TECHNICAL SPECIFICATION

TU 515R - Radial Truck Unloader

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

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: info@telestack.com
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 3rd 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 info@telestack.com

We will be glad to assist you and we look forward to the potential opportunity of working with you.
Rev 1. 03/10/2012 2 TU 515R – Technical Specification
TU 515R Mobile Radial Truck Unloader

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 (20m3) 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.

TU 515R Typical Applications

• 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.

TU 515R Key Advantages

• Production rates of up to 500tph (550 Ton / hr).

• Maximum lump feed size of up to 100mm (4")
• Can receive up to 15 - 30 (20m3) 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.

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TU 515R - Working Dimensions (see pages 20 - 23)

Metric Imperial
• Main Conveyor Length (Drum Centres) 15.5m 50’ 7"
• Machine working Length (23º) 24.8m 80’ 9”
• Discharge height (23º) 7m 22’ 8”
• Truck feed in height 630mm 2’
• Operating Width 3.9m 12’ 7"
• Stockpile Capacity at 120o 3,769 Tonnes 4,155 Ton
• Stockpile capacity at 120o 2,355m3 3,080m3

TU 515R - Transport Information

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)

TU 515R - Key Features & Benefits

• High throughput of up to 500 tph (550 Ton / hr).

• Large 22 m3 (29 yds3) 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 /m3 (100 lb/ft3). If a specific tonnage
is required this should be discussed with the factory.
2) Ideal working angle for conveyor is 13º - 23º
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

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

Stockpiling Capacity

Figures based on material with a bulk density

den of 1.6tonnes per m3 (100 lb/ft3) Stockpile angle of
repose 37 . conveyor luffing angle of 22
o
2 .
o

Angle of Radial Arc Stockpile Height Stockpile Capacity Stockpile Capacity

(Degrees) (Volume) (Mass)
(m) (ft) (m3) (yd3) (Tonnes) (Ton)
0o 6.7 21' 9" 580 760 925 1020
30o 6.7 21' 9" 1010 1320 1620 1785
60o 6.7 21' 9" 1460 1910 2335 2575
90o 6.7 21' 9" 1910 2500 3055 3370
120o 6.7 21' 9" 2355 3080 3770 4155

Feeder

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
29yds3
Includes rubber flaps at rear to eliminate spillage.

Hydraulically Folding Sides

Hydraulically folding sides to quickly and easily

change from transport to working mode.

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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)

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Feeder Belting
2200mm wide (87") - EP 630, 4 ply, 6mm top +
2mm bottom.

40mm (1 1ൗ2") 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.

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 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 Conveyor Raise / Lower Support

Incline Raise / Lower Support

Heavy duty RHS conveyor support above incline

conveyor.

2 x hydraulic rams to raise / lower the incline

conveyor.

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Radial Incline Conveyor

Radial Incline Conveyor

15m Heavy duty ribbed design incline conveyor.

Folded plate design gives structural strength to

conveyor frame.

Incline conveyor has 120o 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 feedboot

to prevent material spillage.

Impact Bed

127mm (5”) Diameter, impact centre rollers with

impact side bars to prevent material spillage.

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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

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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.

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Radial Incline Conveyor

Slew Ring

The incline conveyor is mounted on a

hydraulically operated slew ring, to allow the
conveyor to radial through 120o.

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.

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

Tracks

Tracks

Heavy Duty Tracks

Longitudinal centres: 4300mm

4300mm
Track shoe width: 400mm

Drive: Two integral hydraulic motors

Tensioning: Hydraulic adjuster, grease tension

Tracking: Push button pendant type (dog lead)

2990mm

Chassis

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.

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

Hydraulics

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 C.o

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

Engine

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)

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Outrigger / Jacking Legs

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

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.

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Options

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.

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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.

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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.

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TU 515R General Arrangement - Raised

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TU 515R General Arrangement - Lowered

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TU 515R General Arrangement - Transport

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TU 515R General Arrangement - Stockpile

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

TU 515R Hopper Capacity

Opening At Leveller (mm high at

200mm 330mm 440mm
centre)
M³ Passing Leveller 0.05m³ 0.09m³ 0.13m³
Tonnes per hour @ 0.168m/s Belt
290TPH 520TPH 750TPH
Speed (Approx)

Maximum load in feeder before

levelling blade = Approx. 15 -
20 tonnes @ 1.6 T /m³

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