1. Identify Cable Type and Gauge

Check the cable’s markings (e.g., “12 AWG THHN”) to determine conductor size and insulation material. This dictates tool selection—thin vinyl insulation may require light-gauge strippers, while armored cables need specialized tools.

2. Prepare the Cable

Cut the cable to the desired length using a cable cutter. Ensure the cut is straight to avoid uneven stripping. For multi-conductor cables, separate individual wires gently to prevent tearing insulation.

3. Adjust Strippers (If Using)

Set the wire stripper to a notch slightly larger than the conductor diameter. A too-small notch will nick the conductor; a too-large one may fail to grip insulation. Test on a scrap piece first.

4. Strip Thin to Medium Insulation

• Place the cable in the selected notch, holding the strippers perpendicular to the wire.
• Squeeze the handles firmly to pierce the insulation without cutting the conductor.
• Rotate the strippers 360 degrees to score the insulation, then pull toward the cable end to remove the stripped section.

5. Remove Thick or Rigid Insulation

For heavy-duty cables (e.g., rubber-insulated machine leads):

• Use a utility knife to make a shallow, circular cut around the insulation, 1–2 inches from the end. Apply minimal pressure to avoid slicing the conductor.
• Make a longitudinal cut from the circular score to the cable end, then peel back the insulation like a sleeve.

6. Handle Heat-Shrink or Adhesive Insulation

• Apply low heat (200–300°F) with a heat gun to soften the material, keeping the gun 4–6 inches from the cable to prevent overheating.
• Once pliable, use pliers to gently peel away the insulation while it’s warm.

Special Cases

• Armored or Shielded Cables: First remove the outer metal armor with armor cutters, then strip the inner insulation as above.
• Multi-Layer Insulation: Strip layers sequentially—remove outer sheathing first, then inner insulation from individual conductors.

Safety Tips

• Always disconnect power before working on live cables.
• Wear gloves to protect hands from sharp edges and chemicals in insulation.
• Inspect stripped conductors for nicks or strands—damaged wires should be cut back and re-stripped.

By following these steps and using the right tools, you can strip machine cable insulation efficiently while preserving conductor integrity, ensuring reliable electrical connections.