Telestack Limited

Bankmore Way East

Omagh
Co.Tyrone
Northern Ireland
BT79 0NZ

Tel:+44 (0) 2882 251100
Fax:+44 (0) 2882 252211

Web: www.telestack.com
Email: [email protected]


TECHNICAL SPECIFICATION
TU 515R - Radial Truck Unloader



Model Shown TU 515R (Square to Round Chute Optional Extra)

Rev 1. 03/10/2012 TU 515R Technical Specification 2




























































COMPANY PROFILE
Telestack Limited was formed in 1999 to supply MOBILE Bulk Material Handling Solutions. Based in the United Kingdom, Telestack
operates from a modern 32000 square metres site where we have combined the experience and knowledge of Loughside Engineering
and Telestack to develop a range of MOBILE Bulk Material Handling Solutions.

Our MOBILE solutions offer significant operating cost savings compared to traditional methods of material handling (wheel loaders,
haul trucks, static conveyors) , as well as providing Environmental, Health and Safety and other benefits. We have over 600 installations
to date in 6 continents around the world, this proves that we can deliver on our promises and it is this proven track record that ensures
many of our customers are repeat customers.

Over the years we have invested significantly to ensure that:

We have the design knowledge and expertise to meet the specific requirements of our customers. Our design engineers travel the
world visiting our equipment in the field from Chile to Russia to India to Middle East to Australia etc to learn from our customers on
how we can continue to improve our designs and performance
We are in control of the complete process, as within our factory we design, manufacture, fully assemble, and test EVERY machine.
Only after the machine and all its functions are fully tested do we dis-assemble at our factory into containers and ship to the
customer.
Unlike many competitors, we do everything under one roof we do not outsource fabrications to lower cost countries etc and
hope it will all fit when it gets to site
We are on site during installation to ensure a fast and efficient assembly of our equipment and your system will typically take 2-3
weeks from the containers arrive until you are ready to go to work
Our factory engineers are on site to ensure that the equipment is properly commissioned with material flowing over the belts
achieving the performance our customer expects
We have an aftersales structure and team in place so we can quickly solve problems to ensure the safe and efficient operation of our
equipment in the field
We have a global network of dealers/ agents that ensure you a fast and efficient response.
We have an externally audited Quality Management System that is audited to ISO 9001:2008 International Standards. As an ISO
9001:2008 registered company we understand the importance of delivering equipment that meets or exceeds our customers
expectations. Our process emphasises the importance of understanding what the customer wants and being in a position to offer
advice based on our experience
The robust designs and the unique assembly designs ensure that our equipment will have a much higher resale value that
competitors as it can be easily dis-assembled, packed into containers and shipped anywhere in the world to work in a port, mine,
quarry, rail yard, power station, steel mill etc
We are competitive on price, without compromising on quality and our ability to support customers pre-sale and in aftersales
Telestack has been successful in establishing a reputation as a supplier of choice with many blue chip companies around the
world including:
- BHP Billiton - Cemex - Mechel - Port of Panama
- Rio Tinto - CRH - Suek - Port of Vostochny
- Jindal Steel - Eurovia - Nibulon - Port of Alexandria
- London Mining - Holcim - Ural Kili - Port of Gangavaram
- Norilsk Nickel - La Farge - Rusal - Port of Brisbane
- PT Bumi - Tarmac - Fortescue - Port of Coquimbo
- Tata Steel - Van Oord - Fomento - Port of Belfast
- Thyssen Krupp - Peter Hambro - Tata Steel - Port of Dhamara
- Xstrata - Severstal - Larsen + Toubro
- Arcelor Mittal - Anglo American - Ennstone/Bredon Aggregates

Global engineering consultants/EPC contractors who value their reputations are among our clients. In nearly all cases we design a
system to suit their specific needs but the designs are based on our TRACK RECORD of similar designs/proven designs.

Other OEMs often specify/purchase Telestack equipment as part of their own systems solution because of our reputation of
consistently delivering on our commitments. Unlike many of our competitors, our conveyors are designed for the onerous demands of
mining applications and this is why we are an approved supplier of equipment that meets Western Australian Mining Standards AS
4324.1. Our designs and structural integrity are verified and certified by an independent 3
rd
party.

We would gladly welcome you to visit existing installations around the world in North America, South America, Europe, Africa, Asia,
Oceania. Include a visit to our facility in the UK so you can see the company and meet the people behind the Telestack name to give
you even greater confidence in our ability to deliver on our promises.

To find out more please visit www.telestack.com or contact us on [email protected]
We will be glad to assist you and we look forward to the potential opportunity of working with you.

Rev 1. 03/10/2012 TU 515R Technical Specification 3



The TU 515R is a track mounted fully mobile conveyor designed to work at production rates of up to
500tph. Telestacks Truck Unloader range are designed to be loaded directly from trucks, wheel
loaders, grab cranes, excavators etc. and can receive up to 15 - 30 (20m
3
) tonne pay load. Truck
Unloaders can be used to stockpile material, feed auxiliary equipment, reclaim to other conveyors,
directly load ships, trucks, rail wagons etc. Since the Truck Unloader is track mounted the unit has
excellent mobility on site. Truck Unloaders eliminate double handling of material which reduces
overall costs for operator.







Truck Unloading
Radial Stockpiling / Loading directly from wheel loader, excavator, grab crane etc.
Mobile reclaim hopper feeding overland conveyor / stacker.
Truck and rail wagon loading.
Ship and barge loading / unloading.
Working as part of a mobile system on short to medium term projects.







Production rates of up to 500tph (550 Ton / hr).
Maximum lump feed size of up to 100mm (4")
Can receive up to 15 - 30 (20m
3
) tonne pay load from articulated trucks.
Unload 18 - 20, 30 tonne trucks per hour, based on 3 minute unloading cycle per truck.
15m Radial Incline Conveyor with 120 degrees of radial coverage.
Can be fed by multiple wheel loaders due to large hopper and high tonnage per hour.
Can be transported on one flat bed loader.
Unrivalled mobility and flexibility when in operation.
High specification machine designed for ease of maintenance commanding an excellent
resale value at project conclusion.
Heavy duty design and manufacture.

TU 515R Mobile Radial Truck Unloader
TU 515R Typical Applications
TU 515R Key Advantages

Rev 1. 03/10/2012 TU 515R Technical Specification 4

Metric Imperial
Main Conveyor Length (Drum Centres) 15.5m 50 7"
Machine working Length (23) 24.8m 80 9
Discharge height (23) 7m 22 8
Truck feed in height 630mm 2
Operating Width 3.9m 12 7"
Stockpile Capacity at 120
o
3,769 Tonnes 4,155 Ton
Stockpile capacity at 120
o
2,355m
3
3,080m
3




Metric Imperial
Transport Length (Head Folded) 19.5m 63' 6"
Transport Width (Gearboxes Removed) 3070mm 10
Transport Height 3440mm 11' 2"
Overall Weight 33 Tonnes 72,755 lbs
Unit can be transported complete or without gearboxes fitted on RoRo trailer (More info on page 22)



High throughput of up to 500 tph (550 Ton / hr).
Large 22 m
3
(29 yds
3
) capacity hopper as standard.
Heavy duty apron chain and sprocket feeder.
Cat diesel engine on board for power supply.
Heavy duty slew ring to radial conveyor through 120 degrees.
Hydraulically raise / lower incline conveyor.
Hydraulically folding sides on hopper to transform hopper from transport to working mode.
Heavy duty ribbed design folded plate incline conveyor.
Hydraulically operated outrigger jacking legs for extra stability when radialing.
Hydraulically folding head section for ease of transportation.
Paint specification, Cream: RAL 7032, Red: RAL 3001.
Options available.
Please note:
1) Tonnages quoted are based on free flowing material with a density of 1.6 Tonne /m
3
(100 lb/ft
3
). If a specific tonnage
is required this should be discussed with the factory.
2) Ideal working angle for conveyor is 13 - 23
3) All possible steps have been taken to ensure the accuracy of this publication, however due to continual product
development we reserve the right to change specifications without notice
TU 515R - Working Dimensions (see pages 20 - 23)
TU 515R - Transport Information
TU 515R - Key Features & Benefits

Rev 1. 03/10/2012


Figures based on material with a bulk den
repose 37
o
. conveyor luffing angle of 2

Angle of Radial Arc
(Degrees)
Stockpile Height

(m)
0
o
6.7
30
o
6.7
60
o
6.7
90
o
6.7
120
o
6.7







Hopper
Heavy duty large hopper with 20 degree incline
feeder.

Truck Feed in Height: 630mm 2'
Width: 3870mm 12' 7"
Length: 2900mm 9' 6"
Capacity: 22m
3

Includes rubber flaps at rear to eliminate
Hydraulically Folding Sides
Hydraulically folding sides to quickly and easily
change from transport to working mode.





Feeder
Stockpiling Capacity
TU 515R Technical Specification 5
based on material with a bulk density of 1.6tonnes per m
3
(100 lb/ft
3
) Stockpile angle of
. conveyor luffing angle of 22
o
.
Stockpile Height Stockpile Capacity
(Volume)
Stockpile Capacity
(m) (ft) (m
3
) (yd
3
) (Tonnes)
6.7 21' 9" 580 760
6.7 21' 9" 1010 1320
6.7 21' 9" 1460 1910
6.7 21' 9" 1910 2500
6.7 21' 9" 2355 3080
with 20 degree incline
: 630mm 2'
: 3870mm 12' 7"
: 2900mm 9' 6"
29yds
3

Includes rubber flaps at rear to eliminate spillage.


Hydraulically folding sides to quickly and easily
change from transport to working mode.


Technical Specification
) Stockpile angle of
Stockpile Capacity
(Mass)
(Tonnes) (Ton)
925 1020
1620 1785
2335 2575
3055 3370
3770 4155



Rev 1. 03/10/2012 TU 515R Technical Specification 6

Hydraulically Raise / Lower Feeder
Lifting rams under feeder to quickly and easily lift
feeder for transport.



Mild Steel Liners
Feeder full lined with 6mm bolt in mild steel wear
plates to protect against abrasive material.



Material Levelling Blade
Adjustable material levelling blade located on
incline of feeder to control the flow of material
when handling a range of materials.

Allows for a consistent bed depth of material to
feed onto incline conveyor.

Manual range of adjustment 200mm (8") to
440mm (17").

More information on page 24

(Hydraulic height adjustment option available)






Rev 1. 03/10/2012 TU 515R Technical Specification 7
Feeder Belting
2200mm wide (87") - EP 630, 4 ply, 6mm top +
2mm bottom.

40mm (1
1
2
") high wall each side to eliminate
material spillage.

Belt bolted to apron chain cross members with
countersunk screws.



Apron Chain Feeder
Heavy duty apron chain belt feeder.



4" pitch, 388kN chain with 8 tooth sprockets at the
head and tail of feeder.



Rectangular box section cross members bolted to
chain drive bearings with belt bolted to top of
cross members.



55mm (2") impact bars underneath cross
members for added protection against falling
material.














Rev 1. 03/10/2012 TU 515R Technical Specification 8
Feeder Drives
2 x 15 kW Brevini drive motors and gearboxes for
increased torque under heavy loads.



Transfer Point
Fully tapered designed transfer chute to eliminate
spillage and blockages of material.

2200mm (87") feeder belt feeding onto 1200mm
(48") incline belt.

Large Opening for maximum throughput.

6mm mild steel liners and rubber sealing as
standard.









Incline Raise / Lower Support
Heavy duty RHS conveyor support above incline
conveyor.

2 x hydraulic rams to raise / lower the incline
conveyor.





Incline Conveyor Raise / Lower Support


Rev 1. 03/10/2012




Radial Incline Conveyor
15m Heavy duty ribbed design incline conveyor.

Folded plate design gives structural strength to
conveyor frame.

Incline conveyor has 120
o
of radial coverage.
Feedboot
Feedboot fully lined with bolt in mild steel liners to
protect against abrasive material.

Rubber skirting along the bottom of the
to prevent material spillage.
Impact Bed
127mm (5) Diameter, impact centre rollers with
impact side bars to prevent material spillage.


Radial Incline Conveyor
TU 515R Technical Specification 9
Heavy duty ribbed design incline conveyor.
plate design gives structural strength to
of radial coverage.


Feedboot fully lined with bolt in mild steel liners to

Rubber skirting along the bottom of the feedboot


127mm (5) Diameter, impact centre rollers with
impact side bars to prevent material spillage.



Technical Specification




Rev 1. 03/10/2012 TU 515R Technical Specification 10
Incline Conveyor Belting
1200mm wide (48") belting, EP 500, 3 ply, 5mm +
1.5mm



Troughing Rollers
127mm (5) diameter troughing rollers set.

Wing roller angle adjustable.



Return Rollers
150mm (6") diameter disc return rollers.

Less chance of material build up compared to
traditional plain return roller.

Includes profiled steel nip guard as standard






Rev 1. 03/10/2012
Incline Conveyor Drives
2 x Brevini hydraulic drive motors and gearboxes
for increased torque under loading.
Hydraulically Folding Head Section
Hydraulically folding head section allowing for
compact road transportation.
Head Scraper
Carbide tungsten tip head scraper to remove
material from the belt.
Plough Scraper
Plough Scraper located at tail drum to clear inside
of belt of any material.

TU 515R Technical Specification 11
Brevini hydraulic drive motors and gearboxes
for increased torque under loading.


Folding Head Section
folding head section allowing for


head scraper to remove

Plough Scraper located at tail drum to clear inside



Technical Specification





Rev 1. 03/10/2012 TU 515R Technical Specification 12



Slew Ring
The incline conveyor is mounted on a
hydraulically operated slew ring, to allow the
conveyor to radial through 120
o
.





The heavy duty slew ring system provides an
unbeatably smooth left / right radial movement.





Various pinning options to lock conveyor in place
to avoid any movement when in use or in
transport.

















Radial Incline Conveyor

Rev 1. 03/10/2012 TU 515R Technical Specification 13


Tracks
Heavy Duty Tracks

Longitudinal centres: 4300mm

Track shoe width: 400mm

Drive: Two integral hydraulic motors

Tensioning: Hydraulic adjuster, grease tension

Tracking: Push button pendant type (dog lead)











Chassis
Heavy duty folded plate design sides for
integral strength throughout the unit.

Large hinged and lockable access doors to
allow easy access to components.

Structural RHS cross members to ensure the
chassis is rigid and robust.

All moving joints have incorporated heavy
duty bosses for increased strength and wear
characteristics.

Tracks incorporated directly into chassis for
increased strength.






Tracks
2990mm
Chassis
4300mm

Rev 1. 03/10/2012 TU 515R Technical Specification 14

Hydraulic Pump
Triple pump system.


Easy access for maintenance to all hydraulic
components such as pumps, filters, tanks, valves
etc.



Hydraulic Oil Tank
Large steel fabricated hydraulic tank with fill level
gauge and lockable filler cap.

Capacity: 500 litres 132 gallon (US)

Oil type: Grade 46



Hydraulic Oil Cooler
2 x Hydraulic oil coolers.

Temperature activated oil cooler fitted as standard
with protective guard.

Oil cooler activates when hydraulic oil
temperature reaches 55
o
C.



Hydraulics


Rev 1. 03/10/2012 TU 515R Technical Specification 15


Engine
CAT C 4.4 96KW ACERT (Electronic) 2200rpm
Turbocharged Diesel Engine.


Diesel engine for all functions including tracks,
conveyor belts and hydraulic functions.


Optional Dual Power (Electric driven conveyor
belts).



Engine Control Panel
Full function control panel. All machine functions
operated from panel.

(Optional radio remote control)




Diesel Tank
Large steel fabricated fuel tank with fill level gauge
and lockable filler cap.

Capacity: 240 litres 63.5 gallon (US)





Engine


Rev 1. 03/10/2012 TU 515R Technical Specification 16


Outrigger / Jacking Legs
2 x hydraulically extending jack legs at the front of
the unit to give a wider base to improve stability of
the unit, when incline conveyor is radialling.








Paint Finish
Two Pak Epoxy Primer paint to ADT 60 microns.

Two pak Epoxy top coat to ADT 60 microns.

Total (Average) Dry Thickness of 160 microns.




Outrigger / Jacking Legs
Paint Finish


Rev 1. 03/10/2012 TU 515R Technical Specification 17


Radio Remote Control
All functions in one remote, control all aspects
of the unit form the one remote, tracks, start /
stop conveyor, raise / lower conveyor.



Incline Conveyor Dust Covers
Canvas dust covers up the full length of the
incline conveyor, to suppress dust.

Used with materials that are likely to create a
lot of dust.



Enclosed Hopper
Fully enclosed hopper to suppress dust from
unloading trucks.

Cladding or canvas enclosure.

Used with materials that are likely to create a
lot of dust.



Square to Round Discharge Chute
Square to round discharge chute to
concentrate the flow of material and protect it
from the wind.



Options


Rev 1. 03/10/2012 TU 515R Technical Specification 18
Rubber Track Pads
Rubber track pads for operating on asphalt or
concrete to protect the surface.

Hopper Wheels
Heavy duty wheels under hopper to allow
forward / reverse movement, with material in
the hopper.



Hopper Doors
Bolt on / off or hinged, hopper doors to allow
the unit be fed by wheel loaders.



Hopper Ramps
Rear folding ramps (hydraulic or manual) to
allow different sized trucks to unload into the
hopper.




Rev 1. 03/10/2012 TU 515R Technical Specification 19
Hopper Extensions
Hopper extensions to increase hopper capacity.



Dual Power
Dual Power option, electric motor to drive feeder
and incline conveyor.

Engine still used to drive the tracks and hydraulic
rams to lift hopper, incline conveyor and jacking
legs.






Rev 1. 03/10/2012 TU 515R Technical Specification 20

TU 515R General Arrangement - Raised

Rev 1. 03/10/2012 TU 515R Technical Specification 21

TU 515R General Arrangement - Lowered

Rev 1. 03/10/2012 TU 515R Technical Specification 22


TU 515R General Arrangement - Transport

Rev 1. 03/10/2012 TU 515R Technical Specification 23

TU 515R General Arrangement - Stockpile
Rev 1. 03/10/2012






Opening At Leveller (mm high at
centre)
M Passing Leveller
Tonnes per hour @ 0.168m/s Belt
Speed (Approx)
TU 515R Hopper Capacity
24
200mm 330mm
0.05m 0.09m
290TPH 520TPH
TU 515R Technical Specification
440mm
0.13m
750TPH
Maximum load in feeder before
levelling blade = Approx. 15 -
20 tonnes @ 1.6 T /m