Conveyor Belt Installtion Splicing

11004660-R01-0001-01 Rev.
0

ERNEST HENRY MINING PTY LTD
Underground Expansion Project

Conveyor Belt, Splice Kits and
Sensor Guard Rip Detection

Conveyor Belts

Contract No.
1100 4660

Installation, Operation and
Maintenance Manual

2
TABLE OF CONTENTS
1.0 Veyance Belting Pty Ltd Contacts ........................................Page 4

2.0 GENERAL INFORMATION...................................................Page 5
2.1 Purpose..Page 5
2.2 Statutory Requirement.Page 6
2.3 Belt Specification .Page 6
2.4 Belt Construction .Page 7
2.5 Rubber CompoundPage 7

3.0 SPLICING
3.1 Splice Specification ..Pages 8 - 9
3.2. Splice Kits ..Page 10
3.3 Splice Drawings Pages 11-14

4.0 MAINTENANCE INSTRUCTIONS AND PROCEDURES
Section A Belt Installation................................................. Pages 15-19
Section B Flexsteel Belt Splicing ........................................ Pages 20-38
Section C Repairing Steel Cable Conveyor Belting............... Pages 39-41
Section D Fabric Splice Preparation.................................... Pages 42-46
Section E Fabric Belt Vulcanising....................................... Pages 47-50
Section F Fabric Belt Bias Splice........................................ Pages 51-56
Section G Training The Belt................................................Page 57
Section H Factors Affecting The Training Of The Belt .......... Pages 58-60
Section I Sequence Of Training Operations ....................... Pages 61-62
Section J Cleaning ........................................................... Pages 63-64
Section K Loading ............................................................ Pages 65-67
Section L Pulley Lagging................................................... Pages 67-69
Section M Trouble Shooting............................................... Pages 70-71

5.0 SENSOR GUARD RIP PROTECTION.Separate Section Pages 1-58
Addendum Pages 59-60

6.0 REPAIRING FABRIC CONVEYOR BELTSSeparate Section Pages 1-11

7.0 MATERIAL SAFETY DATA SHEETSSeparate Section Pages 1-30

8.0 LIFTING POINTS AND HANDLING ..Separate Section Pages 1-5

3

9. RECOMMENDED SPARE PARTS LISTSeparate Section 1 Page

10. CERTIFIED DRAWINGS ....Separate Section Pages 1-11

4
1.0 Veyance Belting Pty Ltd Contacts

Sydney

Contact: Bob Patman / Con Michaels

Address: Level 3, 470 Church Street
NORTH PARRAMATTA NSW 2151

Telephone: (02)8839 9602 / (02) 8839 9601

Fax: (02) 9890 8973

Email: robert_patman@veyance.com
con_michaels@veyance.com

Melbourne

Contact: Gus McLennan

Address: 7 Dunlop Court
BAYSWATER VIC 3153

Telephone: (03) 9721 0604

Fax: (03) 9720 5520

Email: gus_mclennan@veyance.com

Mackay

Contact: Michael Anastasi

Address: PO Box 1634
MACKAY QLD 4740

Telephone: 0432 640 649

Email: Michael_anastasi@veyance.com

5
2.0 GENERAL INFORMATION

2.1 Purpose:
Bulk Materials Handling

The ST1800 steel cord belting was manufactured by Veyance Belting Pty Ltd
in the plant located at Bayswater, Melbourne, Australia.

The PN1000/5 fabric belting was manufactured by Shandong Aneng
Conveyor Belt & Rubber Co.Ltd. Joint Venture in Yanzhou City, Shandong
Province, China.

The conveyor belt details are as follows:

Conveyor
Number/ name
Belt Specification Supply
Quantity
(metres)
No. of
Reels
(metres)
Identifier/
Job No.
E752CV001
Crusher
Collector
Conveyor
2000mm PN1000/5 with 15x5mm
ARMA II covers
80 1x80 VB18846
E752CV002
Trunk
Conveyor
1050mm ST1800 15x5mm ARMA II
covers.
1390 3x463.40 JO32065
E755CV003
Loading
Collection
Conveyor
ARMA II covers
95 1x95 VB18846
E756CV004
Loading
Conveyor
ARMA II covers.
110 1x110 VB18847
E771CV005
Overland
Conveyor
1050mm ST1800 15x5mm ARMA II
covers.
1245 3x415 JO32065

6

Supply Lengths

Conveyor Supply
Quantity
No. of Reels Gross Weight
(kgs)
Reel Height
/Length (m)
Reel
Width
(m)
E752CV001

80 1x80 7600 1.9x1.9 2.1
E752CV002

1390 3x463.4 19011 3.9x3.9 1.35
E755CV003

95 1x95 8700 2.0x2.0 2.1
E756CV004

110 1x110 11800 2.7x2.7 2.24
E771CV005

1245 3x415 17109 3.7x3.7 1.35

2.2 Statutory Requirements: Not applicable

2.3 Belt Specifications

Conveyor: E752CV001
E755CV003
E752CV002
E771CV005
E756CV004
Width: 2000mm 1050mm 2400mm
Rating: PN1000/5 ST1800 PN1000/5
Top Cover 15mm 15mm 15mm
Bottom Cover: 6mm 5mm 5mm
Cover Grade: ARMA II ARMA II ARMA II
Sensor Loops: None 45 metre None

7

2.4 Belt Construction

FABRIC BELT E752CV001 E755CV003 E756CV004
Width 2000mm 2000mm 2400mm
Rating: PN1000/5 PN1000/5 PN1000/5
Top cover 15.0mm 15.0mm 15.0mm
Bottom cover 5.0mm 5.0mm 5.0mm
Cover grade ARMA II ARMA II ARMA II
Number of cords: 5 5 5
Cord diameter: 0.5mm 0.5mm 0.5mm
Ply strength: 200 kN 200 kN 200 kN
Ply construction: Polyester/Nylon Polyester/Nylon Polyester/Nylon
Belt breaking strength: 1000kN/m 1000kN/m 1000N/m
Belt rated tension: 100.0 kN/m 100.0 kN/m 100.0 kN/m

STEEL CORD BELT E752CV002 E771CV005
Width 1050mm 1050mm
Rating: ST1800 ST1800
Top cover 15.0mm 15.0mm
Bottom cover 5.0mm 5.0mm
Cover grade ARMA II ARMA II
Number of cords: 84 84
Cord diameter: 4.6mm 4.6mm
Cord strength: 23.0kN 23.0kN
Cord construction: 7x7 7X7
Cord pitch: 12mm 12mm
Belt breaking strength: 1800kN/m 1800kN/m
Belt rated tension: 270.0kN/m 270.kN/m
Sensor Loops Yes@45m
spacing
Yes@45m
spacing

2.5 Rubber Compound

All belt types

Top Cover Grade ARMA II
Minimum Tensile Strength: 16.0 MPa
Elongation Min: 450%
Abrasion Value Max: 120mm

Bottom Cover Grade ARMA II
Minimum Tensile Strength: 16.0 MPa
Elongation Min: 450%
Abrasion Value Max: 120mm

8

3.0 SPLICING

3.1 Splice Specification

3.1.1 Conveyors E752CV001,E755CV003
2000mm PN1000/5 with 15mmx5mm ARMA II covers

Type: Hot vulcanised
Step: 4

Splice details
Cover Saddle Step length Splice type
100mm/75mm 250mm 4 step hot vulcanised

Curing Splice
Cure time: 50 minutes
Cure temperature 143C 3C
Cure pressure: 700 kPa
Humidity: <75%

Thermocouple all Platens
Record all Temperatures

3.1.2 Conveyor E756CV004

2400mm PN1000/5 with 15mmx5mm Grade ARMA II covers

Step: 4

Splice details
Cover Saddle Step length Splice Type
100mm/75mm 250mm 4 step hot vulcanised

Curing Splice
Cure pressure: 700 kPa
Humidity: <75%


9

3.1.3 Conveyors E752CV002 and E771CV005

1050mm ST1800 15mmx5mm Grade ARMA II

Stage: Two Stage

Cord splice details
Belt Splice
Cord diameter 4.6mm 4.6mm
No of cords 84 140
Cord spacing 7.4mm 2.5mm
Cord pitch 12.0mm 7.1mm

Splice Dimensions:
Cover Skive: 15.0mm
Transition Zone: 110mm
Step length 509mm
Splice length 1286mm

Curing Splice
Cure pressure: 1030-1240 kPa
Humidity: <75%


10

3.2 Splice Kits

When a splice kit is required we strongly recommend it be sourced from
Veyance. This will ensure the materials are compatible, fresh and are
prepared to suit the belt construction.

Veyance splice kits are supplied in a sealed box containing all materials
necessary to carry out one splice.

Splice Kit Contents 2000mm PN1000/5 15mmx5mm grade ARMA II and
2400mm PN1000/5 15mmx5mm grade ARMA II

Veyance Reference
1. Top and Bottom Covers fill in strips (Saddles) ZX5066
2. Fill in strips (Saddles) breaker fabric 1498/19722
3. Inside gum (Tie gum) ZX 5032
4. Cover cement Nylobond
5. Inside gum (Tie gum) cement M920C
6. Solvent M 714C
7. Light weight nylon BW1585
8. Polyethylene Plain XA665
9. Cellophane M604

Splice Kit Contents 1050mm ST18000 15mmx5mm Grade ARMA II

Veyance Reference
1. Top and Bottom Covers ZX5066
2. Insulation gum ZX 5032
3. Cover cement Nylobond
4. End fill in gum ZX 5032
5. Edge fill in gum ZX 5032
6. Cable cement M893C
7. Solvent M 714C
8. Light weight nylon BW1585
9. Polyethylene Plain XA665
10. Cellophane M604

Splice Kit Shelf Life
Splice Kit contains uncured rubber and cements.
Therefore the shelf life for the splice kits is 6 months refrigerated at 7C

11

3.3 Splice Drawings

See next five pages:

i. Drawing No. VB-13202-00041 2000mm PN1000/5 15mmx5mm grade ARMA II
ii. Drawing No. VB-13202-00042 2400mm PN1000/5 15mmx5mm grade ARMA II
iii. Drawing No. VB-13201-00081 1050mm ST1800 15mmx5mm grade ARMA II

12

13

14

15

SECTION A
BELT INSTALLATION

1.1 STORAGE AND INSTALLATION

The methods of storing and handling Conveyor Belting
and the procedures for tensioning it prior to making
the final splice are just as important as actually
making the splice.

New conveyor belting should be stored upright in the
factory package until used. A cool dry room, free from
sunlight, steam pipes, oil and corrosive fumes is best.
Under no circumstances should a roll of belting be
stored on its side, even if on a concrete floor. Moisture
will shrink any exposed fabric which gets damp from
such storage and the belt may bow on one edge.
Storage of rolls in an upright position on a dry wooden
floor is recommended. If long term outside storage is
necessary, the lay down area should be prepared by
placing matting or other material to protect the belt
from sharp objects. If long term, storage outside is
necessary, (more than one year) the belt should be
covered with a suitable material such as a tarpaulin or
heavy pigmented plastic sheeting. This will protect the
belt from the effects of weathering.

1.2 HANDLING THE ROLL OF CONVEYOR BELT

Conveyor belts should never be dropped while
unloading from a freight car, truck, or other means of
transportation. Due to their weight, dropping rolls can
break the packaging and may damage the belt.

Belts should never be rolled or skidded. Provisions
should be made to use proper moving equipment.
Care must be taken when hoisting a conveyor belt to
prevent damaging the edges. Insert a bar through the
centre of the roll and lift with cords or chains attached
to a spreader. (Fig.1-1)

Fig. 1-1

Once the roll of belting has been transported to the
installation area it should be mounted on a suitable
shaft for unrolling and stringing onto the conveyor
system. Conveyor belting is normally rolled at the
factory with the carrying side out. Consequently, in
mounting the roll, the belt must lead off the top of the
roll if it is being pulled onto the troughing or carrying
idlers but off the bottom of the roll if it is being pulled
onto the return idlers. Fig. 1-2 illustrates a suitable
method of mounting as well as leading off the top of
the roll for pulling onto the troughing idlers.

Note: Temporary flat roll at bend point,
as roll is pulled onto troughing idlers.

Fig. 1-2

4. Maintenance Instructions
and Procedures

16
To prevent the belt roll from over-running at the let-off a
braking device is often needed. (Fig. 1-3)

Fig. 1-3

1.3 STRINGING THE BELT

Textile belts such as Plylon, Wingfoot, Pathfinder, etc.
that have been slit from a full width slab at the factory,
should be spliced with the factory cut edges on the same
side of the conveyor. (Goodyear identifies these edges
with blue paint applied at the factory after slitting.)

To minimise side travel on steel cord belt rolls, it is
recommended that rolls be strung onto the conveyor in
the exact sequence they were manufactured.

For new installations and major replacements, the
following procedure is recommended for Flexsteel Belting.
Each roll of belting will be clearly identified with a roll
number.

The 1st end cured at the factory will be attached
to the shell.

The last end cured in the factory will be the outer
wrap.

The top cover will face outside.

All rolls of belting are to be spliced onto the conveyor in
the following sequence starting with the last manufactured
roll. (e.g. Roll #8 of a total of 8).

The inside wrap of roll #8 will be spliced to the
outside wrap of roll #7.

The inside wrap of roll #7 will be spliced to the
outside wrap of roll #6 and so on.

After the belt has been positioned, the means of threading
it on the conveyor system must be considered. If the new
belt is a replacement, the old belt can be used to pull it on.
The old belt is clamped off, cut and the new belt then
spliced to the end of the old belt using plate type fasteners
(fabric belts) or pulling plates as illustrated in Fig. 1-4 for
fabric belts and Fig. 1-5 for Flexsteel belts. The trailing
end of the old belt is connected to a suitable power device
to pull the belt through the system. The conveyor drive
motor can be used to pull on the new belt.
Other suitable pulling devices such as cord winches,
belt winders and bulldozers, can also be used. Fig.
1-6.

NOTE: SEE CAUTION STATEMENT
REGARDING TURNOVERS- FIG. 1-8

Fig. 1-4

Fig. 1-5

Fig. 1-6

17
For a new conveyor installation having little or no
slope, a rope or cord of suitable strength should be
attached to steel pulling plates. The rope or cord is
then threaded around the conveyor system and
attached to a suitable power device to pull the belt
into place.

A belt being installed on a system with a relatively
high degree of slope (12or more) must be handled
with more precaution to guard against run-away. The
belt roll is set up as previously mentioned, usually at
or near the head pulley. This is generally the most
accessible Assuming the conveyor is sufficiently long
so as to require more than one splice, the carrying
side and the return side may be threaded on
separately. Care must be taken to see that the
heavier cover is up on the carrying side and down on
the return run.

NOTE: If belts are to be strung on both the carrying
and return side of the system, then rerolling of the
belts for one of the sides is necessary before
stringing to ensure the correct sequence in splicing.
For major installations, rolls can be shipped in this
configuration by prearrangement.

As the belt is fed on the system, tension at the roll
tends to build up due to the weight of the belt on the
slope. For this reason some method of braking is
required such as using a belt clamp mounted on the
conveyor structure, through which the belt is
threaded. Where the slope is very long, additional
clamps should be used, spaced approximately 1000
feet (305m) apart. Mechanical, air and hydraulic
clamps are recommended. Wooden clamping
devices are not recommended.

To estimate the pull required to hold a belt on a
slope, multiply belt weight (Ib/ft) times the vertical lift
of the slope and add 10%. For example, assume a
40 Ib/ft belt and a 300 ft high slope. The approximate
pull is (40 X 300) X 1.1 = 13,200 lb.

If calculating in S.l. units, multiply the belt weight
(kg/m) times the vertical lift and add 10%. For
example, assume a 60 kg/m belt and a 100m high
slope. The approximate pull is (60 x 100) x 1.1 =
6600 kg.

If the conveying side and the return side have been
fed on separately the final splice can be made at the
bottom of the slope where the ends of the belt meet.
In some situations it is advisable to utilise a suitable
temporary splice to index the belt and complete the
final splice at the original location. Making the final
splice at the top of the slope is possible but a greater
force will be required to remove the sag and lift the
counterweight.

Belt clamps must be used on the final pull. The
system illustrated in Fig. 1-7 will avoid dismantling the
work area by allowing a suitable length of belt to lay
back over the clamp.

1.4 TENSIONING

Once the belt has been pulled onto the conveyor
system it must be tensioned prior to splicing to
facilitate correct positioning of the take-up and to
eliminate sag. The tensioning operation takes place
at the location where the last splice will be made.
After final tensioning, clamps are placed on each end
of the belt. These are made of steel and have a
clamping surface as indicated in Fig. 1-7.

Tension is applied by means of a power device which
is used to pretension the belt before clamping off

When tension measuring load cells or scales are
used, they are rigged to measure the pull on the take-
up pulley. The belt is pulled until the load cell or
scales register a tension equal to or slightly greater
than the recommended take-up force. Make
allowance for an amount of belt necessary to
correctly position the counterweight from this point.

Certain basic statements and recommendations can
be made about tensioning for splicing:

a) Belts which are tensioned by pulling in only one
direction require more splicing tension than those
pulled in both directions.

b) Slope belts spliced at the top of the slope require
more splicing tension than those spliced at the
bottom.

c) Slope belts having an anti-rollback device which
cannot be released must be tensioned by pulling
in the direction of belt travel only.

d) Check the belt frequently during tensioning to
ensure that the belt is free and not binding at any
place.

e) During the final tensioning pull be sure the ends
of the belt are lined up properly.

Conveyor installations having limited take-up travel
should be spliced to a tension based on the loaded
running tension. This tension should be specified by
Goodyear and measured by suitable load cells or

18
dynamometers. Where it is practical, fabric belts
should be run for several weeks with mechanical
fasteners before making the final vulcanised splice.

Obtaining the required tension depends heavily on the
experience of the individual making the splice. It is
possible for a gravity type take-up to severely damage
the conveyor structure if it is positioned too close to
the forward or upward stop. Too much tension applied
to a relatively short belt may thus have a harmful
effect on the pulley shafts and bearings as well as the
belt.

Fabric belting (eg. Plylon, Wingfoot, Glide, Pathfinder,
etc.) is usually installed so that most of the take-up
travel is available for subsequent increase in belt
length. Flexsteel belting is usually installed with most
of the take-up filled with belt.

The belt may be tensioned with a suitable take-up
device as follows:

a) When the Counterweight is on: Tie the take- up
off 6 to 8 (150mm to 200mm) above the desired
running position. (Consideration may have to be
made for excessive sag.) Next, pull the belt until
the take-up starts to lift and the tie-off ropes
become slack. Make the final splice allowing a
minimum of belt slack.

b) When the counterweight is not on: Splicing
without the counterweight installed is undesirable,
however the following procedure should be
employed if necessary. Use suitable belt clamps
to hold the take-up pulley 6 to 8 (150mm to
200mm) above the desired running position.
(Consideration may have to be made for
excessive sag.) Pull the belt to its running tension
which can only be estimated in this situation.
Judgement in estimating this tension will improve
with the experience of the splicer.

1.5 TAKE-UP TRAVEL AND INITIAL POSITION

Tables 1-1 and 1-2 show the recommended minimum
take-up travel and initial take-up position respectively.

TABLE 1-1
RECOMMENDED MINIMUM TAKE-UP TRAVEL
IN PERCENT OF CENTER DISTANCED

TYPE OF TAKE-UP AND
PERCENT OF RATED TENSION
CARCASS MATERIAL (WARP) 100% 75% 50% or LESS
MANUAL TAKE-UP**
NYLON 4.0% 3.0% 2.0%
POLYESTER 2.5% 2.0% 1.5%
ARAMID 2.0% 1.5% 1.0%
FIBREGLASS 1.0% 0.75% 0.5%

AUTOMATIC TAKE-UP
NYLON 3.0% 2.50% 1.50%
POLYESTER 1.7% 1.25% 0.75%
ARAMID 1.5% 1.00% 0.75%
FIBREGLASS 0.5% 0.40% 0.25%
STEEL 0.30% 0.23% 0.15%

*For [1] belts installed at average empty running tension [2] take-up position per Table 1 -2, and [3] Drive location at
or near the high tension end of the conveyor.

**Only short endless feeder belts and the like would normally be Vulcanised on conveyors with a manual take-up.

19
TABLE 1-2
RECOMMENDED INITIAL TAKE-UP POSITION

CARCASS MATERIAL
(WARP)
PERCENT AVAILABLE
FOR LENGTH INCREASE
PERCENT AVAILABLE
FOR LENGTH DECREASE
STEEL 25% 75%
NYLON, POLYESTER,
ARAMID, FIBREGLASS

90%

10%

+Take-up conditions and travel amounts as shown in Table 1-1.

1.6 CUTTING BELT TO LENGTH

a) When splicing a belt to a specified length or a net
endless length (NEL), the following total length of
belt will be required: The specified NEL length plus
one splice length plus a minimum of 2 (50mm)
trim allowance. If two or more belt rolls are to be
spliced NEL add a splice length plus a minimum of
2 (50mm) trim for each roll or splice.

b) When replacing a damaged section of belt the
required length of new belt will be: The length of
the damaged section plus 2 splice lengths, plus a
minimum of 4 (100mm) trim allowance. Cut the
ends square. NOTE: Whenever a section of new
belt is to be spliced into an old belt the length of old
belt to be removed should include as many of the
old splices as is reasonably possible on very short
conveyors it is sometimes necessary to remove
the tail pulley in order to have adequate slack for
splicing after cutting to length.

d) When a splice has to be done on the return run,
precaution must be used in measuring the belt
length. The splice area may be located on the
ground requiring an adjustment in belt length, if the
conveyor is elevated above ground level.

e) In most cases it is not possible to pull up and utilise
all of the belt that appears to be available in a take-
up. About 4 ft (1.2m) of belt will be needed for
slack in splicing. In other words, for a re-splice the
take-up should have at least a splice length plus 4
ft (1.2m) available for removal.

f) If a fabric splice is to be remade and there is very
little belt in the take-up, the old splice can be cut
parallel to the bias and
near the centre. The old splice area is then re-
stepped and re-spliced and the take-up is only
raised 1/2 the total length of the steps on one end
of the splice.

g) Belts running on 45idlers on a system with a
minimum take-up should be clamped off at or near
the head pulley. Tension the belt with a centre
pulling plate so the belt will conform to the idlers
when pulled and then mark master line on each
end. Leave minimum slack for the vulcaniser.

CAUTION:

TURNOVERS: THE CONVEYOR PROFILE MUST BE
CONSIDERED WHEN STRINGING THE BELT TO
PREVENT THE FINAL ORIENTATION FROM BEING
UPSIDE DOWN. FOR EXAMPLE, TURNOVERS ADD
A TWIST TO THE BELT THAT MUST BE
ANTICIPATED.

GOODYEAR RECOMMENDS TURNING THE BELT
180AT THE HEAD AND REVERSED 180AT THE
TAIL. SEE FIG 1-8 FOR A TYPICAL TURNOVER
DESIGN.

20
SECTION B
FLEXSTEEL BELT SPLICING

The quality of the finished splice is highly dependent
upon the cleanliness of the work area during all stages
of splice preparation. Good work practices and
cleanliness go hand in hand and are essential in
achieving this goal.

A STEEL CORD SPLICE MUST BE VULCANISED IN
ONE CONTINUOUS LENGTH. THE VULCANISING
PRESS MUST CONTAIN THE ENTIRE SPLICE
LENGTH PLUS THE MINIMUM RECOMMENDED
LENGTH OF BOTH BELT ENDS.

7.1 WORK AREA AND CREW

a) LOCATION OF WORK AREA

If a permanent building is not available then a
temporary shelter must be built to protect the
exposed belt ends from weather, dust, etc.

The temperature in the work area must be
maintained at approximately 68F (20C) or
greater. This is to insure that the thick rubber
materials that must be handled will be both tacky
and flexible. Open flame torpedo style kerosene
heaters are not recommended due to explosive
hazards and the potential contamination by
residual kerosene in the splice area.

b) DIMENSIONS OF WORK AREA

The work area should extend at least 3 feet (1m)
beyond each edge of the belt (more if possible).
The roof of the shelter should be at least 8 feet
(2.5m) above the top of the splice work table.

Fig. 7-1

The length of the work area should be 4.5 times the
total splice length (including the bias)

c) THE WORK TABLE

All idlers must be removed from the work area and
a flat smooth surface provided which extends
approximately 3 (75mm) beyond each edge of the
belt. This is usually accomplished using 5/8
(15mm) or heavier plywood solidly supported by
timbers and firmly anchored so that it will not slip
and misalign the belt ends.

The bottom half of the vulcaniser is used as the
centre section of the work table.

d) WORK CREW

A work crew of 4 to 6 men is usually adequate on
steel cord belt splices depending on belt width and
splice length.

7.2 TOOLS AND MATERIALS

a) TOOLS

The tools necessary for preparing a steel cord belt
splice are listed in Fig. 7-1.

1. Rubber & fabric pulling device
2. Thermocouple unit & wires
3. Steel cable cut off saw
4. Buffer
5. Sharpening stone
6. Foxtail brush
7. Chalk line
8. Cotton sampler knives
9. Square
10. Awl
11. Ply & rubber lifting clamp
12. Tape
13. Pricker roll
14. Hook knife
15. Small T square
16. Stanley knife
17. 4 roller
18. V knife
19. Flexible skiver
20. Cable cutters
21. Silver pencil
22. 1 /16 stitcher
23. Scissors
24. Folding rule

21
FLEXSTEEL SPLICE FLOW CHART

7.1
WORK AREA AND
CREW

7.2
TOOLS AND
MATERIALS

7.3
SPLICE
DIMENSIONS
(CONTACT
GOODYEAR)

7.4
MASTERLINE

7.4.1
SQUARE AND
STRAIGHT EDGE

WHAT TYPE

7.4.3
SWINGING ARC

7.4.2
TRIANGULATION

7.5
MARKING AND
PREPARING
FIRST END

7.5.1
HOOKING
CORD REMOVAL

7.5.2
PIANO METHOD

1

22

1

7.6
CORD AND SKIVE
PREPARATION

7.7
ALIGNMENT,
CORD WASHING
AND CEMENTING

7.7.4
PULLEY COVER
PREPARATION
COMPONENTS

No
PULLEY COVER
SUPPLIED PRE-
ASSEMBLED

Yes
7.7.3
PULLEY COVER
PREPARATION
PRE-ASSEMBLED

7.7.5
PULLEY COVER
INSTALLATION

7.8
CORD LAY-UP
AND EDGE GUM
INSTALLATION

7.9.2
PULLEY COVER
PREPARATION
COMPONENTS
No
TOP COVER
SUPPLED PRE-
ASSEMBLED?

Yes
7.9.1
TOP COVER
PREPARATION
PRE-ASSEMBLED

7.9.3
TOP COVER
INSTALLATION

2

23


2

7.10
FINAL PRESS
ASSEMBLY

7.12
SPLICE
VULCANISATION

711
MONITORING
TEMP. AND PRES.

7.12.2
PRESS REMOVAL
No
PRESS PLATEN
COOLING TO BE
USED?

Yes
7.12.1
PRESS COOLING
AND REMOVAL

13.0
SPLICE
COMPLETION

24
NOTE: AC power supply will be required for buffers or
other power tools.

b) MATERIALS

A splice drawing must be obtained from Goodyear
for each belt to be spliced. Each of these drawings
will list the materials required for one splice. THE
INSULATION GUMS AND CEMENTS USED ON
AND AROUND THE CORDS OF THESE BELTS
ARE VERY CRITICAL AND NO SUBSTITUTIONS
SHOULD BE MADE. Otherwise, proper cord
adhesion in the splice may not be achieved.

IMPORTANT:

CHLORINATED SOLVENTS MUST NOT BE
USED FOR WASHING THE STRIPPED CORDS
NOR FOR THINNING CEMENTS APPLIED TO
CORDS. RESIDUAL CHLORINATED SOLVENTS
REACT WITH THE ZINC COATING ON THE
CORDS DURING VULCANISATION AND CAUSE
SEVERE LOSS OF ADHESION.

URETHANE OR CELLULOSE SPONGES, NEW
CLEAN WHITE COTTON RAGS, AND/OR PAINT
BRUSHES ARE PREFERRED FOR WASHING
AND CEMENTING CORDS AND SHOULD BE
PROPERLY DISPOSED OF AFTER USE. RAGS
THAT HAVE BEEN RECYCLED AND
COMMERCIALLY CLEANED HAVE BEEN
KNOWN TO CONTAMINATE CORD SURFACES
FROM MATERIALS EXTRACTED DURING
CORD CLEANING. PAPER TOWELS SHOULD
NOT BE USED.

7.3 SPLICE DIMENSIONS

Individual splice drawings for each Goodyear
Flexsteel splice will be furnished specifying the
proper dimensions for assembly.

7.4 MASTER LINE

This is normally the first line to be made on the belt
on each of the two ends. The master line is a line
drawn straight across the belt width at a distance
from the belt end equal to the splice length plus the
bias length plus a 2 (50mm) tab length. Three
methods of locating and squaring the master line
are as follows:

Fig . 7-2

7.4.1 SQUARE AND STRAIGHT EDGE -
FIGURE 7-2

a) From the end of belt, measure the length of splice
plus trim allowance.

b) Use a square and straight edge to draw master
line.

c) Check the master line by laying the square along
the opposite edge. Repeat the procedure on the
other belt end.

7.4.2 TRIANGULATION - FIGURE 7-3

Fig. 7-3

25
a) From the end of the belt, measure along one edge
to a point equal to the splice length plus trim
allowance. Mark the edge. This mark is then the
centre point of a line exactly 4 ft (1200mm) long
drawn along this edge.

b) From each end of the 4 ft (1200mm) line measure
equal diagonal lengths to the opposite edge and
mark (Fig. 7-6). Draw the master line.

c) This method is common on belts 72 (1800mm)
and wider.

7.4.3 SWINGING ARC - FIGURE 7-4

Fig. 7-4

a) Carefully mark a point at the exact centre of the
belt width. Measure from this centre point and
make a mark at each edge near the end. These
two diagonal measurements must be exactly
equal.

b) From each of the two edge marks measure back
the total splice length plus trim allowance. Mark
the edges and draw the master line.

Fig. 7-5

7.5 MARKING & PREPARING FIRST END -
FIGURE 7-5

a) Measure the bias length on the correct edge and
mark Point B. The bias length is selected so that
the bias angle will match the vulcaniser angle.

b) Draw the bias line A,B and mark the edges with a
vertical line at these points for opposite cover
marking. As in (Fig. 7-6).

Fig . 7-6

c) From A, measure the splice length and mark point
C.

d) From B. measure the splice length and mark point
C. Join C and D.

e) From C, measure 2 (50mm) and mark point D.

f) From C, measure 2 (50mm) and mark point D.
Join D & D.

g) Remove a strip of cover rubber about 1/2 (12mm)
wide down to the cords by cutting at approximately
45on either side of line D-D.

26
h) Place a suitable piece of lumber underneath the
belt to facilitate cutting and prevent the cut off saw
from damaging the underlying belt or splice press
platen.

i) Cut the belt along line D-D.

j) Starting at point A, remove the edge rubber (to the
first cord) to a point 1 (25mm) from point A (Fig. 7-
7).

Fig. 7-7

k) Repeat the procedure on the other edge from point
C to 1 (25mm) from point B.

I) Make a cut along line A,B at 45angle down to t he
cords (Fig. 7-8).

Fig. 7-8

m) Make a vertical cut along line C,C down to the
cords.

n) The belt over can be divided into widths of 16 to
24 (400mm - 600mm) to facilitate stripping.
To do this, mark the appropriate number of lines
on the surface, parallel to the belt edge and make
a vertical cut through the cover to the cord layer on
each line starting at line C,C and ending about 3
(75mm) from line A,B.

o) Remove cover strips by starting at point A (Fig. 7-
9). Lift the corner of the cover and start skiving
cover and insulation gum from the cords. An air
tugger or electric winch is usually used to keep
tension on the cover and facilitate removal. Skive
sufficient cover into the adjacent strip before
cutting the balance of the strip separation line. This
will provide a point for gripping for the start of the
subsequent strip.

Fig . 7-9

p) Continue this process until all cover has been
removed.

q) Turn the belt end back and draw line A,B on the
pulley cover by joining the vertical lines previously
marked on the edge of the belt.

r) Draw line C,C on the pulley cover by repeating the
process used on the top cover (see Fig. 7-5).

s) Make a cut along line A,B at a 45angle down to
the cords.

t) Make a vertical cut along line C,C down to the
cords.

27
u) For cord diameters up to 7/32 (5.4mm) proceed to
7.5.1. Cord Removal by Hooking. For larger cord
diameters proceed to 7.5.2 Piano Wire Cord
Removal.

7.5.1 CORD REMOVAL BY HOOKING

a) Turn the belt end back onto the table with the
pulley cover down. Mark a line across the belt 1/2
(13mm) from and parallel to line A,B towards the
belt end.

b) Using a Hyde angle knife (Fig. 7-10) with 3/8
(9.5mm) hook blades, begin hooking cords from
the chalk line to the end of the belt. Run the hook
blade on an angle on either side of each cord.
Repeat the process until all cords have been cut
away from the pulley cover rubber.

Fig. 7-10

c) Attach grips to the pulley cover at point A (Fig. 7-
11) and using the winch or tugger remove the
pulley cover.

Fig. 7-11

d) Proceed to cord preparation.

28

7.5.2 CORD REMOVAL BY PIANO WIRE METHOD
(Fig. 7-12)

Use of Piano Wire Loops to Strip out Cables

Fig. 7-12

29
7.5.2 CORD REMOVAL BY PIANO WIRE METHOD

a) Mark a line 4 (l00mm) from and parallel to A,B
towards the end of the belt.

b) Make a vertical cut along this line down to the
cords.

c) Using a skive knife and tugger remove the 4
(100mm) strip of pulley cover between the skive on
line A,B and the newly cut line.

d) Using a sharp knife, remove the web of rubber
between each cord.

e) Install piano wires by bending the wire 180aro und
the centre and inserting one looped end on either
side of the cord. Install wires on all cords before
next step.

f) Turn the belt end back on to the table with the
pulley cover down.

g) Attach four to six wires to the pull plate by crossing
each wire and affixing to the lug on the opposite
corner of plate.

h) Using a winch, pull the plate and wire assembly
towards the end of the belt to separate the cords
from the pulley cover rubber. Pull the wires the
length of the splice, stopping at the tab.

i) Repeat the process until all cords have been
separated from the pulley cover rubber.

j) Attach grips to the pulley cover at point A and
using the winch or tugger remove the pulley cover.

k) Proceed to 7.6 Cord Preparation.

7.6 CORD AND SKIVE PREPARATION

a) Use a V-knife (Fig. 7-13) to trim the ribs of rubber
remaining on cords removed with the hook knife or
the loose rubber created during piano wire removal
of cords. All excess rubber must be removed so
that cords have a round cross section.

Fig . 7-13

NOTE: IF THE CORDS HAVE BEEN CORRODED
THROUGH EXPOSURE TO THE ELEMENTS
OR OTHER CAUSTIC MATERIALS
ADDITIONAL PRECAUTIONS MUST BE
TAKEN. THE GALVANISED COATING
AND/OR RUST MUST BE COMPLETELY
REMOVED BY BUFFING WITH A WIRE
BUFFER UNTIL THE BARE STEEL IS
EXPOSED. CONTINUE WITH NORMAL
SPLICING PROCEDURE

b) Using a wire wheel or wire brush, (Fig. 7-14)
buff the bias skive across the full width of the
belt. Buff the top cover and both edges about
2 (50mm) from the skive.

Fig. 7-14

30
c) Turn the belt back and repeat the process on the
back cover skive and pulley cover:

d) Using a brush or broom, clean off buffing dust from
all areas.

e) Wrap the cords and prepared buffed areas in clean
poly film and fold the belt end back out of the work
area.

f) Repeat procedures in sub section 4 through 6 to
prepare the other belt end for splicing.

7.7 ALIGNMENT, CORD WASHING AND
CEMENTING

7.7.1 LOCATING AND ALIGNING ENDS

a) Place the belt ends on the bottom platen so that
the distance between the top of the skives equals
the splice length. (Fig. 7-15) The centre of the
splice should be located on the centre of the press
(both length and width). THE TOP OF THE SKIVE
MUST BE A MINIMUM OF 6 (150mm) FROM
END OF THE VULCANISING PRESS.

Fig.. 7-15

b) On each end of the belt mark four equally spaced
centre locations from the skive to the end of the
work table.

c) Run a string line from the centre mark at the
outside ends of each work table, supported by a
suitable block to keep line free from interference by
the belt surface.

d) Use a square to align these end marks to the
string. Check remaining centre marks and adjust
belt as necessary until all marks are aligned.
e) Recheck the splice length distance between the
skives. IF THE MEASUREMENTS ARE OUTSIDE
A TOLERANCE OF -0 +1 (25mm) IT IS
NECESSARY TO REPEAT THE ABOVE STEPS.

f) Secure the belt ends in this position. It is common
to C-clamp the belt to the work table and nail
blocks of wood to the table flush with the belt
edges to prevent lateral movement.

7.7.2 CORD WASHING AND CEMENTING

From this point on, CLEANLINESS IS MUCH
MORE CRITICAL. It is imperative that no foreign
material such as dust, dirt, sand etc. be allowed to
contact the cords and other uncured components.
CONTAMINATION WILL CAUSE LACK OF
CURED ADHESION AND CAN RESULT IN
SPLICE FAILURE. All exposed rubber surfaces
should be covered with poly film protection when
not actively being worked on.

Should an area of the splice become
contaminated, in spite of precautions, it can be
cleaned by swabbing with a clean cloth or sponge
soaked in the solvent provided with the kit. DO
NOT USE ANY CHLORINATED SOLVENT.
Ensure that dirt or other contamination is removed
and not merely spread around.

If massive contamination is encountered, the splice
will have to be cut out and restarted.

a) Depending upon individual circumstances and
splice lengths, belt ends are either suspended or
turned back onto the belt for washing and
cementing. Cover all areas under the washing and
cementing locations with poly film.

b) Brush off any loose dirt or rubber dust.

c) Wash cords with the appropriate solvent and allow
sufficient time to dry.

d) Apply two coats of cement to the cords and to the
skived cover cuts. (Fig. 7-16) Allow each coat to
dry thoroughly.

31

Fig. 7-16

IMPORTANT: BE SURE TO CHECK INDIVIDUAL
SPLICE MATERIAL INSTRUCTIONS
TO ENSURE CORRECT CEMENTS
ARE APPLIED IN THESE AREAS.

e) After the final coat of cement on the cords has
dried thoroughly, cut all the cords at the end tab
and discard the tab. When cutting be sure clean
poly film is under the work area. After all cords
have been cut, wrap the cords in poly film to keep
clean (Fig. 7-17).

Fig. 7-17

Typically, the cords from each end of the belt are
wrapped in two separate bundles divided at the
centre line. These bundles are then folded back
over the poly film on the belt surface.

f) Top and bottom cover panels may be supplied
either in separate components or in a factory
assembled composite. If the splice covers are pre
assembled proceed to 7.3. If individual
components are being used proceed to 7.4.

7.7.3 PULLEY COVER PREPARATION - PRE
ASSEMBLED

NOTE: WHEN SPLICING ON A SLOPE, SET THE
UPPER SKIVE FIRST.

a) THE INSULATION GUM SIDE OF THE COVER
ASSEMBLY IS IDENTIFIED WITH A WHITE
STRIPE AND GOES NEXT TO THE CORDS.

b) INSTALL THERMOCOUPLE WIRES ON THE
BOTTOM PLATEN PER THE CURING
INSTRUCTIONS IN SUB SECTION 11.1. ROUTE
THE WIRES OUT ONE END OF THE
VULCANISER AND TAPE IN POSITION ON THE
PLATEN. IT IS RECOMMENDED THAT THE
WIRES BE CONNECTED TO THE MEASURING
DEVICE AND CHECKED FOR FUNCTIONALITY
BEFORE PROCEEDING FURTHER.

c) Lay down the release material on platen over the
thermocouple wires.

d) Place the pulley cover composite (with the white
stripe side up) on the platen extending past the
skive cuts on both belt ends. Remove the poly film
from the platen side of the rubber only.

e) Proceed to 7.7.5.

7.7.4 PULLEY COVER PREPARATION -
COMPONENTS

NOTE: WHEN SPLICING ON A SLOPE BELT SET
THE UPPER SKIVE FIRST.

a) Identify the pulley cover panel and the insulation
gum rolls by referring to the materials list provided
with the kit.

b) INSTALL THERMOCOUPLE WIRES ON THE
BOTTOM PLATEN PER THE CURING
INSTRUCTIONS IN SUB SECTION 11.1. Route
the wires out one end of the vulcaniser and tape in
position on the platen. It is recommended that the
wires be connected to the measuring device and
checked for functionality before proceeding further.

32
c) Lay down the release material on platen over the
thermocouple wires.

d) PLACE THE PULLEY COVER PANEL ON THE
PLATEN EXTENDING PAST THE SKIVE CUTS
ON BOTH BELT ENDS. PLACE THE BARE SIDE
AGAINST THE PLATEN. THE POLY FILM IS ON
THE TOP SIDE.

e) Remove the poly film and wash the surface with
the solvent included in the list. Allow to dry
thoroughly.

f) Apply 18 (450mm) strip of .100 [2.4mm] insulation
gum, slightly overlapping the joints at 1/8 (3mm).
(Fig. 7-18). Cover the entire surface of the pulley
cover.

Fig . 7-18

IMPORTANT: LEAVE THE POLY FILM ATTACHED
TO THE UPPER SURFACE OF THE
INSULATION GUM. IT WILL BE
NECESSARY TO REMOVE A 1/2
(12.7mm) STRIP FROM THE EDGE
OF THE PREVIOUSLY LAID GUM IN
THE OVERLAP AREA. THE FILM ON
THE OVERLAPPED STRIP IS LEFT
INTACT TO PROTECT THE JOINT.

g) Proceed to 7.7.5.

7.7.5 PULLEY COVER INSTALLATION

a) Turn back one of the belt ends onto the pulley
cover composite. Using a straight edge and pen or
a chalk line mark the bias line on the poly covering
insulation gum of the cover composite to locate
starting points for this line.
b) Cut the skive along this line to match the bias
angle of the belt. Lay a straight edge under the
material being cut.

CAUTION: BE SURE NOT TO CUT THROUGH THE
THERMOCOUPLE WIRES IF THEY ARE
AT THIS END.

c) Apply one coat of the appropriate cement on the
freshly cut skive.

d) Refer to the splice diagram included in the kit to
determine location of the first step line. Using a
straight edge and pen or a chalk line mark this line
on the poly film.

e) Using sharp knife cut through the film along the
line, using just enough pressure to cut the film.

f) Remove the short piece of film from the surface,
making sure that no small pieces are left on the
splice area.

g) Scribe a line on the rubber surface at the edge of
the film using a 1/16 (1.5mm) stitcher, using
sufficient pressure to make a visible line.

h) CAREFULLY LOWER THE BELT END INTO
POSITION MAKING SURE A TIGHT FITTING
PULLEY COVER JOINT. USE A MALLET TO
SECURE THE JOINT BY POUNDING ON THE
UPPER SURFACE OF THE BELT.

i) Repeat this procedure on the other end of the belt.

j) Proceed to subsection 7.8.

7.8 CORD LAY UP

a) Refer to the splice diagram supplied with the kit to
determine the location of step line for two-step and
higher splices.

b) Using the methods described in sub section 7.5
scribe the appropriate step lines. Do not remove
poly film at this time. The film will be removed as
cords are laid.

33
c) Make a full length longitudinal cut through the
polyfilm near the belt centre. Then fold the film
back 4 to 5" (100-125mm) on each side of the cut
to expose 8" to 10" (200 - 250mm) of insulation gum
for the full splice length.

d) Stretch an UNCHALKED string down the centre line
of the splice using the previously marked centre
positions.

e) Each cord is cut to length immediately before being
laid down in the pattern in multiple stage splices. To
do this, use the reference lines previously marked
on the bottom cover to locate the step line. For
unbutted cords, cut the cord at the reference line.
For butted cords, cut the cord at a point 1/2 the
specified gap distance (shorter) from the reference
line.

f) Lay the matching centre cords from each end of the
belt parallel to the string line. If a butt is called for in
the splice diagram, make the gap dimension as
specified.

g) Lay a full length strip of noodle gum along the cords
so that each cord is separated by one strip of gum.
(Fig. 7-19)

Fig. 7-19

h) From this point continue laying cords following the
prescribed splice diagram and gum strips alternately
working from centre towards each edge. A clean
hammer is usually used to lightly tap cords into
place. STRAIGHTNESS MUST BE MAINTAINED.
Poly film is turned back as cords are laid. Frequent
light swabbing with solvent keeps the exposed
insulation gum clean and tacky.

i) Check cord straightness with an UNCHALKED
string line every 4 to 5 cords and make adjustments
as needed.

a
1
) If cords are bowing in towards the belt centre, add
additional noodle strips.

b
1
) If cords are bowing out towards the belt edges,
stretch the noodle strip slightly to reduce its
thickness. Cords may also be shifted with additional
tapping of the hammer.

DO NOT CUT OUT CORDS TO CORRECT BOW.

j) After all cords have been laid, build up the edges to
the level of the cord tops with available gum. (Fig. 7-
20) Pulley cover gum, 1/16" (1.5mm) cover build up
gum or 0.050" insulation gum can be used. In some
cases a special strip of the appropriate width and
thickness is supplied for this purpose.

Fig.
7-20

k) Using insulation gum, fill all gaps at cord ends, cord
butt gaps and all voids between cords. Insulation
gum strips are typically used for this purpose and in
some cases a larger strip of insulation is provided
for plugging voids. (Fig. 7-21)

34

Fig. 7-21

An air operated extruder can greatly facilitate the
void filling process.

7.9 TOP COVER PREPARATION AND
INSTALLATION

For a pre-assembled cover composite proceed to sub-
section 7.9.1. For individual cover components proceed
to subsection 7.9.2.

7.9.1 TOP COVER PREPARATION
- PRE-ASSEMBLED

a) Clean the skived top cover cuts at each end of the
splice with solvent and apply a coat of cover
cement.

b) Place a sheet of clean poly film over the entire
splice area.

c) Roll out the top cover composite with the insulation
gum side next to the cords. The insulation gum side
is identified with a white stripe.

d) Proceed to step 7.9.3 Top Cover Installation.

7.9.2 TOP COVER PREPARATION - COMPONENTS

a) Clean the skived top cover cuts at each end of the
splice with solvent and apply a coat of cover
cement.

b) Place a clean sheet of poly film over an area the
size of the splice on the worktable in an area away
from the splice.

c) Roll the top cover with poly film side down.

d) Wash the rubber surface lightly with solvent.

e) Apply .100" (2.4mm) strips of insulation to cover the
entire surface using the same procedures as was
done for the pulley cover (see subsection 7.4.6). Be
sure to leave the film on the insulation side.

Fig. 7 22

f) Place a sheet of clean poly film over the entire
splice area.

g) Place this assembled panel, insulation side down
over the splice area.

h) Insulation gum may be placed over the cables in 18"
sheets. See Fig. 7-22.

i) Proceed to step 7.9.3 Top Cover Installation.

7.9.3 TOP COVER INSTALLATION

a) Fold back the top cover about half way and remove
the film liner on insulation side of the cover. Cut the
film at the bend of the roll, remove and discard.
Carefully roll up the film laid on the splice. ROLL
FROM SPLICE END TOWARDS THE CENTRE TO
ENSURE THAT ANY DIRT WHICH MAY HAVE
BEEN TRANSFERRED FROM THE OUTSIDE OF
THE COVER ROLL IS CONTAINED IN THE FILM.

b) Lay the top cover back in position and repeat the
process at the other end of the splice. After the
underlying film has been rolled to the centre from
this end, carefully remove the entire roll piece (both
ends at once) and discard. (Fig. 7-23) ENSURE
THAT NO FILM IS LEFT IN THE SPLICE.

35

Fig. 7-23

c) Remove the poly film from the outside of the top
cover.

d) Trim off the excess width of the top cover only at
the skive area to assist in locating the cut mark.
(both edges).

e) Mark a point on each edge 1/16" (1.5mm) longer
than the splice cover insert length.

f) Use a chalk line to draw a line between these two
points.

g) Place a clean piece of flat 2" (50m) wide steel
under the cover panel in the area to be cut.

h) Put the top cover matching the angle of the belt
end skive.

i) Tip the flat bar on its edge to raise the cover panel
and apply a light coat of the proper cover cement.
LET IT DRY THOROUGHLY.

j) Remove the flat steel and fit the skive into place.

k) Repeat the process from step g for the other end
of the belt.

I) Using a chalk line straight edge on the original belt
edges, mark & remove excess rubber from the
splice edges. (Fig. 7-24)

Fig. 7 -24

m) With an awl, thoroughly prick the top cover over
the entire splice area down to the cable level.

n) Install thermocouple wires on the top cover as
outlined in the curing instructions in sub section
11.1. Route the wires along with surface and out
the same end of the press as the bottom platen
wires. (Fig. 7-25)

Fig. 7.25

o) Lay down the release material over the top of the
splice.

7.10 FINAL PRESS ASSEMBLY

a) To obtain edge pressure use steel guides along
each edge of the press. Select guides that are
1/32" to 1/16" (0.8mm to 1.0mm) less than the belt
thickness. The recommended width for the guides
is 4" (100mm).

The area between the steel guides and the edge of
the vulcaniser should be filled to avoid possible
distortion and damage to the vulcaniser. Pieces of

36
the belt being spliced are usually used for this
purpose. Plywood of the same thickness or slightly
thinner than the guides can also be used.

b) Following the press manufacturers instructions,
assemble the top platen of the press on the splice
area. (Fig. 7-26).

Fig. 7-26

c) Draw the guides together against the edges as
uniformly as possible using a ratchet-type or cord-
type come-a- longs. DO NOT OVERTIGHTEN AT
THIS TIME.

d) Tighten all bolts joining top and bottom of the
splice press as recommended by the press
manufacturer.

e) Using the come-a-longs, draw in the guides until
they contact the cured belt edges at both ends of
the press.

f) Place wedges between the guide iron and the edge
bolts at sufficient locations to reduce bowing of the
guides. For splices up to 8 (2.4m) the use of one
wedge is usually satisfactory. Additional wedges
will also be necessary if guide irons are less than
the recommended 4 (100mm) width.

g) Make the necessary electrical and hydraulic
connections.

h) Connect the thermocouple wires transducer to the
recording unit and ensure that they are operating
properly.
7.11 GENERAL VULCANISING NOTES

a) TIME AND TEMPERATURE

THE VULCANISATION OF RUBBER
COMPOUNDS NEEDS TO BE CAREFULLY
CONTROLLED AND MONITORED TO ENSURE
OPTIMUM PHYSICAL PROPERTIES FOR
MAXIMUM SPLICE LIFE.

VULCANISATION, AS A RULE OF THUMB,
DOUBLES IN CURE RATE FOR EVERY 18F
(10C) CHANGE IN TEMPERATURE.
OVERCURING A SPLICE CAN BE AS
DETRIMENTAL AS UNDERCURING.

TEMPERATURE CONTROLLERS AND
MEASURING DEVICES ON VULCANISING
EQUIPMENT SHOULD NOT BE RELIED UPON
TO PROVIDE A DEPENDABLE ASSESSMENT
OF THE ACTUAL PLATEN TEMPERATURES.
FOR THIS REASON EACH INDIVIDUAL
HEATING ELEMENT IN A PLATEN MUST BE
MONITORED WITH A THERMOCOUPLE
PLACED ON THE SURFACE OF A BELT. A
PROPERLY CALIBRATED THERMOCOUPLE
UNIT CONNECTED TO A CHART RECORDER
OR OTHER SUITABLE DATA ACQUISITION
UNIT IS REQUIRED.

DURING A CURE, IT IS THE RESPONSIBILITY
OF THE SPLICE OPERATOR TO OBSERVE THE
TEMPERATURES OF EACH THERMOCOUPLE
AND USE THE INFORMATION TO
CONTINUALLY ADJUST THE PRESS CONTROL
UNITS TO MAINTAIN TEMPERATURES WITHIN
+ 5F (3C).

It is recommended that all field vulcaniser
temperature controlling and measuring equipment
be regularly maintained and calibrated to minimise
the amount of manual adjustment required during
a cure cycle.

Cure times and temperatures are shown on Table
3-1.

7.11.2 PRESSURE

The use of a field vulcaniser with a bladder(s) to
apply pressure to the entire platen surface is
preferred because of its uniform pressure
distribution. If multiple bladders are used they must
be connected to a common manifold to ensure
equal pressure in bladders.

37
Other types of pressure systems on field
vulcanisers are acceptable provided that they are
capable of meeting a tolerance of + 5% over the
curing area of the platen.

DURING THE CURE CYCLE ON BLADDER
PRESSES, PRESSURE SHOULD BE
MONITORED THROUGH THE USE OF A
TRANSDUCER CONNECTED TO A SUITABLE
RECORDING DEVICE.

7.11.3 POWER AND PRESSURE FAILURES

a) In case of a power failure while curing, do not
release the pressure, but hold it until power is
restored and then bring the vulcaniser back up to
cure temperature. At that time:

IF THE SPLICE HAD LESS THAN HALF ITS
SPECIFIED CURE TIME BEFORE POWER
FAILURE-REPEAT THE ENTIRE SPECIFIED
CURE TIME.

IF THE SPLICE HAD CURED HALF OR MORE
OF THE SPECIFIED CURE TIME THEN FINISH
CURING THE REMAINING TIME.

b) In case of a pressure failure the splice may have to
be remade depending upon what point in the cure
cycle the failure occurred. If the rubber has not
cured beyond the blow point, porosity will be
evident around the cords.

7.12 VULCANISING THE SPLICE

a) If a bladder type press is being used, pressurise
the press to 200 psi (1380 kPa) and hold for
approximately 2 min. to check for any possible
leaks, then release pressure.

b) Turn on the power to the platen heaters.

c) Apply 100 psi (690 kPa) pressure and hold until the
thermocouple readings all reach 203F (95C).

d) Increase pressure to 150 psi minimum (1035 kPa)
and hold throughout the balance of the cure cycle.
Monitor the pressure carefully during the splice
cycle and adjust as necessary to maintain 200 psi
(1380 kPa).

PRESSURE NORMALLY WILL INCREASE AS
THE TEMPERATURE RISES AND WILL HAVE
TO BE BLED OFF.

e) START TIMING THE CURE WHEN ALL
THERMOCOUPLE READINGS HAVE REACHED
THE SPECIFIED CURING TEMPERATURE.

f) THROUGHOUT THE CURE IT IS NECESSARY
TO MONITOR AND ADJUST THE PLATEN
TEMPERATURES TO WITHIN A TOLERANCE
OF 5F (3C) AFTER THE SPECIFIED CURE
TEMPERATURE HAS BEEN REACHED. (SEE
SUB SECTION 11.1)

g) If the press has cooling capabilities which will be
used proceed to 7.12.1. If cooling is not available
or cannot be used, proceed to 7.12.2.

7.12.1 PRESS PLATEN COOLING

a) At the completion of the specified cure time, leave
the pressure on, turn off the heating elements and
start the flow of cooling fluid through the press.

b) Continue to monitor the temperature readings
using the embedded thermocouples.

c) Continue cooling until all zones have been reduced
to 130F (55C). on quick cool vulcanisers
continue cooling for 10 additional minutes.

d) Release the pressure on the press and remove the
top platen.

e) Proceed to 7.13.0.

7.12.2 WITHOUT PLATEN COOLING

a) It is Goodyears policy to water cool all vulcanised
splices to prevent over-cure. This section is
included only to address those rare instances
where the Vulcaniser is not fitted with water cooling
ports.

b) At the completion of the specified cure time, TURN
OFF HEATING ELEMENTS, RELEASE THE
PRESSURE AND REMOVE THE TOP PLATEN
IMMEDIATELY. This procedure is necessary to
avoid overcuring the splice.

c) DO NOT LET THE BELT SIT ON A HOT PLATEN.
Either remove the bottom of the press or carefully
elevate the belt to provide an air space for cooling.
Lift the belt off the press using a support bar at
each end of the splice.

d) Proceed to 7.13.

7.13 SPLICE COMPLETION

a) Inspect the splice and trim flash off the edges. Buff
flash on the top and bottom covers at the skive
joints so that the belt surface is level in these
areas.

NOTE: DO NOT PUT A BELT INTO SERVICE OR
DROP THE COUNTERWEIGHT UNTIL THE
SPLICE HAS COOLED TO AMBIENT
TEMPERATURE.

38

THE 10 MOST COMMON MISTAKES MADE IN BELT
SPLICING THAT LEAD TO PREMATURE SPLICE
FAILURE.

1. Not using thermocouples to control cure temperatures can result in overcure or undercure of
compounds.

2. Nicking the fabric plies with knives can damage the warp and fill cords.

3. Overbuffing the fabric destroys warp and fill cord strength and reduces adhesion.

4. Curing with wet cement in splice area can cause ply blows or cover blows.

5. Over prodding the fabric when lifting the plies can damage warp and fill cords.

6. Reducing step lengths to fit a splice into a shorter Vulcaniser can reduce the Vulcanised splice
strength.

7. Assembling a splice with contamination can reduce adhesions.

8. Using overage compound and cements can reduce cover and ply adhesions.

9. Use of incorrect compounds and cements can reduce adhesions and cause ply/cover blows.

10. Improper splice alignment can cause splice section to track off centre.

39
SECTION C

REPAIRING STEEL CABLE
CONVEYOR BELTING

CLASSIFICATION OF MAJOR REPAIRS

A DAMAGE TO THE COVER WHICH
DOES NOT EXTEND DOWN TO
THE CABLES

B EDGE DAMAGE WHICH DOES NOT
EXTEND TO THE CABLES

C EDGE OR COVER DAMAGE WHICH
DOES EXTEND TO THE CABLES

D DAMAGE COMPLETELY THROUGH
BELT, E.G., LONGITUDINAL TEAR
WHERE CABLES ARE NOT
DAMAGED

E DAMAGE WHICH RESULTS IN
CABLES BEING DAMAGED OR
BROKEN

A

Damage to the cover which does not
extend to the cables. Cut out damaged
section, taking care to keep the depth of
the cut at least 3mm from the steel cables.
Roughen the cut out section well including
approximately 25mm of the cover surface
around the repair. Apply 2 coats of cover
cement and fill in with regular repair
materials, and vulcanise.

B

Edge damage which does not extend to the
cables. Cut out damaged edge section.
Roughen cut surface of the repair and
about 25mm of cover surface all around
the repair. Apply 2 coats of cover cement
to the roughened surfaces. Fill in with
regular repair materials, and vulcanise.

Fig. 49
C
Edge or cover damage which does extend
to the cables. Cut or damaged section
down to the cables similar to the method
used to remove cover at splicing.
Roughen or buff all cut out section of repair
and about 25 mm of cover surface all
around the repair. Clean off all dust and
wash with solvent. Apply 2 coats of cable
cement to the skinned cable surface. Apply
2 coats of cover cement to the buffed
skived cover surface. Fill in with
combination cover stock.

40

D
Damage completely through belt, e.g. a
longitudinal tear where cables are not
damage. (Fig 51).
Remove cover from damaged area on
both sides of the belt. Skin the covers
down to the cables similar to the method
used to remove the cover at splicing. Off-
set the dimension of cut out on opposite
covers by at least 25mm. Remove the
damaged gum from between the cables,
flush with the Cable edges(Fig.52)
Roughen or butt all cut out sections of the
repair and about 25 mm of cover surface
all around the repair. Clean off all dust and
wash with solvent. Apply 2 coats of cable
cement to the bottom of repair, i.e., the
skinned cable surface. Apply 2 coats of
cover cement to the buffed skived cover
surfaces. Fill in pulley side of repair with
combination cover stock. Cut a piece of
wire fill-in gum stock gauge = cable
diameter, width= wire spacing, length=
repair length. Wash with solvent and fill in
gap between the cables. Fill in conveyor
side with combination cover stock. On a
long repair use a Vulcaniser wider than the
belt and use guides, sash clamps and
wedges (if necessary) so that the repair will
not spread under vulcaniser pressure.
Again on long repairs it would be an
advantage to use a Vulcaniser with cold
ends to eliminate porosity that can occur at
the ends of a conventional vulcaniser
where both temperature and pressure are
low. This problem may be eliminated by
using a steel or aluminium plate
approximately 150 mm longer than the
press between each platen and the belt.
The use of channel iron clamps over these
protruding plates will be of further aid to
eliminate porosity. If this method fails it will
be necessary to re-do repair at press end
after each cure.

41

E
Damage which results in cables being damaged
or broken (Fig.No.53) Remove cover from
damaged area on both sides of the belt. Skin
covers down to the cables similar to the method
used to remove covers at splicing. Off-se the
dimension of cut out on opposite covers by at
least 25 mm. Strip the rubber from between the
damaged cables and cut out damaged section of
cables using bolt cutters (Fig.No.54) New lengths
of steel cable are to be placed between the
damaged cable or cables and the inserts will
overlap the break at each end (Fig.No.55). Buff or
roughen all cut out sections of the repair and
about 25mm of cover surfaces all around the
repair. Clean off all dust and wash with solvent.
Apply 2 coats of cable cement to the bottom of
the repair, i.e. the skinned cable surface and
cables. Apply 2 coats of cover cement to the
buffed skived cover surfaces. Fill in pulley side or
repair with combination cover stock. Wash cable
inserts thoroughly in solvent and place in position.
Apply a strip of wire fill-in gum each side of the
inserts. Fill gaps between ends of cut cables with
wire fill-in gum. Fill in conveyor side with
combination cover stock.

It may be necessary to displace unbroken wire
slightly to maintain minimum 1.5mm gum gauge
between inserts and original wires.

42

SECTION D
FABRIC SPLICE PREPARATION

2.1 PREPARATION OF WORK AREA
2.1.1 LOCATION FOR SPLICE WORK
On incline or decline belts, it is desirable to
work at the lower end if possible. Splices can be
made at the upper end but high belt tensions can
cause difficulties in restraining the belt with
clamping devices. At the upper end, there is a
risk of the belt breaking away from the clamps
and running loose down the slope.
Level belts may be spliced at any location
where power is available and it is convenient to
set up the equipment. The location must have
facilities for hoisting the vulcanizer or other heavy
equipment and placing them in the desired
positions.
The locations must be long enough and wide
enough to accommodate the necessary work
area and shelter. One must be accounted for the
weight of splicing, personnel, and ancillary
equipment if the splicing is to be completed on
the conveyor structure.
2.1.2. SHELTER FOR WORK AREA
a) A shelter must be provided to keep the belt
ends clean and dry at all times. In hot
weather, the cemented belt ends must never
be exposed to direct sunrays. In cold weather,
the shelter must be heated to 60F-(15C)
minimum.
b)The size of the shelter depends on the width
and construction of the belt to be spliced.
Generally it should be 4 to 6 ft (1.2m to 2.0m)
wider than the belt, 12 to 18 ft (3.6m to 5.5m)
longer than the splice and have 8 ft (2.4m) or
more between roof and the work table. As a
rule of thumb, 4.5 times the splice length is a
good starting point.
2.1.3 THE WORK TABLE
Laying out the splice and cutting of the
plies must be done on a flat, smooth surface.
This surface should be 6" (150mm) wider than
the belt being spliced and at least 4' (1.2m)
longer than the splice. The surface should be
one piece or smoothly joined and firmly held in
position. Plywood with a thickness of 5/8"-3/4"
(15mm-19mm) is usually sufficient. The table
must be elevated to provide clearance for clamps
used to hold the belt ends in alignment.

43
2.2. SPLICE TOOLS
2.2.1 IDENTIFICATION
The tools used for preparing a belt for a
vulcanized splice are shown in Fig. 2-1.

44

2.2.2 MISCELLANEOUS ITEMS
a) A tugger will greatly reduce the time spent
stripping the belt ends. Power is a prerequisite
when tearing down high-tension belts. An air or
electric winch should be available.
b) Water - for cooling the vulcanizer.
c) Appropriate power supply to operate electric
buffers, tuggers, etc.
d) Thermocouple unit and pressure transducer
with chart recorder.
e) Required personal Safety equipment.
2.2.3 THE ONE PLY KNIFE
The one ply knife as the name implies is intended to
cut only one ply. Therefore, certain points should
be carefully observed.
a. The depth of the cutting edge should be sharp
and approximately 75% of the thickness of one
ply of the fabric being cut. Various weights and
types of fabric require different depths of the
cutting edge. (Figure 2-2)

b. The cutting edge should be sharp.
c. The knife should be held at approx. 45from
the belt surface so that the land of the knife will
be flat on the ply below the one being cut.
d. Practice sessions with its use are
recommended.
e. Never cut deeper than intended or cut into
or destroy any fabric, which is to remain a
part of the splice.

CAUTION: A HIGH PERCENTAGE OF
FABRIC SPLICE FAILURES ARE CAUSED
BY
THE ONE PLY KNIFE-NICKING, CUTTING
OR GOUGING THE ADJACENT PLY.
f. Inspect one-ply knives frequently and see that
the hook or cutting edge is not too deep.
Regardless of the condition of the knife, it is
possible to cut through more than one ply and
the operator should always watch this closely.
Keeping knives in proper condition is
important.

2.2.4 THE PLY LIFTER
The care and handling of the ply lifter is important.
a) The corners should be rounded. Approx.
1/8" (3mm) radius is recommended. Sharp
corners will injure the ply beneath the one
Being loosened. (Fig.2-3)

b) The edge at the end or tip, after considerable
use, will become worn and sharp. This should
be kept dull, rounded and free from burrs.
c) Use the ply lifter so that it is parallel to the cut
and held at an approximate 30 angle from the
belt. The flat end or tip of the ply lifter should
also be at about a 30angle from the belt. In
this manner, it will loosen the edge of the fabric
without "digging into" or injuring the next ply.
(Fig. 2-4)

45

CAUTION: IMPROPER CARE AND USE OF THE
PLY LIFTER CAN ALSO DAMAGE THE
ADJACENT PLY AND CAN CONTRIBUTE TO
SPLICE FAILURE.

2.3 DIRECTION OF SPLICE AND BIAS
a)In most level or inclined (power requiring) belts,
it is recommended that the belt ends be
stepped down so that the pulley side joint leads
and the top side joint trails the direction of belt
travel. (Fig 2-5 and Fig 2-6)
b) In most decline (regenerative) belts the
splice is prepared according to Fig. 2-7 so that the
pulley side joint trails and the top side joint leads the
direction of belt travel.

c) An exception to the above splice directions
sometimes occurs when splicing a new belt into
an old one. If the old belt covers are badly worn
then both ends of the new section should be
stepped from the pulley side. This leaves new
unworn top cover on both splices and will
provide more uniform vulcanizer pressure. In
doing this, one splice will run in reverse to the
usual recommendation.
d) Be sure that the bias direction will conform to that
of the vulcanizer and that the entire cover insert
can fit within one setting of the vulcanizer. Slight
adjustments of 1" to 3" (25mm to 75mm) of the
bias angle are permissible if necessary.
2.4 MASTER LINE
This is normally the first mark to be made on the
belt on each of the two ends. The mark is drawn
straight across the belt width at a distance from the
belt end and equal to the total splice length plus trim
allowance. Three methods of locating and squaring
the master line are as follows:
2.4.1 SQUARE AND STRAIGHT EDGE
a) From the end of the belt, measure back the
length of splice plus trim allowance.
b) Use a square and straight edge to the draw
master line.
c) Check the master line by laying the square
along the opposite edge. As a final check,
mark off the bias lengths on each edge and
check that the two diagonal lengths are equal.

46

To prepare the second (opposite) end fold the belt
back and repeat the procedure. Make sure that the
bias is on the opposite edge on the other end.

2.4.2 TRIANGULATION
(Fig 2.9) Draw the master line.
a) From the end of the belt, measure back along
one edge the splice length plus trim allowance.
Mark the edge. This mark is then the center point
of a line exactly 4 ft (1200mm) long drawn along
this edge.
b) From each end of the 4 ft (1200mm) line
measure equal diagonal lengths to the opposite
edge and mark.
Fig. 2-9: Triangulation method of obtaining a master
line.
c) This method is common on belts 72" (1800mm)
and wider.

2.4.3 SWINGING ARC
a. Carefully mark a point at the exact center of
the belt width. Measure from this center point and
make a mark at each edge near the end. These
two diagonal measurements must be exactly
equal.
b. From each of the two-edge marks measure
back the total splice length plus trim allowance.
Mark the edges and draw the master line.
2.5 BELTS WITH DAMAGED EDGE (S)
When belt edges are damaged it is necessary to
establish a master line on one end only by one of
the above methods and proceed to step that end
down. Then lay the ends together, align by eye as
well as possible, and transfer all marks to the
second end.

2.6. BELTS WITH UNEQUAL END WIDTHS

If the two belt ends are not the same width, the wide
end is to have bias and step points marked along
the edges in the normal manner. Then measure in
from these marks at right angles to the edge a
distance 1/2 the width difference and make marks.
Connect these new marks for correct bias and step
lines.

47
SECTION E
FABRIC BELT VULCANISING

3.1 TIME AND TEMPERATURE
The vulcanization of rubber compounds
needs to be carefully controlled and monitored to
ensure optimum rubber properties for maximum
splice life. Vulcanization, as a rule of thumb,
doubles in the rate of cure for every 18F
(10C) change in temperature. Over curing, a
splice can be as detrimental as under curing.
Temperature controllers and measuring devices
on vulcanizing equipment should not be relied
upon to provide a dependable assessment of the
actual platen temperatures. For this reason,
each individual heating element in a platen must
be monitored with a thermocouple placed on the
surface of the belt. A properly calibrated
thermocouple unit connected to a chart recorder
or other suitable data acquisition unit is required.
During a cure, it is the responsibility of
the splice operator to observe the temperatures
of each thermocouple and continually adjust the
press control units to maintain temperatures
within +/- 5F (3C).
It is recommended that all field vulcanizer
temperature controlling and measuring
equipment be regularly maintained and calibrated
to minimize the amount of manual adjustment
required during a cure cycle.
a) Cure times and temperatures are shown on
Table 3-1, (next page)
b) THE TIMING OF A SPLICE CURE IS NOT
TO START UNTIL ALL THERMOCOUPLE
READINGS HAVE REACHED THE
SPECIFIED TEMPERATURE.
c) In windy and cool conditions, the use of
tarpaulins or similar cover over the vulcanizer
to minimize heat loss and promote uniform
heating is recommended.
d) The temperature in the work area must be
maintained between 60F - 90 F
(15 C - 32 C)and less than 75% relative
humidity. This is to insure that the thick rubber
materials that must be handled will be tacky
and flexible. In hot, humid conditions this will
also prevent condensation. Open flame
torpedo style kerosene heaters are not
recommended due to explosive hazards and
the potential contamination by residual
kerosene in the splice area.
e) Due to heat radiation, about 2" (50mm) of the
edge of most vulcanizers will not rise to cure
temperature and should not contain belt.
f) THE SPLICE MUST NOT BE PUT INTO
SERVICE UNTIL THE SPLICE HAS COOLED
TO AMBIENT TEMPERATURE.

48
TABLE 3-1
CURE TIME AND TEMPERATURES
For double platen vulcanizers only. Single platen vulcanizers are not recommended.
BELT THICKNESS
FABRIC BELT
CURE TIME
STEEL CORD BELT
CURE TIME
mm Inches Time (in minutes)
Up to 3.1 Up to 1/8 20
3.1 6.3 1/8 1/4 25
6.3 9.5 1/4 3/8 25
9.5 12.7 3/8 1/2 30
12.7 15.8 1/2 5/8 35
15.8 19 5/8 3/4 35
19 22.2 3/4 7/8 40
22.2 25.4 7/8 1 45
Add 5 min. for Neoprene belts over 1" gauge (25.4mm)
25.4 28.5 1 1 1/8 50
28.5 31.7 1 1/8 1 1/4 50
31.7 34.9 1 1/4 1 3/8 55
34.9 38.1 1 3/8 1 1/2 60
38.1 41.2 1 1/2 1 5/8 60
41.2 44.4 1 5/8 1 3/4 65

CURE TEMPERATURES
Cure Temperatures Fahrenheit Celsius
Super Thermo-Flo and Thermo-Chem 310 154
Solarshield 325 162
All other belts / compounds 290 143
Control all cures 5 2.5

49
3.2 PRESSURE
The use of a field vulcanizer with a
bladder(s) to apply pressure to the entire platen
surface is preferred because of its uniform
pressure distribution. (Fig 3-1) If multiple
bladders are used, they must be connected to a
common manifold to ensure equal pressure in all
bladders.

Other types of pressure systems on field
vulcanizers are acceptable if they are capable of
meeting a tolerance of +/- 5% over the curing
area of the platen.
During the cure cycle on bladder presses,
pressure should be monitored using a transducer
connected to a suitable recording device.
a) Follow operating and safety procedures
recommended by the vulcanizer
manufacturer.
b) Use care if pressure is applied while the
vulcanizer is still cold. Platens can
expand when heated causing extreme
pressures, which may damage the
vulcanizer.
c) To obtain edge pressure use steel guides
along each edge which are approximately
1/32"~1/16" (0.8mm - 1.6mm) less than
belt thickness. The guides should be
drawn together against the edges as
uniformly as possible with ratchet chain
type or cord type come-along. These
come-along should be only drawn up
snug initially. Then, after the vulcanizer
pressure is applied, they should be drawn
tight.
USE OF WEDGES AGAINST THE
EDGE IRONS IN THE SPLICE AREA
WILL LIMIT BOWING.
d) The recommended vulcanizer pressure
for fabric belts is 100 PSI, however
precautions should be taken NOT to
exceed the manufactures maximum
pressure.
3.3 GENERAL CURING NOTES
a) The area between the steel guides and the
outside edge of the vulcanizer should be filled
to avoid possible vulcanizer distortion and
damage. Pieces of the belt being spliced are
usually used for this purpose.
b) To help release steam on an obviously wet
belt, an awl should be used to perforate the
belt every 2"~4" (50-100mm) along the
vulcanizer ends.
c) Though not recommended there are instances
when the vulcanizer dimensions are such that
a splice will be cured in two or more heats.

IN THESE CASES EACH OF THE COVER
(FILL-IN) STRIPS SHOULD BE
COMPLETELY CURED IN A SINGLE HEAT.
The bias length is sometimes adjusted a few
inches to insure that this can be done. Note that
the one end of the vulcanizer should extend at
least 2" (50mm) beyond the fill-in strip and onto
original belt to insure adequate cure temperature.
The other end should extend at least 4" (100mm)
beyond the fill-in and onto splice area to prevent
possible slippage and buckling. Always start
curing at one end of the splice and never in the
center.

50
d) In case of a power failure while curing, do not
release the pressure, but hold it until power is
restored and then bring the vulcanizer back up to
cure temperature. At that time:
If the splice had less than half of its specified
cure time before power failure, repeat the
entire specified cure time.
If the splice had cured 1/2 or more of the
specified time, then finish curing the
remaining time after all thermocouples again
register the specified temperature.
e) If vulcanizing pressure is lost on the surface of
the splice, it must be remade.
f) To prevent blistering, the vulcanizer should be
cooled to 130F (55C), or less, before
releasing pressure. This is a good practice at
all times since unexpected blisters are
undesirable and requires repair or sometimes
a complete remake of the splice.
g) After the splice is cured, remove release
material. If Holland cloth is used a water soak
may be necessary. Trim and/or buff the
overflow at the edges.
h) Do not leave the belt on a hot vulcanizer.

51
SECTION F
FABRIC BELT BIAS SPLICE

4.2 PROCEDURE
The technique for splicing fabric belts is essentially the same for any number of plies. A 3-ply construction is
illustrated in the sketches and instructions that follow.
a. Measure the splice length; in addition, 1" (25mm) trim starting from the end of the belt. (Fig 4-1) Draw the
master line. A square and straight edge is generally used to mark the master line on the belt as described in
section 2. In checking both edges if there is a difference, it can be halved and the result will usually give an
accurate line
b. .Measure off the bias length and draw the bias
line to the end of the master line on the opposite
edge. (Fig. 4-2) This line marks the location of
the top ply cut after the cover gum is removed.
c. Extend the end of the bias line down over the
belt edge.
d. From the bias line measure toward the end of
the belt a distance equal to the total number of
steps plus 1" (25mm) trim for Example:
A 2-ply fabric belt requiring 8" steps would equal
9" (230mm)
3 ply = 17" (430mm)Mark the cut off line, which
is parallel to the bias line. Fig 4-1.
e. Lay out the cover strip for removal. Draw one
line parallel to and approximately 1/2" (13mm)
from the bias line and on the splice side. Draw a
second line on the belt side of the bias line but at
a distance of 2" (50mm). (Fig 4-3)

52

f. Cut along the two covers cut lines just made.
The line on the belt side of the bias line should
be skived per Fig. 4-3. The other cut may be
vertical. Do not cut too deep. IF YOU FEEL
FABRIC, YOU HAVE DAMAGED THE BELT.
g. Cut off the belt at the cutoff line. (Fig 4-1)
h. Remove the cover strip. Note the one skived cut
and one vertical cut in the cover. (Fig 4-4)

i. From marks made down the edges, redraw the
bias line where the cover was removed. Then
cut the top ply along this line. (Fig 4-5)

j. Prod the top ply loose along the bias line where
the cut was just made. BE VERY CAREFUL AS
YOU CAN EASILY DAMAGE THE FABRIC. (Fig
4-6)

53

k. Turn the belt end over and mark the cover strip
for removal. (Fig 4-7) Cut and remove this cover
strip. (Fig 4-8)

l. Turn the belt end back down and remove the
cover and top ply. (Fig 4-9) This is a very
difficult pull. If a winch or equivalent is not
available, use a come-along and very carefully
cut the inside gum with a ply knife. NOTE: DO
NOT KNICK THE FABRIC. DAMAGE TO THE
UNDERNEATH PLY WILL CAUSE
PREMATURE SPLICE FAILURE.

m. The other end of the belt is torn down from the
opposite side using the same system. Note the
bias length on this end must be measured from
the opposite edge that was used on the first end.
n. Use a light weight, low-speed buffer with a wire
wheel brush and remove most of the gum from
the fabric. (Fig 4-10) Do not contact the fabric.
Buffing the fabric not only reduces its strength
but removes the chemical treatment from the
fabric which reduces adhesions.

Roughen up the cover cut edges on top and pulley
sides as well as an inch or so of cover surface
adjacent to the cuts. Blow or brush away all rubber
dust.
o. Mark a center line on each end of the belt by
connecting three center marks, the furthest
being a minimum of three times the splice length

54
distance from the master line.

Align the belt using the center marks and dry fit
the ends to ensure the steps fit together
properly. Do not allow any steps to overlap; trim
to fit as necessary.

After completing adjustments, secure the belt
ends in this position. It is common to C-clamp
the belt to the work table and nail blocks of wood
to the table flush with the belt edges to prevent
lateral movement.
p. Clean all rubber areas with the appropriate
solvent and allow to dry thoroughly. (Fig 4-11)
q. Apply 2 coats of the proper cement over the
entire fabric step area starting at the first ply
fabric cut. (Fig 4-12)
ALLOW FIRST COAT TO DRY THOROUGHLY
BEFORE APPLYING SECOND COAT.
r. After cement is dry, apply inside gum to the
fabric step area starting at the first ply cut and
proceeding to the end of the splice area. (Fig 4-
13) Be sure the correct gauge gum and the
proper number of layers are used. Roll gum
thoroughly with a 2" (50mm) roller. The gum is
applied to only one of the stepped ends. Do not
remove film from the gum at this time.
s. On the end, which now has the splice gum, mark
a ply cut-off line as follows. Measure both edges
from the master line. On one edge measure the
total step length plus bias length. On the other
edge measure only the total step length. Then
draw the cutoff line.
t. Cut film, gum and the one ply with a smooth
straight cut across the line just marked.
u. About 2"~ 3" (50-75mm) from the cut just made,
make a cut through the film only. Remove the 2"
~ 3" (50-75mm) strip of film.
v. Assemble breaker, fill-in gum, and release
material on the pulley side using the same
system except the pulley gum is to overlap the
original cover 1/16" to 3/32" (1 to 2 mm).
w. With the belt edges properly aligned, carefully
lay the ends together making a tight uniform joint
at the bottom ply. MAKE SURE FABRIC IS NOT
OVERLAPPED. (Fig 4-14)

x. Remove the remaining film and lower the
remainder of the splice into place. Keep edges
aligned.

55

y. Trim the top ply step making a tight joint with no
gap. (Fig 4-15)

z. Apply a second coat of the proper cement after
the first coat of cement is dry) to the fill-in area
on the topside. (Fig 4-16) Lay in the breaker.
(Fig 4-17) The breaker is 1/4" (6mm) narrower
than the exposed fabric.
aa. Cement a strip of top cover, roll it into place, and
trim.
bb. Use a small straight edge to check for the proper
gauge of fill-in gum. The straight edge should
make imprints on the gum. (Fig 4-18)
ANY LOW SPOTS SHOULD BE BUILT UP.

cc. Prick the fill-in gum with an awl to release
trapped air. Cover with a cemented strip of
release material 2" (50mm) wider than the gum
strip. (Fig 4-19)

56

dd. To insure solid edges, guides of the proper
gauge must be used. The guides must contact
the belt edges for the full length of the splice and
extend 6" (150mm) on both ends of the press.
(Fig 4-20)
NOTE: An exception to the above splice directions
sometimes occurs when splicing a new belt into an
old one. If the old belt covers are badly worn then
both ends of the new section should be stepped
from the pulley side. This leaves new unworn top
cover on both splices and will provide more uniform
vulcanizer pressure. In doing this, one splice will
run in reverse to the usual recommendation.

ee. After cure, trim the edges of the splice. It is
normal for the fabric joints to be spaced
1/4"(6mm) or so during cure due to shrinkage.
ff. Refer to Section 3 of this manual for vulcanizing
instructions.
gg. The splice must not be put into service until the
splice has cooled to ambient temperature.
hh. Buff inserts and overflows down to original belt
gauge to prevent damage from scrapers.

57
SECTION G
TRAINING THE BELT

Training the belt is a process of adjusting
idlers, pulleys and loading conditions in a
manner which will correct any tendency of the
belt to run other than centrally.

When all portions of a belt run off through a
part of the conveyor length the cause is
probably in the alignment or levelling of the
conveyor structures, idlers or pulleys in that
area.

If one or more portions of the belt run off at all
points along the conveyor the cause is more
likely in the belt itself, in the splices or in the
loading of the belt. When the belt is loaded
off-center the center of gravity of the load
tends to-find the center of the troughing idlers,
thus leading the belt off on its lightly loaded
edge. (See Fig. 4)

These are the basic rules for diagnosis of belt
running ills. Combinations of these things
sometimes produce cases that do not appear
clear cut as to cause but if a sufficient number
of belt revolutions is observed the running
pattern will become clear and the cause
disclosed. The usual cases when a pattern
does not emerge are those of erratic running
which may be found on an unloaded belt that
does not trough well or a loaded belt which is
not receiving its load uniformly centred.

Fig. 3
Reefing the Belt

Fig. 4
Effects of Off-Centre Loading

58
SECTION H
FACTORS AFFECTING THE
TRAINING OF THE BELT

1. Pulleys and Snubs

Relatively little steering effect is obtained from
the crown of conveyor pulleys. Crown is most
effective when there is a long unsupported
span of belting, (approximately four times belt
width) approaching the pulley. As this is not
possible on the conveyor carrying side, head
pulley crowning is relatively ineffective and is
not worth the lateral mal-distribution of tension
it produces in the belt.

Tail pulleys may have such an unsupported
span of belt approaching them and crowning
may help except when they are at points of
high belt tension. The greatest advantage
here is that the crown, in some degree, assists
in centring the belt as it passes beneath the
loading point which is necessary for good
loading. Take-up pulleys are sometimes
crowned to take care of any slight mis-
alignment which occurs in the take-up carriage
as it shifts position. Consult the Goodyear
Handbook of Belting for a more detailed
discussion of pulley crown.

All pulleys should be level and with their axis at
90 to the intended path of the belt. They
should be kept that way and not shifted as a
means of training with the exception that snub
pulleys may have their axis shifted when other
means of training have provided insufficient
correction. Pulleys with their axis at other than
90 to the belt path will lead the belt in the
direction of the edge of the belt which first
contacts the mis-aligned pulley. When pulleys
are not level the belt tends to run to the low
side. This is contrary to the old rule of thumb
statement that a belt runs to the high side of
the pulley. When combinations of these two
occur, the one having the stronger influence
will become evident in the belt performance.

2. Carrying Idlers

Training the belt with the troughing idlers is
accomplished in two ways. Shifting the idler
axis with respect to the path of the belt,
commonly known as knocking idlers is
effective where the entire belt runs to one side
along some portion of the conveyor. The belt
can be centred by knocking ahead (in the
direction of belt travel) the end of the idler to
which the belt runs. (See Fig. 5). Shifting
idlers in this way should be spread over some
length of the conveyor preceding the region of
the trouble. It will be recognised that a belt
might be made to run straight with half the
idlers knocked one way and half the other,
but this would be at the expense of increased
rolling friction between belt and idlers. For this
reason all idlers should initially be squared with
the path of the belt and only the minimum
shifting of idlers used as a training means. If
the belt is over-corrected by shifting idlers it
should be restored by moving back the same
idlers, not by shifting additional idlers in the
other direction.
3. Return Idlers

Return idlers, being flat, provide no self-
aligning influence as in the case of tilted
troughing idlers. However, by shifting their
axis (knocking), with respect to the path of the
belt, the return roll can be used to provide a
constant corrective effect in one direction. As
in the case of troughing rolls, the end of the roll
toward which the belt is shifting should be
moved longitudinally in the direction of return
belt travel to provide correction (Fig. 5).

Self aligning return rolls should also be used.
These are pivoted about a central pin. Pivoting
of the roll about this pin results from an off-
centre belt and the idler roll axis becomes
shifted with respect to the path of the belt in a
self correcting action (Fig. 8). Some return
idlers are made with two rolls forming a 10 to
20 V-trough which is effective in helping to
train the return run.

A further aid to centring the belt as it
approaches the tail pulley may be had by
slightly advancing and raising the alternate
ends of the return rolls nearest the tail pulley
(Fig. 9).

59

4. Assuring Effectiveness of Training
Rolls

Normally, extra pressure is desired on self
aligning idlers and, in some cases, on standard
idlers where strong training influence is
required. One way to accomplish this is to
raise such idlers above the line of adjacent
idlers. Idlers or bend pulleys on convex
(hump) curves along the return side have extra
pressure due to component of the belt tension
and are therefore effective training locations.
Carrying side self aligners should not be
located on a convex curve since their elevated
positions can promote idler juncture failure of
the carcass.

5. Side Guide Rollers

Guides of this type are not recommended for
use in making belts run straight (Fig. 10).
They may be used to assist in training the belt
initially to prevent it from running off the pulleys
and damaging itself against the structure of the
conveyor system. They may also be used to
afford the same sort of protection to the belt as
an emergency measure, provided that they do
not touch the belt edge when it is running
normally. If they bear on the belt continually,
even though free to roll, they tend to wear off
the belt edge and eventually cause ply
separation along the edge. Side guide rollers
should not be located so as to bear against the
belt edge once the belt is actually on the
pulley. At this point no edge pressure can
move the belt laterally.

Obviously such idler shifting is effective for
only one direction of belt travel. If the belt is
reversed, a shifted idler, corrective in one
direction, is mis-directive in the other. Hence
reversing belts should have all idlers squared
up and left that way. Any correction required
can be provided with self-aligning idlers
designed for reversing operation. Not all self-
aligners are of this type, as some work in one
direction only.

Tilting the troughing idler forward (not over two
degrees) in the direction of belt travel produces
a self aligning effect. The idlers may be tilted
in this manner by shimming the rear leg of the
idler stand. Here again this method is not
satisfactory where belts may be reversing.
This method is illustrated in Fig. 6.

This method has an advantage over knocking
idlers in that it will correct for movement of the
belt to either side of the idler, hence is useful
for training erratic belts. It has the
disadvantage of encouraging accelerated
pulley cover wear due to increased friction on
the troughing rolls. It should therefore be used
as sparingly as possible - especially on the
higher angle troughing idlers.

Special, self aligning troughing idlers are
available to assist in training the belt (Fig. 7).
For a more complete discussion of these idlers
refer to the Goodyear Handbook of Belting.

60
6. The Belt Itself

A belt having extreme lateral stiffness relative
to its width, will be more difficult to train due to
its lack of contact with the centre roll of the
carrying idler. Recognition of this fact enables
the user to take extra precaution and, if
necessary, load the belt during training to
improve its steerability. Observation of
troughability design limitations will normally
avoid this trouble (Fig. 11).

Some new belts may tend to run off to one
side, in a certain portion or portions of their
length, because of temporary lateral mal-
distributions of tension. Operation of the belt
under tension corrects this condition in
practically all cases. Use of self-aligning idlers
will aid in making the correction.

61
SECTION I
SEQUENCE OF TRAINING OPERATIONS

Initial installation of conveyor equipment
should ensure good alignment of all pulleys,
troughing and return idlers, i.e., they should be
placed at right angles to the direction of belt
travel, leveled and centred on a straight line.
First movement of the belt should be slow and
intermittent so that any tendency of the belt to
run off may be quickly observed and the belt
stopped before damage occurs.

When the conveyor is a long centre
installation, men should be stationed at
frequent intervals to observe the action of the
belt. They should be provided with an effective
method of communication so as to report their
observations and, if necessary, cause the belt
to be stopped.

Initial movement of the belt will provide
indication of where corrections of the types
described are required. The first corrections
must be those at points where the belt is in
danger of being damaged. Once the belt is
clear of all danger points, a sequence of
training operations can be followed.

The best procedure to use in starting the
training sequence is probably to start with the
return run and work toward the tail pulley. This
assures early centring of the belt on the tail
pulley so that it can be centrally loaded.

If the empty belt troughs readily, so that its
running tendencies are not erratic, the training
can and should be completed. Should the belt
tend toward stiffness and erratic running,
getting some load onto the belt as soon as the
return run has been straightened up and the
belt centred on the tail pulley will help hold the
top run.

Normally, the belt can be trained properly onto
the tail pulley by manipulation of return idlers
and with the assistance of self-aligning return
rolls. Seldom is any adjustment of snub or tail
pulley necessary but the snub can be used as
a supplementary training means.

Training of the top run, with the belt empty, is
usually no problem if the belt troughs readily.
In this case self-aligners on top are not
required except as insurance against damage
in the region approaching the head pulley.
There, two self-aligners, placed approximately
12 and 24 metres preceding the pulley, will
help re-centre the belt if it is ever forced off
due to some temporary disturbance.

It should not be necessary to use the head
pulley for training purposes if it has been
aligned properly. Likewise, the snub following
the head pulley should not be required as a
training means. It is relatively ineffective as a
training device due to the strong influence of
the head pulley.

The take-up carriage has a strong influence on
the running of the belt at that point and, due to
its movement as belt length changes, is
subject to mis-alignment. A vertical take-up
carriage, hanging in a festoon of belt, must be
guided in its travel so that the pulley shaft
remains horizontal. The belt cannot be
depended upon to centre itself on the pulley
and, once it moves off centre, the pulley will tip
out of horizontal if not guided closely on its
posts.
A horizontal takeup carriage is subject to mis-
alignment due to loose track gauge, fouled
rails or even jumping off the track. V-shaped
rails will hold the gauge tight and, with the apex
upward, are self-cleaning. Hold-down rails
above the wheels with sufficient clearance so
that they do not touch under normal operation
will help prevent jumping off the track. (Fig.12)

With the empty belt trained satisfactorily, good
operation with load is usually assured.
Disturbances which appear with load are
usually due to off-center loading or to
accumulation of material from the load on snub
pulleys and return idlers.

When equipment is known to be properly
aligned, training action should be taken slowly
and in small steps because the belt requires
some time to respond to corrective measures.
It should begin at some point preceding that
where run-off occurs and the gradually
proceed forward, in the direction of belt travel,
until the run-off condition has been corrected.

Under some conditions of operation where the
conveyor is not level, is extremely short or too
wide to be affected by permissible crowning,
belts with a special guide strip have been
used. This V-guide strip runs loosely in
grooved pulley and idler rolls. Guide strips are
not recommended or necessary for the long
conveyors normally encountered in industrial
use.

62

63
SECTION J
CLEANING

Special care must be exercised to keep the
return rolls and snub pulleys clean. Buildup of
material on this equipment has a destructive
effect upon training with the result that the belt
may run against the structure and damage
itself. It is advisable wherever possible that
return idlers be suspended far enough below
the structure so that any mis-alignment or dirty
idlers can be easily seen.

Keeping the return rolls and snubs clean
requires that the belt be clean when it enters
the return run. Scraping is the most common
method of doing this.

Rubber scrapers can be made by clamping
rubber slabs 13 mm to 25 mm thick (not old
belting) between two metal or wooden bars.
Extend the rubber about twice its thickness
beyond the bars and suspend the mechanism
with a counter-weight to provide pressure
against the belt (Fig. 13). Replace the rubber
when it wears down near the bars. Two or
three such scrapers can be used in
succession.

The most common steel scraper is a series of
diagonally set blades mounted on the end of a
leaf spring to maintain pressure against the
belt. These will scrape sticky materials which
rubber scrapers may ride over (Fig. 14).

Washing the belt with a water spray before
wiping with a rubber scraper will do a good
cleaning job on almost any material, including
iron ores and mixed concrete.

Dry materials can be cleaned off the belt with
rotating bristle or rubber vane brushes, driven
at fairly high surface speed, usually three to
five times the belt speed (Fig. 15). They wear
rapidly, require considerable maintenance and
are likely to fill up solid if used with wet and
sticky materials.

It is preferable to clean just after the head
pulley and before the snub. An exception to
this is that sticky material often requires
scraping on the head pulley. This is because a
large part of the fine material sticks to the belt
and must be scraped into the chute.

In some cases the best possible cleaning is
insufficient and steps must be taken to
compensate for the effect of a dirty belt. Snub
pulleys can be kept from building up by the use
of soft rubber lagging or by scraping directly
against the pulley. Diagonal grooving will
distort and discharge accumulations on these
pulleys. Rubber disc or spiral type return rolls
prevent build up on themselves and thus save
a training problem (Fig. 16 & 17).

The only cleaning required on the pulley side is
removal of material, principally lumps, which
may fall or bounce onto the return run, and be
carried between the belt and tail pulley if not
removed (Fig. 20). Rubber faced plows
immediately in front of the tail pulley are used
for this purpose (Fig. 18 & 19). They are
usually held against the belt by gravity and set
at an angle to the direction of belt travel.

64

65
SECTION K
LOADING

Receiving material off centre will cause the belt to
move sideways after loading as the centre of the load
seeks the lowest point in the troughing idlers. This
can be corrected by proper chute arrangement
provided, of course, that the belt is centred as it enters
the loading point (Fig. 4, Section D).

The loading point of any conveyor is nearly always the
critical point, the life determining point of the belt.
Here the conveyor receives its major abrasion, and
practically all of its impact. The ideal condition is to
have the material pass from chute to belt at the same
speed and direction of travel as the belt with a
minimum amount of impact.

The subject of chute design and arrangement is too
broad to be discussed in detail here. In lieu of such
discussion, the following suggestions are offered:

The width of the receiving end of the loading chute
should be great enough to accept material lying on the
extreme edge of the preceding belt or feeder, and its
position determined by the trajectory of the material
coming into it. At no place should the chute be less
than twice the size of the largest lumps, if fines are
present, and 3-1/2 times the size of lumps, if uniform.
The discharge width of the chute thus determined
should not exceed about 2/3 of the receiving belts
width (Fig. 21).

The slope of the chute is determined by the nature of
the material, its entering velocity and length of the
chute. This value varies with each particular
installation, but about 35has been found satisfac tory
for most dry industrial materials such as coal and rock
.

66

An attempt to approach the above ideal condition
should be made continually by adjusting the chute
arrangement. Optimum loading and transferring
through chutes still requires considerable
experimental adjustment in the field.

Skirt boards should be used to further center and
settle the load as it leaves the loading point. The steel
structure of the chute and skirts never should be
placed closer to the surface of the belt than 25 mm,
this distance to be made increasing the direction of
belt travel to free any material trapped between the
belt surface and the skirt. (Fig 22) Skirt boards are
usually 4 to 5 times the belt width in length, but may
vary considerably due to belt speed, type of material
and lump size. Sample skirt board arrangements are
shown in Fig.23.

67
Impact of material being loaded on the belt is often the
cause of sever cuts and gouges. The degree of
impact can be lessened to some extent by providing a
cushion in the form of rubber covered disc type or
semi-pneumatic idlers which also tend to prevent
material from crowding under the skirt boards at the
instant of impact. (Fig.24)

The use of a Grizzly, a slightly fanned row of bars, at
the bottom of the transfer chute reduces wear on the
belt. It distributes the impact of large lumps by
allowing the fines to fall onto the belt first which act as
a cushion. The fan shape of the Grizzly in the
direction of travel prevents jamming of the lumps. (Fig.
25)

A V-slot cut in the bottom of the chute is another
very satisfactory method of allowing fines to fall on the
belt before the lumps and thereby reduce belt wear at
this point. (Fig.26)

SECTION L
PULLEY LAGGING

Lagging is recommended for drive pulleys for the
following reasons:

1. Improved co-efficient of friction. This permits
a belt to be driven by lower slack side tension
and sometimes results in lower total tension.

2. Reduction of slippage due to wet conditions if
grooved lagging is used.

3. Increased life for pulley and pulley cover of
belt.

Other pulleys in the system, especially those
contacting the carrying side of the belt, are often
lagged to prevent build-up of material. Grooving
improves cleaning action on the lagging and the belt.

68

Fig. 25
Grizzly Chute

Fig. 26
V-Slot Chute

Types of Lagging:

1. Bolted lagging is usually fabric reinforced, the
fabric being necessary to give proper bolt-
holding. This type has no inner or pulley
cover; where no grooving is intended, 3mm
top cover is the proper minimum, but if the
lagging is to be grooved a minimum of 6mm
top cover must be used.

Bolted lagging is usually applied in two or
more circumferential strips, applied under
tension with the points in the different strips
staggered around the pulley. (On flat-faced
pulleys one strip the width of the pulley may
be used.)

For open end pulleys 8mm or 10mm diameter
flat head elevator bolts with nuts may be
used. Alternate methods include slotted bolts
with tapped holes or self tapping screws for
use in welded steel pulleys. It is necessary
that the bolt heads be sunk below the level of
the surrounding lagging to prevent damage to
the belt as it passes over the pulley. This may
be accomplished by counter-sinking the holes
in the pulley or, where the lagging cover is
greater than about 3mm, it is possible to sink
the heads merely by tightening the bolts.

Ends of the strips should be bolted in a
dovetail joint as shown in Fig. 27. In addition,
bolts should be used in rows running across
the face and around the circumference of the
pulleys no further than 254mm apart in either
direction. Edges of all strips should be bolted
down and it is recommended that all exposed
fabric edges be cemented to keep out
moisture.

2. Vulcanised lagging is a sheet of rubber,
usually 13mm thick, bonded directly to the
metal. No fabric is used because no bolt-
holding reinforcement is needed. It is much
longer wearing, has better and more uniform
adhesion to the pulley and eliminates the
hazard of serious belt damage due to a loose
bolt.

This type of lagging can be applied in two
different ways:

Spiral method - generally used for lower
tension applications. A 100mm wide strip is
recommended for ease of handling (Fig. 28).
The length of the strip may be calculated by
the formula:
C x W
L =
4
+ C

In application by the sheet wrap method, a
bevelled lateral splice is recommended (Fig.
29). The tie gum side should contact the
bevelled leading edge for maximum adhesion
at the splice.

3. Grooved lagging should be used on drive
pulleys if they are liable to be wet. The
grooves break the film of moisture between
the belt and lagging thereby eliminating
slippage. Either bolted or vulcanised lagging
can be furnished with grooves. Either type can
be grooved in the field with a tire-groover if
there is sufficient rubber to prevent cutting into
the fabric carcass or metal pulley.
Herringbone grooving 5mm deep and wide
spaced 25mm apart is recommended (Fig.
30).

69

4. A modified type of bolted pulley lagging is also
available which features replaceable rubber
pads that slip into metal guides bolted or
welded to the pulley.(Fig.31)

70
SECTION M
TROUBLE SHOOTING
The previous portions of this manual have described some methods for training and maintaining your
conveyor system. The section which follows will allow you to trouble shoot your belt system and apply
recommended corrective actions.

PROBLEM/Cause ..In Order of Probable Occurrence PROBLEM/Cause ..In Order of Probable Occurrence

A. Conveyor runs to one
side at given point on
structure.

5

4

1

2

3

44

M. Covers harden or
crack.

23

37

-

-

-

-

B. Particular section of
the belt runs to one
side at all points on
conveyor.

6

7

-

-

-

-

N. Cover swells in spots
or streaks.

21

-

-

-

-

-

C. Belt runs to one side
for long distance or
entire length of
conveyor.

39

8

5

1

2

3

O. Belt breaks at or
behind fasteners;
fasteners pull out.

24

22

12

23

-

-

D. Belt runs off at tail
pulley.

39

10

1

-

-

-

P. Vulcanised splice
separation.

38

30

12

17

25

-

E. Belt runs off at head
pulley.

33

10

1

3

-

-

Q. Excessive edge
wear, broken edges.

8

10

40

7

-

-

F. Belt slip.

34

33

31

10

4

-

R. Transverse breaks at
belt edge.

18

25

26

-

-

-

G. Belt slip on starting.

34

31

33

-

-

-

S. Short breaks in
carcass parallel to
belt edge, star
breaks in carcass.

16

17

-

-

-

-

H. Excessive belt
stretch.

41

42

43

12

32

35

T. Ply separation.

29

30

23

-

-

-

I. Grooving, gouging or
stripping of top
cover.

13

14

15

16

-

-

U. Carcass fatigue at
idler junction.

25

26

27

28

29

36

J. Excessive top cover
wear, uniform around
belt.

19

20

10

8

36

-

V. Cover blisters or
sand blisters.

45

21

-

-

-

-

K. Severe pulley cover
wear.

4

9

10

17

11

27

W. Belt Cupping -
New belt.

46

-

-

-

-

-

L. Longitudinal grooving
or cracking of bottom
cover.

4

10

9

33

-

-

X. Belt Cupping -
Old belt. (Was
OK when new.)

21

23

-

-

-

-

The idler junction is the gap between the
functioning surfaces of the centre rolls and
one of the side rolls of the idler (see Fig.
32). This gap poses a potential hazard for
the belt by providing a narrow space in
which the belt can settle, experiencing
highly detrimental flex and possible
exposure to oil or grease from the idler
bearings (see Fig. 33). When slipping of
the belt into the idler junction is the cause
of belt damage, it is called idler junction
failure.

Fig. 32

Fig. 33

71

CAUSES AND THEIR SOLUTIONS

1. Idlers or pulleys out-of-square with centre line of belt: readjust
idlers in affected area.

2. Conveyor frame or structure crooked: straighten in affected area.

3. Idler stands not centred on belt: readjust idlers in affected area.

4. Sticking idlers: free idlers and improve maintenance and
lubrication.

5. Buildup of material on Idlers: remove accumulation; improve
maintenance; install scrapers or other cleaning devices.

6. Belt not joined squarely: remove affected splice and resplice.

7. Bowed belt: for new belt this condition should disappear during
break-in; in rare instances belt must be straightened or replaced;
check storage and handling of belt rolls.

8 Off-centre loading or poor loading: adjust chute to place load on
centre of belt; discharge material in direction of belt travel at or
near belt speed.

9. Slippage on drive pulley: increase tension through screw takeup or
add counterweight; lag drive pulley; increase arc of contact.

10. Material spillage and buildup: improve loading and transfer
conditions; install cleaning devices; improve maintenance.

11. Bolts heads protruding above lagging: tighten bolts; replace
lagging; use vulcanised-on lagging.

12. Tension too high: increase speed, same tonnage; reduce tonnage,
same speed; reduce friction with better maintenance and
replacement of damaged idlers; decrease tension by increasing
arc of contact or go to lagged pulley; reduce CWT to minimum
amount.

13. Skirt boards improperly adjusted or of wrong material: adjust skirt
board supports to minimum 25mm between metal and belt with
gap increasing in direction of belt travel use skirt board rubber (not
old belt).

14. Belt spanking down under load impact: install cushion idlers.

15. Material hanging up in or under chute: improve loading to reduce
spillage: install baffles widen chute.

16. Impact of material on belt: reduce impact by improving chute
design install impact idlers

17. Material trapped between belt and pulley: install plows or scrapers
on return run ahead of tail pulley

18. Belt edges folding up on structure: same corrections as for 1 2 3;
install limit switches; provide more clearance.

19. Dirty stuck or misaligned return rolls:remove accumulations; install
cleaning devices; use self-cleaning return rolls; improve
maintenance and lubrication

20 Cover quality too low: replace with belt of heavier cover gauge or
higher quality rubber.

21. Spilled oil or grease over-lubrication of idlers: improve
housekeeping reduce quantity of grease used check grease seals.

22. Wrong type of fastener, fasteners too tight or too loose: use proper
fasteners and splice technique: set up schedule for regular
fastener inspection.

23. Heat or chemical damage: use belt designed for specific
condition.

24. Fastener plates too long for pulley size: replace with smaller
fasteners; increase pulley size.

25. Improper transition between troughed belt and terminal pulleys:
adjust transition in accordance with Goodyear Handbook of
Belting

26. Severe convex {hump) vertical curve: decrease idler spacing in
curve; increase curve radius; consult Goodyear Handbook of
Belting for assistance.

27. Excessive forward tilt of trough rolls: reduce forward tilt of idlers to
no more than 2from vertical.

28. Excess gap between idler rolls: replace with heavier belt

29. Insufficient transverse stiffness: replace with the proper belt.

30. Pulleys too small: use larger diameter pulleys.

31. Counterweight too light: add counterweight or increase screw
take-up tension to value determined from calculations.

32. Counterweight too heavy: lighten counterweight to value
determined by calculations.

33. Pulley lagging worn: replace pulley lagging.

34. Insufficient traction between belt and pulley: lag drive pulley;
increase belt wrap; install belt cleaning devices.

35. System underbelted: recalculate belt tensions and select proper
belt

36. Excessive sag between idlers causing load to work and shuffle on
belt as it passes over idlers: increase tension if unnecessarily low;
reduce idler spacing.

37. Improper storage or handling: refer to Goodyear for proper
storage and handling instructions

38. Belt improperly spliced: resplice using proper method as
recommended by Goodyear

39. Belt running off-centre around the tail pulley and through the
loading area: install training idlers on the return run prior to tail
pulley

40. Belt hitting structure: install training idlers on carrying and return
run.

41. Improper belt installation causing apparent excessive belt stretch:
pull belt through counterweight with a tension equal to at least
empty running tension; run belt in with mechanical fasteners.

42. Improper initial positioning of counterweight in its carriage causing
apparent excessive belt stretch: check Goodyear Handbook of
Belting for recommended initial position.

43. Insufficient counterweight travel: consult Goodyear Conveyor and
Elevator Belt Selection Manual for recommended minimum
distances.

44. Structure not level: level structure in affected area

45. Cover cuts or very small cover punctures allow fines to work
under cover and cut cover away from carcass: make spot repair
with Vulcaniser or self-curing repair material.

46. Excessive cover gauge ratio: use a belt with a lower gauge and/or
a thicker carcass.

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