www.telestack.

com

OPERATION MANUAL
 TRACKED PUGMILL

Operation, Maintenance Telestack Limited

Bankmore Way East, Omagh
Co.Tyrone Northern Ireland
& Spare Parts Manual BT79 0NZ

Tel: +44(0)2882 251100

Issue Date: 06/04/2022 Fax: +44(0)2882 252211
Language: English
Revision: 0.1 Web: www.telestack.com
Email: [email protected]

2022 THE POWER TO MOVE MATERIALS

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 CONTENTS

Section 1 Introduction
Section 2 Safety
Section 3 Installation
Section 4 Operation
Section 5 Technical Information
Section 6 Maintenance
Section 7 Troubleshooting
Section 8 Spare Parts
Section 9 Warranty – Aftermarket
Section 10 CE Certificate
Section 11 Terminology
Section 12 Hydraulic Circuit Diagram
Section 13 Electrical Schematics
Section 14 Appendix

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EC Conformity

This plant is in conformity with the

provisions of the EC Machinery
Directive 2006/42/EC together with
appropriate EN Harmonised
Standards and National BS
Standards and Specifications.

Copyright

The copyright of this User Manual is reserved by TELESTACK LIMITED

This User Manual contains information and technical drawings, which may not
be copied, distributed, altered, stored on electronic media, revealed to others
or used for the purpose of competition, either partially or in its entirety. Some
images are shown for illustrative purposes only and may not show the specific
machine.

The right is reserved to alter any details contained in this manual without
notice. Copyright 2022.

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 INTRODUCTION

INTRODUCTION

1. INTRODUCTION ........................................................................................ 2
1.1 CUSTOMER INFORMATION ..................................................................... 2
1.2 NOTES TO THE OPERATION MANUAL .................................................. 2
1.3 INTENDED USE......................................................................................... 4
1.4 PROHIBITED USE ..................................................................................... 6
1.5 CONTACT DETAILS ................................................................................. 6

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 INTRODUCTION
1. INTRODUCTION
1.1 CUSTOMER INFORMATION
Telestack appreciates your decision to purchase this machine.
Before operation, it is the responsibility of the customer/end user to ensure,
that all personnel who operate this machine are trained in its safe and correct
use. Also they must ensure that the machine is fit for purpose, maintained in
accordance with the guidance stated and all protection is fitted correctly and in
working condition.

1.2 NOTES TO THE OPERATION MANUAL

This operation manual contains important information on how to operate the
machine safely and correctly. Read this manual carefully to learn how to
operate your machine. Failure to do so could result in personal injury or
equipment damage. Consider this manual a permanent part of your machine.
Keep it with the machine at all times.

The following procedure bar indicates the start of a procedure. Any safety
warnings related to the procedure will be highlighted before the procedure.

The following notice bar indicates information considered important, but not
hazard related. This is a message related to property damage.

Follow all applicable safety regulations and recommendations in this manual

as appropriate to your machine.
Federal, State, National and Local laws and safety regulations must be
complied with at all times to prevent possible danger to person(s) or property
from accidents or harmful exposure.
Telestack will not be responsible for addressing environmental issues and/or
health and safety protection measures for the machine installation as a whole
and will bear no responsibility for ensuring compliance with any regulations

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 INTRODUCTION
and/or statutory requirements that may apply unless specifically included in
the contract of sale.

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 INTRODUCTION
1.3 INTENDED USE
The machine is typically used to mix the applications below, if you wish to use
it for any other material or applications contact your dealer or Telestack Ltd
directly.

 Cement-Treated Base
Cement-treated base is a mixture of aggregate and/or soils combined
with Portland cement and water. The mixture hardens after compaction
to form a durable paving material. CTB can be used to consume surplus
or contaminated materials and is widely used as a pavement base for
highways, parking areas, airports and storage areas.
 Cold-Mix Asphalt.
Cold mixes are made with emulsified asphalt and a blend of virgin
aggregate and/or RAP material. Cold mix has been commonly used as
patching material and on lesser trafficked service roads, but with new
mixing technology, it can be put right back on the roadways.
 Stabilisation.
Environmental clean-up projects generally require the stabilization or
encapsulation of hazardous materials like drill cuttings, contaminated
soils or fly ash. A pugmill mixing system is ideal for blending the
contaminated materials with a stabilizing agent. Once treated, stabilized
materials can be used as a pavement base or construction fill material.
 Additional applications include,
Road Base, Salt Blending and Lime Addition.

Without the pugmill fitted the machine is typically used in the applications
below, if you wish to use it for any other material or applications contact your
dealer or Telestack Ltd directly.

 Stockpiling from secondary crushers and screens.

 Stockpiling crushed stone, sand and gravel, mineral ores.
 Receiving crushed material and stockpiling safely over a quarry
face/bench.
 Working as part of a mobile system on short to medium term projects.

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 INTRODUCTION
 Ship and truck loading.

Never use the machine for any application that it has not been specifically
designed. This will place the machine outside our standard warranty
conditions and can render your warranty void.

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 INTRODUCTION
1.4 PROHIBITED USE
Operating the machine outside of its recommended range of applications or
for any use which it is not intended, will result in a loss of any guarantee.
Telestack cannot be held liable for any damage or injury resulting from such
misuse.
Use of this product in any way other than its intended use is prohibited.
Telestack will not be liable for any damage resulting from such use.

1.5 CONTACT DETAILS

Telestack Ltd
Bankmore Way East
Omagh
Co. Tyrone
BT79 0NZ

Tel: +44 (0) 2882251100

Fax: +44 (0) 2882252211
Email – [email protected]
Web: www.telestack.com

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 SAFETY

SAFETY

2. SAFETY ............................................................................................. 2-2

2.1. GENERAL SAFETY ........................................................................... 2-3
2.1.1 Safety Alert Symbol ......................................................................... 2-5
2.1.2 ANSI Multi-tier Hazard Classification System ................................ 2-5
2.1.3 California Proposition 65 Warning .................................................. 2-6
2.2. DESCRIPTION OF THE SAFETY SYMBOLS ................................... 2-7
2.3. SAFETY SIGNS ON YOUR MACHINE ............................................ 2-14
2.4. MACHINE FAMILIARISATION ........................................................ 2-18
2.5. LOCATION OF SAFETY SIGNS ON YOUR MACHINE .................. 2-19
2.6. PERSONAL SAFETY ...................................................................... 2-20
2.7. PERSONAL PROTECTIVE EQUIPMENT (P.P.E.) .......................... 2-21
2.8. WORK AREA SAFETY .................................................................... 2-22
2.9. EXCLUSION AREA AROUND THE MACHINE ............................... 2-23
2.10. ELECTRICAL SAFETY ................................................................... 2-24
2.11. HYDRAULIC SAFETY ..................................................................... 2-26
2.12. MAINTENANCE SAFETY ................................................................ 2-28
2.13. EXHAUST FUMES AND DUST ....................................................... 2-30
2.14. NOISE LEVELS ............................................................................... 2-30
2.15. LOCK OUT, TAG OUT, TRY-OUT PROCEDURE (LOTOTO)......... 2-31
2.16. PRE-START CHECKS ..................................................................... 2-34
2.17. MANOEUVRING ON SITE ............................................................... 2-35
2.18. TRANSPORTATION ........................................................................ 2-36
2.19. EMERGENCY SHUTDOWN / EMERGENCY STOPS ..................... 2-37

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 SAFETY
2. SAFETY
This safety section covers a wide variety of hazardous situations which are
given for general guidance only to assist the operator in installing, operating
and maintaining this machine. Where the machine is supplied for
incorporation into plant/equipment designed, supplied and located by others,
Telestack cannot be aware of particular hazards that may be present or might
occur and therefore accept no liability for addressing or resolving these
issues.

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 SAFETY
2.1. GENERAL SAFETY
As general safe working practice, the following procedures should be observed
at all times before and during operation of the machine.
Additional precautions may be necessary to ensure site safety and compliance
with local regulations. If you are in doubt ask for local Health and Safety
Regulations, never assume anything.

Please note that there is an ANSI multi-tier hazard classification system, this is
used throughout the manual to communicate the severity of danger posed at
any time.

 The Operation Manual must be read and understood before operating this
machine. Particular attention should be paid to the safety and warning
signs on the machine.
 Before the machine is started, It is the responsibility of the operator to
ensure that there is no-one on or around the machine or likely to be injured
when the machine starts.
 Always follow local lockout procedures when working on the machine.
 Ensure all control levers are in the neutral position before starting the
machine. It is recommended that all control levers are left in the neutral
position when stopping the machine to avoid inadvertent movement on the
next start-up.
 Check all electrical connections are fitted correctly and in good condition.
 Only use remote stop buttons in emergency situations or while carrying
out safety checks.
 Operate this machine with extreme care and only in accordance with the
methods specified in this manual.
 Do not start an engine in an enclosed space or in an area with inadequate
ventilation. Exhaust fumes from internal combustion engines can kill.
 The standards of maintenance, safety, and operation set out in this
manual should be considered minimum standards. Exercise extreme care
in the use and maintenance of your machine. Repairing and replacing
wearing parts in good time is always cheaper in the long term.

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 SAFETY
 Perform the daily safety checks and maintenance as detailed below before
operation of the machine. Inspect all ‘wear points’ and safety-related
devices regularly.
 Ensure only trained, competent personnel operate and maintain this
equipment
 Do not operate in high winds.
 Always wear the correct protective equipment.
 Do not wear baggy clothes or jewellery when operating this equipment.
 Only material that has been specified for use may be transferred, if
changing materials contact your dealer for advice.
 Check the condition of all guards daily; replace damaged or missing ones
immediately.
 Keep away from overhead electric lines where possible.
 Do not attempt to operate under the influence of alcohol or drugs.
 Do not transport or track the machine while in a raised position or with the
conveyor unfolded.
 Replace all damaged safety signs as soon as practicable.
 To minimise the risk of personnel injury, when working close to moving
parts ensure that they are stopped and the power supply is isolated before
commencement of the work. Site lockout procedures must be followed in
addition to the guidance given in the Telestack manual.

Telestack equipment is designed with the safety of all personnel in mind. Never
attempt to change, modify, eliminate or bypass any of the safety devices
installed.

Guards, covers and shields installed around moving parts are designed and
fitted to prevent accidental injury to operators and other personnel.
THE MACHINE MUST NOT BE OPERATED WITHOUT THE GUARDING IN
PLACE. Make sure that everyone working on or near this equipment is familiar
with the relevant safety precautions.

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 SAFETY
2.1.1 Safety Alert Symbol

The safety alert symbol is used throughout the manual to alert you to the
potential risk of personal injury. Always obey this symbol and the specific
message that follows.

2.1.2 ANSI Multi-tier Hazard Classification System

A multi-tier hazard classification system is used to alert you to potential
personal injury hazards.
Signal words used with the safety alert symbol indicate a specific level of
severity of the potential hazard. Signal words used without the safety alert
symbol relate to property damage and protection only. All are used as
attention-getting devices throughout this manual as well as on ANSI type
decals and labels fixed to the machine.

DANGER Indicates a hazardous situation that, if not avoided, will result in

death or serious injury. (Contains white letters on red background).

WARNING This indicates a hazardous situation that, if not avoided, could

result in death or serious injury. (Contains black letters on orange
background).

CAUTION This indicates a hazardous situation which, if not avoided, could

result in minor or moderate injury. (Contains black letters on yellow
background).

CAUTION without the safety symbol is used for practices that could result in
damage to the machine if not observed. (Contains black letters on yellow
background).
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 SAFETY
2.1.3 California Proposition 65 Warning

Operating, servicing and maintaining this equipment can expose you to

chemicals including engine exhaust, carbon monoxide, phthalates, and lead,
which are known to the State of California to cause cancer and birth defects or
other reproductive harm.
These chemicals can be emitted from or contained in other various parts and
systems, fluids and some component wear by-products. To minimize
exposure, avoid breathing exhaust, do not idle the engine except as
necessary, service your equipment and vehicle in a well-ventilated area and
wear gloves or wash your hands frequently when performing maintenance on
your equipment or after operation.

For more information go to

www.P65Warnings.ca.gov

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 SAFETY
2.2. DESCRIPTION OF THE SAFETY SYMBOLS

Symbol Description
Electrocution hazard
Electrical shock/ electrocution from
conveyor to power line contact.

Stay sufficient distances from electrical

power lines.

Entanglement hazard
Entanglement in belt drive or conveyor.

Entanglement hazard
Arm entanglement in belt drive.

Stay clear of conveyor.

Install covers and guards before

operation.

Turn machine off and remove the key.

Lockout machine.

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 SAFETY
Symbol Description
Read and understand operations
manual before using equipment.

Injection hazard
Skin injection from high pressure fluid.

Use cardboard or wood to check for

leaks.

Crush hazard
Crushed foot from support leg.

Stay clear of support legs and jacks.

Falling material hazard

Struck from falling or flying material.

Stay clear of hopper during operation.

Fall Hazard
Falling from a height.

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 SAFETY
Symbol Description
Do not climb onto the machine.

Use personnel lift to reach high places.

Check tyre pressures prior to transport.

Check wheel nut torque. Recheck wheel

nut torque every 150 miles (200km).

Connect and check braking system.

Crush hazard
Crushing of fingers or hand. Force
applied in one direction.

Keep hands clear of openings.

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Symbol Description
Hand entanglement in pulley/ winch

Keep hands clear of moving

components

Electrocution hazard
Electric shock/ electrocution.

Hearing hazard
Loss or degradation of hearing.

Wear hearing personal protective

equipment.

Explosion hazard
Explosion during an operation or service
procedure.

Burn hazard
Burns from corrosive material.

Keep open flame away.

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 SAFETY
Symbol Description
Emergency Stop
Press to engage, twist to reset.

Flying Material Hazard

Face struck by flying objects

Wear eye personal protective equipment

Crush Hazard
Crush from overhead impact.

Unauthorized persons prohibited.

Flying Material Hazard

Struck by flying material.

Do not stand on machine while in

operation.

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 SAFETY
Symbol Description
Inhalation Hazard
Inhalation of poisonous/ toxic fumes or
dust.

Use dust suppression (water spray) or

dust collection (filter) during operation of
this equipment.

Wear respiratory personal protective

equipment.

Crush Hazard
Crush from track machine run over

Stay clear of track machine.

Crush Hazard
Crush from wheel machine run over.

Stay clear of wheeled machine.

Explosion Hazard
Battery Explosion.

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 SAFETY
Symbol Description
Keep welding sparks away from the
battery area.

Burn Hazard
Burn from hot surface or liquid

Stay clear of hot surface or liquid.

Impact Hazard
Impact from spring loaded door.

Stay clear of spring loaded door while

opening.

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 SAFETY
2.3. SAFETY SIGNS ON YOUR MACHINE

The table below shows the safety signs that are on your machine.

ITEM ANSI ISO

1

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ITEM ANSI ISO
5

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 SAFETY
ITEM ANSI ISO
9

10

11

12

13

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 SAFETY
ITEM ANSI ISO
14

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 SAFETY
2.4. MACHINE FAMILIARISATION

1
2

7 3

5
6

1. Incline Conveyor
2. Pugmill
3. Front Telescopics
4. Canopy, Engine, Exhaust, Hydraulic Tank, Fuel Tank
5. Tracks
6. Jacklegs
7. Hopper, Feed Conveyor

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 SAFETY
2.5. LOCATION OF SAFETY SIGNS ON YOUR MACHINE
The images below shows the location of the safety signs that are on your
machine. Each number refers to the table shown in Safety Signs on your
Machine.

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 SAFETY
2.6. PERSONAL SAFETY
Operators must be trained in the correct and safe use of all equipment.

Before operation the operator(s) must:

• Have received specific and adequate training in the task to be carried
out.
• Have read and understood the operations manual and the Safety Signs
in this manual and around the machine(s).
• Knows the location and function of controls and safety features such as
emergency stop buttons and safety guards.
• Be aware of all moving parts of the machine.

Any work on the machine must be carried out by trained and authorised
personnel only. Statutory minimum age limits must be observed.
Work on the electrical system must be carried out only by a skilled electrician
or by instructed persons under the supervision and guidance of a skilled
electrician and in accordance with electrical engineering rules and regulations.
Work on the hydraulic system must be carried out only by personnel with
special knowledge and experience of hydraulic equipment.

Maintenance and repairs should only be carried out on this machine when the
operator user has completed the lock out, tag out, try out procedure.
Some maintenance procedures do require the conveyor to be running to
complete. On such occasion, remember to keep tools, test equipment and all
other parts of your body well away from the moving parts. Loose or baggy
clothing can get caught in running machinery.
For reasons of safety, long hair must be tied back or otherwise secured,
garments must be close fitting and no jewellery such as rings may be worn.
Injury may result from being caught up in the machinery or from rings catching
on moving parts.

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 SAFETY
2.7. PERSONAL PROTECTIVE EQUIPMENT (P.P.E.)
P.P.E. is equipment that will protect the user against health or safety risks at
work. It can include items such as a Hard Hat, Safety Glasses, Ear Protection,
Dust Mask, close fitting Overalls, Steel Toed Boots and a High Visibility Vest.
Always wear correctly fitting (EN/ANSI approved) protective clothing.

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 SAFETY
2.8. WORK AREA SAFETY
Operators must have received specific training in all operation and
maintenance tasks required for the safe operation and service of the machine.
Operators must know the location and correct operation of all controls and
safety components such as emergency stop buttons and isolator switches.
Operators must be aware of all moving parts on the machine.
Be alert and wary around any pressurized system, hydraulic or pneumatic.
High pressure oils and gases are very dangerous.
Keep the work area as neat and as clean as practical. Keep your equipment
clean and free of dirt and grease. Replace defective parts straight away.
Keep all product safety signs clean and legible. Replace any damaged or
missing safety signs as soon as possible.
Maintenance platforms should only be used when the machine is turned off,
unless to perform specific maintenance procedures which require the machine
to be operational. Always check that maintenance platforms and handrails are
fully secured in place before using.
Do not smoke or allow smoking near flammable fuels or solvents. Use non-
flammable solvents for cleaning parts and equipment. Know where fire
extinguishers and other fire suppression equipment are located and learn how
to use them.
Avoid electrical and static sparks and any open flame while handling fuel,
electrolytes for batteries, hydraulic fluids or coolants.

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 SAFETY
2.9. EXCLUSION AREA AROUND THE MACHINE
Under normal working conditions, no-one is permitted to enter the areas shown
in the plan view below before the machine is powered down and locked out.
The exclusion zone at the discharge end will extend to a 5m radius before the
formation of a stockpile if the machine is used at full discharge height.

Recommended Access to Control Panel for

3m Exclusion Zone Operator with P.P.E. Recommended
5m Exclusion Zone
at Discharge End

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 SAFETY
2.10. ELECTRICAL SAFETY
The equipment detailed in this manual operates at 12 Volts DC or 380-690 Volts
AC or both, and local safety procedures must be strictly adhered to. Serious
injury can result from the misuse or the incorrect installation of electrical
equipment and it is imperative that local electrical regulations are followed when
drawing up the site safe working practices for the machine. As general safe
working practice, the following procedures are given as guidance and should
be observed at all times when using or carrying out electrical work on the
machine. Again, these are minimum standards only.

 Electrical work must only be carried out by a qualified electrician. What

constitutes qualification is normally controlled by local regulations.
 In addition, work on the electrical system must only be carried out by
individuals with a full understanding of the electrical system.
 Special care should be taken when disconnecting, replacing or charging
batteries.
 Ensure batteries are disconnected and reconnected correctly.
 Note: Inadvertent short circuiting across the battery terminals can cause
the battery to explode.
 Always disconnect battery leads before carrying out any maintenance to
the electrical system. To avoid damage to electrical components, always
isolate the batteries and electrical system when welding on the machine
frame.
 Batteries contain sulphuric acid, can cause severe burns. Avoid contact
with the skin, eyes or clothing. Battery charging produces explosive
gases, keep the battery area well ventilated at all times and do not allow
sparks or naked flames nearby.
 Regular inspections of all the electrical equipment must be carried out.
Any damaged cables, components or loose connections must be repaired
before continuing to operate the machine. Use only the manufacturer’s
genuine replacement parts when performing maintenance work.
 Use only original fuses with the specified current rating

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 Modification to any part of the electrical system on this machine can cause
the machine to operate in an unsafe manner. No such modifications
should be carried out without prior written permission from Telestack Ltd.
 Unauthorised modifications will invalidate the warranty conditions of the
electrical system. (Conditions available on request).

See Electrical Schematic, Section 13 for further details on the system.

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 SAFETY
2.11. HYDRAULIC SAFETY
 Only persons having special knowledge and experience in hydraulic
systems may carry out work on hydraulic equipment. Never disable or
alter any hydraulic circuit or component without consulting with
Telestack.
 Relieve all pressure in the hydraulic system by returning all controls to
the neutral position.
 Check all lines, hoses and screwed connections regularly for leaks and
obvious damage. Splashed oil may cause injury and fire. Repair any
damage immediately. Repair any defects found before continuing to
operate the machine
 Depressurise all system sections and pressure pipes before carrying out
any repair work.
 Hydraulic fluid under pressure can penetrate the skin or eyes causing
serious injury. It is important to note that a high velocity stream of fluid
capable of causing severe injury may not be visible. Always use a
flashlight or a piece of cardboard to check for leaks. Never use your hand.
The consequences of having fluid is injected under the skin are serious.
If this happens, it must be surgically removed or gangrene will result.
Never use an open flame to check for leaks. Wear personal protective
equipment including goggles and gloves.
 Hydraulic oil and equipment can become hot when working. There is a
high risk of a burn hazard.
A minimum cooling down time of 30 minutes must be allowed before any
maintenance activities are carried out on the hydraulic system. A
minimum cooling down time of 90 minutes must be allowed before any
maintenance activities are carried out on the engine and powerunit. The
cool down times reduce the risk of a burn hazard. Wear gloves when
working with hydraulic and pneumatic equipment.
 Always practice extreme cleanliness when servicing hydraulic
components. For continued system reliability, it is imperative that no
foreign material is introduced to the hydraulic system.

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 Do not exceed safe limits. Never set a pressure relief valve to a pressure
higher than that set at the factory.

Trapped air can become compressed when the hydraulic system is started,
causing sudden movements of the machine, which can lead to problems
resulting in injury or damage. Due to the risks involved of damage to personal
and equipment the hydraulic cylinders on Telestack, equipment should be
charged on a regular basis. This is also required when there has been
maintenance carried out on the hydraulic system and prior to the cylinder
function being required when there has been a prolonged period of no use. This
is particularly important on conveyor fold over cylinders.

1. Remove the rod end pin from the cylinder and support the cylinder in such
a way that the rod can extend fully and retract fully without striking any
part of the machine or other objects.
2. With the engine running at a fast idle only, using the control lever fully
extend and retract the cylinder.
3. Repeat three times.
4. Reconnect the rod end to the link using the pin and secure.

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 SAFETY
2.12. MAINTENANCE SAFETY
 Understand the service procedures before doing work.
 Whenever maintenance is being carried out a minimum of 2 people
should be present at all times. NEVER WORK ALONE.
 Keep working area clean and dry.
 Keep hands, feet and clothing clear of nip-points.
 Operate controls to relieve pressure.
 Stop the engine, implement the lockout, tag out and try out procedure.
 Allow the machinery to cool before carrying out any maintenance.
 Keep all parts in good condition and are properly installed. Fix any
damage found immediately.
 Never attempt repairs or adjustments to the machine while it is running
unless specified to do so.
 Before carrying out any maintenance, relieve all hydraulic pressure by
returning the controls to the neutral position and secure all hydraulically
operated attachments with pins provided.
 Disconnect the battery ground cable before making adjustments on
electrical systems or welding on machinery.
 Only remove guards needed to carry out the maintenance task. Never
leave guards off or access doors open when unattended.
 When working beneath raised equipment, always use blocks, jack-
stands or other rigid and stable supports. Never work under unsupported
equipment.
 When working at height make sure you take all necessary precautions in
line with local regulations and use approved PPE.
 Never allow unqualified or untrained personnel to attempt to remove or
replace any part of the machine, or anyone to remove large or heavy
components without adequate lifting equipment.
 Diesel fuel is highly flammable. Never remove the filler cap, or refuel,
with the engine running. Never add gasoline or any other fuels mixed to
diesel because of increased fire or explosion risks. Do not carry out
maintenance on the fuel system near naked lights or sources of sparks,
such as welding equipment or whilst smoking.

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 After maintenance, tighten all bolts, fittings and connections. Install all
guards, covers and shields. Replace or repair any damaged ones.
 Refill and recharge pressure systems with recommended fluids.
 Start the engine and check for leaks. Operate all controls and make sure
the machine is functioning properly. After testing, shut down, check the
work you performed. Recheck all fluid levels before releasing machine
for operation.

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 SAFETY
2.13. EXHAUST FUMES AND DUST
Death, serious injury or delayed lung disease may result from breathing dusts
that are generated when certain hazardous materials are being conveyed with
this equipment.
Always operate engines outside or in a well-ventilated area.
Before starting the machine in enclosed areas, make sure that there is
sufficient ventilation.
Dust found on the machine or produced during work on the machine should
be removed by extraction, not blowing. Dust waste should be dampened,
placed in a sealed container and marked, to ensure safe disposal.
Use approved respiratory protection, as required by Federal, State and Local
safety and health regulations.
Ensure operators wear a suitable face mask where exposed to possible
harmful effects of air pollution of any kind.

2.14. NOISE LEVELS

Always ensure that operators wear ear defenders at all times when the
machine is operating.
Not wearing these ay cause loss or degradation of hearing over a period of
time.

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 SAFETY
2.15. LOCK OUT, TAG OUT, TRY-OUT PROCEDURE (LOTOTO)

What is Lockout, Tagout, Try-out?

Lockout, Tagout, Try-out, is a planned safety procedure which involves turning
off the energy supply whilst maintenance work or repairs are being carried
out.
These procedures are to be followed every time a machine is to be cleaned,
maintained, adjusted or repaired.

Why do it?
This procedure protects the operator(s) from the dangers of uncontrolled,
unplanned release of energy (movement of equipment or materials; electrical,
hydraulic or pneumatic).

Never give your key to anyone else and where more than one person is
working on the equipment they must fit their lock also.

Depending on the type of machine, there may still be several kinds of energy
remaining after the power is turned off. The written lock-out procedure should
have a complete list of all these secondary energy sources. Secondary energy
sources may be hydraulic (fluid under pressure), pneumatic (air under
pressure), kinetic (force of moving parts) and/ or potential (force contained in
weights that have been raised). / or potential (force contained in weights that
have been raised).

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1. Turn off the engine at the control panel and remove key.
2. After 40 seconds, rotate the isolator switch from position 1 to position 2.

1
2

3. Fit the lock out multi-hasp (3) and unique padlock (4) on the isolator and
keep the key to make sure no one can remove your lock and turn the
power back on.
4. Place a tag (5) on the lock that identifies you (name, photograph,
telephone number) as well as the date and time you locked it out.
5. Release any stored energy from the system, such as hydraulic fluid
under pressure.

6. Try to start or activate the machine to make sure the power is off.
Don’t forget to return all switches / buttons again after attempting to start
the machine.

Lock it Out – Tag it Out – Try it Out

IT’S NOT LOCKED OUT UNTIL YOU’VE TRIED IT OUT!

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 SAFETY
Restoring the machine to normal operations
 After maintenance is completed and the machine is ready for normal
operation.
 Check the area around the machine to ensure that no one is at risk.
 Remove all tools from the machine and replace all guards.
 Remove all lockout or tagout devices.
 Warn others that the lockout or tagout devices has been removed and
before starting the machine.
 Start the machine and proceed with your work.

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2.16. PRE-START CHECKS
The following checks must be carried before commencement of work with the
machine every day. These should be considered a minimum, site operating
procedures and local regulations may well dictate further checks.

 Visually check, verify and record that all guards, covers and doors are in
position and secure.
 Make sure all warning and safety signs are clean and legible.
 Check, test and record that all safety equipment, alarms and interlocks are
operative.
 Check conveyor belts for damage and fraying.
 Visually check the condition of all hydraulic hoses and connectors for
fraying and leaks.
 Check the engine oil level and top up if necessary.
 Check the fuel oil level and top up if necessary.
 Check the hydraulic oil level and top up if necessary. The reason for a low
level should also be found.
 Visually check all the pins, bolts and fasteners on the machine are present
and correctly fitted.
 Check for material build-up on the conveyor frame which may become
dislodged in operation causing a hazard. See the section on stability.
 It is important that the machine is not started up with large amounts of
material lodged in the feed boot which may become dislodged and cause
an instantaneous increase in mass traveling up the conveyor which may
lead to an unstable machine. Material lodged in the feed boot must be
cleared prior to operating the machine.
 Material lodged in the pugmill must be cleared prior to operating the
machine.
 Perform a visual check on all exposed electrical equipment, paying
particular attention to apparent damage to cables or connectors.

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2.17. MANOEUVRING ON SITE
 Before manoeuvring machine, ensure that all personnel are at a safe
distance, and that there is sufficient clearance around the machine to
move.
 Never track this machine when the conveyor is in an elevated position.
The conveyor should be lowered and the pugmill in the transport position
before manoeuvring.
 Do not travel on grades or ramps that are wet, muddy, slippery, or are
likely to have poor surface condition along any part of the intended route.
 Caution must be exercised when moving machinery on soft or uneven
surfaces. Surface must be prepared and the travel path free from
hazards such as pot holes and bumps.
 It is recommended that machines are not driven or turned along a slope.
 To minimise the risk of overbalancing the machines should be only moved
vertically up or down shallow slopes.
 Stop the machine for 20 minutes after tracking it continuously for 20
minutes, to allow the components to cool down.
 Before moving the machine, ensure the siren and beacon are working
correctly and that there is no-one on or around the machine or likely to be
injured when the machine commences moving.
 Always adjust your speed to an appropriate level when travelling in uneven
terrain
 When working with or moving the machine, always maintain a safe
distance from overhead electric lines. If work is to be carried out close to
overhead lines, the working equipment must be kept at least the minimum
recommended distance away from them. Know and practice the
prescribed safety distances from high voltage cables as governed by local
regulations. If your machine does come into contact with a live cable, the
cable must be isolated before continuing to operate the machine. Warn
others against approaching and touching the machine before the area is
made safe. Investigate and report all incidents to the site manager.
 Read the Operation Section 4.5, Manoeuvring on Site for more details.

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2.18. TRANSPORTATION

Low Loader

Containers

 Use only the appropriate means of transport and lifting gear of adequate
capacity.
 The machine should be secured when transporting using the welded
securing eyes on the chassis and conveyor mid-section sides.

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2.19. EMERGENCY SHUTDOWN / EMERGENCY STOPS
Activation of any of the emergency stop pushbuttons located around the
machine, will cause the machine to shut down.
Before the machine can be restarted, the button must be released and the
control panel reset.
It is not recommended that the emergency stop function is used to stop the
machine under normal conditions as the primary function is to stop the machine
as quickly as possible without regard to the ease of restarting of the machine.

Activation of the engine kill button on the handheld will cause the engine to shut
down. This engine kill button has the same function as an emergency stop but is
not classed as such as the circuit is not fail safe.

Daily testing of the emergency shutdown system must be carried out.

This machine is fitted with 2 emergency stop buttons and the engine kill button on
the handset.

Engine
Kill Button

Emergency Stop Buttons Locations

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 INSTALLATION

INSTALLATION

3. INSTALLATION ........................................................................................... 2
3.1 REMOVING YOUR MACHINE FROM THR TRANSPORT METHOD ....... 3
3.1.1 REMOVING FROM A LOW LOADER .................................................... 4
3.1.2 REMOVING FROM A CONTAINER ....................................................... 5
3.2 INITIAL INSPECTION ............................................................................... 9
3.3 WORKING LOCATION ............................................................................. 9
3.4 PRE-INSTALLATION CHECKS .............................................................. 10
3.5 EQUIPMENT THAT MAY BE REQUIRED FOR INSTALLATION ........... 11
3.6 INSTALLATION SEQUENCE – LOW LOADER ..................................... 14
3.7 INSTALLATION SEQUENCE - CONTAINER ......................................... 16
3.8 FINAL CHECK LIST ................................................................................ 29
3.9 REMOVING THE PUGMILL .................................................................... 30

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 INSTALLATION
3. INSTALLATION
Your machine will either arrive on a Low Loader or packed into a Container.
This section will guide you through how to unload, install and setup of your
machine safely.

Low Loader

Containers

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 INSTALLATION
3.1 REMOVING YOUR MACHINE FROM THR TRANSPORT METHOD

All personnel who operate this equipment must read and understand the
operating manual. Failure to do so may damage the machine and possibly
cause serious injury to yourself or others.
Extreme caution is required when removing your machine from the chosen
transport method.
The following procedures will provide information on how to unload the
machine without causing any damage to the machine.

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 INSTALLATION
3.1.1 REMOVING FROM A LOW LOADER

Wear personal protective equipment.

Ensure all personnel are clear from the machine.

Removing the fastenings securing the machine and any loose items from a
trailer is the responsibility of the haulage contractor.
The head section of the conveyor may be raised to allow adequate ground
clearance.

1. Observe all safety warnings.

2. Lower ramps of the low loader
3. Remove all chains/ties that are holding the machine in place.
When carrying out this operation be careful that the machine doesn’t
become unstable.
4. Attach the handset. See Operation, Section 4.
5. Start the machine. See Operation, Section 4.
6. Make sure there is no-one with in the exclusion zone. See Safety,
Section 2.
7. At low RPM, slowly start to track the machine of the loader.

The RPM for machines fitted with a constant speed engine must be off
idle before the machine will track.
8. The conveyor can be raised slightly to aid removal from a low loader by
using the raise/lower head section control lever.

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 INSTALLATION
3.1.2 REMOVING FROM A CONTAINER

Wear personal protective equipment.

Crush Hazard.
Ensure all personnel are clear from the area that will be used to unload the
machine.
When maneuvering your machine out of the container, make sure you stand
well clear of the machine but in a position to see any obstacles or hazards.

It is mandatory to have a second person present when removing the machine

from the container.
Check that the components can be removed safely without causing any
damage.
Containers can be unloaded on the ground with a forklift or telehandler to
facilitate.
The toes of the forklift or telehandler should be moved slowly into the
container and the toes of the forklift or telehandler should be evenly space to
take the load safely.
Attach a chain to the forklift or telehandler mast and thread through tow bar
eye.

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 INSTALLATION
Gently lift each component about 50mm of the floor of the container and drag
from the container.
Do not use chains to lift the components out of container. There is serious risk
of damage to each component. Chain lifts are not stable and each component
may move side wards.
Ensure each component is supported at all times.

The machine is packed so that movement is minimalized during shipment.

However any transport damage should be notified to Telestack immediately.

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 INSTALLATION
Container 1

1. Tracks are bolted together for containerisation. Remove the tracks and
set clear of the container. Separate tracks for fitting later.

2. Using a telehandler, gently raise the back of the machine off the
container floor. Attach chains to aid removal and drag the machine out
so that straps can be attached with a crane to support the load when
removing the machine free from the container.

Timber in place
for removal

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 INSTALLATION

Strap

Strap

Track Transport Brackets Rear Transport

Brackets and Aids

Container 2

3. Remove the incline conveyor containing the telescopic and pugmill.

4. Remove the telescopic and pugmill by removing the transport aids and
straps and then set them aside for assembly later.

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 INSTALLATION
3.2 INITIAL INSPECTION
Thoroughly check for any damage that might have occurred during transport.
Record, photograph and report any damage found.
Check all loose parts and check the packing box to ensure all items are
present.

3.3 WORKING LOCATION

Ensure there is enough space available around the machine to enable easy
setup, maintenance and repairs.

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 INSTALLATION
3.4 PRE-INSTALLATION CHECKS

1. The components must be placed on solid and level surface capable of

carrying the machine‘s weight.
2. Visually check, verify and record that all guards, covers and doors are in
position and secure.
3. Visually check all the pins, bolts and fasteners on the machine are present.
4. Remove any components stacked for transport purposes and items
stored the feedboot and belt.
5. Make sure all warning and safety signs are clean and legible.
6. Check conveyor belt for damage and fraying.
7. Visually check the condition of all hydraulic hoses and connectors for
fraying and leaks.
8. Check the engine oil and fuel level and top up if necessary.
9. Check the hydraulic oil level and top up if necessary. The reason for a low
level should also be found.
10. Perform a visual check on all exposed electrical equipment, paying
particular attention to apparent damage to cables or connectors.

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 INSTALLATION
3.5 EQUIPMENT THAT MAY BE REQUIRED FOR INSTALLATION

Item Image Description

Suitable Mobile Crane will be required at

all times during the build (Only
1
Authorised Personnel should use a
crane).

A lifting contractor to recommend crane size based on

estimated machine weights and dimensions
1 x Telescopic Handler to be made
available for the duration of the build
2
operator to be included in the assembly
team.

A lifting contractor to recommend crane size based on

estimated machine weights and dimensions

2 x 10mm to 46mm Socket Set, 3/8

3
Drive

2 x 10mm to 46mm Spanner Set

½” and ¾” Impact Guns (Electric or Air)
4 with Genset or Air Compressor.
An Air Line or Extension Lead will also
be needed to power the gun.

5 14lb Sledge Hammer

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 INSTALLATION

Sockets to suit the gun are also required

6 – 17, 19, 22, 24, 27, 30, 32, 36, 41,
46mm should be available.

Magnetic Drill with 12, 14, 16, 18, 20

7
and 22mm Sluggers Available

Access to an Engineers Toolkit

8
(Hammer, Pliers, Allen Keys etc.)

9 2 x 3 Tonne Chain Block

4 x 10 Tonne Lifting Slings to help lift

10
component parts during installation.

11 2 x 12” Step Ladders

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 INSTALLATION
Quantity of timber spares/blocks. (To set
under sections to aid assembly and to
keep sections clear of the floor)
This is very important as the conveyor
12 section needs to be set on the ground
on wood.
Not possible to set down without a good
selection of wood, railway sleepers,
planks, etc are all ok.

13 Suitable Lifting Shackles

Cherry Picker/Genie Required

Throughout the duration of the build.
14 Access is required at height. If this isn’t
available a man cage should be
supplied for the Telehandler.

4” and 9” Angle Grinder complete with

15
cutting and grinding discs.

2 x Heavy lifting chains required for

16 assembly, a 4 leg chain, suitable for the
component

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 INSTALLATION
3.6 INSTALLATION SEQUENCE – LOW LOADER

Wear personal protective equipment.

Do not climb onto machine components always use a suitable platform.

1. Ensure the hopper extensions are fitted into the working position with the
fittings provided before operation.

2. To lift the hopper extensions into position, fix a lifting hook or similar into
the lifting eyes and lift up into the working position using a telescopic
handler or similar lifting device. Fix the side extensions before the rear
and front extensions.

3. Bolt each extension to the hopper. Once all hopper extensions are
raised bolt extensions to each other using the fittings provided.

4. Fit the hopper splitter using the fittings provided.

Rear
Extensions

Side Rear
Extensions Extensions

Bolt Locations
3 x Bolts on sides, front and rear

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 INSTALLATION

Bolt Locations
2 x Bolts

Bolt Locations Hopper

2 x Bolts in each corner Splitter

5. Using the control levers manoeuvre the pugmill into the working position
and adjust the working angle. For more details see Operation, Section 4.

6. Fit both sides of the inlet chute using the fittings provided.

Inlet Chute
Side

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 INSTALLATION
3.7 INSTALLATION SEQUENCE - CONTAINER
This is an installation sequence guide and is not a comprehensive step by
step instruction guide. Assemble the sections as shown.

Wear personal protective equipment.

Do not climb onto machine components always use a suitable platform.

1. Raise the machine and remove the transport brackets.

Strap

Strap

Track Transport Brackets Rear Transport

Brackets and Aids

2. Fit the tracks then lower the machine to the ground.

Tracks

3. Connect all hydraulic hoses, secure with fitted clamps, ensure neat
routing of hoses to avoid abrasive contact.

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 INSTALLATION
4. Pin the telescopic on to the chassis.

Telescopic

5. Connect all hydraulic hoses, secure with fitted clamps, ensure neat
routing of hoses to avoid abrasive contact.

6. Raise the telescopic and insert a trestle to support the conveyor.

700mm
2000mm

Trestle

7. Remove the rear transport legs and aids then lower the jacklegs for
support.

Jacklegs

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 INSTALLATION
8. Locate the incline conveyor.

9. Lift the incline tail section into the working position and pin to secure.

10. Using the 4 lifting points on the incline conveyor and strapping the tail
section lift the complete incline conveyor and manoeuvre into position.

Lifting Points Strap

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 INSTALLATION
11. Bolt and pin the incline conveyor using the fittings provided.

Bolt
Location

Pin
Location

Pin
Location

12. Release the cranes supporting the incline conveyor.

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 INSTALLATION
13. Set the pugmill on a raise platform. Ensure the platform is capable of
supporting the weight of the pugmill. Minimum 2.5 Tonne, 2.2 US Ton.

14. Raise the jacklegs and slowly manoeuvre the incline conveyor over the
pugmill.

570mm

Platform

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 INSTALLATION
15. Fit the pugmill linkage using the fittings provided. Use the following
images to aid installation.

3
2

4 5 6 7 8

1 2

4 5 6 7

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 INSTALLATION
16. Fit the feedboot pugmill chute and spray bar using the fittings provided.

Chute and
Spray Bar

17. Slowly reverse the pugmill clear of the platform so the rubber chute can
be fitted with the fittings provided.

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 INSTALLATION
18. Ensure the hopper extensions are fitted into the working position with the
fittings provided before operation.

19. To lift the hopper extensions into position, fix a lifting hook or similar into
the lifting eyes and lift up into the working position using a telescopic
handler or similar lifting device. Fix the side extensions before the rear
and front extensions.

20. Bolt each extension to the hopper. Once all hopper extensions are
raised bolt extensions to each other using the fittings provided.
Rear
21. Fit the hopper splitter using the fittings provided. Extensions

Side Rear
Extensions Extensions

Bolt Locations Bolt Locations

3 x Bolts on sides, front and rear 2 x Bolts

Bolt Locations Hopper

2 x Bolts in each corner Splitter

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 INSTALLATION
22. Fit the variable gate using the fittings provided.

Variable
Gate

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 INSTALLATION
23. Fit the cement chute, rubber and guards using the fittings provided.

Cement
Chute

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 INSTALLATION
24. Fit the cement hopper frame and cement hopper using the fittings
provided.

Cement
Hopper

Cement
Hopper
Frame

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 INSTALLATION
25. Fit the platform and the walkway ladder using the fittings provided.

Walkway
Ladder

Platform

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 INSTALLATION
26. Using the control levers manoeuvre the pugmill into the working position
and adjust the working angle. For more details see Operation, Section 4.

27. Fit both sides of the inlet chute using the fittings provided.

Inlet Chute
Side

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 INSTALLATION
3.8 FINAL CHECK LIST

1. The machine must be placed on solid and level surface capable of

carrying the machine‘s weight.
2. Visually check, verify and record that all guards, covers and doors are in
position and secure.
3. Visually check all the pins, bolts and fasteners on the machine are present.
4. Remove any tools and excess bolts from the conveyor and chassis.
5. Make sure all warning and safety signs are clean and legible.
6. Check conveyor belt for damage and fraying.
7. Check the engine oil and fuel level and top up if necessary.
8. Check the hydraulic oil level and top up if necessary. The reason for a low
level should also be found.
9. Perform a visual check on all exposed electrical equipment, paying
particular attention to apparent damage to cables or connectors.

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 INSTALLATION
3.9 REMOVING THE PUGMILL

1. Remove the rubber chute.

2. Track the pugmill over a raise platform. Ensure the platform is capable of
supporting the weight of the pugmill. Minimum 2.5 Tonne, 2.2 US Ton.

570mm

Platform

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 INSTALLATION
3. Remove the pugmill linkage.

3
2

4 5 6 7 8

4. Slowly track the machine from the pugmill.

570mm

Platform

The pugmill feature will need to be deactivated on the control panel. See
Deactivating the Pugmill Feature in the Operation Section.

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 OPERATION

OPERATIONS

4. OPERATION OF YOUR MACHINE ................................................. 4-4

4.1. CONTROL PANEL ..........................................................................4-5
4.2. TELEMIX AND TELEMIX AUTO MACHINE ....................................4-8
4.2.1 Enabling Telemix Auto on the machine .......................................4-8
4.2.2 Configuring Telemix Auto .............................................................4-8
4.2.3 Operating Telemix Auto .................................................................4-9
4.3. SCREEN OVERVIEW .................................................................... 4-10
4.3.1 Screen Layout and Elements ...................................................... 4-10
4.3.2 Screen Summary .......................................................................... 4-13
4.4. MAIN SCREEN – TELEMIX........................................................... 4-17
4.4.1 Buttons.......................................................................................... 4-19
4.4.2 Engine Speed ............................................................................... 4-21
4.4.3 Machine Interlock ......................................................................... 4-22
4.4.4 Fuel Level...................................................................................... 4-23
4.4.5 Hours of Engine/Motor Use ......................................................... 4-24
4.4.6 Countdowns ................................................................................. 4-25
4.4.7 Engine Aftertreatment Information ............................................. 4-26
4.5 ENGINE SCREEN ......................................................................... 4-27
4.5.1 Monitoring Data ............................................................................ 4-28
4.5.2 Buttons.......................................................................................... 4-29
4.6 TRACKING RADIO SCREEN ........................................................ 4-30
4.6.1 Buttons.......................................................................................... 4-32
4.6.2 Large Handset Image ................................................................... 4-34
4.6.3 Large Handset Auxiliary Mode .................................................... 4-35
4.6.4 Countdowns ................................................................................. 4-36
4.6.5 Handset Connection Mode .......................................................... 4-37
4.6.6 Remote Operation Indicator ........................................................ 4-38
4.6.7 Conveyor Limits ........................................................................... 4-39
4.6.8 Engine Speed ............................................................................... 4-40
4.7 PRIMARY MACHINE SCREEN - TELEMIX .................................. 4-41
4.7.1 Buttons.......................................................................................... 4-42
4.7.2 Arrows ........................................................................................... 4-44
4.7.3 Conveyor/Feeder Animations ..................................................... 4-45
4.8 SECONDARY MACHINE SCREEN ............................................... 4-46
4.8.1 Buttons.......................................................................................... 4-47
4.9 SETTINGS SCREEN ..................................................................... 4-49
4.9.1 Buttons.......................................................................................... 4-50
4.10 ACTIVATING/DEACTIVATING THE PUGMILL FEATURE .......... 4-52
4.11 MACHINE SETTINGS SCREEN .................................................... 4-54
4.12 INTERLOCK SCREEN .................................................................. 4-55

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 OPERATION
4.12.1 Buttons.......................................................................................... 4-56
4.12.2 Link Status Indicators .................................................................. 4-58
4.13 ERROR SCREENS (TELEMIX) ..................................................... 4-59
4.14 ERROR SCREENS (TELEMIX AUTO) .......................................... 4-60
4.15 STATUS AND WARNING INDICATORS ...................................... 4-61
4.15.1 Engine Indicators ......................................................................... 4-62
4.15.2 Hydraulic Indicators ..................................................................... 4-63
4.15.3 Exhaust Aftertreatment Indicators ............................................. 4-64
4.15.4 Other Indicators ........................................................................... 4-65
4.15.5 Telemix Auto Indicators............................................................... 4-66
4.16 MAIN SCREEN – TELEMIX AUTO ............................................... 4-67
4.16.1 Buttons.......................................................................................... 4-68
4.17 TELEMIX AUTO SCREEN............................................................. 4-70
4.17.1 Buttons.......................................................................................... 4-72
4.17.2 Operation Mode and Active Recipe ............................................ 4-74
4.18 TELEMIX AUTO SCREEN (SERVICE MODE) .............................. 4-75
4.18.1 Buttons.......................................................................................... 4-77
4.18.2 Recipe Selection .......................................................................... 4-79
4.18.3 Valve Testing ................................................................................ 4-80
4.19 PRIMARY MACHINE SCREEN – TELEMIX AUTO....................... 4-81
4.19.1 Buttons.......................................................................................... 4-82
4.19.2 Animated Symbol ......................................................................... 4-82
4.20 RECIPES SCREEN ....................................................................... 4-83
4.20.1 Buttons.......................................................................................... 4-85
4.20.2 Recipe Editing .............................................................................. 4-87
4.20.3 Recipe Mixing Ratios with Min and Max TPH ............................ 4-89
4.21 CALLIBRATION SCREEN ............................................................ 4-92
4.21.1 Buttons.......................................................................................... 4-93
4.21.2 Parameters.................................................................................... 4-95
4.21.3 Parameter Editing ........................................................................ 4-96
4.22 CAMERA SCREEN........................................................................ 4-97
4.23 LARGE AND SMALL HANDSETS ................................................ 4-98
4.23.1 Large Handset .............................................................................. 4-98
4.23.2 Large Handset Controls and LED’s ............................................ 4-99
4.23.3 Tracking Mode Control Functions ............................................ 4-100
4.23.4 Auxiliary Mode Control Functions ............................................ 4-102
4.23.5 LED’s ........................................................................................... 4-104
4.23.6 Operation Modes ........................................................................ 4-105
4.23.7 Medium Handset ........................................................................ 4-106
4.23.8 Handset Keypad and Control Functions .................................. 4-108
4.23.9 Activating/Deactivating the Handset ........................................ 4-111
4.23.10 Small Handset ............................................................................ 4-112
4.23.11 Handset Keypad and Control Functions .................................. 4-113
4.23.12 Activating/Deactivating the Handset ........................................ 4-116
4.23.13 Handset Charging ...................................................................... 4-117
4.24 HYDRAULIC CONTROL LEVERS .............................................. 4-119
4.25 PUGMILL SPEED CONTROL ..................................................... 4-122
4.26 ENGINE STARTING PROCEDURE ............................................ 4-123
4.27 ENGINE AFTERTREATMENT FEATURES ................................ 4-127
4.28 MANOEUVRING ON SITE........................................................... 4-128

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4.29 TRACKING .................................................................................. 4-131
4.29.1 TRACKING/SLEWING SAFETY DECALS .................................. 4-131
4.29.2 TRACKING HAZARD ZONES ..................................................... 4-132
4.30 UNLOCKING THE LARGE HANDSET ........................................ 4-133
4.31 USING THE LARGE HANDSET TO CONTROL THE TRACKS . 4-136
4.32 OPERATION MODES AND RECIPES ........................................ 4-140
4.32.1 Automatic Mode ......................................................................... 4-140
4.32.2 Manual Mode .............................................................................. 4-140
4.33 STARTING THE MACHINE ......................................................... 4-141
4.34 STOPPING THE MACHINE ......................................................... 4-142
4.35 START/STOP THE INCLINE CONVEYOR .................................. 4-143
4.36 START/STOP THE FEED CONVEYOR ...................................... 4-151
4.37 CONTROLLING THE FEED CONVEYOR SPEED ...................... 4-159
4.38 REVERSING THE FEED CONVEYOR ........................................ 4-162
4.39 START/STOP THE PUGMILL (TELEMIX) .................................. 4-167
4.40 START/STOP THE TELEMIX AUTO ........................................... 4-171
4.41 REVERSING THE PUGMILL (TELEMIX) .................................... 4-175
4.42 REVERSING THE PUGMILL (TELEMIX AUTO) ......................... 4-179
4.43 START/STOP ADDITIVE/WATER FLOWS ................................. 4-181
4.44 START/STOP VIBRATING MOTOR............................................ 4-183
4.45 MONITORING DATA ................................................................... 4-185
4.45.1 Additive Weight .......................................................................... 4-185
4.45.2 Water Flow-rate .......................................................................... 4-185
4.45.3 Material Throughput................................................................... 4-186
4.45.4 Service Mode .............................................................................. 4-186
4.45.5 Recipes ....................................................................................... 4-187
4.45.6 Calibration .................................................................................. 4-187
4.46 UNBLOCKING THE TELEMIX AND THE TELEMIX AUTO ........ 4-188
4.47 PLACING THE PUGMILL INTO THE WORKING POSITION ..... 4-189
4.48 PLACING THE PUGMILL INTO THE TRANSPORT POSITION . 4-193
4.49 PUGMILL PRESSURE SENSOR ................................................ 4-197
4.50 RAISE/LOWER THE HOPPER JACKLEGS/INCLINE CONVEYOR
HEAD SECTION .......................................................................... 4-198
4.51 REMOTE CONTROL TIPPING GRID .......................................... 4-206
4.52 INTERLOCK SYSTEM OF THE MACHINES .............................. 4-213
4.53 SUPPORTING THE MACHINE .................................................... 4-215
4.54 ADJUSTING THE VARIABLE GATE .......................................... 4-217
4.55 CONFIGURING THE TELEMIX AUTO ........................................ 4-218
4.55.1 Enabling Telemix Auto............................................................... 4-218
4.55.2 Selecting Operational Mode and Recipe .................................. 4-220
4.55.3 Editing a Recipe ......................................................................... 4-223
4.55.4 Setting Parameter Values .......................................................... 4-227
4.55.5 Adjusting Additive/Water Rates (Manual Mode) ...................... 4-229
4.56 SHUTDOWN PROCEDURE ........................................................ 4-233

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 OPERATION
4. OPERATION OF YOUR MACHINE

All personnel who operate this equipment must be trained to correctly

and safely use it as it was intended.

Before operation the operator must:

 Have received specific and adequate training in the task to be carried out.

 Have read and understood the machine operating Manual and the Safety
signs on the Machine

 Know the location and function of controls and safety features such as
Machine Stop buttons and mains isolator switches.

 Be aware of all moving parts on the Machine.

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4.1. CONTROL PANEL
The diagram below shows the machine’s control panel, which incorporates:

1. Display Unit used to control and monitor the machine.

2. Key Switch used to start and stop the engine.

3. Conveyor Button used to start and stop the incline conveyor belt.
(This button also starts/stops the feed conveyor and pugmill on
machines with one fitted).

4. Panel Lock used to lock and unlock the cover of the control panel.

Conveyor
Key Button
Switch

Panel
Lock

LCD Panel

Multi-function Multi-function
Buttons Buttons

LED

Navigation/Other
Buttons

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Multi-function Buttons
There are eight multi-function buttons, four down each side of the LCD panel.
For convenience in this manual, these buttons are referenced using the
numbers 1 to 8, as indicated below.

The functionality of a button depends on the screen being displayed and is

indicated by the adjacent on-screen icon. Not all of the buttons are used by all
of the screens.

Navigation/Other Buttons

There are six buttons under the LCD panel, shown below.

ESC - Used to return to the Main screen or to dismiss an Error screen.

Left Arrow - Used for specific functions, dependent on screen.
Right Arrow - Used for specific functions, dependent on screen.
Up Arrow - Used to move up on-screen list or increase an on-screen value.
Down Arrow - Used to move down on-screen list or decrease an on-screen
value.
OK - Press to select, confirm or save an on-screen item/value.

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LED
There is a LED in the bottom-left of the display unit. During machine operation,
you may see the LED in the following colours and states.

Colour State Description

Green Flashing Unit is running the control system application (normal
operation)
Amber Steady Unit is booting up or has stopped due to software issue
Red Steady Fatal hardware fault

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4.2. TELEMIX AND TELEMIX AUTO MACHINE
The TELEMIX is a track mounted fully mobile Pugmill designed to work at
production rates of up to 300tph (330 Ton per hr).

The TELEMIX AUTO is a track mounted fully mobile Automatic PLC

controlled Pugmill designed to work at production rates of up to 300tph (330
Ton per hr).

4.2.1 Enabling Telemix Auto on the machine

If a machine has Telemix Auto fitted, this feature must be enabled in the
machine’s control software to allow Telemix to be configured and operated
through the user-interface on the machine. Telemix Auto is enabled via the
Factory Settings screen, Section 4.55.3.

4.2.2 Configuring Telemix Auto

Telemix Auto must be configured for use and this is done via the Telemix Auto
screen, as well as the Recipes screen and Calibration screen.

Most of the configuration via the Telemix Auto screen must be performed with
the screen in Service mode.

The following configuration can be performed:

 Automatic/manual mode and recipe selection – see Section 4.20.2
 Recipe editing via Recipe screen – see Section 4.55.3
 Parameter setting via Calibration screen – see Section 4.55.4

For more information on configuring the Telemix Auto see Section 4.55.

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4.2.3 Operating Telemix Auto
Telemix Auto can be operated from the display unit via the Main, Telemix Auto
screen and Primary Machine screen in the following ways:

 Start/stop pugmill on the Main and Primary Machine screens – see
Section 4.40
 Reverse pugmill on the Main and Primary Machine screens – see
Section 4.42
 Start/stop additive/water flow on the Main and Telemix Auto screens –
see Section 4.43
 Start/stop vibrating motor (for additive silo) on the Telemix Auto screen
– see Section 4.44

The pugmill must be started before the conveyor is started.

Telemix Auto can also be started as part of a ‘sequential start’ of pugmill, conveyor
and feeder (if fitted) via the large Conveyor button on the machine’s control panel.

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4.3. SCREEN OVERVIEW
4.3.1 Screen Layout and Elements
The screens that can appear on the display unit of the control panel have some
common elements. The screen layout and these elements are shown below.

Status / Error
Warning Bar Message

Icons for Icons for

buttons 1-4 buttons 5-8

Icons for arrow-buttons

below LCD Panel

Status/Warning Bar
Warning/status symbols are displayed in the top-left of most screens, when
needed. Up to three symbols can be displayed at any moment in time. They
appear from right to left. For the right-most symbol, an error message is also
displayed (see below).

If more than three symbols need to be displayed, they are all displayed by
means of an automatic cyclic scrolling mechanism - the symbols shift one place
to the right every 3 seconds.

If more than 3, symbols shift one place to the right every 3 seconds

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The possible warning/status symbols and their meanings are listed in the
supplement documentation.

Error Message
An error message is displayed in the top-right of most screens. The error
message contains an error code and description, displayed over three lines.

The error message corresponds to the symbol at the right of the

Status/Warning bar.

The symbols in the Status/Warning bar can be shifted one place to the right by
pressing the OK button below the LCD panel.

This updates the displayed error message associated with the right-most
symbol.

If more than three symbols are displayed and cyclic scrolling is in operation
(see above), the OK button can be used to advance the symbols manually by
one place without having to wait the three seconds of the automatic
mechanism.

Errors are described in more detail in the supplement documentation.

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Telemix Auto must be enabled and configured before it can be used on a

machine. Enabling, configuring and operating Telemix Auto is conducted via
the usual graphical user-interface on the display unit of the machine, which is
described in the supplement documentation.

When Telemix Auto is enabled, the machine’s user-interface is updated to

incorporate features for Telemix Auto, including additional screens and
changes to existing screens.

See Sections 4.14 to 4.22

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4.3.2 Screen Summary
Screen Name Screen Image Description
First screen displayed after boot-up.
Displays key monitoring data.
Main Provides certain control functions and
access to other screens. Can be
accessed from other screens by
pressing ESC button.

Accessed from Main screen. Displays

Engine the current values of certain engine-
related parameters. Only available for
electronically controlled engines.

Accessed from Main screen. Entering

this screen enables tracking mode.
Tracking/Radio Displays information about the large
handset and allows radio pairing of
handsets.

Accessed from Main screen. Allows

control of radial/rotational motion (if
available), incline conveyor and feed
Machine conveyor (if fitted).
A machine with the auto-radial motion
feature has two Machine screens (1
and 2).

Accessed from Main screen. Allows

language selection, software updates,
Settings and access to Services, Interlock,
Error Log and Factory Settings
screens.

Accessed from Settings screen.

Machine Settings Allows parameter values for machine
features to be set.

Accessed from Settings screen.

Services Allows machine services to be
individually enabled/disabled.

Accessed from Settings screen.

Interlock Allows interlock features to be
monitored and configured.

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Displayed spontaneously when an

Engine Error engine error occurs. Shows engine
error information. Can be dismissed
by pressing ESC button.

Displayed spontaneously when a

Machine Error machine error occurs. Shows machine
error information. Can be dismissed
by pressing ESC button.

Accessed from Services screen.

Error Log Allows error log to be viewed,
containing list of most recent errors on
the machine.

Accessed from Services screen.

Allows machine type and machine
features to be specified, as well as the
Factory Settings settings for the machine in an
interlock system. For use at time of
machine manufacture and also for
retro-fitting options at any time.

The Main screen can be returned to from other screens by pressing the ESC
button below the LCD panel. However, for Error screens this button dismisses
the error and returns to the previously displayed screen.

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The screens described below are added to or modified in the user-interface of
the machine’s control system when Telemix Auto is enabled on the Factory
Settings screen

Screen Name Screen Image Description

First screen displayed after boot-up.
Displays key monitoring data.
Main Provides certain control functions and
access to other screens. Can be
accessed from other screens by
pressing ESC button.
The Telemix Auto screen provides an
interface for controlling, monitoring
Telemix Auto and configuring Telemix Auto
operation. It is accessed from the
Screen Main screen by pressing button 2
(second-down on left) with the
following on-screen icon.
Telemix Auto
Screen
(Service Mode)
Automatic Mode Service Mode can be entered from the
Telemix Auto screen by pressing
Telemix Auto button 4 (fourth-down on the left).
Screen
(Service Mode)
Manual Mode
Accessed from Main screen. Allows
control of radial/rotational motion (if
available), incline conveyor and feed
conveyor (if fitted).
A machine with the auto-radial motion
feature has two Machine screens (1
and 2).
When Telemix Auto is fitted, the first
Primary Machine machine screen that can be accessed
from the Main screen is the Telemix
Auto screen. The Primary Machine
screen can be accessed from there by
pressing the right-arrow button below
the LCD panel (if there is no
Secondary screen for the machine,
the Primary Machine screen can also
be accessed by pressing the left-
arrow button).

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Recipes Screen
Automatic Mode
The Recipes screen allows the four
recipes (R1, R2, R3, R4) for each of
automatic and manual mode to be
user-defined. It is accessed from the
Recipes Screen Telemix Auto screen by pressing
button 2 (second-down on left).
Manual Mode

The Calibration screen allows limits to

be set on some of the operating
Calibration
parameters of the Telemix Auto
Screen feature. It is accessed from the
Telemix Auto screen by pressing
button 6 (second-down on right).

The Camera screen shows the current

image from the camera (if fitted) over
Camera Screen the additive silo. It is accessed from
the Telemix Auto screen by pressing
button 7 (third-down on right).

The Main screen can be returned to from other screens by pressing the ESC
button below the LCD panel. However, for Error screens this button dismisses
the error and returns to the previously displayed screen.

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4.4. MAIN SCREEN – TELEMIX
The Main screen automatically appears following boot-up of the display unit.
You can also return to the Main screen from other screens by pressing the
ESC button below the LCD panel.

The screen is shown below.

The Main screen contains the following elements:

 Engine Speed [RPM] (central meter)

 Interlock indicators (central meter)

 Fuel Level [%] (central meter) when fuel sensor fitted

 Hours of Engine Use (left)

 Hours of Conveyor Use (right)

 Countdowns (left)
- Engine start
- Incline Conveyor start
- Feed Conveyor start

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 Diesel Particulate Filter (DPF) Soot Level [%] (left) when DPF fitted

 Diesel Exhaust Fluid (DEF) Level [%] (right) when DEF tank fitted

 Button icons (left)
- Engine screen button
- Machine screens button
- Tracking/Radio screen button
- Settings screen button

 Button icons (right)

- Manual DPF Regeneration button
- Feed Conveyor button
- Incline Conveyor button

 Button icons (bottom)

- Work lights button
- Engine Speed Up button
- Engine Speed Down button

▪ Software version numbers

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4.4.1 Buttons
The left, right and bottom buttons on the Main screen are described below.

Left and Right Buttons

The eight buttons to the left and right of the LCD panel are used as described
below.

No. Icon Function Function Icon No.

Engine screen
1 Press to access the Not used 5
Engine screen

Manual DPF Regen

Machine screen Press
Press to initiate a
2 to access the Machine
manual DPF 6
screen
regeneration
Tracking/Radio screen
Start/Stop Feeder *
Press to access the
Press to start the
3 Tracking/Radio screen
feeder (if fitted) and 7
and enable tracking
press again to stop it
mode
Start/Stop Conveyor *
/ ** Press to start the
Settings screen Press
conveyor and press
4 to access the Settings
again to cancel the 8
screen
start-up or to stop the
running conveyor

* The right-edge of this button is green when the feeder/conveyor is not

running and red when it is running (the colour indicates the action of the next
button-press – green for start, red for stop).

** When the conveyor is started using this button, a 10-second delay is

applied before the conveyor starts running. During this time, the machine’s
siren beeps (fast) and its beacon illuminates.

The conveyor button on the Main screen starts the incline conveyor only. Unlike
the large conveyor button on the control panel, it does not start the feed
conveyor (where fitted). The feed conveyor can be started separately using the
feed conveyor button on the Main screen.

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Bottom Buttons
The buttons below the LCD panel are used as described below.

Left arrow Right arrow Up arrow Down arrow OK

Work lights Not used Engine Speed Engine Speed Speed-

On/Off Up Down Change Mode
Press to switch Press to Press to decrease Hold down for
the work lights increase engine engine speed 5 seconds to
on and press speed toggle speed-
again to switch change mode
them off

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4.4.2 Engine Speed
The current engine speed (rpm) is displayed in the central meter on the Main
screen.

Engine Speed Monitoring

The engine speed is indicated in two ways:
 In a semi-circular bar-chart which is colour-coded from green to red:
- Green: engine speed OK
- Red: engine speed too high
 In figures (rpm)

For more information on Speed Control and Speed Change Modes see the
Engine Starting Procedure 4.26.

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4.4.3 Machine Interlock
The two link symbols in the central meter of the Main screen are used when the
machine is operating with other machines in an interlock system (see Section
4.52).

 The down-arrow symbol (left) represents the link with a downstream

machine 
 The up-arrow symbol (right) represents the link with an upstream
machine 

The symbols are colour-coded to indicate the status of the link between the
local machine and linked machine, as follows.

Symbol Description
Green: The local machine and linked machine are both running as
normal

Blue: The conveyor on the local machine has been detected as

not running properly and a signal has been sent to the linked
upstream machine (if it exists) to request it to stop

Red: The local machine and linked machine are both in the
stopped state

Grey: The link does not exist (no linked machine)

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4.4.4 Fuel Level
The current fuel-level is displayed in a bar-chart and as a percentage figure on
the Main screen (this information is only presented when the fuel sensor is
fitted).

The bar-chart is coloured-coded from red to green, where red indicates that
the fuel-level is very low and green indicates that it is sufficient to run the
machine.

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4.4.5 Hours of Engine/Motor Use
Two hours-of-use figures are displayed on the Main screen.

The left and right figures are as follows.

Symbol Description

Engine Hours (left)

The total hours for which the engine has run so far (since new)

Conveyor Hours (right)

The total hours for which the conveyor has run so far (since new)

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4.4.6 Countdowns
Time-delays are implemented between certain machine services (engine,
incline conveyor, feed conveyor) being initiated by the machine operator and
the service actually starting. Countdowns are displayed as pop-ups on the left
of the Main screen during these time-delays, as described below.

Pop-up Symbol Description

Engine Start Countdown
A time-delay of 7 seconds is applied between the key switch on the
control panel being turned to the Crank position and the engine
starting to crank.
Incline Conveyor Start Countdown
A time-delay of 10 seconds is applied between the incline conveyor
being triggered and actually starting.

Feed Conveyor Start Countdown

A time-delay of 5 seconds is applied between the feed conveyor (if
fitted) being triggered and actually starting.

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4.4.7 Engine Aftertreatment Information
Engine aftertreatment information is displayed on the Main screen only if the
engine features one or both of:

 Diesel Particulate Filter (DPF)

 Diesel Exhaust Fluid (DEF)

DPF and DEF data appear on the left and right of the screen, respectively.

The presented information is as follows:

Symbol Description
DPF Soot Loading (left)
The DPF soot loading is shown as a percentage level

DEF Level (right)

The DEF level is shown as a percentage of a full DEF tank

Engine aftertreatment is fully described in Section 4.27.

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4.5 ENGINE SCREEN
The Engine screen displays key information about the state of the engine. It is
available on machines with electronically controlled engines only. This screen
is accessed from the Main screen (described in Section 4.4 (Telemix) or Section
4.16 (Telemix Auto) by pressing button 1 (top-left).

The Engine screen is shown below.

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4.5.1 Monitoring Data
The engine monitoring information displayed on the Engine screen is
described in the table below.

Engine load (%) Battery voltage (V) Fuel rate DEF* level (%)
(litres/hour)

Engine coolant Engine oil Fuel temperature Exhaust

temperature (oC) pressure (kPa) (oC) temperature (oC)

Engine Speed Engine air intake Engine Usage DPF** soot loading
(rpm) pressure (kPa) (hours) (%)
Time in hours, minutes, seconds since DPF was last regenerated
(automatically or manually)

* DEF = Diesel Exhaust Fluid ** DPF = Diesel Particulate Filter

The information relating to the Diesel Exhaust Fluid (DEF) and Diesel
Particulate Filter (DPF) is only displayed when the engine is fitted with an
exhaust aftertreatment unit with these features (see Section 4.27).

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4.5.2 Buttons
The left, right and bottom buttons on the Engine screen are described below.

Right Buttons
Three buttons to the right of the LCD panel are used as described below.

No. Icon Function Function Icon No.

1 Not used Not used 5

2 Not used Manual DPF Regen 6

Press to initiate a
manual DPF
regeneration

3 Not used Not used 7

4 Not used Reset Oil Quality 8

Press to reset the oil
quality indication
after replacing the
engine oil

During a DPF regeneration, beware of the high-temperature exhaust fumes

from the engine.

Bottom Buttons
The buttons below the LCD panel are used as described below.

Left-arrow Right-arrow Up-arrow Down-arrow

Not used Not used Engine Speed Up Engine Speed Down

Press to increase Press to decrease
engine speed engine speed

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4.6 TRACKING RADIO SCREEN
The Tracking/Radio screen enables the tracks of the machine to be controlled
from the large handset, in order to move the machine. It also allows both the
large and small handsets to be paired with the machine for wireless (radio)
use.

This screen is accessed from the Main screen (described in Section 4.4
(Telemix) or Section 4.16 (Telemix Auto) by pressing button 3 (third-down on
the left).

Entering the Tracking/Radio screen automatically puts the machine into

tracking mode. Once the large handset has been unlocked, a 9-second delay
is implemented before the tracks are enabled – during this time, a countdown
is shown on the screen, the machine’s siren beeps (fast) and its beacon
illuminates. Leaving the Tracking/Radio screen automatically brings the
machine out of tracking mode.

The Tracking/Radio screen is also automatically displayed when the large

handset is switched on and put into in tracking mode. The same time-delay is
applied as described above. For more information on the large handset, see
Section 4.23.

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The Tracking/Radio screen is shown below.

The Tracking/Radio screen provides an interface for:

 Putting the machine into tracking mode
 Selecting the tracking speed
 Pairing the remote handsets with the machine’s radio transceiver
 Obtaining visual status information about the large handset

In tracking mode, the tracks can be controlled using levers on the large
handset. In addition, on some machines the conveyor can be rotated from
buttons on the large handset. For more information on the large handset, see
Section 4.23.

The large handset can be used in tracking mode or auxiliary mode. In

auxiliary mode, it can be used to control certain features of the machine (see
Section 4.23) and this mode is indicated by ‘AUX’ at the bottom of the
Tracking/Radio screen (see below).

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4.6.1 Buttons
The left, right and bottom buttons on the Tracking/Radio screen are described
below.

Left and Right Buttons

The eight buttons to the left and right of the LCD panel are used as described
below.

No. Icon Function Function Icon No.

1 Not used Not used 5

2 Radio Pairing Engine Speed Up 6

Press to initiate Press to increase
radio pairing for a engine speed (see
remote handset. A Section 4.26) and
35-second pairing therefore tracking
interval begins and speed (variable-
a countdown is speed engine only)
shown on the
screen.
3 Disable Tracking Engine Speed 7
Mode Down Press to
Press to disable decrease engine
tracking mode and speed (see Section
return to the Main 4.26) and therefore
screen tracking speed
(variable-speed
engine only)
4 Not used Not used 8

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Bottom Buttons
The buttons below the LCD panel are used as described below.

Left-arrow Right-arrow Up-arrow Down-arrow

Enable/disable slow tracking Not used Not used Not used

Press to switch between normal
tracking speed and slow tracking
speed (only available with a fixed-
speed engine and not shown with
a variable-speed engine)

The ESC button below the LCD panel can be used to escape from the
Tracking/Radio screen and return to the Main screen. This will also bring the
machine out of tracking mode.

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4.6.2 Large Handset Image
An image of the large handset is displayed in the middle of the Tracking/Radio
screen. Yellow and blue arrows accompany this image to indicate the currently
selected tracking direction for each of the left and right tracks.

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4.6.3 Large Handset Auxiliary Mode
When the large handset is used in Auxiliary mode, the handset image is
shown in blue with ‘AUX’ displayed under the image at the bottom of the
Tracking/Radio screen.

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4.6.4 Countdowns
Countdowns are displayed in the lower-left of the Tracking/Radio screen.

Two possible countdowns may be displayed:

 Tracking Enable Countdown: When tracking mode is entered, a 9-
second delay is applied before the tracks are enabled - a countdown is
displayed
 Radio Pairing Countdown: When radio pairing is initiated for a
handset, a 35-second pairing interval is started - a countdown is
displayed

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4.6.5 Handset Connection Mode
The large handset can be connected to the machine in wired (doglead) or
wireless (radio) mode. The small handset only operates in wireless (radio)
mode. The connection mode is indicated in the top-left of the Tracking/Radio
screen by the following symbols.

Wired (Doglead) connection

Wireless (Radio) connection

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4.6.6 Remote Operation Indicator
The circular symbol in the lower-right of the Tracking/Radio screen that a
command has been received from a remote handset. The following symbols
may be displayed.

Conveyor Started/Stopped

Feeder Started/Stopped

Radial/Rotational Motion Clockwise

Radial/Rotational Motion Anti-Clockwise

Auxiliary Mode entered on Large Handset

Lock/Unlock Button pressed on Large Handset

Large Handset Unlocked

Large Handset Locked

Engine Stop Button pressed on Handset

Siren Button pressed on Small Handset

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4.6.7 Conveyor Limits
When the large handset is used in auxiliary mode, a box in the lower-left of the
Tracking/Radio screen is used to indicate when movement of the conveyor has
reached a physical limit – for example:

The possible messages and their meanings are:

 LOWER SENSOR: Appears when lowering the front or back of the

conveyor remotely from the small handset and the lower limit is reached.
When displayed, the conveyor’s ‘rear raise’ and ‘front lower’ functions
are temporarily disabled in the software to prevent attempts to lower the
conveyor further and avoid damage to the machine (the conveyor can
still be moved in the left and right directions). However, the software
cannot prevent damage that may be caused by using the manual valves
on the machine.

 LH LIMIT SWITCH: Appears when rotating the conveyor from a remote

handset and the rotation reaches its left-hand (LH) limit. When
displayed, the left-track forward and right-track reverse functions are
disabled in the software until the limit switch is deactivated.

 RH LIMIT SWITCH: Appears when rotating the conveyor from a remote

handset and the rotation reaches its right-hand (RH) limit. When
displayed, the right-track forward and left-track reverse functions are
disabled in the software until the limit switch is deactivated.

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4.6.8 Engine Speed
For a machine with a variable-speed engine, the engine speed (rpm) and
therefore tracking speed can be adjusted from the Tracking/Radio screen using
buttons 6 and 7. The current engine speed is shown between these buttons.

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4.7 PRIMARY MACHINE SCREEN - TELEMIX
The Primary Machine screen allows certain aspects of the machine to be
controlled. This screen is accessed from the Main screen by pressing button 2
(second-down on the left).

The Primary Machine screen is illustrated below.

The screen provides an interface for:

 Starting/stopping the incline conveyor
 Starting/stopping the feed conveyor (on machines equipped with a feed
conveyor)
 Rotating the incline conveyor (and feed conveyor, if relevant)
 Raising and lowering the front of the incline conveyor
 Raising and lowering the hopper jacklegs
 Controlling Telemix (on machines equipped with the pugmill)
 Viewing the engine speed
 Accessing the Secondary

The machine image shown on the screen is dependent on the machine type
(the one on the screen shown above is just an example).

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4.7.1 Buttons
The left, right and bottom buttons on the Primary Machine screen are described
below.

Left and Right Buttons

The eight buttons to the left and right of the LCD panel are used as described
below.

No. Icon Function Function Icon No.

1 Rotate Left * Rotate Right * 5
Hold down to rotate Hold down to rotate
the conveyor to the the conveyor to the
left (anti-clockwise). right (clockwise). A
A left-arrow appears right-arrow appears
in green when in green when
button is pressed. button is pressed.
2 Raise Rear * Raise Front * 6
Press to raise the Press to raise the
rear of the front of the
conveyor. A rear conveyor. A front up-
up-arrow appears in arrow appears in
green when button green when button is
is pressed. pressed.
3 Lower Rear * Lower Front * 7
Press to lower the Press to lower the
rear of the front of the
conveyor. A rear conveyor. A front
down-arrow down-arrow appears
appears in green in green when
when button is button is pressed.
pressed.
4 Start/Stop Feeder Start/Stop 8
** Press to start or Conveyor *** Hold
stop the feeder (if down for at least 1
fitted). Before second to start the
starting the feeder, conveyor. Press
the conveyor must again to cancel the
be running. start-up or to stop
the running
conveyor.

* This button is momentary-acting, so the machine only moves while the

button is held down.
** This button-icon only appears for machines fitted with a feeder.
*** On starting the conveyor using this button, a 10-second delay is applied
before the conveyor starts running. During this time, a countdown is shown on
the screen, the machine’s siren beeps and its beacon illuminates.

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 The first time a button is pressed to raise or lower the conveyor, it must
be held down for at least 3 seconds before the conveyor will move. During
this delay, the siren will beep (fast) on the machine. The conveyor will then
respond immediately to further presses of any of the buttons (but see
below). When the conveyor moves, the beacon illuminates on the
machine.
 Once a button has been released, there is a 15-second window for the
next button to be pressed with an immediate response from the machine.
Beyond this window, the 3-second delay will apply again. 
 Raising/lowering the rear of the conveyor will have the effect of
raising/lowering the feed hopper at the rear of the machine, if fitted. For a
feed hopper with legs, the legs are raised off or lowered to the ground. 

Bottom Buttons
The buttons below the LCD panel are used as described below.

Left-arrow Right-arrow Up-arrow Down-arrow OK

Not used Other Machine Engine Speed Engine Speed Telemix

Screens Press Up Press to Down Press to Control Use
to access increase engine decrease to start, stop
Secondary speed engine speed and reverse
Machine screen the Telemix
pugmill, if
fitted

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4.7.2 Arrows
When raising/lowering or rotating the conveyor from the Primary Machine
screen, a green arrow appears next to the machine image on the screen to
indicate the current operation. The following screen example shows the
possible arrows simultaneously (in practice, only one arrow can appear at a
time).

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4.7.3 Conveyor/Feeder Animations
When the conveyor and feeder are running, this is indicated on the Primary
Machine screen by animated (rotating) symbols on either side of the machine
image.

The feeder symbol is on the left and the conveyor symbol is on the right.

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4.8 SECONDARY MACHINE SCREEN
The Secondary Machine screen is available only if either (or both) of the
variable-speed feed conveyor and deflector plate features are present on the
machine. In this case, the screen is accessed from the Primary Machine screen
(described in Section 4.7 (Telemix) or Section 4.19 (Telemix Auto) by pressing
the right-arrow button below the LCD panel.

Press right arrow button to

access Secondary
Machine screen.

The Secondary Machine screen is illustrated below.

The screen provides an interface for:

 Controlling the feed conveyor speed (if variable-speed feed conveyor
fitted)
 Raising and lowering the deflector plate (if fitted)

The Secondary Machine screen is visible only if at least one of the Variable
Speed Feed Conveyor and Deflector Plate features is enabled on the Factory
Settings screen).

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4.8.1 Buttons
The left, right and bottom buttons on the Secondary Machine screen are
described below.

Left and Right Buttons

The eight buttons to the left and right of the LCD panel are used as described
below.

No. Icon Function Function Icon No.

1 Feeder Speed Up * Lower Deflector 5
Hold down to Plate
increase the feeder Hold down to lower
speed. (move in) the
deflector plate.

2 Feeder Speed Raise Deflector 6

Down * Plate
Hold down to Hold down to raise
decrease the feeder (move out) the
speed. deflector plate.

3 Not used Not used 7

4 Not used Not used 8

* Feeder speed increases/decreases by 5% of the maximum speed for each

second the relevant button is held down.

 The first time a button is pressed to raise or lower the deflector plate, it
must be held down for at least 3 seconds before the plate will move.
During this delay, the siren will beep (fast) on the machine. The plate will
then respond immediately to further presses of any of the buttons (but see
below). When the plate moves, the beacon illuminates on the machine.

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 Once a button has been released, there is a 15-second window for the
next button to be pressed with an immediate response from the machine.
Beyond this window, the 3-second delay will apply again.

Bottom Buttons
The buttons below the LCD panel are used as described below.

Left-arrow Right-arrow Up-arrow Down-arrow

Primary Auto-Radial Not used Not used

Machine Screen Machine Screen
Press to return to Press to access
Primary Machine Auto-Radial
screen Machine screen,
if available

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4.9 SETTINGS SCREEN
The Settings screen is accessed from the Main screen by pressing button 4
(bottom-left).

The Settings screen is shown below.

The Settings screen provides an interface for:

 Selecting the language of the user interface
 Accessing the Machine Settings screen for setting machine parameters
 Accessing the Services screen for enabling/disabling machine services
 Accessing the Interlock screen for using the machine in an interlock
system
 Accessing the Error Log screen
 Updating software of a module within the control panel
 Viewing the software versions within the control panel

In addition, the Factory Settings screen can be accessed from the Settings
screen by pressing the ESC and OK buttons (under the LCD panel)
simultaneously. The Factory Settings screen is described in the supplement
documentation but is for factory use only.

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4.9.1 Buttons
The left, right and bottom buttons on the Settings screen are described below.

Left and Right Buttons

The eight buttons to the left and right of the LCD panel are used as described
below.

No. Icon Function Function Icon No.

1 Language Select Not used 5
Press to enter the
Language Select
mode

2 Services screen Not used 6

Press to access the
Services screen

3 Interlock screen Machine Settings 7

Press to access the screen Press to access
Interlock screen the Machine Settings
screen

4 Error Log screen Software Update Press 8

Press to access the to update software of a
Error Log screen module within the control
panel

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Bottom Buttons
The buttons below the LCD panel are used as described below. The button-
icons only appear when the Language Select button is pressed.

Left-arrow Right-arrow Up-arrow Down-arrow OK

Not used Not used Browse Browse Select

Languages Languages Language
Press to browse Press to Press to select
languages in the browse displayed
up direction languages in language
the down
direction

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4.10 ACTIVATING/DEACTIVATING THE PUGMILL FEATURE
The pugmill feature should be deactivated via the display unit if the Telemix
P2000T is to be used without the pugmill fitted.

No other configurations should be changed via the display unit without prior
approval from Telestack. If you have any questions please contact Telestack
directly.

1. Ensure that there is power to the control panel on the machine – that is,
the key switch is in the power-only position.

2. Ensure that the engine is not running (and there are no engine errors).

3. From the Main screen, access the Settings screen by pressing button 4
with the following on-screen icon.

4. Once on the Settings screen, access the Factory Settings screen by

pressing the ESC and OK buttons (below the LCD panel) together for at
least 5 seconds. The Factory Settings screen will now appear.

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5. Navigate to the telemix/pugmill machine feature using the up/down-
arrow buttons below the LCD panel (the current feature is highlighted in
blue).

6. Press the OK button to select the feature. The slide-switch for the
feature will change from left/red to right/green.

7. Escape from the Factory Settings screen by pressing the ESC button.

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4.11 MACHINE SETTINGS SCREEN
The Machine Settings screen allows the parameter values of certain machine
features to be set. This screen is accessed from the Settings screen by pressing
button 7 (third-down on the right).

The screen is shown below.

The Machine Settings screen is designed to provide a page of settings for

each machine feature (with the pages navigated using the up-arrow and
down-arrow buttons below the LCD panel).

Currently, only one page is supported, which is for feeder settings (shown
above).

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4.12 INTERLOCK SCREEN
The Interlock screen relates to the machine’s involvement in an interlock
system of machines (see Section 4.52). This screen is accessed from the
Settings screen by pressing button 3 (third-down on the left).

The Interlock screen is illustrated below.

The Interlock screen provides an interface for:

 Viewing the states of the links to upstream and downstream machines
 Configuring three timers (Look, Reset, Stop) used in the control logic for
the upstream link (described in the supplement documentation).
 Enabling/disabling automatic restart of local conveyor when downstream
machine restarts
 Enabling/disabling signal to upstream machine when local machine is
running

The machine image shown on the screen is dependent on the machine type
(the one on the screen shown above is just an example).
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4.12.1 Buttons
The left, right and bottom buttons on the Settings screen are described below.

Left and Right Buttons

The eight buttons to the left and right of the LCD panel are used as described
below.

No. Icon Function Function Icon No.

1 Not used Not used 5

2 Look Timer Edit Not used 6

Mode Press to
select the Look
timer for editing

3 Reset Timer Edit Downstream Auto- 7

Mode Press to Restart Enable/Disable
select the Reset * Press to disable (red)
timer for editing automatic restart of local
conveyor when
downstream machine
restarts. Press again to
enable (green).
4 Stop Timer Edit Conveyor Speed 8
Mode Press to Sensor Enable/Disable
select the Stop */** Press to disable (red)
timer for editing conveyor speed sensor.
Press again to enable
(green). When enabled,
the sensor affects
start/stop signal to
upstream machine

* These settings are maintained through a power-cycle

** Conveyor speed sensor can be disabled only on machines fitted with a
feeder

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Bottom Buttons
The buttons below the LCD panel are used as described below.

Left-arrow Right-arrow Up-arrow Down-arrow OK

Not used Not used Increase Timer Decrease Save Timer

Value Press to Timer Value Value Press to
increase the Press to save the value
value (in decrease the (in seconds) of
seconds) of the value (in the selected
selected timer seconds) of the timer
selected timer

The timer values are shown in boxes alongside the icons for the left buttons 2,
3 and 4. The box for the timer currently selected for editing is highlighted in
yellow.

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4.12.2 Link Status Indicators
The current status of the links to upstream and downstream machines in an
interlock system are shown on the Interlock screen.

 The up-arrow symbol (left) represents the link with an upstream

machine
 The down-arrow symbol (right) represents the link with a downstream
machine

The symbols are colour-coded to indicate the status of the link between the
local machine and linked machine, as follows.

Symbol Description

Green: The local machine and linked machine are both running as normal

Blue: The conveyor on the local machine has been detected as not running
properly and a signal has been sent to the linked upstream machine (if it exists)
to request it to stop

Red: The local machine and linked machine are both in the stopped state

Grey: The link does not exist (no linked machine)

The states of the interlock links are also shown on the Main screen.

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4.13 ERROR SCREENS (TELEMIX)
The Error screens are displayed spontaneously when an error is detected on
the machine (and they cannot be accessed again, once they have been
dismissed).

There are two types of Error screen:

 Engine Error screen

 Machine Error screen

Both types of screen have the same red background.

Once an Error screen has been displayed and seen, it can be dismissed by
pressing the ESC button on the display unit. However, when an error is
dismissed but not resolved, it may be re-displayed if an attempt is made to
track the machine or start the conveyor belt.

Additional information on errors can be found in the supplement

documentation.

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4.14 ERROR SCREENS (TELEMIX AUTO)
This chapter list and describes the errors that can be reported relating to
Telemix Auto. These are ‘machine errors’, with error codes of the format
800xxx.
A Telemix Auto error is reported on a Machine Error screen as it occurs (this
screen can be dismissed by pressing the ESC or OK button) – for example:

The error will also be recorded in the machine’s error log and can later be
viewed on the Error Log screen.

The Machine Error screen and Error Log screen are described in the
machine’s control system manual.

The machine errors that apply to Telemix Auto are listed in the table below.

Error Code Text

800246 Pugmill Blocked with Material
800258 Water Pump Issue – No Water
800259 Additive Blocked or Empty
800294 Throughput Too Low – Water at Minimum Limit
800295 Throughput Too Low – Additive at Minimum Limit

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4.15 STATUS AND WARNING INDICATORS
Status and warning indicators are displayed in a bar at the top of most
screens on the LCD panel.

Status Warning Bar

The contents of the Status/Warning bar are independent of the displayed

screen and do not change when navigating between screens.

The bar can display up to three status/warning indicators. The indicator

symbols appear from right to left. If more than three indicators need to be
displayed, they are all displayed by means of an automatic cyclic scrolling
mechanism – the symbols move one place to the right every 3 seconds.

If more than 3, symbols shift one place to the right every 3 seconds

An error message is also displayed for the symbol at the right of the
Status/Warning bar.

The indicators can be divided into the following categories:

 Engine indicators
 Hydraulics indicators
 Exhaust Aftertreatment indicators
 Other indicators

Additional information on errors can be found in the supplement

documentation.

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4.15.1 Engine Indicators
The engine indicators that can be displayed on the Status/Warning bar are as
follows:

Symbol Meaning
Engine Pre-heat: The engine is pre-heating before cranking. Wait for this
warning to disappear before cranking the engine.
Engine Warning: There is an engine problem (but not severe enough to
automatically stop the engine).

Crank Over-current: The engine cranking is drawing too much current from
the battery.

Engine Speed Low: The engine speed is low for the current operations.

Engine Speed Too Low for Tracking: The engine speed is too low (less
than 1800 rpm) to track the machine. For a fixed-speed engine only.

Engine Stop: The engine is stopping due to an issue of high severity.

Oil Pressure Low: The engine oil pressure is too low.

Engine Oil Quality: The engine oil quality is poor and the oil should be
replaced. Only displayed for CAT 3.4 engine.

Coolant Level Low: The level of engine coolant is too low and should be
replenished.

Coolant Temperature High: The temperature of the engine coolant is too

high.

Blocked Air Filter: The engine’s air filter is blocked and should be unblocked.

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4.15.2 Hydraulic Indicators
The engine indicators that can be displayed on the Status/Warning bar are as
follows:

Symbol Meaning
Hydraulic Oil Level Low: The level of hydraulic oil is too low and should be
replenished.

Hydraulic Oil Temperature High: The temperature of the hydraulic oil is

high.

Hydraulic Oil Temperature Too High: The temperature of the hydraulic oil is
too high.

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4.15.3 Exhaust Aftertreatment Indicators
The exhaust aftertreatment indicators that can be displayed on the
Status/Warning bar are as follows, but these are engine-dependent.

Symbol Meaning
Aftertreatment Warning: There is a problem with the engine’s exhaust
aftertreatment unit.

DEF Level Low: The level of Diesel Exhaust Fluid (DEF) is low (at 20% or
less of full capacity) and should be replenished.

DPF Regeneration Needed: The Diesel Particulate Filter (DPF) needs to be

‘regenerated’.

DPF Regeneration Active: A DPF regeneration is underway. Beware of high-

temperature exhaust fumes during this process.
Manual DPF Regeneration Active: A DPF regeneration has been activated
manually on the control panel. Beware of high-temperature exhaust fumes
during this process.
Ash in DPF: There is ash in the DPF. It is necessary to replace the DPF (as it
cannot be cleaned by regeneration).

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4.15.4 Other Indicators
The other indicators that can be displayed on the Status/Warning bar are as
follows:

Symbol Meaning
Battery Not Charging: The battery is not charging - the alternator should be
checked.

Water in Fuel: Water has been detected in the fuel.

Doglead Not Charging: The doglead cable to the large handset is not
supplying power and therefore not charging the handset’s internal battery. It is
necessary to check fuse F5 in the control panel’s master module.
Wired Tracking Handset Stopped: No communications have been received
from the large handset in wired (doglead) mode.

Wireless Tracking Handset Stopped: No communications have been

received from the large handset in wireless (radio) mode.
No Downstream Signal: In an interlock system, no signal is detected from
the downstream machine, indicating that the machine may have stopped
working.
E-stop: An E-stop (emergency stop) button has been pressed on the
machine.

Pugmill Blocked with Material: High pressure detected in (optional) Telemix

unit (pugmill), indicating a possible blockage.

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4.15.5 Telemix Auto Indicators
There are specifically Telemix Auto indicators that can be displayed on the
Status/Warning bar are as follows:

Symbol Meaning
IO Module Timeout: The IO module is not responding and may not be
connected to Telemix Auto.

No Signal from Water Flow Sensor: The water flow sensor has a
fault or is disconnected.

No Signal from Additive Weight Sensor: The weight sensor in the

additive silo has a fault or is disconnected.

No Signal from Throughput Sensor: The material throughput sensor

has a fault or is disconnected.

Silo Filling in Progress: The additive silo is in the process of being

refilled.

Silo Empty: The additive silo is empty and needs to be refilled.

Silo Blocked: The additive silo is blocked with material.

No Water: There is no water supply for the water pump.

No Aggregate: There is no aggregate material on the belt scale.

Throughput Low Due to Low Water Flow: The material throughput

is below what it should be due to low water flow-rate (near minimum).

Throughput Low Due to Low Additive: The material throughput is

below what it should be due to low additive level (near minimum).

Pugmill Pressure High: The pugmill pressure is too high because it is

blocked with material.

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4.16 MAIN SCREEN – TELEMIX AUTO
The Main screen automatically appears following boot-up of the display unit.
You can also return to the Main screen from other screens by pressing the
ESC button below the LCD panel.

The screen is shown below.

The Main screen is described in the control system manual for the machine but
when Telemix Auto is enabled, it provides the following extra features:

 Start/Stop/Reverse Pugmill button
 Start/Stop Additive/Water Flows button
 Access to Telemix Auto screen

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4.16.1 Buttons
The left, right and bottom buttons on the Main screen are described below.

Left and Right Buttons

The eight buttons to the left and right of the LCD panel are used as described
below.

No. Icon Function Function Icon No.

Start/Stop
Engine screen Additive/Water *
1 Press to access the Press to start 5
Engine screen additive/water flows,
press again to stop
Start/Stop/Reverse
Pugmill *
Telemix Auto screen Press to start the
2 Press to access the pugmill, press again to 6
Telemix Auto screen stop it. Hold down for
at least 3 seconds to
reverse the pugmill
Start/Stop Feeder *
Tracking/Radio screen
Press to start the
Press to access the
feeder (if fitted), press
3 Tracking/Radio screen
again to stop it. Also, 7
and enable tracking
hold down to reverse
mode
variable-speed feeder.
Start/Stop Conveyor *
Press to start the
Settings screen Press
conveyor, press again
4 to access the Settings
to cancel the start-up 8
screen
or to stop the running
conveyor

* The right-edge of this button is green when the component is not running
and red when it is running (the colour indicates the action of the next button-
press – green for start, red for stop).

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Bottom Buttons
The buttons below the LCD panel are used as described below.

Left arrow Right arrow Up arrow Down arrow OK

Work lights Not used Engine Speed Engine Speed Speed-Change

On/Off Up Down Mode
Press to switch Press to increase Press to Hold down for 5
the work lights engine speed decrease seconds to
on and press engine speed toggle speed-
again to switch change mode
them off

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4.17 TELEMIX AUTO SCREEN
The Telemix Auto screen provides an interface for controlling, monitoring and
configuring Telemix Auto operation. It is accessed from the Main screen by
pressing button 2 (second-down on left) with the following on-screen icon.

Without the Telemix Auto feature fitted, this button provides access to the
Primary Machine screen. With the feature fitted, the latter screen can be
accessed from the Telemix Auto screen (see below).

The Telemix Auto screen can be used to:

 Select automatic or manual operation of Telemix Auto
 Start/stop additive/water flows
 Start/stop vibrating motor for additive
 Enter Service mode for Telemix Auto
 Access Recipes screen
 Access Calibration screen

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 Monitor Telemix Auto operation, as follows:
 Mode of operation (automatic or manual)
 Recipe used
 Weight of material in additive silo (kg)
 Water flow-rate (litres per minute)
 Material throughput for final mix (tonnes per hour)
 Control and monitor engine speed
 Access Camera screen for monitoring additive silo
 Access Primary Machine screen (and Secondary Machine screen, if
available)

Service mode allows the Telemix Auto operation to be configured on the

Telemix Auto screen, but the left/right buttons are different in this mode.

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4.17.1 Buttons
The left, right and bottom buttons on the Telemix Auto screen are described
below.

Left and Right Buttons

The eight buttons to the left and right of the LCD panel are used as described
below.

No. Icon Function Function Icon No.

Operational Mode
Start/Stop
Press to toggle between
Additive/Water *
automatic (A) and
1 manual (M) modes,
Press to start 5
additive/water flows,
where selection is
press again to stop
shown on screen
Recipes Screen
Calibration Screen
Press to access the
2 Recipes screen for the
Press to access the 6
Calibration screen
selected mode
Start/Stop Vibrating
Camera Screen
Motor *
Press to access the
3 Press to start vibrating
Camera screen for the 7
motor for additive, press
additive silo
again to stop it

Service Mode *
4 Press to enter Service Not Used 8
mode

* The edge of this button is green when the component/service is not running
and red when it is running (the colour indicates the action of the next button-
press – green for start, red for stop).

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Bottom Buttons
The buttons below the LCD panel are used as described below.

Left arrow Right arrow Up arrow Down arrow

Secondary Primary Machine Engine Speed Engine Speed

Machine Screen Screen Up Down
Press to access Press to access Press to Press to decrease
Secondary Primary Machine increase engine engine speed
Machine screen, if screen. speed
available.
Otherwise, goes to
Primary Machine
screen.

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4.17.2 Operation Mode and Active Recipe
The Telemix Auto operational mode can be selected as automatic (A) or manual
(M) using button 1 (top-left) on the Telemix Auto screen.

This button toggles between the two modes and the current mode is shown on
the screen along with the recipe that is currently selected for the mode. In each
case, one of four possible recipes (R1, R2, R3, R4) is used - the active recipe
can be changed in Service mode.

Automatic Mode
Automatic mode is indicated by an A and the recipe comprises the percentage
amounts of aggregate, additive and water by weight in the final mix.

Manual Mode
Manual mode is indicated by an M and the recipe comprises the additive speed
(percentage of maximum) and the water flow-rate (litres per minute).

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4.18 TELEMIX AUTO SCREEN (SERVICE MODE)
Service Mode can be entered from the Telemix Auto screen by pressing button
4 (fourth-down on the left).

In Service mode, the Telemix Auto screen remains displayed but the button-
icons down the left and right sides change. The button functions differ
according to the currently selected mode of operation (automatic or manual).

The Telemix Auto screens in Service mode for automatic and manual
operational modes are shown below.

Automatic Mode

For automatic mode, Service mode allows the active recipe to be selected.

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Manual Mode

For manual mode, Service mode allows:

 Active recipe to be selected
 Additive valve to be turned on/off and adjusted (for test purposes)
 Water valve to be turned on/off and adjusted (for test purposes)
 Engine speed to be adjusted

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4.18.1 Buttons
The left, right and bottom buttons on the Telemix Auto screen in Service mode
are described below.

Left and Right Buttons

The eight buttons to the left and right of the LCD panel are used as described
below.

No. Icon Function Function Icon No.

Additive Value On/Off * Water Valve On/Off *
Press to turn the additive Press to turn the water
valve on, press again to valve on, press again to
turn if off. When on, turn it off. When on,
1 allows additive speed to allows water flow-rate to 5
be varied. be varied.
Only present in manual Only present in manual
mode. mode.

Water Flow-rate Up
Additive Speed Up
Press to increase water
Press to increase additive
2 speed. Only present when
flow-rate. 6
Only present when water
additive valve is on.
valve is on.

Additive Speed Down Water Flow-rate Down

Press to decrease Press to decrease water
3 additive speed. Only flow-rate. 7
present when additive Only present when water
valve is on. valve is on.

Exit Service Mode *

4 Press to leave Service Not Used 8
mode for Telemix Auto.

* The edge of this button is green when the valve/service is off and red when it is on
(the colour indicates the action of the next button-press – green for On, red for Off).

The button-icons relating to the additive and water valves, additive speed and
water flow-rate are only present in manual mode. Also, the up/down button-icons
(2, 3, 6, 7) only appear if the relevant valve is ‘on’.

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Bottom Buttons
The buttons below the LCD panel are used as described below.

Left arrow Right arrow Up arrow Down arrow

Not Used Not Used Recipe Select or Recipe Select or

Engine Speed Engine Speed
Up Down
Press to browse Press to browse
up recipes recipes
(R1>R2>R3>R4). (R4>R3>R2>R1)

If additive or If additive or
water valve is on, water valve is on,
press to increase press to decrease
engine speed. engine speed.

The up-arrow and down-arrow buttons can be used to adjust the engine speed only
if either or both of the additive and water valves are on.

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4.18.2 Recipe Selection
The currently active recipe can be selected on the Telemix Auto screen in
Service mode. The recipe selection is made from the four available recipes for
the current operational mode (automatic or manual) and are labelled R1, R2,
R3, R4.
When in Service mode, the currently selected recipe is shown on the screen
in red, as indicated in the following examples for automatic and manual
modes.

The recipes can be browsed up and down using the up/-down arrow buttons
below the LCD panel. Once the required recipe is shown, leave it on the screen.

In manual mode, the recipes can be only be browsed using the up/down-arrow
buttons when both the additive and water valves are off.

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4.18.3 Valve Testing
In manual mode, Service mode allows the additive and water valves to be
tested via the Telemix Auto screen. This feature is useful in evaluating the
required additive speed and water flow-rate before defining the recipes for
manual mode.

Once a valve has been turned on, it can be adjusted to vary the
corresponding rate:

 Turning on the additive valve using button 1 (top-left) allows the additive
speed to be varied (as a percentage of the maximum). Two button-icons
for adjusting the speed appear on-screen – button 2 (up) and button 3
(down).
 Turning on the water valve using button 5 (top-right) allows the water
flow-rate to be varied (in litres per minute). Two button-icons for
adjusting.

As each valve is adjusted, the corresponding rate alters on the screen.

Adjusting the valves in the above way does not affect any of the recipes for
manual mode. The recipes can only be changed via the Recipes screen.

Recipe selection via the up/down-arrow buttons on the Telemix Auto screen is
disabled when either of the additive and water valves is on. These buttons can
then be used to adjust the engine speed.

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4.19 PRIMARY MACHINE SCREEN – TELEMIX AUTO
The Primary Machine screen is as described in the machine’s control system
manual but has additional features when Telemix Auto is fitted to the
machine, as described below.

When Telemix Auto is fitted, the first machine screen that can be accessed from
the Main screen is the Telemix Auto screen. The Primary Machine screen can
be accessed from there by pressing the right-arrow button below the LCD panel
(if there is no Secondary screen for the machine, the Primary Machine screen
can also be accessed by pressing the left-arrow button).

Press right arrow

button to access
Primary Machine
screen
The Primary Machine screen including Telemix Auto features is shown below.

The screen provides the following Telemix Auto features:

 Start/Stop/Reverse Pugmill button
 Pugmill running’ animated symbol

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4.19.1 Buttons
The left/right buttons are as described in the control system manual but the
bottom buttons when Telemix Auto is fitted are as described below.

Left arrow Right arrow Up arrow Down arrow OK

Telemix Auto Secondary Engine Speed Engine Speed Pugmill Control

Screen Machine Up Down Use to start, stop
Press to return to Screen Press to increase Press to decrease and reverse the
Telemix Auto Press to access engine speed. engine speed. pugmill (must hold
screen. Secondary down for at least
Machine screen, 3 seconds to
if available. reverse).

Otherwise,
press to return
to Telemix Auto
screen.

4.19.2 Animated Symbol

When the pugmill is running, this is indicated by an animated symbol on the
Primary Machine screen (alongside symbols for the feeder and conveyor).

The animated ‘pugmill running’ symbol is shown on the right.

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4.20 RECIPES SCREEN
The Recipes screen allows the four recipes (R1, R2, R3, R4) for each of
automatic and manual mode to be user-defined. It is accessed from the Telemix
Auto screen by pressing button 2 (second-down on left).

The Recipes screen that is displayed depends on the currently active

operational mode. The Recipes screens for automatic and manual modes are
shown below.

Automatic Mode

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Manual Mode

In both modes, there is one recipe per line and the field values can be adjusted
(for automatic mode, the three field values must add up to 100% but only the
additive and water values can be edited, with the aggregate field automatically
adjusted).

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4.20.1 Buttons
The left, right and bottom buttons on the Recipes screen are described below.

Left and Right Buttons

The eight buttons to the left and right of the LCD panel are used as described
below.

No. Icon Function Function Icon No.

Edit Recipe R1 *
1 Press to initiate editing Not Used 5
of recipe R1.

Edit Recipe R2 *
2 Press to initiate editing Not Used 6
of recipe R2.

Edit Recipe R3 *
3 Press to initiate editing Not Used 7
of recipe R3.

Edit Recipe R4 *
4 Press to initiate editing Not Used 8
of recipe R4.

* The left edge of this button is yellow when the corresponding recipe is selected
for editing and green when it is not selected.

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Bottom Buttons
The buttons below the LCD panel are used as described below.

ESC Left arrow Right arrow Up arrow Down arrow OK

Escape Move Left Move Right Increase Decrease Save

Press to Press to move Press to move Value Value Changes
abandon edit to the next to the next Press to Press to Press to save
without saving field on the field on the increase decrease changes to
any changes. left. right. highlighted currently
If not editing,
highlighted value. edited recipe.
press to return value.
to the Telemix
Auto screen.

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4.20.2 Recipe Editing
To edit one or more recipes for a particular operational mode (automatic or
manual), the required mode must be selected on the Telemix Auto screen
before accessing the Recipes screen. The relevant version (automatic or
manual) of the Recipes screen will then be displayed.

On the Recipes screen, one of the four recipes (R1, R2, R3, R4) can be
selected for editing by pressing the corresponding button (1 to 4) on the left of
the LCD panel. The edge of the button-icon and the recipe name are then
both highlighted in yellow – in the example below, this is recipe R1.

A field for editing can then be selected using the left/right-arrow buttons below
the LCD panel – the field currently being edited is highlighted in yellow.

The value in the currently highlighted field can be adjusted using the up/down-
arrow buttons below the LCD panel.

For automatic mode, it is not possible to edit the aggregate field – its value is
automatically adjusted according to the changes made in the additive and water
fields, such that the three values add up to 100%.

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For manual mode, only the additive and water fields are present. For the water
field in manual mode, there is an upper limit on its value, which is set on the
Calibration screen.

Once the edits to a recipe have been made, the changes can be saved by
pressing the OK button with the following on-screen icon.

The edit of a recipe can be abandoned without saving the changes by pressing
the ESC button.

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4.20.3 Recipe Mixing Ratios with Min and Max TPH
The graphs and tables below show the water and cement percentages with the
minimum and maximum TPH.

Water – Maximum / Minimum

Water % Min TPH Max TPH

0 0 300
1 275 300
2 150 300
3 100 300
4 75 275
5 75 225
6 50 175
7 50 150
8<9 50 125
10<11 50 100
12<15 50 75
16<21 25 50
22<40 25 25

Minimum water pump delivery is 45 l/min

Maximum water pump delivery is 180 l/min.

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Cement – Maximum / Minimum

Cement % Min TPH Max TPH

0 0 300
1 275 300
2 150 300
3 100 300
4 75 300
5 75 300
6 50 300
7 50 300
8<9 50 300
10 50 275
11 50 250
12 25 225
13 25 200
14<15 25 175
16<19 25 150
20<22 25 125
23<27 25 100
28<36 25 75
37<54 25 50
>50 25 25

Minimum rotary valve delivery is 45 kg/min

Maximum rotary valve delivery is 450 kg/min.

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The Min TPH and Max TPH of the machine will be determined by the limits of
the water pump and the rotary valve. See examples below.

Example 1 Min TPH Max TPH

Water 1 % 275 300
Cement 5 % 75 300
Machine Output 275 300

Example 2 Min TPH Max TPH

Water 5 % 75 225
Cement 10 % 50 275
Machine Output 75 225

Example 3 Min TPH Max TPH

Water 10 % 50 100
Cement 15 % 25 175
Machine Output 50 100

Example 4 Min TPH Max TPH

Water 20 % 25 25
Cement 20 % 25 125
Machine Output 25 25

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4.21 CALLIBRATION SCREEN
The Calibration screen allows limits to be set on some of the operating
parameters of the Telemix Auto feature. It is accessed from the Telemix Auto
screen by pressing button 6 (second-down on right).

The Calibration screen allows the following parameter values to be set:

 Timer countdown to vibrate additive motor
 Minimum fill-level of additive silo
 Maximum fill-level of additive silo
 Maximum additive weight in silo
 Maximum water flow-rate
 Maximum material throughput

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4.21.1 Buttons
The left, right and bottom buttons on the Calibration screen are described
below.

Left and Right Buttons

The eight buttons to the left and right of the LCD panel are used as described
below.

No. Icon Function Function Icon No.

Edit Motor Vibration
Edit Max Silo Weight *
Timer *
Press to initiate editing
1 Press to initiate editing of
of maximum weight of 5
timer countdown until
material in additive silo.
additive motor is vibrated.
Edit Max Water Flow
Edit Mini Silo Fill level *
Rate *
Press to initiate editing of
2 minimum fill level of
Press to initiate editing 6
of maximum water flow
additive silo.
rate.
Edit Max Silo Fill level * Edit Max Throughput *
Press to initiate editing of Press to initiate editing
3 maximum fill level of of maximum material 7
additive silo. throughput into final mix.

4 Not Used Not Used 8

* The edge of this button is yellow when the corresponding parameter is

selected for editing and green when it is not selected.

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Bottom Buttons
The buttons below the LCD panel are used as described below.

ESC Left arrow Right arrow Up arrow Down arrow OK

Escape Not Used Not Used Increase Decrease Save

Press to Value Value Changes
abandon edit Press to Press to Press to save
without saving increase decrease changes to
any changes. highlighted currently
If not editing,
highlighted value. edited
press to return value. parameter.
to the Telemix
Auto screen.

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4.21.2 Parameters
The operational parameters that can be set on the Calibration screen are
described in the table below.

Parameter Parameter
Description Description
Name Name
Time to Vibe Mtr Time to vibrate Max Hpr Weight Maximum weight in
motor silo
Timer value (in Maximum weight (in
seconds) until kg) of material in
vibrating motor is additive silo.
started when no Range is 1 to 7500
additive flow is kg, in steps of 5 kg.
detected from silo.
Range is 1 to 30
seconds.
Min Refill Level Minimum fill-level Max Wtr Flow Maximum water
of silo flow-rate
Minimum percentage Maximum water flow-
fill-level of additive rate (in litres per
silo. Must be less minute).
than maximum. Range is 0 to 600
l/min.
Max Refill Level Maximum fill-level Max TPH Maximum
of silo throughput
Maximum Maximum throughput
percentage fill-level of material into final
of additive silo. Must mix (in tonnes per
be greater than hour).
minimum. Range is 0 to 500
tph.

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4.21.3 Parameter Editing
On the Calibration screen, one of the six parameters can be selected for editing
by pressing the corresponding button (1 to 3, 5 to 7) down the sides of the LCD
panel. The edge of the button-icon and the parameter background are then both
highlighted in yellow – in the example below, this is for the parameter Max Hpr
Weight.

The value of the currently highlighted parameters can be adjusted using the
up/down-arrow buttons below the LCD panel.

Once the parameter edit has been made, the change can be saved by pressing
the OK button below the LCD panel.

The edit of a parameter can be abandoned without saving the change by

pressing the ESC button or initiating edit of another parameter.

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4.22 CAMERA SCREEN
The Camera screen shows the current image from the camera (if fitted) over
the additive silo. It is accessed from the Telemix Auto screen by pressing button
7 (third-down on right).

The above example screen shows the details of the optional camera kit where
the camera image would normally be displayed.

The only functional button on the Camera screen is the ESC button which is
used to return to the Telemix Auto screen.

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4.23 LARGE AND SMALL HANDSETS
The machine can be operated using the large and small handset.

4.23.1 Large Handset

A large remote handset is supplied that can be used to
control the tracks and other features of the machine. This
handset is available in two types – wired/wireless and
wired-only. Depending on the type, the handset can be
used in the following communication modes:

 Wired mode: Handset communicates with the machine via a doglead

cable.

 Wireless mode: Handset communicates with the machine via a radio

link.

A wireless connection between the wired/wireless handset and machine is not

possible while this handset is connected to the machine via the doglead
cable.

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4.23.2 Large Handset Controls and LED’s
An overview diagram of the controls and LEDs of the large handset is shown
below.

Levers used to control

tracks or raise/lower
functions
Blue/Grey Buttons:
Grey button used to
change mode

Mode LEDs: Information LEDs:

Tracking Mode RF LED
Auxiliary Mode Battery LED
Lock LED

Engine Stop Power On or

Request Unlock/Lock

The use of the handset depends on its mode of operation – it can operate in
one of:

 Tracking mode (default): Used for moving and turning the machine.

 Auxiliary mode: Used for controlling features/services of the machine.

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4.23.3 Tracking Mode Control Functions
The handset controls in tracking mode are depicted below.

Both Tracks
Forward/Reverse

Right Track
Left Track
Forward/Reverse
Forward/Reverse

Blue/Grey Buttons
Tracking Mode LED Blue Left: Slew Left
* Revolution machines only.
Grey: Change Mode or select
tracking speed
Blue Right: Slew Right
* Revolution machines only.

Engine Stop Power On or

Request Unlock/Lock

In tracking mode, the ‘Track’ LED on the left will be illuminated.

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The control functions are described in more detail in the table below.
Control Function
Controls both tracks together:
Top lever
- Push forward to rotate tracks in the yellow direction
(small)*
- Pull back to rotate tracks in the blue direction
Controls only the left track:
- Push forward to rotate track in the yellow direction
Left lever*
- Pull back to rotate track in the blue direction
Also used in unlocking and pairing the handset.
Controls only the right track:
- Push forward to rotate track in the yellow direction
Right lever*
- Pull back to rotate track in the blue direction
Also used in unlocking and pairing the handset.
Controls slew motion left: Press to turn the incline conveyor
Blue button
left (anti-clockwise).
left*
* Revolution machines only.
Changes handset mode: Press for 3 seconds to change
handset mode between tracking and auxiliary modes.
Grey
Changes tracking speed (fixed-speed engines only): Press
button*
twice within 2 seconds to change tracking speed between
‘normal’ and ‘slow’.
Controls slew motion right: Press to turn the incline
Blue button
conveyor right (clockwise).
right*
* Revolution machines only.
Engine stop request: Press to request an immediate engine
stop.
Red button
This is NOT an emergency stop and must not be relied
upon as such.
Lock/unlock handset: Used to power-on, unlock and lock
the handset:
Green
- When off, hold down to power-on
button
- When locked, use to unlock
- When unlocked, press to lock

* Momentary action – need to be held in position to perform requested

action

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4.23.4 Auxiliary Mode Control Functions
The handset controls in auxiliary mode are depicted below.

Hopper Jacklegs Incline Conveyor Head Section

Raise/Lower Raise/Lower

Blue/Grey Buttons
Blue Left: Start/Stop Feed Conveyor
Grey: Change Mode
Auxiliary Mode LED Blue Right: Start/Stop Incline Conveyor

Engine Stop Power On or

Request Unlock/Lock

In auxiliary mode, the ‘AUX’ LED on the left will be illuminated.

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The control functions are described in more detail in the table below.
Control Function
Top lever
(small)*
N/A
Also see
Note below
Controls hopper jacklegs.
Left lever*
- Push forward to raise the jacklegs.
Also see
- Pull back to lower the jacklegs.
Note below
Also used in unlocking and pairing the handset.
Controls head section of conveyor.
Right lever*
- Push forward to raise the head section of the conveyor
Also see
- Pull back to lower the head section of the conveyor
Note below
Also used in unlocking and pairing the handset.
Blue button
N/A
left
Changes handset mode.
Grey button Press for 3 seconds to change handset mode between
auxiliary and tracking modes.
Blue button Start/Stop incline conveyor.
right Press to start or stop the incline conveyor.
Engine stop request.
Press to request an immediate engine stop.
Red button
This is NOT an emergency stop and must not be relied
upon as such.
Lock/unlock handset.
Used to power-on, unlock and lock the handset:
Green button - When off, hold down to power-on
- When locked, use to unlock
- When unlocked, press to lock

* Momentary action – need to be held in position to perform requested

action

When raising/lowering the hopper jacklegs and incline conveyor head section,
the first time a handset lever is pushed up or pulled down, it must be held in
position for at least 3 seconds before the hopper jacklegs or incline conveyor
will move. During this delay, the siren will beep (fast) on the machine. The
hopper jacklegs or incline conveyor will subsequently respond immediately to
further manipulations of the levers, provided that they occur within 15 seconds
of each other. When the hopper jacklegs or incline conveyor moves, the
beacon illuminates on the machine.

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4.23.5 LED’s
The handset features two columns of LEDs.

Mode LEDs: Information LEDs:

Tracking Mode RF LED
Auxiliary Mode Battery LED
Lock LED

 The left column of LEDs relates to the mode of operation (tracking or

auxiliary), as indicated above. Only one of these LEDs is illuminated at
any one time.

 The right column of LEDs provides status information, as detailed below.

LED Colour Appearance Description

RF LED Handset paired with machine for radio
Not used Green Steady
control
when
doglead Orange Flashing Handset in the process of pairing
cable Handset not paired with or out of radio
Red Steady
connected range
Green Flashing Handset battery is charging
Battery Green Steady Handset battery is charged
LED Orange Steady Handset battery is low on charge
Red Steady Handset battery needs charging
Red Flashing Handset is locked
Lock LED
Green Steady Handset is unlocked (can be used)

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4.23.6 Operation Modes
The large handset can be used in either of two operational modes and its
control functions depend on the currently active mode:

 Tracking mode: In this mode, the handset is used to:

- Control the tracks to move the machine forwards and backwards (and to
turn the tracks), see Section 4.29.

 Auxiliary mode: In this mode, the handset is used to:

- Raise/Lower the Hopper Jacklegs /Incline Conveyor Head Section – see

Section 4.50.

- Start/Stop the Incline Conveyor – see Section 4.35.

- Start/Stop the Feed Conveyor – see Section 4.36.

- Start/Stop the Pugmill (Telemix) – see Section 4.39.

- Start/Stop the Telemix Auto – see Section 4.40.

When switched on and unlocked, the handset defaults to tracking mode. The
handset can be switched between modes using the central grey button.

Press for 3 seconds

To change the operating mode, hold down the grey button for at least 3
seconds. The left LEDs indicate the current mode.

The control functions of the handset in the two modes are detailed in the next
two sections.

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4.23.7 Medium Handset
The medium handset can be used to remotely control a range of machines
features via a radio link, as follows:

 Start/Stop the Incline Conveyor

 Start/stop the Feed Conveyor (if fitted)

 Control the feed conveyor speed and reverse the feed conveyor (if
variable-speed feed conveyor fitted)

 Perform grid tips (if grid fitted)

 Raise/Lower the Deflector Plate (if fitted)

 Start/Stop/Reverse the Telemix Pugmill (if fitted)

The handset is shown below.

Keypad
(12 keys)

LEDs
(Row of 3)

Battery Charger Connector

This handset communicates with the machine only via a wireless (radio) link.

The handset incorporates a lithium-ion rechargeable battery which must be

charged using the supplied charger.

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If no button on the keypad is pressed within a 10-second interval, the handset
enters a low-power sleep mode to conserve battery charge. It is woken from
sleep by pressing any button on the keypad.

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4.23.8 Handset Keypad and Control Functions
The keypad controls and LEDs of the medium handset are shown and
summarised below.

Grid Tip Up Deflector Plate

(Manual) In/Lower

Conveyor On/Off

Grid Tip Down Deflector Plate

(Manual) Out/Raise
Feed Conveyor Feed Conveyor
On/Off Speed Up

Grid Tip Cycle

Pugmill On/Off
(Automatic)
Feed Conveyor
Speed Down

Engine Stop
Function
Request

The buttons and LEDs on the keypad are described further below.

When moving the deflector plate or feed conveyor hopper grid, the first time a
handset button is pressed, it must be held down for at least 3 seconds before
the plate/grid will move. During this delay, the siren will beep (fast) on the
machine. The plate/grid will subsequently respond immediately to further
button-presses, provided that they occur within 15 seconds of each other.
When the plate moves, the beacon illuminates on the machine.

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Buttons
The keypad buttons are described in the table below.
Control Function Icon Description
Incline Conveyor On/Off Press to start or stop the incline conveyor.
See Section 4.35 for instructions.

Feed Conveyor On/Off Press to start or stop the feed conveyor, if fitted
(to start the feed conveyor, the incline conveyor
must already be running). Also, hold down to
reverse the feed conveyor.
See Section 4.36 for instructions.
Feed Conveyor Speed Hold down to increase the feed conveyor speed
Up (it increases by 5% of the maximum speed for
each second the button is held down).
See Section 4.36 for instructions.

Feed Conveyor Speed Hold down to decrease the feed conveyor

Down speed (it decreases by 5% of the maximum
speed for each second the button is held
down).
See Section 4.36 for instructions.
Grid Tip Up (Manual) Hold down to raise the grid as part of a manual
grid tip (grid moves only while button is held
down and must initially be held down for at least
3 seconds – see Note above table).
See Section 4.51 for instructions.
Grid Tip Down (Manual) Hold down to lower the grid as part of a manual
grid tip (grid moves only while button is held
down and must initially be held down for at least
3 seconds – see Note above table).
See Section 4.51 for instructions.
Grid Tip Cycle Press for at least 1 second to start an automatic
(Automatic) grid tip cycle (a 3-second delay applies before
the grid moves). Press again to pause/resume
the grid tip.
See Section 4.51 for instructions.
Deflector Plate In/Lower Hold down to lower (or move in) the deflector plate
(plate moves only while button is held down and
must initially be held down for at least 3 seconds –
see Note above table).
See Section ** for instructions.
Deflector Plate Out/Raise Hold down to raise (or move out) the deflector plate
(plate moves only while button is held down and
must initially be held down for at least 3 seconds –
see Note above table).
See Section ** for instructions.

Pugmill On/Off Press for at least 1 second to start the Telemix

pugmill. Press again to stop it. Hold down the
button to reverse the pugmill (it will reverse
after 3 seconds) and release the button to
resume forward operation (which will then
resume after a 10-second delay).
See Section 4.29 or 4.30 for instructions.

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Function Unused (for future use).
The Function LED on the handset is illuminated
when this button is pressed.

Engine Stop Request Press to transmit an engine stop request to the

control panel (if within radio range, the panel will stop
the engine immediately).
This is NOT an emergency stop and must not be
relied upon as such.

* These buttons are momentary-acting. There is only motion while a button is

being pressed.

LED’s
The medium handset LEDs are described in the table below.

Function Battery Transmit

LED LED LED

LED Description
Function LED Illuminates when the Function (Fn) button is pressed on the handset
(currently unused - for future use).
Battery LED Illuminates when the battery charge is low.
Flashes during battery charging and extinguishes when charging is
complete.
Transmit LED Flashes continuously when a button is pressed or intermittently if no
buttons are being pressed.
Also flashes when pairing the handset with a machine.

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4.23.9 Activating/Deactivating the Handset
The small handset defaults to a low-power sleep mode to conserve battery
charge.

 If no button on the keypad is pressed within a 10-second interval, the

handset automatically enters sleep mode

 The handset is woken from sleep mode by pressing any button on the
keypad

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4.23.10 Small Handset
The small handset can be used to remotely control the machine, via a radio
link in the following ways:

 Start/Stop the Incline Conveyor

 Start/Stop the Feed Conveyor

 Raise/Lower the Hopper Jacklegs and Incline Conveyor Head Section

 Slew the Conveyor, * Revolution machines only.

The handset is shown below.

Keypad

Battery Charger Connector

This handset communicates with the machine only via a wireless (radio) link.

The handset incorporates a lithium-ion rechargeable battery which must be

charged using the supplied charger.

If no button on the keypad is pressed within a 10-second interval, the handset

enters a low-power sleep mode to conserve battery charge. It is woken from
sleep by pressing any button on the keypad.

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4.23.11 Handset Keypad and Control Functions
The keypad controls and LEDs of the handset are shown and summarised
below.

Raise Incline Conveyor Lower Incline Conveyor

Head Section Head Section

Raise Lower
Hopper Jacklegs Hopper Jacklegs

Slew Left Slew Right

* Revolution machines only. * Revolution machines only..

Start/Stop Start/Stop
Feed Conveyor Incline Conveyor

Engine Stop Transit LED

Request
Information LED

The buttons and LEDs on the keypad are described further below.

When raising/lowering the hopper jacklegs and incline conveyor head section,
the first time a handset button is pressed, it must be held down for at least 3
seconds before the hopper jacklegs or incline conveyor will move. During this
delay, the siren will beep (fast) on the machine. The hopper jacklegs or incline
conveyor will subsequently respond immediately to further button-presses,
provided that they occur within 15 seconds of each other. When the hopper
jacklegs or incline conveyor moves, the beacon illuminates on the machine.

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Buttons

The keypad buttons are described in the table below.

Control Function Icon Description

Raise Incline Conveyor Press to raise the incline conveyor head
Head Section * section.
See Section 4.50 for instructions.

Lower Incline Conveyor Press to lower the incline conveyor head

Head Section * section.
See Section 4.50 for instructions.

Raise Hopper Jacklegs * Press to raise the hopper jacklegs.

See Section 4.50 for instructions.

Lower Hopper Jacklegs * Press to lower the hopper jacklegs.

See Section 4.50 for instructions.

Slew Left * Press to slew the conveyor left (anti-

clockwise).
* Revolution machines See Section N/A for instructions.
only.

Slew Right * Press to slew the conveyor right (clockwise).

See Section N/A for instructions.
* Revolution machines
only.

Start/Stop Feed Conveyor Press to start or stop the feed conveyor, (to
start the feed conveyor, the incline conveyor
must already be running).
See Section 4.36 for instructions.

Start/Stop Incline Press to start or stop the incline conveyor.

Conveyor See Section 4.35 for instructions.

Engine Stop Request Press to transmit an engine stop request to

the control panel (if within radio range, the
panel will stop the engine immediately).
This is NOT an emergency stop and must not
be relied upon as such.

* These buttons are momentary-acting. There is only motion while a button is

being pressed.

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LED’s

The handset LEDs are described in the table below.

LED Description
Transmit LED Flashes continuously when a button is pressed or intermittently if no
buttons are being pressed
Information LED Flashes when pairing the handset with a machine and during battery
charging.

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4.23.12 Activating/Deactivating the Handset
The small handset defaults to a low-power sleep mode to conserve battery
charge.

 If no button on the keypad is pressed within a 10-second interval, the

handset automatically enters sleep mode

 The handset is woken from sleep mode by pressing any button on the
keypad

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4.23.13 Handset Charging
The internal batteries of the handsets can be charged as follows:

 The large handset of the wired/wireless type can be charged from the
machine via the doglead cable or from a DC source via the supplied
charger (which uses the same socket on the handset as the doglead
cable). The Battery LED on the handset flashes green during charging
and illuminates solidly in green when charging is complete.

 The medium handset can be charged from a DC source via the

supplied charger, which must be connected to a socket on the bottom-
end of the handset. The Transmit LED (right) on the handset flashes
during charging and is extinguished when charging is complete.

 The small handset can be charged from a DC source via the supplied
charger, which must be connected to a socket on the bottom-end of the
handset. The Information LED (lower) on the handset flashes during
charging and is extinguished when charging is complete.

The charger is shown below.

DC Source Small/Medium Handset

Connector Connector

Large Handset
Connector

The source of charge must be a 12V or 24V DC supply.

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For the large handset, if the handset is connected to the machine via the
doglead cable but handset’s internal battery is not charging, the following
warning symbol is displayed on the Main screen, indicating that the fuse F5 in
the control panel’s master module is open.

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4.24 HYDRAULIC CONTROL LEVERS

The Engine RPM should be set low when operating the hydraulic controls
levers. Never operate the control levers at full RPM.

3 4 5

Item Function
1 Pugmill Speed Control Switch
2 Hydraulic Enable Button
3 Raise or Lower Hopper Jacklegs Lever (Option)
4 Raise or Lower Incline Conveyor Head Section Lever
5 Pugmill Transport or Working Position Lever
6 Adjust Pugmill Working Angle Lever

1. Pugmill Speed Control Switch

This control switch is used to increase/decrease the speed of the pugmill.
Turn the switch anticlockwise or clockwise to achieve the desired speed.

To increase the speed, turn the switch anticlockwise.

To decrease the speed, turn the switch clockwise.

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2. Hydraulic Enable Button
This enable button is used to activate the control levers.

Press and hold button to activate the control levers. Operate the control levers
as required. Release the button once the procedure is complete.

3. Raise/Lower Hopper Jacklegs

This control lever are used to raise/lower the jacklegs.
Move the lever in the directions allowed to achieve the desired position.

Press and hold button to activate the control levers. Operate the control lever
as required. Release the button once the procedure is complete.

4. Raise/Lower Incline Conveyor Head Section

This lever is used to raise/lower the head section of the conveyor.
Move the lever in the directions allowed to achieve the desired elevation of
the conveyor head section.

Do not operation control level at full RPM.

Extreme care must be taken so that the machine does not come into contact
with any overhead power lines.

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5. Manoeuvre Pugmill Transport/Working Position
This lever is used to manoeuvre the pugmill into the transport or working
position. Move the lever in the directions allowed to achieve the desired
position.

Do not operation control level at full RPM.

The pugmill hydraulic hoses must be disconnected before placing the pugmill
into the transport position or reconnected after the pugmill has been placed into
the working position.
The pugmill inlet chute sides must be removed before placing the pugmill into
the transport position or fitted after the pugmill has been placed into the working
position.

6. Adjust Pugmill Working Angle Position

This lever is used to adjust the pugmill’s working angle.
Move the lever in the directions allowed to achieve the desired angle.

Do not operation control level at full RPM.

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4.25 PUGMILL SPEED CONTROL
The pugmill’s speed can be controlled by using the speed control switch as
shown below.

Pugmill
Speed Control

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4.26 ENGINE STARTING PROCEDURE

The engine is started using the ignition start switch

(Figure 4.2) located on the main control panel at the right
hand side of the machine (Figure 4.1).
Perform all the daily pre-start checks in section 2.4 and
verify that starting and operating the machine will not cause
a hazard to other personnel in the vicinity. Figure 4.1

Make sure that no-one is in or likely to enter the operating

exclusion zone for the machine (Figure 2.2 in the Safety
Section) that the isolator switch is in the position shown
(Figure 4.3) and that all emergency stop buttons are
released.

To start the engine, Figure 4.2

 Insert the key into the key switch on the control panel.
 Turn the key clockwise to the power only position ( ).
 Wait until the display shown the main screen (Figure 4.4).
 If the engine has a pre-heat system, turn the key further
clockwise to the Heat position ( ) and hold the key in
this position for between 7 and 10 seconds until the Figure 4.3
Engine Pre-heat warning ( ) disappears from the
main screen.
 Turn the key clockwise to the crank position ( ) and
hold it in this position until the engine starts.
Figure 4.4
Before cranking begins, a 7 second time-delay is
implemented during which the machine’s siren beeps (fast) and its
beacon illuminates. A countdown is shown on the main screen.
When the engine starts, the engine speed is shown on the main screen
moves off 0 RPM.

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 As soon as the engine starts, release the key switch. The engine will be
now running at its idle speed (e.g. 800 RPM), as indicated on the main
screen.
 Before increasing the engine speed and operating the machine, run the
engine at the idle speed for 5 minutes to allow the running temperature
to be reached. Similarly, it should be run at the idle speed for a few
minutes before switching off. This will prolong the engine life.

 For Electronic Engines, increase and decrease the

RPM using the up and down arrows on the navigation
button (Figure 4.5) on the display unit. See
Electronically Controlled Engine Speed Modes Figure 4.5
below.

 For Mechanical Engines, increase and decrease the

RPM by using the throttle lever (Figure 4.6) located to
the left of the control panel.
Raising the throttle lever increases the RPM.
Lowering the throttle lever decreases the RPM.
Figure 4.6

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Electronically Controlled Engine Speed RPM Modes
The engine speed can also be controlled from the Main screen using the
up/down arrows of the navigation button.

 The up arrow increases the engine speed.

 The down arrow decreases the engine speed.

The engine speed can be increased/decreased in either of two modes –

stepped mode or milestone mode. The speed-change mode is toggled using
the OK button on the display unit – hold it down for 5 seconds to change
mode.

The current speed-change mode is indicated by the symbol to the right of the
‘RPM’ on the screen, as shown below.

Stepped Mode
In stepped mode, the engine speed increases/decreases in 50rpm steps.
This mode is only available for a variable-speed engine and is indicated by
the following on-screen symbol.

Pressing an arrow (on the Navigate button) once changes the speed in one
50rpm step. Holding down the arrow changes the speed continuously in
50rpm steps.

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Milestone Mode
In milestone mode, the engine speed increases/decreases to a fixed milestone.
This is the only speed-change mode available for a fixed-speed engine. This
mode is indicated by the following on-screen symbol.

A variable-speed engine has three speed-milestones (in addition to 0 rpm):

 Idle Speed (typically 800 or 900 RPM)

 1800 RPM

 2200 RPM

A fixed-speed engine has only two speed-milestones: idle and 1800 rpm.
Pressing an arrow (on the Navigate button) once changes the speed to the
next milestone (up or down, depending on the arrow used).

 To turn off the engine return the key to the position ( ).

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4.27 ENGINE AFTERTREATMENT FEATURES
The machine’s engine may be equipped with one or both of the following
exhaust aftertreatment features:

Diesel Exhaust Fluid (DEF)

Some engines are fitted with an aftertreatment unit which injects Diesel
Exhaust Fluid (DEF) into the exhaust system to convert nitrogen oxides into
nitrogen and water. It is important to maintain the DEF level of the machine in
order to support this exhaust aftertreatment feature – it should typically be
replenished when the level falls to 20% of full capacity.

Diesel Particulate Filter (DPF)

Some engines are fitted with a Diesel Particulate Filter (DPF) to catch
particles of soot in the exhaust gases. The DPF can be monitored from the
display unit. DPF maintenance can also be controlled from the display unit.

More information on the Engine Aftertreatment is described in the supplement

documentation.

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4.28 MANOEUVRING ON SITE

Before manoeuvring the machine, ensure that all personnel are at a safe
distance, and that there is sufficient clearance around the machine to move.

Do not travel on grades or ramps that are wet, muddy, slippery, or are likely
to have poor surface condition along any part of the intended route.
Caution must be exercised when moving machinery on soft or uneven
surfaces.
Surface must be prepared and the travel path free from hazards such as pot
holes and bumps.
It is recommended that machines are not driven or turned along a slope.

Never track this machine when the conveyor is in an elevated position. The
conveyor should be lowered and the pugmill in the transport position before
manoeuvring.

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Make sure you have trained personal on hand to guide with the safe
movement of the track conveyor
To minimise the risk of overbalancing the machine when travelling up a
gradient, the machine should be driven backwards (i.e. idlers and feedboot
end first, drive sprocket and discharge end to the rear).
When travelling down a gradient, the machine should be driven forwards
(sprocket and discharge end first, idlers and feedboot to the rear.
Descend the slope slowly and in a controlled manner.
Do not permit the machine to gather speed and accelerate under its own
momentum down any slope.

Your machine should be only moved front to back up to 15 degrees and a

maximum of 5 degrees side to side.

The planned route surface must be prepared and the travel path free from
hazards such as pot holes and bumps.

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ALWAYS:-
 Park the machine on flat, level ground. If it is necessary to park the
machine on a gradient, the tracks should be solidly blocked.
 Ensure the terrain the machine is working on is firm enough to adequately
support the machine.
 Make certain the machine is tracked at least 10m in either direction on a
daily basis, to minimise risk of track chain seizure.
 Ensure the track systems are free from debris before moving the machine.
 Make certain the tracks are not frozen to the ground before moving the
machine.
 Ensure no leakage of oil from gearbox, roller and idler before and during
tracking.
 Stop the machine for 20 minutes after tracking it continuously for 20
minutes, to allow the components to cool down.
NEVER:-
 Attempt to track the machine if there is any build-up of material around the
tracks and drive sprockets.
 Attempt to track the machine if the tracks are frozen to the ground.
 Push or tow the machine when it is unable to free itself.
 Track the machine constantly more than 20 minutes without providing
adequate rest.

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4.29 TRACKING

Prior to tracking please read and understand manoeuvring the machine, the
dangers, warnings, and hazard zones.
Ensure that all personnel are clear of the machine.
The operator MUST NOT use any of the functions on the pendant while
standing next to the control panel.
The operator should be as clear of the machine as the pendant lead will allow.

4.29.1 Tracking/Slewing Safety Decals

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4.29.2 Tracking Hazard Zones

TRACKING IMPACT
HAZARD AREA
WHEN OPERATING THE
TRACK FUNCTION THE
OPERATOR SHOULD MIMIC
THE MOVEMENT OF THE
MACHINE AND KEEP THE
DOG LEAD TENSIONED AT
ITS MAXIMUM LENGTH

CRUSH / NIP
HAZARD AREA

THE OPERATOR’S
LOCATION USING THE
HANDSET

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4.30 UNLOCKING THE LARGE HANDSET
Before the large handset can be used to control the tracks, it must be
unlocked as described below.

If the large handset is to be used in wireless (radio) mode, the internal battery
must be charged through either a wired (dog-lead) connection with the
machine or independently via the supplied handset charger.

1. Ensure that there is power to the control panel on the machine – that is,
the key switch is in the Power-only position.

2. Ensure that the Tracking/Radio screen is shown on the display unit of the
machine’s control panel – you can access it from the Main screen) by
pressing the Tracking/Radio button, indicated by the following button-
icon:

At this moment, a red, closed padlock is shown in the top-left of the

Tracking/Radio screen to indicate that the large handset is locked.

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To unlock the large handset, it is not strictly necessary to display the

Tracking/Radio screen, but you will need to be on this screen to facilitate machine
tracking.

3. Start the unlocking sequence on the large handset by pressing the green
Lock button (key symbol), as indicated on the large handset image below.

If the large handset was off, you will need to hold down this button for at
least 3 seconds until the Lock LED above the button starts to flash red.

You must now complete the rest of the unlocking sequence within 40
seconds
(Otherwise the large handset will automatically switch off).

Start unlocking
sequence here

4. Perform the following sequence of movements using the left and right
control levers on the large handset (also refer to the arrows in the large
handset image above):

- LEFT Lever – Move UP (2)

- LEFT Lever – Move DOWN (3)
- RIGHT Lever – Move UP (4)
- RIGHT Lever – Move DOWN (5)
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The above movements must be made in quick succession for the large
handset to successfully unlock.

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4.31 USING THE LARGE HANDSET TO CONTROL THE TRACKS
It is assumed that the large handset is ready for use – that is, either of the
following applies:

 For wired use, the doglead cable is connected between the large
handset and machine.

 For wireless use, the large handset has been charged and the doglead
cable is not connected.

If you need to urgently stop the engine during the tracking operation, press
the red button on the large handset. This will request the engine to stop but
is not an E-stop and should not be relied upon as one.

Both Tracks
Forward/Reverse

Right Track
Left Track
Forward/Reverse
Forward/Reverse
Blue/Grey Buttons
Blue Left: Slew Left
* Revolution machines only.
Grey: Change Mode or select
Tracking Mode LED tracking speed
Blue Right: Slew Right
* Revolution machines only.

Information LEDs:
RF LED
Battery LED
Engine Stop Power On or Lock LED
Request Unlock/Lock

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To control the tracks:

1. Ensure that the engine is running.

Allow the engine to warm up before starting to track. If starting the engine
from cold, leave it to run for at least 5 minutes at the idle speed before
continuing.

2. Increase the Engine RPM.

3. Go to the Tracking/Radio screen on the display unit. Accessing this

screen puts the machine into the tracking mode.

Accessing the Tracking/Radio screen enables tracking mode on the machine

and you must remain on this screen while tracking. If you leave this screen,
tracking will be disabled.

4. Ensure that the large handset is unlocked. This is indicated by the Lock
LED on the handset being constantly illuminated in green.

5. Ensure that the large handset is in tracking mode (on being unlocked,
the handset will default to tracking mode) – the ‘Track’ LED on the
handset will be illuminated.

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If the large handset is not in tracking mode (but in auxiliary mode), it can be
switched to tracking mode by pressing the central grey button on the
handset for 3 seconds. This also enables tracking mode on the machine –
the Tracking/Radio screen will be displayed on the machine’s LCD panel (if
not already done).

Once the large handset is unlocked and in tracking mode, a 9-second pre-
tracking delay is applied. During this time, the siren beeps (fast) on the
machine and its beacon illuminates. If one of the tracking levers is moved
on the handset during this time, the pre-tracking delay will restart from 9
seconds. You can also cancel tracking mode by pressing the green (Lock)
button on the handset.

6. Ensure that the required tracking speed is selected. The tracking speed
defaults to ‘normal’ speed. If slow tracking is required, you can select it
in either of two ways:

 From the large handset by pressing the central grey button twice within
two seconds (repeating these button-presses will return you to normal
tracking)

 From the Tracking/Radio screen on the display unit by pressing the Slow
Tracking button, shown below (the snail icon is white for normal tracking
and turns green when slow tracking is selected)

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 The tracking speed varies with the engine speed, which can be
controlled from the Tracking/Radio screen using buttons 6 (speed up)
and 7 (speed down).

7. Use the three control levers on the large handset to operate the left and
right tracks. A lever must be held in position to maintain tracking – when
it is released, tracking stops. During tracking, the machine’s siren
sounds continuously during normal tracking or beeps (slowly) during
slow tracking.
Both Tracks
Forward/Reverse

Left Track Right Track

Forward/Reverse Forward/Reverse

On a machine with a fixed-speed engine, the tracking speed can be toggled

between ‘normal’ and ‘slow’ using the central grey button on the large
handset. Press the button twice within 2 seconds to change the speed.

8. Once finished, to disable tracking, press the green Lock button ( )

on the large handset to exit tracking mode and lock the handset (the
Lock LED will flash red). The large handset will automatically switch off
after 50 seconds in the locked state.

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4.32 OPERATION MODES AND RECIPES
Telemix Auto can operate in either of two modes – automatic or manual.
Each mode has four possible ‘recipes’ (labelled R1, R2, R3, R4) that
determine the input of additive and water into the final mix.

4.32.1 Automatic Mode

In automatic mode, the rates at which water and additive are introduced are
varied according to the amount of aggregate arriving via the conveyor.
In this mode, the recipe comprises the relative amounts of aggregate, additive
and water by weight in the final mix, expressed as percentages – for example:

 Aggregate – 90%
 Additive – 5%
 Water – 5%

The three percentages must add up to 100% but in defining a recipe for
automatic mode, only the additive and water percentages can be specified –
the aggregate percentage is automatically adjusted to make the total 100%.
During automatic operation, the additive and water rates are automatically
adjusted in response to variations in aggregate weight on the conveyor, in
order to maintain the percentage weights of aggregate/additive/water
specified by the recipe used.

4.32.2 Manual Mode

In manual mode, the rates at which additive and water are introduced to the
mix are fixed, according to the recipe used. The recipe states just two
quantities:

 Additive speed in terms as a percentage of the maximum speed

 Water rate measured in litres per minute (l/min)

These rates do not vary, regardless of the weight of aggregate on the

conveyor.

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4.33 STARTING THE MACHINE

1. Ensure that all E-stops on the machine are released.

2. Start the engine, as described in the Section 4.26.

3. Ensure that the machine is deployed in the required working position.

This may involve:

a) Moving the machine on its tracks to the desired location, as described
in Section 4.31.

b) Placing the pugmill in the working position and adjusting to the required
angle of inclination as described in Section 4.47.

c) Adjusting the conveyor to the required angle of inclination, as described

in Section 4.50.

4. Start the Incline Conveyor, as described in Section 4.35.

5. Start the Feed Conveyor, if applicable, as described in Section 4.36.

6. Once the Feed and Incline Conveyor has started, material can be
passed through the machine.

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4.34 STOPPING THE MACHINE

If you need to stop and shut down a fully operational machine, proceed as
follows:

Proceed as follows:
1. Make sure the Feed and Incline Conveyor belt is clear of material.

2. Stop the Feed Conveyor, as described in Section 4.36.

3. Stop the Incline Conveyor, as described in Section 4.35.

4. Reduce the engine speed to the idle state as described in Section 4.26,
and leave it running for at least 5 minutes (to prolong engine life).

5. Shut down the engine by turning the key switch on the control panel anti-
clockwise to the off (12 ‘o’clock) position.

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4.35 START/STOP THE INCLINE CONVEYOR
The incline conveyor can be started and stopped from a button on the control
panel, from a button on the display unit or from one of the remote handsets
(large or small).

a) Starting the Incline Conveyor using the Control Panel

The control panel features a dedicated conveyor button to stop and start the
incline conveyor.

Using this button to start/stop the incline conveyor will also start/stop the
feed conveyor (if fitted).

1. Ensure that the engine is running at a speed greater than the idle speed.
When the incline conveyor is not running, the conveyor button is green.

2. Press and hold down the conveyor button for at least 1 second, until the
button turns red.

A 10-second delay is then implemented before the incline conveyor starts.

During this time, a countdown is shown on the Main screen of the display
unit, the machine’s siren beeps (fast) and its beacon illuminates. Also during
this time, the incline conveyor start can be cancelled by pressing the button
again.

The feed conveyor will be automatically started once the incline conveyor is
running. There is a 5-second delay between the incline conveyor starting
and the feed conveyor starting. During this time, a countdown is shown on
the Main screen and the siren continues to sound.

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3. Once the incline conveyor and feed conveyor is running, you can feed
material through the machine.

Stopping the Incline Conveyor

To stop the incline conveyor using the conveyor button on the control panel,
simply press the button. It will then turn from red to green and the incline
conveyor will stop immediately.

The feed conveyor will also be stopped.

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b) Starting the Incline Conveyor using the Display Unit
On the display unit, the incline conveyor can be started/stopped from either of
two screens:

 Main screen.

Incline Conveyor
Start/Stop

 Primary Machine screen.

Incline Conveyor
Start/Stop

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When the incline conveyor and feed conveyor are running, this is indicated on
the Machine screen by animated (rotating) symbols on either side of the
machine image.

The feed conveyor symbol is on the left and the incline conveyor symbol is on
the right.

Starting the incline conveyor from the display unit does not start the feed
conveyor. The feed conveyor can be started as described in Section 4.36.

1. Ensure that the engine is running at a speed greater than the idle speed.

2. Ensure that either the Main or Primary Machine screen is displayed on

the LCD panel.

3. Press and hold down the Conveyor On/Off button for at least 1 second
until the button-icon turns red.

A 10-second delay is then implemented before the incline conveyor

starts. During this time, a countdown is shown on the screen, the
machine’s siren beeps (fast) and its beacon illuminates. Also during this
time, the incline conveyor-start can be cancelled by pressing the button
again.

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4. Now start the feed conveyor as described in Section 4.36.

5. Once the incline conveyor and feed conveyor is running, material can be
fed through the machine.

Stopping the Incline Conveyor

To stop the incline conveyor using the display unit on the control panel, simply
press the conveyor on/off button on either the Main or Primary Machine
screen. The incline conveyor will stop immediately.

The feed conveyor will also be stopped.

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c) Starting the Incline Conveyor using the Large Handset
The incline conveyor can be started/stopped from the large handset, when the
handset is used in auxiliary mode.

The handset will automatically lock after 300 seconds of inactivity. On

unlocking again, it will default to tracking mode.

1. Ensure that the handset is switched on and in auxiliary mode – the ‘AUX’
LED on the handset will be illuminated.

2. Press the button ( ) on the handset to start the incline conveyor.

A 10-second delay is then implemented before the incline conveyor starts.

During this time, a countdown is shown on the Main screen of the display
unit, the machine’s siren beeps (fast) and its beacon illuminates. Also during
this time, the conveyor-start can be cancelled by pressing the button again.

3. Now start the feed conveyor as described in Section 4.36.

4. Once the incline conveyor and feed conveyor is running, material can be
fed through the machine.

Stopping the Incline Conveyor

To stop the incline conveyor using the handset, simply press the conveyor
on/off button on handset (with the handset still in auxiliary mode). The incline
conveyor will stop immediately.

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d) Starting the Incline Conveyor using the Medium Handset
The incline conveyor can be started/stopped via a radio link from the medium
handset.

1. Press the grey Conveyor On/Off button on the medium handset to start
the incline conveyor.

A 10-second delay is then implemented before the incline conveyor

starts. During this time, a countdown is shown on the Main screen of the
display unit, the machine’s siren beeps (fast) and its beacon illuminates.
Also during this time, the conveyor-start can be cancelled by pressing
the button again.

2. Now start the feed conveyor as described in Section 4.36.

3. Once the incline conveyor and feed conveyor is running, material can be
fed through the machine.

Stopping the Incline Conveyor

To stop the incline conveyor remotely from the medium handset, simply press
the grey conveyor on/off button on the handset again. The incline conveyor
will stop immediately.

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e) Starting the Incline Conveyor using the Small Handset
The incline conveyor can be started/stopped via a radio link from the small
handset.

1. Press the white Start/Stop Conveyor button on the small handset to start
the incline conveyor.

Conveyor
Start/Stop

A 10-second delay is then implemented before the incline conveyor

starts. During this time, a countdown is shown on the Main screen of the
display unit, the machine’s siren beeps (fast) and its beacon illuminates.
Also during this time, the conveyor-start can be cancelled by pressing
the button again.

2. Now start the feed conveyor as described in Section 4.36.

3. Once the incline conveyor and feed conveyor is running, material can be
fed through the machine.

Stopping the Incline Conveyor

To stop the incline conveyor remotely from the small handset, simply press
the white Start/Stop Conveyor button on the handset again. The incline
conveyor will stop immediately.

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4.36 START/STOP THE FEED CONVEYOR
The feed conveyor can be started and stopped from a button on the control
panel, from a button on the display unit or from one of the remote handsets
(large or small).

For the feed conveyor to start, the incline conveyor must already be running. It
is, however, possible to start the feed conveyor without the incline conveyor
running for maintenance purposes, see Section 4.36, Part C.

a) Starting the Feed Conveyor using the Control Panel

The Conveyor button on the control panel starts/stops both the incline
conveyor and feed conveyor.

When the incline conveyor is started using the Conveyor button on the control
panel, the feed conveyor is automatically started once the incline conveyor is
running. However, a time-delay of 5 seconds is implemented between the
incline conveyor starting and the feed conveyor starting. During this time, a
countdown is shown on the Main screen of the display unit and the machine’s
siren beeps (fast). Also during this time, the feed conveyor start can be
cancelled by pressing the button again.

Cancelling the feed conveyor start by pressing the button again will also stop
the conveyor.

Stopping the Feed Conveyor

To stop the feed conveyor using the conveyor button on the control panel,
simply press the button. It will then turn from red to green and the feed
conveyor and incline conveyor will stop immediately.

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b) Starting the Feed Conveyor using the Display Unit
On the display unit, the feed conveyor can be started/stopped from either of
two screens:

 Main screen.

Feed Conveyor
Start/Stop

 Primary Machine screen.

Feed Conveyor
Start/Stop

The Start/Stop Feed Conveyor button on the display unit has the same icon
on both screens (but different positions – button 7 on Main screen, button 4
on Machine screen).

The feed conveyor cannot be started unless the incline conveyor is running.

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When the feed conveyor is running, an animated feed conveyor symbol is
displayed on the left of the Machine screen

The feed conveyor symbol is on the left and the incline conveyor symbol is on
the right.

1. Ensure that the engine is running at a speed greater than the idle speed.

2. Ensure that the Main or Primary Machine screen is displayed on the

LCD panel.

3. Press and hold down the Conveyor On/Off button for at least 1 second.

A 10-second delay is then implemented before the feed conveyor starts.

During this time, a countdown is shown on the screen, the machine’s
siren beeps (fast) and its beacon illuminates. Also during this time, the
feed conveyor start can be cancelled by pressing the button again.

4. Once the feed conveyor and incline conveyor is running, material can be
fed through the machine.

Stopping the Feed Conveyor

To stop the feed conveyor using the display unit on the control panel, simply
press the conveyor on/off button on Main or Primary Machine screen. The
feed conveyor will stop immediately.

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c) Starting the Feed Conveyor without the Incline Conveyor
(Maintenance Purposes Only)

While the incline conveyor must normally be running to start the feed
conveyor, it is possible to start the feed conveyor without having the incline
conveyor running, but this mode is for maintenance purposes only.

1. Ensure that the Main or Primary Machine screen is displayed on the

LCD panel.

 Main screen.

Feed Conveyor
Start/Stop

 Primary Machine screen.

Feed Conveyor
Start/Stop

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2. Press and hold down both the Start/Stop Feed Conveyor button and the
OK button for at least 5 seconds. A countdown is shown on the screen
during this time.

3. Once the feed conveyor is running, maintenance tests can be carried out
(but do not feed material through the feed conveyor).

Stopping the Feed Conveyor

To stop the feed conveyor using the display unit on the control panel, simply
press the Start/Stop Feed Conveyor button on Main or Primary Machine
screen. The feed conveyor will stop immediately.

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d) Starting the Feed Conveyor using the Large Handset
The feed conveyor can be started/stopped from the large handset, when the
handset is used in auxiliary mode.

The handset will automatically lock after 300 seconds of inactivity. On

unlocking again, it will default to tracking mode.

The feed conveyor cannot be started unless the incline conveyor is running.

1. Ensure that the conveyor is running.

2. Ensure that the handset is switched on and in auxiliary mode – the ‘AUX’
LED on the handset will be illuminated.

3. Press the left blue button on the large handset to start the feed
conveyor.

4. Once the feed conveyor is running, material can be fed through the
machine.

Stopping the Feed Conveyor

To stop the feed conveyor using the large handset, simply press the feed
conveyor on/off button on handset (with the handset still in auxiliary mode).
The feed conveyor will stop immediately.

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e) Starting the Feed Conveyor using the Medium Handset
The feed conveyor can be started/stopped via a radio link from the medium
handset.

The feed conveyor cannot be started unless the incline conveyor is running.

1. Ensure that the incline conveyer is running.

2. Press the orange Feed Conveyor On/Off button on the medium handset
to start the feed conveyor.

3. Once the feed conveyor is running, material can be fed through the
machine.

Stopping the Feed Conveyor

To stop the feed conveyor remotely using the medium handset, simply press
the Feed Conveyor On/Off button on medium handset again. The feed
conveyor will stop immediately.

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f) Starting the Feed Conveyor using the Small Handset
The feed conveyor can be started/stopped via a radio link from the small
handset.

The feed conveyor cannot be started unless the incline conveyor is running.

1. Ensure that the incline conveyor is running.

2. Press the orange button on the small handset to start the feed conveyor.

3. Once the feed conveyor is running, material can be fed through the
machine.

Stopping the Feed Conveyor

To stop the feed conveyor remotely using the small handset, simply press the
orange feed conveyor on/off button on the small handset. The feed conveyor
will stop immediately.

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4.37 CONTROLLING THE FEED CONVEYOR SPEED
If the machine is fitted with a variable-speed feed conveyor, the feed conveyor
speed can be controlled from the display unit or from the medium handset.

Telestack would recommend that the feed conveyor to be set to a slow speed
initially and then increased at the user discretion to achieve the required
throughput.

It is strongly recommended that the variable gate is always present and set to
a maximum opening of 60mm when running sand, due to the potential to
cause instability caused by excessive weight on the incline conveyor if run at
maximum speed without gate control.

User-defined maximum and minimum feed conveyor speeds are set via the
Machine Settings screen, where a default feed conveyor speed is also set as
a percentage of the maximum speed. The feed conveyor speed is also
controlled as a percentage of the maximum speed.

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a) Controlling the Feed Conveyor Speed using the Display Unit
To adjust the feed conveyor speed from the display unit:

1. Ensure that the feed conveyor is running.

2. Access the Primary Machine screen on the display unit.
3. Now access the Secondary Machine screen. This screen will include
two button-icons on the left for the feed conveyor speed.

4. Press and hold down the button corresponding to the required direction
of speed change. The relevant buttons are indicated by the following on-
screen icons.

Increase
Feed Conveyor Speed

Decrease
Feed Conveyor Speed

The speed changes by 5% (of the maximum speed) for every second
that the button is held down. The current percentage speed is shown to
the right of the button-icons on the screen.

5. Release the button when the desired feed conveyor speed is reached.

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b) Controlling the Feed Conveyor Speed using the Medium Handset
To adjust the feed conveyor speed remotely from the medium handset:

1. Ensure that the feed conveyor is running.

2. Press and hold down the orange Feed Conveyor Speed Up or Feed
Conveyor Speed Down button on the medium handset according to the
required direction of speed change.

Increase
Feed Conveyor Speed

Decrease
Feed Conveyor Speed

The speed changes by 5% (of the maximum speed) for every second
that the button is held down. The current percentage speed can be
viewed on the Secondary Machine screen.

3. Release the button when the desired feed conveyor speed is reached.

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4.38 REVERSING THE FEED CONVEYOR
If the machine is fitted with a variable-speed feed conveyor, the feed conveyor
can be reversed. This feed conveyor reverse-action can be controlled from a
button on the display unit (on the control panel) or from a button on one of the
remote handsets (large, medium or small).

In all cases, the button is momentary-acting – the feed conveyor will run in the
reverse direction only while the button is held down.

a) Reversing the Feed Conveyor using the Display Unit

On the display unit, the feed conveyor can be reversed from either of two
screens:

 Main screen
 Primary Machine screen

On both screens, the Start/Stop Feed Conveyor button with the following on-
screen icon is used for the feed conveyor reverse-action.

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1. Ensure that the incline conveyor and feed conveyor are running.

2. Ensure that either the Main or Primary Machine screen is displayed on

the LCD panel.

3. Hold down the Start/Stop Feed Conveyor button.

The following actions will then take place on the machine:

a) After 3 seconds, the feed conveyor will momentarily stop for 1 second.
b) The feed conveyor will then run in reverse (provided that the button is
held down).

4. When you wish return to forward operation of the feed conveyor, release
the button.

The following actions will then take place on the machine:

a) The feed conveyor will momentarily stop for 1 second.

b) The feed conveyor will then start to run in the forward direction.

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b) Reversing the Feed Conveyor using the Large Handset
The feed conveyor can be reversed from the large handset, when the handset
is used in auxiliary mode.

The large handset will automatically lock after 300 seconds of inactivity. On
unlocking again, it will default to tracking mode.

1. Ensure that the incline conveyor and feed conveyor is running.

2. Ensure that the handset is switched on and in auxiliary mode – the ‘AUX’
LED on the handset will be illuminated.

3. Hold down the left blue button on the large handset.

The following actions will then take place on the machine:

a) After 3 seconds, the feed conveyor will momentarily stop for 1 second.
b) The feed conveyor will then run in reverse (provided that the button is
held down).

4. When you wish return to forward operation of the feed conveyor, release
the button.

The following actions will then take place on the machine:

c) The feed conveyor will momentarily stop for 1 second.

d) The feed conveyor will then start to run in the forward direction.

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c) Reversing the Feed Conveyor using the Medium Handset
The feed conveyor can be reversed via a radio link from the medium handset.

1. Ensure that the incline conveyor and feed conveyor is running.

2. Hold down the orange Feed Conveyor On/Off button on the medium
handset.

The following actions will then take place on the machine:

a) After 3 seconds, the feed conveyor will momentarily stop for 1 second.
b) The feed conveyor will then run in reverse (provided that the button is
held down).

3. When you wish return to forward operation of the feed conveyor, release
the button.

The following actions will then take place on the machine:

c) The feed conveyor will momentarily stop for 1 second.

d) The feed conveyor will then start to run in the forward direction.

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d) Reversing the Feed Conveyor using the Small Handset
The feed conveyor can be reversed via a radio link from the small handset.

1. Ensure that the incline conveyor and feed conveyor is running.

2. Hold down the orange button on the medium handset.

The following actions will then take place on the machine:

a) After 3 seconds, the feed conveyor will momentarily stop for 1 second.
b) The feed conveyor will then run in reverse (provided that the button is
held down).

3. When you wish return to forward operation of the feed conveyor, release
the button.

The following actions will then take place on the machine:

c) The feed conveyor will momentarily stop for 1 second.

d) The feed conveyor will then start to run in the forward direction.

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4.39 START/STOP THE PUGMILL (TELEMIX)
The pugmill can be started and stopped from a button on the control panel
and from a button on the display unit.

The pugmill can also be reversed to help relieve material blockages as

described in Section 4.41 (Telemix) or Section 4.42 (Telemix Auto).

a) Starting the Pugmill using the Control Panel

When the pugmill is present on the machine, the conveyor button on the
control panel starts/stops the pugmill, the incline conveyor and the feed
conveyor in a sequential start/stop.

1. Ensure that the engine is running at a speed greater than the idle speed.

2. Press and hold down the Conveyor On/Off button for at least 1 second.

A 10-second delay is then implemented before the sequential start. The

machine components are then started in the following order.

Pugmill Incline Conveyor Feed Conveyor

Once the pugmill has started, there is a 5 second delay before the
incline conveyor starts and then a further 5 second delay before the feed
conveyor starts. During this time, a countdown is shown on the screen,
the machine’s siren beeps (fast) and its beacon illuminates. Also during
this time, the sequential start can be cancelled by pressing the button
again (the components will be stopped).

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3. Once all three components are all running, you can be feed material
through the machine.

Stopping the Pugmill

To stop the pugmill in a sequential stop, simply press the conveyor button on
the control panel. It will then turn from red to green and the machine
components will be stopped in the following order:

Feed Conveyor Incline Conveyor Pugmill

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b) Starting the Pugmill using the Display Unit
On the display unit, the pugmill can be started/stopped from the machine
screen using the Start/Stop Pugmill Button (OK) with the following on-screen
icon.

Starting the Pugmill from the display unit does not automatically start the
incline conveyor and feed conveyor. Also, you cannot start the incline
conveyor or feed conveyor without the pugmill already running.

1. Ensure that the engine is running at a speed greater than the idle speed.

2. Ensure that the Machine screen is displayed on the LCD panel.

3. Press the pugmill button (shown above) for at least 1 second.

A 10-second delay is then implemented before the pugmill starts. During

this time, a countdown is shown on the screen, the machine’s siren
beeps (fast) and its beacon illuminates. Also during this time, the pugmill
start can be cancelled by pressing the button again.

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4. Now start the incline conveyor as described in Section 4.35.

5. Now start the feed conveyor as described in Section 4.36.

6. Once all three components are all running, you can be feed material
through the machine.

Stopping the Pugmill

To stop the pugmill using the display unit on the control panel, simply press
the pugmill start/stop button on Machine screen. The pugmill will then stop
(after the feed conveyor and incline conveyor, if running.

Stopping the pugmill from the display unit also stops the incline conveyor and
feed conveyor (if running). The components are stopped in the following
order:

Feed Conveyor Incline Conveyor Pugmill

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4.40 START/STOP THE TELEMIX AUTO
The Telemix Auto can be started and stopped from a button on the control
panel and from a button on the display unit.

The pugmill can also be reversed to help relieve material blockages as

described in Section 4.41 (Telemix) or Section 4.42 (Telemix Auto).

Telemix Auto can be started as part of a ‘sequential start’ of machine

elements that is initiated via the large button, known as the ‘Conveyor button’,
on the control panel.

Pressing this button for at least one second starts Telemix Auto, the conveyor
and feeder (if fitted), in that order. It can also be used to stop all elements
immediately.

a) Starting the Telemix Auto using the Control Panel

1. Ensure that there is power to the control panel or that the engine is
running at a speed greater than the idle speed.

2. Press and hold down the Conveyor On/Off button for at least 1 second
until the button turns from green to red.

On a dual power machine, a 3 second delay is implemented before the

electric motors start (this delay does not apply to direct drive machines).

A 10-second delay is then implemented before the pugmill starts and

then there is a further 5-second delay before the conveyor starts. During
this time, a countdown is shown on the Main screen of the display unit,

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the machine’s siren beeps (fast) and its beacon illuminates. Also during
this time, the start can be cancelled by pressing the button again.

If a feeder is fitted to the machine, the feeder will be automatically

started once the conveyor is running. There is a 5-second delay between
the conveyor starting and the feeder starting. During this time, a
countdown is shown on the Main screen and the siren continues to
sound.

Additive/water flows start one second after all the above elements are
running.

3. Once the pugmill and conveyors are fully running, you can feed material
through the machine.

Stopping the Telemix Auto

To stop Telemix Auto along with the conveyor and feeder (if fitted), press the
Conveyor button on the control panel again. The button colour will turn from
red to green. The machine elements will all stop immediately.

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b) Starting the Telemix Auto using the Display Unit
Telemix Auto can be started/stopped from the Main screen on the display unit.

You can alternatively start/stop the pugmill from the Primary Machine screen
and start the additive/water flows from the Telemix Auto screen.

1. Ensure that there is power to the display unit and:

- if a diesel machine, ensure that the engine is running

- if a dual-power machine, ensure that the electric motors are running

2. Ensure that the Main screen is displayed on the LCD panel.

3. Start the pugmill by pressing the Start/Stop Pugmill button (shown

above).

The pugmill will start but the additive and water flows still need to be
started (see Step 6).

4. Now start the incline conveyor as described in Section 4.35.

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5. Now start the feed conveyor as described in Section 4.36.

6. On the Main screen, start the pugmills additive and water flows by pressing
button 5 with the following on-screen icon.

7. Once the pugmill and conveyors are fully running, you can feed material
through the machine.

Stopping the Telemix Auto

To stop the pugmill using the display unit on the control panel, simply press
the pugmill start/stop button on Machine screen. The pugmill will then stop
(after the feed conveyor and incline conveyor, if running.

To stop the pugmill from the display unit, press button 6 on the Main screen
again. This will also stop the additive/water flows.

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4.41 REVERSING THE PUGMILL (TELEMIX)
If the pugmill becomes blocked with material it may be necessary to relieve
the blockage by running the pugmill in reverse. The pugmill can be reversed
from the Machine screen on the display unit.

Reversing the pugmill is described below for two situations:

 Only the pugmill running (feed conveyor and incline conveyor not
running)

 The pugmill, incline conveyor and feed conveyor running

If the pugmill, the incline conveyor and feed conveyor were started collectively
in a sequential start but have been stopped due to high pressure in pugmill
then the reverse action is executed as described in Reversing the Pugmill with
the Pugmill, Incline Conveyor and Feed Conveyor running (Sequential Start),
resulting in a restart of all three components.

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a) Reversing the Pugmill with only the Pugmill running
If only the pugmill is running (feed conveyor and incline conveyor not running),
it can be reversed as follows:

1. Ensure that the Machine screen is displayed on the LCD panel.

2. Hold down the Start/Stop Pugmill Button (OK) with the following on-
screen icon.

The following actions will then take place on the machine:

a) After 3 seconds (of holding down the button), the pugmill will stop.
b) The pugmill will then run in reverse (provided that the button is still held
down).

3. When you wish to return to forward operation, release the button.

The following actions will then take place on the machine:

a) The pugmill will stop.
b) A pugmill restart delay of 10 seconds will begin.
c) After the 10 second delay, the pugmill will start to run in the forward
direction.

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b) Reversing the Pugmill with the Pugmill, Incline Conveyor and Feed
Conveyor running (Sequential Start)

The procedure in this section is applicable where the pugmill, the incline
conveyor and the feed conveyor were started collectively in a sequential start
but have been stopped due to high pressure in pugmill.

If the pugmill, the incline conveyor and feed conveyor are all running (after a
sequential start), the pugmill can be reversed as follows:

1. Ensure that the Machine screen is displayed on the LCD panel.

2. Hold down the Start/Stop Pugmill Button (OK) with the following on-
screen icon.

The following actions will then take place on the machine:

a) After 3 seconds (of holding down the button), the pugmill will stop.
b) The pugmill will then run in reverse (provided that the button is still held
down).
c) The feed conveyor and incline conveyor will be stopped while the pugmill
is running in reverse.

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3. When you wish to return to forward operation, release the button.

The following actions will then take place on the machine:

a) The pugmill will stop.
b) A pugmill restart delay of 10 seconds will begin.
c) After the 10 second delay, the pugmill will start to run in the forward
direction.
d) After a further 5 second delay, the incline conveyor will restart.
e) After a further 5 second delay, the feed conveyor will restart.
During these delays, a countdown is shown on the screen, the machine’s
siren beeps (fast) and its beacon illuminates.

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4.42 REVERSING THE PUGMILL (TELEMIX AUTO)
If the pugmill becomes blocked with material it may be necessary to relieve
the blockage by running the pugmill in reverse. The pugmill can be reversed
from the Machine screen on the display unit.

If the conveyor and feeder (if fitted) are running when the pugmill is reversed,
they will be automatically stopped on a temporary basis.

The pugmill can alternatively be reversed using the OK button on the Primary
Machine screen in a similar way as described in the steps below.

1. Ensure that the Main screen is displayed on the LCD panel.

2. Hold down the Start/Stop/Reverse Pugmill button (6) with the following
on-screen icon.

The following actions will then take place on the machine:

a) After 3 seconds (of holding down the button), the pugmill will stop.
The additive/water flows will also be stopped.
b) The pugmill will then run in the reverse direction (provided that the
button is still held down).
c) If the conveyor and feeder (if fitted) are running, they will be
automatically stopped while the pugmill is running in reverse.

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3. When you wish to return to forward operation, release the button.

The following actions will then take place on the machine:

a) The pugmill will stop.
b) A restart delay of 10 seconds will begin.
c) After the 10-second delay, the pugmill will start to run in the forward
direction.
d) After a further 5-second delay, the conveyor will restart (if previously
running).
e) After a further 5-second delay, the feeder will restart (if previously
running).

The additive/water flows will then be automatically restarted.

During the above delays, a countdown is shown on the screen, the

machine’s siren beeps (fast) and its beacon illuminates.

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4.43 START/STOP ADDITIVE/WATER FLOWS
During normal Telemix Auto operation, an additive (cement) and water are
added to the aggregate material supplied via the conveyor.

The additive/water flows can only be started while the pugmill is running. The
pugmill can be started from the Main screen or Primary Machine screen.

The additive and water flows are normally started as follows:


 Automatically when Telemix Auto is started as part of a ‘sequential start’
via the Conveyor button on the control panel (as described in Section
4.40)
 Separately via a button on the display unit when the pugmill is started
manually (as described in Section 4.40)

In both cases, the flows are stopped automatically when the pugmill is
stopped.

Starting the additive/water flows requires the pugmill, conveyor and feeder (if
fitted) to be already running.

However, the flows can be manually stopped and restarted during pugmill
operation from the Main screen (described in Section 4.16) and from the
Telemix Auto screen (described in Section 4.17).

The additive and water flows are started/stopped together but can be
individually controlled via the Telemix Auto screen in Service mode (described
in Section 4.18).

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To stop and restart the additive/water flows while the pugmill is running:
1. Ensure that the pugmill is running (with the additive and water flows
active).
2. Access the Main screen or Telemix Auto screen.
3. Stop the additive/water flows by pressing button 5 with the following on-
screen icon.

4. When you later want to restart the additive/water flows, press the same
button again.

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4.44 START/STOP VIBRATING MOTOR
The vibrating motor can be used to break up the additive material in the silo in
order to prevent blockages and ensure a steady flow of material coming out of
the silo. It is used while the pugmill is running, as follows:

 Automatically: If no additive flow from the silo is detected, a timer

(configurable between 1 and 30 seconds) begins to count down until
additive flow is detected again. If the timer expires before additive is
detected, the vibrating motor will be run for 10 seconds to loosen any
material stuck in the silo. If a blockage remains in the silo then the
following Silo Blocked warning is displayed. 

The timer value for the vibrating motor is set on the Calibration screen,
described in Section 4.21.

 Manually: The vibrating motor can be started/stopped via a button (3) on

the Telemix Auto screen (described in Section 4.17). If started in this way,
it will run indefinitely until stopped.

1. Ensure that the pugmill is running (with the additive and water flows
active).
2. Access the Telemix Auto screen.
3. Start the vibrating motor by pressing button 3 with the following on-
screen icon.

Once started, the motor runs indefinitely until stopped using the same button.
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The vibrating motor normally operates automatically. If no additive flow from

the silo is detected, a timer begins to count down until additive flow is
detected again. If the timer expires before additive is detected, the vibrating
motor will be run for 10 seconds to loosen any material stuck in the silo. If a
blockage remains in the silo then a Silo Blocked warning is displayed.

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4.45 MONITORING DATA
The following ‘live’ data can be monitored via the Telemix Auto screen:
 Weight of material in additive silo
 Water flow-rate
 Material throughput for final mix

The relevant screen elements are shown and described below.

4.45.1 Additive Weight

The weight of material in the additive silo is indicated on the left of the screen
in a bar-chart and in figures (kilograms).

The green bar indicates the weight of the additive material in the silo and the
grey bar corresponds to the maximum possible weight in the silo (when full).

4.45.2 Water Flow-rate

The water flow-rate (litres per min) is shown on the right of the screen.

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4.45.3 Material Throughput
The throughput of material by weight (tonnes per hour) going into the final mix
is shown on the right of the screen.

This throughput figure includes aggregate, additive and water.

4.45.4 Service Mode

Service mode allows the currently active recipe to be selected from the four
possible options (R1, R2, R3, R4). This mode can be accessed from the
Telemix Auto screen by pressing button 4 (fourth-down on left).

In Service mode, the Telemix Auto screen remains displayed but the button-
icons down the left and right sides change. The button functions differ
according to the currently selected mode of operation (automatic or manual).
In manual mode, Service mode also allows the additive and water valves to
be tested.

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4.45.5 Recipes
Four recipes (R1, R2, R3, R4) are available for each Telemix operational
mode (automatic and manual) and the current recipe is shown on the Telemix
Auto screen, as described in Section 4.17.2. The selected recipe can be
changed in Service mode, described in Section 4.45.4.

Each of the four recipes for each mode (automatic and manual) can be user-
defined via the Recipes screen. The Recipes screen for the current mode is
accessed from the Telemix Auto screen by pressing button 2 (second-down
on left).

The Recipes screen is described in Section 4.20.

4.45.6 Calibration
Some parameters relating to pugmill operation require minimum and/or
maximum values to be specified. These values can be set via the Calibration
screen, which is accessed from the Telemix Auto screen by pressing button 6
(second-down on right).

The Calibration screen is described in Section 4.21.

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4.46 UNBLOCKING THE TELEMIX AND THE TELEMIX AUTO
Telemix can be freed of material blockage in the following way:
 A blockage that hinders material flow through the pugmill can be relieved
by temporarily reversing the pugmill, as described in Section 4.2.

Telemix Auto can be freed of material blockages in two ways:

 A blockage that hinders material flow through the pugmill can be relieved
by temporarily reversing the pugmill, as described in Section 4.2.
 A blockage in the additive silo can be relieved by starting the vibrating
motor, as described in Section 4.4.

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4.47 PLACING THE PUGMILL INTO THE WORKING POSITION
The pugmill must be placed into the working position before any material can
be introduced.

Before adjusting,
 Ensure the conveyor head section is lowered and nobody else is within
the exclusion area of the machine (See Safety Section).
 Ensure that the pugmill is clear of material.
 Ensure the pugmill is not running.
 Ensure that the engine is running and at low RPM.

Failure to follow this procedure and remove pins when required can cause
damage to your machine.

Pugmill shown in Transport Position

Pugmill shown in Working Position

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1 Press and hold the hydraulic enable button to activate the control levers.
2 Operate the pugmill control lever to manoeuvre the pugmill so the linkage
arms are in the vertical position as shown below.

Hydraulic Pugmill
Enable Button Adjustment

3 Release the hydraulic enable button once the procedure is complete.

4 Remove the pin (1) from the linkage arm on both sides.

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5 Press and hold the hydraulic enable button to activate the control levers.
6 Operate the pugmill control lever to manoeuvre the pugmill into the
working position.

Hydraulic Pugmill
Enable Button Adjustment

7 Release the hydraulic enable button once the procedure is complete.

8 Insert the pin (1) into the working position shown below on both sides.

1 1

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9 Press and hold the hydraulic enable button to activate the control levers.
10 Operate the pugmill control lever to adjust the pugmill working angle.

Hydraulic Pugmill
Enable Button Adjustment

11 Release the hydraulic enable button once the procedure is complete.

12 Connect the pugmill hydraulic hoses.

13 Fit both sides of the inlet chute using the fittings provided.

Inlet Chute
Side

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4.48 PLACING THE PUGMILL INTO THE TRANSPORT POSITION
The pugmill will need to be placed into the transport position before
manoeuvring on site.

Before adjusting,
 Ensure the conveyor head section is lowered and nobody else is within
the exclusion area of the machine (See Safety Section).
 Ensure that the pugmill is clear of material.
 Ensure the pugmill is not running.
 Ensure that the engine is running and at low RPM.

Failure to follow this procedure and remove pins when required can cause
damage to your machine.

Pugmill shown in Working Position

Pugmill shown in Transport Position

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1 Remove the both sides of the pugmill inlet chute.

2 Disconnect the hydraulic hoses from the pugmill.

Inlet Chute
Side

3 Press and hold the hydraulic enable button to activate the control levers.
4 Operate the pugmill control lever to adjust the pugmill until horizontal.

Hydraulic Pugmill
Enable Button Adjustment

5 Release the hydraulic enable button once the procedure is complete.

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6 Remove the pin (1) from the working position shown below on both sides.

1 1

7 Press and hold the hydraulic enable button to activate the control levers.

8 Operate the pugmill control lever to manoeuvre the pugmill the pugmill so
the linkage arms are in the vertical position as shown below.

Hydraulic Pugmill
Enable Button Adjustment

9 Release the hydraulic enable button once the procedure is complete.

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10 Insert the pin (1) into the linkage arm on both sides.

11 Operate the pugmill control lever to manoeuvre the pugmill into the
transport position.

Hydraulic Pugmill
Enable Button Adjustment

12 Release the hydraulic enable button once the procedure is complete.

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4.49 PUGMILL PRESSURE SENSOR
The pugmill features a pressure sensor that allows automatic control of the
feed conveyor, incline conveyor and pugmill itself when the pugmill becomes
blocked with material (high pressure detected). The following table indicates
the action taken when the switch of the pressure sensor remains closed for
different amounts of time.

Time for which pressure switch is closed Resulting action

Less than 5 seconds No action taken
 Warning indicator is displayed on screen.
 Feed and incline conveyor are stopped.
Between 5 and 20 seconds  Restarted after 20 seconds – first incline
conveyor and then feed conveyor one
second later.
 Pugmill is stopped along with feed and
incline conveyor.
More than 20 seconds
 Can only be restarted manually.
 Error screen is displayed

Therefore, the pugmill is stopped (along with the feed conveyor and incline
conveyor) only if the pressure switch is closed for more than 20 seconds. In
this case, the blockage must be addressed before restarting manually.
A material blockage can be relieved by running the pugmill in the reverse
direction.

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4.50 RAISE/LOWER THE HOPPER JACKLEGS/INCLINE CONVEYOR
HEAD SECTION
The operator can raise and lower the hopper jacklegs and the head section of
the incline conveyor by using the hydraulic control levers, from a button on the
display unit or from the handset.

 Make sure that nobody else is within the exclusion area of the machine.
(See Safety Section).
 Ensure that the conveyor is clear of material.
 Ensure the conveyor is not running.
 Ensure that the engine is running and at low RPM.

Extreme care must be taken so that the machine does not come into contact
with any overhead power lines.

Hopper Jackegs Up – Incline Conveyor Head Section Down

Hopper Jacklegs Down – Incline Conveyor Head Section Up

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Operational angle should be appropriate to the material being stockpiled. N.B.

The use of excessively steep angles will result in material roll back. This
causes increased material damage and reduces conveyor throughput as well
as increasing the risk to operators through falling debris along the conveyor
sides.

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a) Raising and lowering using the Hydraulic Control Levers

1 Once the engine has been started and at low RPM, press and hold the
hydraulic enable button to activate the control levers.
2 Operate the controls levers as required.
3 Release the button once the procedure is complete.

Hydraulic Incline Conveyor

Enable Button Head Section

When the operator is finished using the control levers, they must switch off
power to the engine.

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b) Raising and lowering using the Display Unit

1. Access the Machine 2 screen on the display unit.

2. Press and hold down the relevant button for at least 3 seconds.
2 (raise jacklegs), 3 (lower jacklegs), 6 (raise incline conveyor head
section), 7 (lower incline conveyor head section).

3. Press and hold down the relevant button for at least 3 seconds.

 During the first 3 seconds that the button is held down, the hopper
jacklegs or incline conveyor head section will not move and the siren will
beep (fast) on the machine. At the end of this delay, the hopper jacklegs
or incline conveyor head section will start to move, as required.

 The four buttons are momentary-acting – therefore, the hopper jacklegs

and incline conveyor head section only moves while a button is being
held down.

 When a button is pressed, the relevant part of the machine and direction
of movement are indicated on-screen by a green arrow, as illustrated
below.

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4. The machine will react immediately to the next button press provided
that it occurs within 15 seconds of the release of the last button. If not
then the 3 second delay will apply again.

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c) Raising and lowering using the Large Handset
The hopper jacklegs or incline conveyor head section can be raised/lowered
from the large handset, when the handset is used in auxiliary mode.

The large handset will automatically lock after 300 seconds of inactivity. On
unlocking again, it will default to tracking mode.

1. Ensure that the large handset is switched on and in auxiliary mode – the
‘AUX’ LED on the handset will be illuminated.

2. Move and hold in position for at least 3 seconds the first lever on the
handset required to raise or lower the hopper jacklegs or incline
conveyor head section of the machine.

Hopper Jacklegs Incline Conveyor Head Section

Raise/Lower Raise/Lower

- Moving a lever up (in yellow direction) will raise and moving a lever down
(in blue direction) will lower

- During the first 3 seconds that the lever is held in position, the hopper
jacklegs or incline conveyor head section will not move and the siren will
beep (fast) on the machine. At the end of this delay, the hopper jacklegs
or incline conveyor head section will start to move, as required.

- The levers are momentary-acting – therefore, the hopper jacklegs and

incline conveyor head section only moves while a lever is being held in
position

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- The small central lever at the top can also be used to raise/lower the
incline conveyor head section.

3. Perform more lever movements to raise or lower the hopper jacklegs or

incline conveyor head section. The hopper jacklegs or incline conveyor
head section will react immediately to the next lever movement provided
that it occurs within 15 seconds of the release of the last lever – if not,
the 3-second delay will apply again.

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d) Raising and lowering using the Small Handset
The hopper jacklegs or incline conveyor head section can be raised/lowered
via a radio link from the small handset.

1. Press and hold down for at least 3 seconds the first button on the small
handset required to raise or lower the hopper jacklegs or incline
conveyor head section. The relevant buttons are green (front) and blue
(rear), as illustrated below.

Raise Lower
Incline Conveyor Head Section Incline Conveyor Head Section

Raise Lower
Hopper Jacklegs Hopper Jacklegs

- During the first 3 seconds that the button is held down, the hopper
jacklegs or incline conveyor head section will not move and the siren will
beep (fast) on the machine. At the end of this delay, the hopper jacklegs
or incline conveyor head section will start to move, as required

- The buttons are momentary-acting – therefore, the hopper jacklegs or

incline conveyor head section only moves while a button is being held
down

2. Perform more button-presses to raise or lower the hopper jacklegs or

incline conveyor head section. The hopper jacklegs or incline conveyor
head section will react immediately to the next button-press provided
that it occurs within 15 seconds of the release of the last button – if not,
the 3-second delay will apply again.

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4.51 REMOTE CONTROL TIPPING GRID
This machine has the optional capability to power a hydraulic tipping grid. It is
operated by a remote control that is supplied with the machine if selected as
an option.

The grid can be tipped up and then down again in a ‘Grid Tip cycle’ to discard
over-sized material that has accumulated on the grid.

A Grid Tip cycle can be performed automatically or manually:

 Automatic grid tip: Once initiated, the Grip Tip cycle is performed
automatically with no operator intervention (but can be paused and
resumed at any point)

 Manual grid tip: The Grid Tip cycle is controlled completely by the
operator (the grid will only move while a button is being held down)

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Grid tip operation is controlled from a dedicated Grid Tip handset, which is
battery-powered and communicates with the machine over a radio link.

Custom grid up and down timings can be configured for an automatic Grid Tip
cycle.

Automatic Sound
Grid Tip Siren

Grid Tip Grid Tip

Down Up

Stop Feed Start Feed

Conveyor Conveyor

Engine Stop Transmit LED

Requested
Battery LED

Automatic Grid Tip

During an automatic Grid Tip cycle, the grid automatically rises to the
maximum angle and then returns back to its default position. An automatic
grid tip is initiated by pressing the left yellow button on the handset for at least
one second.

Start/Pause/Resume
Automatic Grid Tip

Once an automatic grid tip up/down cycle has been started, it can be paused
and resumed at any point during the cycle using the same button on the
handset. Also, pressing either of the (blue) manual grid tip buttons will cancel
the automatic grid tip and switch to manual grid tip operation.
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When an automatic grid tip is initiated, the automatic grid tip symbol is
displayed on the right of the Main screen and a 3-second delay is
implemented before the grid tip starts — during this time, the machine’s siren
sounds.

Automatic
Grid Tip
Symbol

The up and down phases of the grid tip cycle are then indicated by the
following symbols (replacing the above symbol) on the Main screen.

Main Screen Main Screen

Grid Up Grid Down
Symbol Symbol

The above symbols are accompanied by countdowns (in seconds) for the up
and down phases of the grid tip cycle. There is a 1-second gap between the
up and down phases of the cycle.

The up and down times for an automatic grid tip are by default 38 seconds
and 45 seconds respectively (the up-time determines the maximum tipping
angle). These times can be changed by the operator as described in the
section Configuring Automatic Grid Tip Times.

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Manual Grid Tip
During a manual grid tip, the up and down movements of the grid are
controlled by the operator using the two blue buttons on the Grid Tip handset
— right button for up, left button for down.

Manual Manual
Grid Down Grid Up

These buttons are momentary-acting — the grid will move only while a button
is being held down.

The following rules apply to the use of these buttons during a manual grid tip:

 On first pressing a button, a 3-second delay is applied before the grid will
move — during this time, the machine’s siren sounds

 After releasing the button, if either button is pressed within 15 seconds

then no further delay is applied.

 If there is a gap of more than 15 seconds between consecutive button-

presses, the 3-second delay is applied again.

While a button is being held down during a manual grid tip, one of the
following symbols is shown on the right of the Main screen on the display unit
to indicate that a grip tip instruction is being received.

Main Screen Main Screen

Grid Up Grid Down
Symbol Symbol

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Configuring Automatic Grid Tip Times
The up and down times of an automatic Grid Tip cycle are by default set to 38
seconds and 45 seconds respectively. However, these times can be changed
by the operator as described below.

The up-time determines the maximum tipping angle of the grid during the
cycle. The maximum up-time that can be set is 90 seconds.

The grid up and down times are set as follows (note that the grid moves
during this process):

1. Enter the time settings mode by simultaneously pressing the orange

Siren button and blue Grid Up button on the Grid Tip handset — you
must hold them down for at least 5 seconds.

Press
together for
5 seconds

After 5 seconds, the machine’s siren and beacon are activated until the
buttons are released. The Grid Up symbol then appears on the right of the
Main screen.

Main Screen
Grid Up
Symbol

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2. Set the up-time by holding down the Grid Up button on the handset.
The machine’s siren and beacon are active while the button is pressed,
and a count in seconds is shown on the Main screen — release the
button when the count reaches the desired up-time (see Note above).

Grid Up
Symbol

You can release the button and later resume without spoiling the setting.

3. Save the up-time by pressing the Siren button on the handset (the
machine’s siren and beacon are active while the button is pressed). On
releasing the button, the Grid Down symbol appears on the right of the
Main screen.

Main Screen
Grid Down
Symbol

4. Now set the down-time by holding down the Grid Down button on the
handset. The machine’s siren and beacon are active while the button is
pressed, and a count in seconds is shown on the Main screen — release
the button when the count reaches the desired down-time (see Note
below).

Grid Down
Symbol

You can release the button and later resume without spoiling the setting.

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5. Save the down-time by pressing the Siren button on the handset (the
machine’s siren and beacon are active while the button is pressed). On
releasing the button, the Grid Down symbol disappears from the Main
screen and the time settings are complete.

In setting the grid down-time to a value greater than the default 45 seconds,
the grid will reach its lowest position before the count reaches the desired
time. There is a pressure relief feature to cope with this and you should keep
the Grid Down button held down until the required time is shown.

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4.52 INTERLOCK SYSTEM OF THE MACHINES
The machine can be incorporated in an ‘interlock system’ of machines. In
such a system, two or more machines form a chain in which one machine
feeds the next one with material – for example, a rock screener may feed a
stacker.

 A machine supplying material to the local machine is said to be

upstream
 A machine receiving material from the local machine is said to be
downstream

Adjacent machines are connected via a cable, which allows signalling

between the two machines. In this way, an event on one machine in the chain
can be used to control the next upstream machine – for example, if the
conveyor of a stacker stops, the upstream machine that feeds the stacker can
be automatically stopped.

Material

Cable Cable
Upstream Machine Local Machine Downstream Machine

The interlock features that are available through the machine’s display unit
are described in the rest of this section:

 The link to an upstream machine is described in the supplement

documentation.
 The link to a downstream machine is described in the supplement
documentation.
 The logic behind the automatic control of the machines in an interlock
system is described in the supplement documentation.
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This manual does not cover the physical cable connections between
machines in an interlock system.

More information on the Interlock System is described in the supplement

documentation.

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4.53 SUPPORTING THE MACHINE
It is important to ensure your machine is on firm level ground and is supported
by lowering the jacklegs into the working position before adding any material
to the hopper. This will help to prevent any damage to your machine while
material is being added.

Under no circumstances must the machine be loaded with the hopper

jacklegs raised. Jacklegs should be lowered with the securing pins fitted.

Manual Jacklegs

1 Remove the pin from the jacklegs.

2 Lower the jacklegs.
3 Insert securing pins to secure the jacklegs.

Hydraulic Jacklegs

1 Ensure the engine has been started and at low RPM.

2 Remove the pin from the jacklegs.
3 Press and hold the hydraulic enable button to activate the control levers.
4 Operate the jackleg control lever to lower the jacklegs.

Hydraulic
Jacklegs
Enable Button

5 Release the button once the procedure is complete.

6 Insert securing pins to secure the jacklegs.

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The jacklegs must have the locking pins in place, these pins must support the
load and not the jacking cylinder. Failure to use the securing pins will result in
failure of the jacking cylinder.

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4.54 ADJUSTING THE VARIABLE GATE

Increasing the opening the gate allows for a higher volume of material to be
removed from the hopper resulting in a deeper flow of material and typically
higher volume off the end of the feed conveyor.
Likewise, reducing the gate opening restricts the volume of flow out of the
hopper resulting in a shallow flow of material and typically a lower volume off
the end of the feed conveyor.

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not climb onto the machine. Always use a suitable platform.

1 Loosen the bolt (1) securing the gate.

2 Use the chain (2) to adjust position of the gate.
3 Secure gate in position by tightening the bolt (1).

Bolt Bolt

Chain Chain

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4.55 CONFIGURING THE TELEMIX AUTO
Setting up the Telemix Auto for operation:
 Enabling Telemix Auto - see Section 4.55.1
 Selecting an operational mode and recipe - see Section 4.55.2.
 Editing a recipe - see Section 4.55.3.
 Setting parameter values - see Section 4.55.4.
 Adjusting additive/water rates (in manual mode) - see Section 4.55.5.

4.55.1 Enabling Telemix Auto

Where fitted to a machine, Telemix Auto must be enabled on the Factory
Settings screen (described in the machine’s control system manual).

The Telemix slide-switch on the Factory Settings screen has three positions
(unlike the other slide-switches, which have just two positions). These
positions cover the following possibilities: no Telemix, Telemix (with pugmill
only) and Telemix Auto.

Telemix Off (left/red)

No pugmill fitted to machine.
Telemix On (centre/green)
Only pugmill fitted (no additive or
water supplies)
Telemix Auto On (right/green)
Pugmill with additive and water
supplies fitted

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 OPERATION
Therefore, when Telemix Auto is fitted to the machine, it must be enabled by
setting the Telemix slide-switch on the Factory Settings screen to the
right/green position. This will enable the user-interface to display the relevant
screens and buttons for Telemix Auto.

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 OPERATION
4.55.2 Selecting Operational Mode and Recipe
Before operating Telemix Auto, an operational mode (automatic or manual)
and a recipe for the final mix must be selected. The recipe depends on the
chosen mode – there are four possible recipes per mode (R1, R2, R3, R4).
Operational modes and recipes are introduced in Section 4.17.2.

 The operational mode is selected on the Telemix Auto screen (described

in Section 4.17)
 The recipe is selected on the Telemix Auto screen in Service mode
(described in Section 4.18)

The four recipes per mode can be user-defined on the Recipes screen, as
described in Section 4.20.

To select an operational mode and recipe:

1. Access the Telemix Auto screen. The current operational mode is

shown in the upper-right of this screen as A (Automatic) or M (Manual),
as illustrated below.

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 OPERATION
2. If you wish to change the mode, press button 1 (A/M) to toggle the
mode.

The current recipe for the selected mode is also shown on this screen,
as illustrated in the following examples for automatic and manual mode –
one of:

If you wish to select a different recipe, continue with this procedure.

3. Enter Service Mode by pressing button 4 with the following on-screen

icon.

The button-icons on the screen now change, depending on the

operational mode (as described in Section 4.18). The name of the
currently selected recipe is also highlighted in red, as indicated in the
following examples for automatic and manual modes – one of:

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 OPERATION
4. Browse the available recipes using the up/down-arrow buttons below the
LCD panel and stop on the required recipe.

In manual mode, the recipes can be only be browsed using the up/down-
arrow buttons when both the additive and water valves are off.

5. Leave Service mode by pressing button 4 with the following on-screen

icon (or the ESC button).

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 OPERATION
4.55.3 Editing a Recipe
The four recipes (R1, R2, R3, R4) for each operational mode (automatic and
manual) can be user-defined on the Recipes screen (described in Section
4.20). The contents of the Recipes screen depend on the currently selected
operational mode, but the methods of editing the recipes are similar for both
modes.

Automatic Mode

Manual Mode

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 OPERATION
To edit one or more recipes for a particular operational mode:

1. Ensure that the Telemix Auto screen is displayed.

2. Ensure that the operational mode (automatic or manual) for which the
recipes are to be edited is selected.
3. Access the Recipes screen by pressing button 2 with the following on-
screen icon.

4. On the Recipes screen, select the recipe to be edited (R1, R2, R3 or R4)
by pressing one of the buttons 1 to 4 on the left.

The left edge of the button-icon for the selected recipe is highlighted in
yellow (rather than green), as is the recipe name in the on-screen table.

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 OPERATION
5. Use the left/right-arrow buttons below the LCD panel to move to the field
to be edited (also highlighted in yellow), as illustrated in the following
examples for automatic and manual mode.

Automatic Mode

Manual Mode

For automatic mode, it is not possible to edit the aggregate field – its value is
automatically adjusted according to the changes made in the additive and
water fields, such that the three values add up to 100%.

6. Adjust the value in the currently highlighted field using the up/down-
arrow buttons below the LCD panel.

For manual mode, only the additive and water fields are present. For the
water field in manual mode, there is an upper limit on its value, which is set on
the Calibration screen (as described in Section 4.21).

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 OPERATION
7. Once the edits to a recipe have been made, save the changes by
pressing the OK button with the on-screen icon.

You can abandon a recipe edit without saving the changes by pressing the
ESC button.

8. If required, edit another recipe as described in Steps 4 to 7.

9. Once all edits have been made and saved, exit the Recipes screen by
pressing the ESC button.

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 OPERATION
4.55.4 Setting Parameter Values
Certain parameters of Telemix Auto can be set via the Calibration screen
(described in Section 4.21).

The six parameters on the Calibration screen are described in Section 4.21.2.

To edit the parameters on the Calibration screen:

1. Ensure that the Telemix Auto screen is displayed.

2. Access the Calibration screen by pressing button 6 with the following

on-screen icon.

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 OPERATION
3. On the Calibration screen, press the button corresponding to the
parameter to be edited.

1 Time to Vibe Mtr Max Hpr Weight 5

2 Min Refill Level Max Wtr Flow 6

3 Max Refill Level Max TPH 7

The right edge of the button-icon and the parameter background are
then both highlighted in yellow – in the following example, for Max Hpr
Weight.

4. Adjust the value of the currently highlighted parameter using the

up/down-arrow buttons below the LCD panel.

5. Once the parameter edit has been made, save the change by pressing
the OK button below the LCD panel.

You can abandon a parameter edit without saving the change by pressing the
ESC button or initiating the edit of another parameter.

6. If required, edit another parameter as described in Steps 3 to 5.

7. Once all the required parameter edits have been made and saved, exit
the Calibration screen by pressing the ESC button.

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 OPERATION
4.55.5 Adjusting Additive/Water Rates (Manual Mode)
In order to assess the required additive and water inputs for the final mix in
manual mode, the additive and water valves can be individually adjusted on a
temporary basis. This adjustment is performed on the Telemix Auto screen in
Service mode (described in Section 4.18).

Adjusting the additive and water valves does not change a stored recipe. It
allows the additive speed and water flow-rate to be varied and assessed
outside of the currently active recipe. If a recipe then needs to be modified,
this must be done as described in Section 4.55.3.

To adjust the additive and water valves (for assessment purposes):

1. Ensure that the pugmill, conveyor and feeder (if fitted) are running, as
described in Section 4.40, but do not feed aggregate material through
the machine yet.

2. Access the Telemix Auto screen.

3. If the additive and water flows are currently active, stop them by pressing
button 5 with the following on-screen icon.

4. Ensure that manual mode is selected (by pressing button 1, if

necessary).

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 OPERATION
5. Enter Service mode by pressing button 4 with the following on-screen
icon.

The left/right buttons of the Telemix Auto screen will now change.
Button-icons will appear (buttons 1 and 5) for turning the additive and
water valves on/off.

1 Additive Valve Water Valve 5

On/Off On/Off

2 Water Flow-rate 6
Additive Speed Up *
Up *

3 Additive Speed Water Flow-rate 7

Down * Down *

* Icons for button-pairs 2 & 3 and 6 & 7 will appear only when the
corresponding valves are turned on (via buttons 1 and 5)

6. Look at the current additive speed and water flow-rate on the screen,
and decide how you want to adjust them.

7. Start to feed aggregate material through the machine.

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 OPERATION
8. Turn on the additive valve and/or water valve, as required:
a) If required, turn on the additive valve by pressing button 1 with the
following on-screen icon.

Icons for buttons 2 and 3 now appear on the screen (see table in Step
5).

b) If required, turn on the water valve by pressing button 5 with the

following on-screen icon.

Icons for buttons 6 and 7 now appear on the screen (see table in Step
5).

9. Adjust the valves, as required:

a) If required, adjust the additive speed up/down using buttons 2 and 3
until the desired value is shown on the screen.

b) If required, adjust the water flow-rate up/down using buttons 6 and 7

until the desired value is shown on the screen.

10. Repeat Step 9 to make further adjustments until the final mix is as
desired, then make a note of the additive speed and water flow-rate
values.

11. Exit Service mode by pressing the ESC button to return to the default
Telemix Auto screen.

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 OPERATION

The additive and water valves are automatically turned off on leaving Service
mode.

12. Stop the feeder, conveyor and pugmill.

13. If desired, update a (manual mode) recipe with the noted additive speed
and water flow-rate values, as described in Section 14.5.3.

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 OPERATION
4.56 SHUTDOWN PROCEDURE

 Stop the feed of material to the machine.

 Allow both the feed and incline conveyor belts to run until all material has
cleared the belt.
 On control panel press stop conveyor.
 Reduce the speed to idle and allow the engine to idle for 5 minutes.
 Turn the ignition key anti-clockwise to the off position and remove the
key.
 After 40 seconds, rotate the engine isolator switch from position 1 to
position 2. (See Below Image).

Engine Isolator

 Check machine for hazards i.e. lodged stones etc. and remove before the
conveyor is started again.
 It is recommended that under normal operation the machine is run until
completely empty before powering the machine down. This is to minimise
the starting load on the machine when next run, but will normally reduce
the likelihood of material wedging in hoppers and building up on the belts.

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TECHNICAL SPECIFICATION
TELE-MIX® P2000T Automatic – TRACKED PUGMILL
This page was intentionally left blank
TELE-MIX® P2000T Automatic –
TRACKED PUGMILL

The TELE-MIX® P2000T is a track mounted fully mobile Automatic PLC controlled Pugmill designed to work at
production rates of up to 300tph (330 Ton per hr). The Telestack Tracked Pugmill is designed to be loaded directly
from wheel loaders, grab cranes, excavators etc., feed directly into Trucks or any road base. Since the Pugmill is
track mounted, the unit has excellent mobility on site and will eliminate double handling of material, which reduces
overall costs for operator.

TELE-MIX® P2000T Automatic –

TYPICAL APPLICATIONS
 Road Base – optimising moisture content in road base
 Blending
 Lime Addition
 Cold-Mix Asphalt – made from a blend of aggregate and/or emulsified asphalt and/or RAP
material, to be used in applications as patching material
 Cement-Treated Base (CTB) – using a mixture of soil, aggregate, Portland cement and water,
a hardened, compact form of paving material is created, with a more durable characteristic
 Stabilization – a process which consists of hazardous or contaminated materials being mixed
with a stabilizing agent to reduce its environmental impact

TELE-MIX® P2000T Automatic – KEY FEATURES

 High throughput of up to 300 tph (330 Ton / hr)
 Large 7 m3 (9.18 yds3) capacity hopper as standard
 Twin rotor Pugmill with proven design, incorporating direct hydraulic drive, mesh gears
for rotors, and removable paddles
 Engine protection shutdown system
 Natural design of the Pugmill gives integral strength and stability in working position
 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
 Options available

2 THE POWER TO MOVE MATERIALS

TELE-MIX® P2000T Automatic –
HOPPER CAPACITIES

Hopper Capacities

® Hopper Capacity Heaped Capacity

TELE-MIX P2000T Feed in Heights
® Hopper Capacity 3 Heaped Capacity 3
TELE-MIX P2000T
Hopper Extensions (m3) (yds ) (m3) (yds ) Feed in Heights
Hopper Extensions (m3) (yds3) (m3) (yds3)
300mm (Std) 6.1 7.98 7.02 9.18 2920mm 9’ 6”
300mm (Std) 6.1 7.98 7.02 9.18 2920mm 9’ 6”
500mm 8.02 10.5 9.22 12.06 3120mm 10’ 2”
500mm 8.02 10.5 9.22 12.06 3120mm 10’ 2”
700mm
700mm 10.3
10.3 13.47
13.47 11.85
11.85 15.5
15.5 3320mm
3320mm 10’
10’ 9”
9”
Hopper Capacities

*Hopper shown fitted with 500mm extensions and central dividing plate options.

Discharge Height

®
TELE-MIX Discharge Height Working Length
Discharge Height
P2000T Conveyor
Angle (m) (ft) (m) (ft)
24° 6.00 19’ 8 ’’ 18.12 58’ 4’’

22° 5.68 18’ 6’’ 18.24 59’ 3’’

20° 5.36 17’ 7’’ 18.32 59’ 7’’

18° 4.70 15’ 5’’ 18.40 59’ 10’’

3 THE POWER TO MOVE MATERIALS

TELE-MIX® P2000T Automatic – WORKING DIMENSIONS

TELE-MIX® P2000T Automatic – WORKING DIMENSIONS

Metric Imperial
Conveyor Length 12.30m 40’
Discharge Height (24º) 4.34m 14’ 1”
Feed in Height 300mm
2.92m 9’ 6”
Extension
Feed in Height 500mm
3.12m 10’ 2’’
Extension
Feed in Height 700mm
3.32m 10’ 9’’
Extension
Operating Width 3.45m 11’ 2”

4 THE POWER TO MOVE MATERIALS

TELE-MIX® P2000T Automatic – TRANSPORT DIMENSIONS
Fully Assembled
TELE-MIX® P2000T Automatic – TRANSPORT DIMENSIONS
Fully Assembled

Metric Imperial
Transport Length 17.15m 55’ 9’
Transport Width 3.45m 11’ 2’’
Transport Height 4.35m 14’' 2”
Overall Weight 17,500 Kg 38,581 lbs

5 THE POWER TO MOVE MATERIALS

TELE-MIX® P2000T Automatic – TRANSPORT DIMENSIONS
Ladder and Dust Filter Removed

Metric Imperial
Transport Length 17.15m 55’ 9’
Transport Width 2.75m 8’ 11’’
Transport Height 3.78m 12’' 3”

6 THE POWER TO MOVE MATERIALS

TELE-MIX® P2000T Automatic – TRANSPORT DIMENSIONS
Cement Silo and Walkway Removed

Metric Imperial
Transport Length 17.15m 55’ 9’
Transport Width 2.75m 8’ 11’’
Transport Height 2.85m 9’ 3”

7 THE POWER TO MOVE MATERIALS

 TELE-MIX® P2000T Automatic
MACHINE FEATURES

Hopper Feeder
 Manual adjustable jacking legs mounted
under hopper side to support the hopper
during the feeding procedure.
 300mm Hopper Extension Dimensions
 Hopper Width: 2.08m (6’ 9”)
 Hopper Length: 4.36m (14’ 2")
 Feed in Height: 2.92m (9’ 6”)
 Capacity: 7m3 (9.2yds3)
 Impact centre rollers 127mm (5”).
 Impact bars along sides to eliminate
material spillage.
 150mm (6") diameter disc return rollers.
 1050mm (41") wide EP 500 3 ply, 5
+1.5mm feeder belting, feeding onto
1050mm (42") incline belt.
 150mm (6”) Return rollers.
 Large transfer point opening for
maximum throughput, spring tension
face scraper, to clear the feeder belt.
 Twin Internal planetary drive motors for
high torque output, with flow control
valve mounted in power unit to regulate *Hopper shown fitted with 500mm extensions and
central dividing plate options.
feeder belt speed.
 Manual adjustable hopper door to
regulate material flow.

 Optional centre split hopper addition

(detailed right) allowing for rudimentary
material mixing at feeding stage.

8 THE POWER TO MOVE MATERIALS

 Incline Conveyor
 Heavy duty 12.3m (40ft) folded plate design
incline conveyor to give structural strength
to the conveyor frame.
 Primary spring mounted poly blade face
scraper, to clear excess belt material.
 1050mm (42") wide EP 400 3 ply, 4 +2mm
belting.
 Belt speed of 1.2 m/s (236 ft/min).
 102mm (4”) diameter Troughing rollers set.
 150mm (6") diameter disc return rollers.
 Single Orbital Hydraulic Drive Motor.

Hydraulics
 Cast Iron Hydraulic pump mounted on
flywheel to power hydraulic system.
 Additional pump mounted on PTO.
 Easy access for maintenance to all
hydraulic components such as pumps,
filters, tanks, valves etc.
 Steel fabricated hydraulic oil tank
complete with fill level gauge and
locking filler cap.
 Capacity: 406 litre (107 US gallons)
 Oil type: Grade 32

9 THE POWER TO MOVE MATERIALS

 Chassis
 Heavy Duty FL4 Tracks
 Longitudinal centres: 4000mm (13’)
 Track shoe width: 400mm (16”)
 Drive: Two integrated hydraulic motors.
4000mm (13’)
 Tensioning: Hydraulic adjuster, grease
tension.
 Tracking: Push button pendant type (dog
lead).
 Speed of tracks: 1.12 (0.69 mph). 2760mm (8’ 11”)
 Heavy duty structural steel chassis, with
integrated webbed plate design for high
stress areas.
 All moving joints have incorporated heavy
duty bosses for increased strength and
wear characteristics.
 Multiple large, locking doors for easy access
to internal workings for service / repair.

Pugmill
 Twin Shaft Mixing Chambers
 Spraybars
 Hydraulic Drive
 Removable Guard
 Discharge Chute
 Options
- Extra Spraybars
- Cement Feed inlet
- Self-wearing dead box
- Rotatable Paddles for increased lifespan

Pugmill Characteristics
Width Length Depth Weight
(m) (ft) (m) (ft) (m) (ft) (kg) (lbs)

1.35 4’ 5’’ 2.55 8’ 4’’ 0.9 2’ 11’’ 2,025 4,464

10 THE POWER TO MOVE MATERIALS

 Engine & Control

Standard / Unregulated Countries

 CAT C4.4 Mechanical, Water Cooled, Power:
75Kw (100Hp) @ 2200 Rpm.
 Option to upgrade to CAT C4.4 Electronic
96.6 kw (130Hp) @ 2200Rpm.
EU Stage III / (EU Only)
 CAT C4.4 ACERT, 98.1kW, Constant Speed
@2200 Rpm.
EU Stage V/USA Tier 4 Final
 CAT C 3.6 74.5kw ACERT Industrial Power
Unit.

 Start-up system with safety features; fully

fused and fault display.
 Engine monitoring and tracking system.
 Standard electrical PCB microprocessor
technology with led indication.
 Faults are logged on led indicators until
resolved.
 LED indicator self-test executed every time
unit is powered on.
 Standardised symbols on all operational
buttons.
 Full frequency certified CE, FCC, AU and
Japanese remotes systems.
 Panel mounted in secure canopy with
locking doors.
 4 way push button pendant to track machine
(dog lead).

Diesel Tank
 Steel fabricated fuel tank complete with fill
level gauge and locking filler cap.
 Capacity: 200 litres (52 US gallons).

11 THE POWER TO MOVE MATERIALS

 TELE-MIX® P2000T Automatic
MACHINE FEATURES

Cement Silo
2m3 Conical Cement Silo including the
following features:
 Pressure Relief Valve.
 Dust Filter.
 3x load cells on cement hopper c/w
load cell junction box and load cell
amplifier.
 Automated cement hopper fill using
signal from load cells.
 Hydraulically driven Rotary Valve,
actuated by hydraulic proportional
valve control linked to PLC,
adjusting cement flow to the mix.
 Hydraulically driven Vibrating motor,
operated when no weight reduction
occurs with an open rotary valve,
ensuring adequate material flow and
preventing rat-holing / bridging.

12 THE POWER TO MOVE MATERIALS

Belt Weigh Scales

 Single idler belt weigh scales

located on incline conveyor.
 Measures combined weight
of hopper material and
cement and linked back to
the PLC program.
 Choice of either Loadrite or
Mechtronics system.

Water pump, Flow

Metre and Spray
Nozzles

 Hydraulically driven water pump

 Flow metre to measures the flow of
water and linked back to the PLC
program.
 Hydraulic water pump is controlled via
Proportional control valve Controls the
volume of water which can be added
to mix.

13 THE POWER TO MOVE MATERIALS

Upgraded Panel
with PLC Control

 Upgraded panel with PLC Control

allowing the operator to set and
adjust the percentages of cement
and water to be added to the mix.
 User friendly touch screen HMI.
 Settings adjustable in increments of
0.5%.

Access Platform with

choice of Vertical Access
Ladder or Steps

 Galvanised Access platform on

Cement Silo to enable operator
access for maintenance.
 Options of either vertical access
ladder or steps.
 Can be supplied to local Standards
if required.

14 THE POWER TO MOVE MATERIALS

TELE-MIX® P2000T Automatic – MIXING RATIOS

Water – Maximum / Minimum

NOTE: Minimum water pump delivery is 45 l/min.

Maximum water pump delivery is 180 l/min.

Cement – Maximum / Minimum

NOTE: Minimum rotary valve delivery is 45 kg/min.

Maximum rotary valve delivery is 450 kg/min.

15 THE POWER TO MOVE MATERIALS

 TELE-MIX® P2000T Automatic – OPTIONAL

Bolt in Feedboot Liners

 Option 1: 6mm (1/4") mild steel liners
 Option 2: 6mm (1/4") abrasive resistant hardened steel liners
Hopper Extensions
 Option 1: 500mm Extension (9.22 m3 Heaped Capacity)
 Option 2: 700mm Extension (11.85 m3 Heaped Capacity)
Feedboot, Fall Break System
 Integrated, Bolt in, fall break system to stop larger pieces in the material hitting the belt and causing damage to
the conveyor
Split Feedboot
 A vertically split Hopper Plate that 2 separate products can be fed from right / left hand side of unit. This will
allow for 2 products to be fed into one hopper albeit in a fairy basic mixing ratio format. Available for 500 and
700 mm Hopper Extensions
Hydraulic Tipping Grid
 Hydraulic Tipping grid over the hopper. 100mm aperture bofor bars. (Hydraulic perperation option below must
Dust Suppression System
 Dust suppression system is used with materials that are likely to create a lot of dust
 The system has dust covers running the full length of the conveyor and a head chute with rubber sock
Twin Drives
 Twin Drives on the Incline Conveyor
Dual Power
 Dual power. Machine upgraded to dual power. Electric motor to run belts and Pugmill
Oil Upgrade
Option 1: Type 68 Hydraulic Oil
Belting Upgrade
 Incline Belt Upgrade: 1050m (42”) 3 ply EP 500 5+ 1.5mm Heavy Duty Belt
 Incline conveyor upgrade: to Chevron. EP 315 3ply 3+1.5 with 15mm high cleat. Includes beater roller
 Feeder Belt Upgrade: EP630 4 ply 6 + 2mm. Heavy Duty Belt
Remote
 Option 1: Radio remote to start/stop feeder, start/stop incline, raise/lower incline, raise/lower Pugmill
 Option 2: Radio remote to start/stop feeder, start/stop incline, raise/lower incline & track machine, raise/lower
Pugmill
Drive Drum upgrade
 Feeder conveyor drive drum upgraded to ceramic lagging
Hydraulic Jacking Legs
 Upgrade to 2 x hydraulic jacking legs at the rear of hopper

16 THE POWER TO MOVE MATERIALS

Conveyor Options
 Option 1: Bolt on rubber side skirting up the length of the conveyor to avoid material spillage
 Option 2: Incline Conveyor Drive drum upgraded to Ceramic lagging
 Option3: Anti Roll back x 3 sets. Folds down for transport
 Option 4: Basket guards on incline conveyor return rollers. (Painted Yellow)
 Option 5: Overband magnet mounted over the incline conveyor. (Hydraulic). Includes stainless steel discharge
chute
 Option 6: Centralised Greasing of Hopper, Incline and Pugmill bearings
Track Upgrade
 Tracks upgraded to Heavy Duty FL6 Tracks x 400mm shoe
 Dual Speed Tracks Slow and High Speed. (Pendant upgraded with fast / slow function)
 Track Shoes upgraded to Flat Steel with chamfered edge for protection of working surface
Double Deck Vibrating Grid (DDVG)
 Option 1: Machine prepared hydraulically run (DDVG), includes remote control
 Option 2: Machine prepared hydraulically to tip a standard grid, includes remote control
 Option 3: Double Deck Live Head: Vibrating Grid
Pugmill Options
 Cement in Feed Box at Transfer point from Hopper to Incline
 Cement in Feed Box at Discharge Point of Incline with Direct feed into Pugmill
 6mm Mild Steel Wear liners on Pugmill rolled Bottom

TELE-MIX® P2000T Automatic –

TRANSPORT INFORMATION

Options
The TELE-MIX P2000T can be transported in a number of ways:

1. Machine can be transported via low loader trailer with all features folded into transport position
2. Machine can also be transported in 2 x 40’ High Cube containers for global distribution

17 THE POWER TO MOVE MATERIALS

TELE-MIX® P2000T – GENERAL ARRANGEMENT
OPERATIONAL – Pugmill at Lowest Angle

18 THE POWER TO MOVE MATERIALS

TELE-MIX® P2000T – GENERAL ARRANGEMENT
Operational – Pugmill at 4 Degrees

19 THE POWER TO MOVE MATERIALS

TELE-MIX® P2000T – GENERAL ARRANGEMENT
TRANSPORT

20 THE POWER TO MOVE MATERIALS

Telestack Limited
Bankmore Way East
Omagh, Co.Tyrone
Northern Ireland
BT79 0NZ
THE
Tel:+44 (0) 2882 251100 POWER
Fax:+44 (0) 2882 252211
Web: www.telestack.com TO MOVE
Email: [email protected] MATERIALS
The information in this document is for information only and is subject to change without notice. Telestack assumes no liability resulting from errors
or omissions in this specification, or from the use of the information contained herein. Due to the continual product development we reserve the right
to change specifications without notice. Any product dimensions and figures given out in this specification are for guidance purposes only. These
results will vary depending on product, commodity and application. Some or all of the machines in these pictures may be fitted with optional extras.
Telestack is a registered trademark.
 MAINTENANCE

MAINTENANCE

6. MAINTENANCE ................................................................................. 6-3

6.1. GENERAL INFORMATION................................................................ 6-3
6.2. CLEARING BLOCKAGES ................................................................. 6-4
6.3. MAINTENANCE SAFETY .................................................................. 6-5
6.4. MAINTENANCE GUARDS ................................................................ 6-7
6.5. MAINTENANCE SCHEDULE ............................................................ 6-8
6.6. LUBRICATION ................................................................................. 6-12
6.6.1. LUBRICATION CHART ................................................................... 6-13
6.6.2. GREASE CANISTER ....................................................................... 6-14
6.6.3. LOW LEVEL GREASING OPTION.................................................. 6-16
6.6.4. PUGMILL GREASING ..................................................................... 6-17
6.7. FEED AND INCLINE CONVEYOR MAINTENANCE ....................... 6-18
6.7.1. CLEANING AND CHECKING THE CONVEYOR BELT .................. 6-18
6.7.2. TENSIONING THE CONVEYOR BELT ........................................... 6-19
6.7.3. ALIGNING THE CONVEYOR BELT ................................................ 6-21
6.7.4. FEED CONVEYOR GEARBOX OIL DRAINING.............................. 6-24
6.7.5. FEED CONVEYOR GEARBOX OIL FILLING ................................. 6-25
6.7.6. INCLINE CONVEYOR GEARBOX OIL DRAINING ......................... 6-26
6.7.7. INCLINE CONVEYOR GEARBOX OIL FILLING............................. 6-27
6.8. TRACK MAINTENANCE ................................................................. 6-28
6.8.1. CLEANING THE TRACKS............................................................... 6-28
6.8.2. CHECKING TRACK TENSION ........................................................ 6-29
6.8.3. ADJUSTING THE TRACK TENSION .............................................. 6-30
6.8.4. TRACK GEARBOX OIL DRAINING ................................................ 6-33
6.8.5. TRACK GEARBOX OIL FILLING .................................................... 6-34
6.9. PUGMILL MAINTENANCE .............................................................. 6-35
6.9.1. CLEANING THE PUGMILL BOX..................................................... 6-35
6.9.2. PUGMILL GEARBOX OIL DRAINING ............................................ 6-37
6.9.3. PUGMILL GEARBOX OIL FILLING ................................................ 6-38
6.9.4. PUGMILL GEAR CASE OIL DRAINING ......................................... 6-39
6.9.5. CHECKING THE GEAR CASE OIL LEVEL .................................... 6-40
6.9.6. ADDING GEAR CASE OIL .............................................................. 6-41
6.9.7. CHANGING GEAR CASE OIL......................................................... 6-42
6.10. HYDRAULIC TANK ......................................................................... 6-44
6.10.1. CHECKING THE HYDRAULIC FLUID LEVEL ............................ 6-46
6.10.2. ADDING HYDRAULIC FLUID ...................................................... 6-47
6.10.3. CHANGING HYDRAULIC FLUID / SUCTION FILTER / RETURN
FILTER 6-48
6.11. FUEL SYSTEM ................................................................................ 6-50
6.11.1. CHECKING THE FUEL LEVEL ................................................... 6-51
6.11.2. ADDING FUEL ............................................................................. 6-52
6.12. BATTERY ........................................................................................ 6-53
6.12.1. DISCONNECTING THE BATTERY ............................................. 6-53

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6.12.2. CONNECTING THE BATTERY ................................................... 6-54
6.12.3. JUMP STARTING THE BATTERY .............................................. 6-55
6.13. HYDRAULIC RAM MAINTENANCE ................................................ 6-56

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6. Maintenance

6.1. General Information

Exercise due care for the environment when carrying out any servicing or repair
work. Potentially harmful waste which may arise from working on this
equipment includes such items as oil, fuel, coolant, filters and batteries.
Improperly disposing of waste can damage the environment. Be responsible.

A proper routine for inspection and maintenance will ensure a longer and more
reliable service life for your machine. The information provided in this section
represents the minimum guidelines for inspection and maintenance and
regularly undertaking these guidelines/procedures is an essential part of your
obligations for continued warranty cover.

When performing maintenance, always observe rules provided in the safety

section. Breakdown caused by insufficient or improper maintenance will cause
high repair cost and long term standstill. Therefore, regular maintenance is
essential.

In addition to other factors, the reliability and life of the machine depends on
regular and proper maintenance. The following section contains maintenance
instructions as well as maintenance schedules for normal operating conditions.

This machine has been designed to facilitate easy routine maintenance, if you
find any problems contact your local Telestack dealer who will contact our
Support Department.

When this machine is operated in extreme climate conditions (e.g. below -15ºC
or above 33ºC) or in very dusty conditions for long periods of time, the
maintenance schedule will change.

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6.2. Clearing Blockages

Under no circumstances should the hopper be accessed when the machine or

equipment that is feeding the machine is in operation.

It is imperative that the hopper is cleared of material before attempting to restart

the machine. If not cleared the full weight of the material will travel up the incline
conveyor causing the machine to become unstable.

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not climb onto the machine to perform any maintenance tasks. Always use
a suitable maintenance platform.

1. Observe all safety warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Retract front telescopic hydraulic cylinders.
4. Shut down the machine and remove the ignition key.
5. Implement the lockout, tagout, try-out procedure.
6. Clear blockage using appropriate tools.

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6.3. Maintenance Safety

Practice safe maintenance.

Read and understand the operator’s manual before doing any work
Wear personal protective equipment.
Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not climb onto the machine to perform any maintenance tasks. Always use
a suitable maintenance platform.

Maintenance should only be carried out by trained and qualified personnel.

1. Whenever maintenance is being carried out a minimum of two people

should be present at all times. NEVER WORK ALONE.
2. When performing maintenance tasks, always observe the local site
safety rules or as provided in the safety section of this manual.
3. Wear a hard hat, safety goggles, hearing protection and other protective
equipment as required. Do not wear loose clothing or jewellery that can
catch on controls or moving parts. Long hair must be tied back.
4. Move the machine onto a level surface.
5. Engage the brake on radial machines.
6. Shut off the engine and remove the key. Implement the lock out, tag out,
try-out procedure.
7. Relieve all hydraulic pressure by returning controls to neutral. Secure all
hydraulically operated attachments with pins provided.
8. Isolate all electrical supplies to the machine before starting any
maintenance work.
9. Never attempt maintenance work on the machine while it is running.
10. Remove only guards or covers that provide access.
11. Never leave guards off or access doors open when unattended.

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12. Never work under unsupported equipment, use blocks, jack-stands or
other rigid and stable supports.
13. When working at height make sure you take all necessary precautions in
line with local regulations and use approved PPE, safety harnesses and
maintenance platforms.
14. Keep all steps, handrails, walkways and ladders free from dirt, oil, snow
and ice.
15. Never operate the machine without proper ventilation – EXHAUST
FUMES CAN KILL.
16. Checking for hydraulic leaks. Beware hydraulic fluid under pressure can
penetrate the skin or damage eyes. Fluid leaks under pressure may not
be visible. Use a piece of cardboard to find leaks but do not use bare
hand.
17. Wear safety goggles for eye protection. If fluid enters skin or eye, get
immediate medical attention.
18. Clean or replace damaged, missing or painted over safety signs that
cannot be read.
19. Rotating and moving parts must be checked during maintenance and
replaced if cracked or damaged. Excessively worn or damaged parts can
fail and cause injury or death.
20. After maintenance, tighten all bolts, fittings and connections. Install all
guards and covers. Replace or repair any damaged ones. Check
hydraulic fluid level and add if necessary. Start the engine and check for
leaks. Operate all controls and make sure each is functioning properly.
21. NEVER make any modifications, additions or conversions which might
affect safety without Telestack’s approval.
22. Prevent any burns or scalds by allowing the hydraulic fluid to cool down
for approximately 3 hours before carrying out any maintenance tasks.

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6.4. Maintenance Guards

Do not remove any guards while the machine is running or start the machine
while a guard is removed.

Pugmill
Guards

Gearbox / Motor
Guard

Radiator
Guard

Bearing
Guards

Engine
Guards

Hydraulic and
Fuel Tank
Guards

Track
Guards

Incline Tail
Guards

Incline Tail
Guards
Hopper / Feeder
Guards

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6.5. Maintenance Schedule

This is a minimum amount of maintenance required to be carried out on

Telestack equipment, we actively encourage you to put in place extra
procedures /guideline in accordance your company health and safety policy.
Failure to carry out scheduled maintenance or exercise due care invalidates
any warranty that applies.
Ask your local Telestack dealer or Telestack Support Department for advice.

General
10 H o urs 5 0 H o urs 10 0 250 500 10 0 0
Maintenance Task Action ( D a ily) ( We e k ly) H o urs H o urs H o urs H o urs
O t he r

Emergency sto p Check / Repair 

M aterial build up Check / Clean 

Under Trays Check / Clean 

Safety guards are in place Check / Replace 

Lo o se parts, nuts, bo lts and pins Check / Tighten 

Diesel in fuel tank Check / Refill 

Hydraulic ho ses fo r leaks and wear Check / Tighten / Replace 

Co ntro l levers functio n Check / Replace 

Inspectio n o f structure Check / Clean / Repair 

Co nditio n o f wearplates Check / Replace 

Hydraulic cylinders fo r leaks Check / Clean / Replace 

Hydraulic pumps fo r leaks Check / To rque / Replace 

Hydraulic mo to rs fo r leaks Check / To rque / Replace 

M aintenance platfo rm, steps and railings are safe and secure
Check / Tighten 
(o ptio nal)
Grease pipelines fo r leaks and wear (o ptio nal) Check / Tighten / Replace 

Electrical functio n Check / Repair 

Safety decals clear, damaged o r missing Check / Clean / Replace 

Grease po t dispensers Check / Replace 

P ins Grease, Qty: 2 Grams / 1P ump 

B attery Electro lyte Level Check 

Clean o r apply water resistant
Expo sed chro me o n hydraulic cylinders 
grease

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**Not all tasks listed below are applicable to this unit**
Feeder
10 H o urs 5 0 H o urs 10 0 250 500 10 0 0
Maintenance Task Action ( D a ily) ( We e k ly) H o urs H o urs H o urs H o urs
O t he r

Feeder belt fo r damage and wear Check / Replace 

B elt alignment Check / A lign 

B elt tensio n Check / Tensio n 

Ro llers are free mo ving and uno bstructed Check / Clean / Free 

B elt scraper Check / A djust / Replace 

Skirting rubbers Check / A djust / Replace 

Obstructio n to drums Check / Clean / Free 

Feeder chains fo r damage and wear Check / Replace 

Chain tensio n Check / Tensio n 

Feeder spro cket fo r damage, wear and lubricant Check / Replace / Lubricate 

A pro n P ans Check / Tighten / Replace 

Gearbo x fo r leaks and o il level Check / Refill 

Gearbo x bo lts Check / To rque   

Gearbo x o il (1st replace at 100 ho urs)
Replace  A nnually
Oil Type: EP 220 (Quanitity 1.2 Litres - 0.32 US Gal)
Tail drum bearings Check / Clean   

Drive drum bearings Check / Clean   

Conveyor
10 H o urs 5 0 H o urs 10 0 250 500 10 0 0
Maintenance Task Action ( D a ily) ( We e k ly) H o urs H o urs H o urs H o urs
O t he r

Co nveyo r belt fo r damage and wear Check / Replace 

B elt alignment Check / A lign 

B elt tensio n Check / Tensio n 

Ro llers are free mo ving and uno bstructed Check / Clean / Free 

B elt scraper Check / A djust / Replace 

Skirting rubbers Check / A djust / Replace 

Obstructio n to drums Check / Clean / Free 

Gearbo x fo r leaks and o il level Check / Refill 

Gearbo x bo lts Check / Tighten   

Gearbo x o il (1st replace at 100 ho urs)
Replace  A nnually
Oil Type: EP 220 (Quanitity 1.2 Litres - 0.32 US Gal)
Tail drum bearings Check / Clean   

Drive drum bearings Check / Clean   

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Pugmill Unit
10 H o urs 5 0 H o urs 10 0 250 500 10 0 0
Maintenance Task Action ( D a ily) ( We e k ly) H o urs H o urs H o urs H o urs
O t he r

M aterial build up Check / Clean 

Lo o se parts, nuts, bo lts and pins Check / Tighten 

Safety guards are in place Check / Replace 

Hydraulic ho ses fo r leaks and wear Check / Tighten / Replace 

Inspectio n o f structure Check / Clean / Repair 

Co nditio n o f paddles/wearplates Check / Replace 

Hydraulic cylinders fo r leaks Check / Clean / Replace 

Hydraulic pumps fo r leaks Check / To rque / Replace 

Hydraulic mo to rs fo r leaks Check / To rque / Replace 

Grease pipelines fo r leaks and wear (o ptio nal) Check / Tighten / Replace 

Electrical functio n Check / Repair 

Safety decals clear, damaged o r missing Check / Clean / Replace 

Grease po t dispensers Check / Replace 

P ins Grease, Qty: 2 Grams / 1P ump 

Clean o r apply water resistant
Expo sed chro me o n hydraulic cylinders 
grease
B earings Check / Clean 

Gear case o il level Check / Refill 

Gear case o il
Replace A nnually
Oil Type: EP 220 (Quanitity 5 Litres - 1.33 US Gal)
Gearbo x fo r leaks and o il level Check / Refill 

Gearbo x bo lts Check / To rque   

Gearbo x o il (1st replace at 100 ho urs)
Replace  A nnually
Oil Type: EP 220 (Quanitity 1.5 Litres - 0.40 US Gal)

Hydraulic System
10 H o urs 5 0 H o urs 10 0 250 500 10 0 0
Maintenance Task Action ( D a ily) ( We e k ly) H o urs H o urs H o urs H o urs
O t he r

Hydraulic o il level Check / To p up 

ISO32 Hydraulic o il (Quanitity 480 Litres - 127 US Gal) A nalysis - Check / To p up /

Sample every 500 ho urs and replaced if test fails. Replace if necessary
Oil sho uld be changed at a maximum o f 2000 ho urs. Replace

ISO68 Hydraulic o il (Quanitity 480 Litres - 127 US Gal) A nalysis - Check / To p up /

 
Sample every 500 ho urs and replaced if test fails. Replace if necessary
Oil sho uld be changed at a maximum o f 2000 ho urs. Replace 

Hydraulic ho ses fo r leaks and wear Check / Tighten / Replace 

Oil co o ler Check / Clean 

Filter blo ckage indicato r Check 

Hydraulic cylinders Charge / B leed  

Return Filters (1st replace at 100 ho urs) Remo ve / Replace   

Hydraulic P ressure Relief Check / A djust 

Suctio n Filters (1st replace at 100 ho urs) Remo ve / Replace  

Track System
10 H o urs 5 0 H o urs 10 0 250 500 10 0 0
Maintenance Task Action ( D a ily) ( We e k ly) H o urs H o urs H o urs H o urs
O t he r

Track tensio n Check / A djust 

M aterial build up Check / Clean 

Inspectio n o f structure Check / Clean / Replace 

Run machine 10 metres in either directio n P erfo rm 

B o lts, nuts Check / Tighten 

Lo wer ro llers and idlers o il leakage Check / To p up 

Track links, pins, sho e damage Check / Replace 

Gearbo x fo r leaks and o il level Check / Refill 

Gearbo x o il (1st replace at 100 ho urs)
Replace   
Oil Type: SA E80W/90 (Quanitity 2 Litres - 0.53 US Gal)

Electrics
10 H o urs 5 0 H o urs 10 0 250 500 10 0 0
Maintenance Task Action O t he r
( D a ily) ( We e k ly) H o urs H o urs H o urs H o urs
Co ntro l P anel Check / Clean 

Check wiring fo r fraying o r damage Check / Replace 

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Engine
10 H o urs 5 0 H o urs 10 0 250 500 10 0 0
Maintenance Task Action ( D a ily) ( We e k ly) H o urs H o urs H o urs H o urs
Ot he r

Fo r engine maintenance info rmatio n, refer to the engine manufacturer‘ s o peratio n manual supplied.

Conveyor Scales - Option

10 H o urs 5 0 H o urs 10 0 250 500 10 0 0
Maintenance Task Action Ot he r
( D a ily) ( We e k ly) H o urs H o urs H o urs H o urs
Fo r co nveyo r scales maintenance info rmatio n, refer to the co nveyo r scales manufacturer‘ s o peratio n manual supplied.

Cement Hopper Gearbox - Option

10 H o urs 5 0 H o urs 10 0 250 500 10 0 0
Maintenance Task Action O t he r
( D a ily) ( We e k ly) H o urs H o urs H o urs H o urs
Gearbo x fo r leaks and o il level Check / Refill 
Gearbo x o il (1st replace at 100 ho urs)
Replace   
Oil Type: ISO VG 220 (Quanitity 2.2 Litres - 0.58 US Gal)

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6.6. Lubrication

It is important that a strict routine of regular maintenance is undertaken from

the start of operation of the machine.
Regular checks on fluids and the lubrication of the machine, in accordance
with the maintenance schedule, is essential.

Fluid injection hazard

There is a high pressure system and only qualified experienced engineers
should tackle any problems that may arise. Always relieve the pressure from
the hydraulic system before carrying out any kind of maintenance or
adjustment.

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not climb onto the machine to perform any maintenance tasks. Always use
a suitable maintenance platform.
Incorrect grease and/or lubrication schedules can cause premature wear or
damage to bearings.

Do not mix greases. USE ONE BRAND/SPECIFICATION ONLY.

Telestack may have fitted grease canisters to deliver the specified quantity of
grease to shaft bearings. See 6.6.2 Grease Canister

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6.6.1. Lubrication Chart

Detailed is a chart of lubricants recommended by Telestack for different

machine elements and ambient temperature ranges.

Machine Lubricant Ambient Trade Name Grade

Element Temperature
Bearings Grease -10 oC to +40 oC EP 1 L-XACGB 1
-10 oC to +40 oC EP 2 L-XBDHB 2
10 oC to +45 oC HD 220 L-XDGFB 2
Gear Gear Oil -20 oC to +25 oC Gear Oil 100 ISO VG 100
Reducers -10 oC to +40 oC Gear Oil 220 ISO VG 220
0 oC to +45 oC Gear Oil 460 ISO VG 460
Hydraulic Hydraulic -15 oC to +30 oC Hydraulic Oil 32 ISO VG 32
System Fluid 0 oC to +45 oC Hydraulic Oil 68 ISO VG 68

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6.6.2. Grease Canister

Installing the Grease Canister

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not climb onto the machine to perform any maintenance tasks. Always use
a suitable maintenance platform.

1. Observe all safety warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Retract front telescopic hydraulic cylinders.
4. Shut down the machine and remove the ignition key.
5. Implement the lockout, tagout, try-out procedure.
6. Use a grease gun to grease each bearing before first installation.
7. Fit the grease canister starter cap by hand & tighten down firmly (you will
hear the seal break while doing this). Use a screw driver or similar to
tighten completely.
8. Record change over date.
9. Fit grease canister hand tight into grease point on each bearing (two
drive drum bearings and two tail drum bearings).

Grease canisters fitted may not last 12 months and are subject to site
conditions.
This canister is designed to operate at an average temperature of 25˚C.

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See table below in order to get the discharge rate at various temperatures

Version 01W (1month) 03B(3months) 06R(6months) 12G(12months)

Ambient Duration Discharge Duration Discharge Duration Discharge Duration Discharge in
environmental in in g/day in in g/day in in g/day in g/day
temperature months months months months
65º 0.5 8 1 3.6 2 1.8
55º 0.3 12 1.0 3.6 2 1.8 4 0.9
45º 0.5 7.3 1.5 2.3 3 1.7 6 0.6
35º 0.7 5.2 2.5 1.5 4.5 0.8 9 0.4
25º 1 3.6 3 1.2 6 0.6 12 0.3
15º 1.5 2.3 4.5 0.8 9 0.4 18 0.2
5º 2 1.8 6 0.6 14 0.26 28 0.13
-5º 4 0.9 12 0.3 24 0.15 48 0.08
-15º 6 0.6 18 0.2 36 0.1
-25º 9 0.4 27 0.13

Grease Max uses a small quantity of potassium hydroxide as part of its

operation. If it is opened or accidentally damaged and the liquid escapes onto
the skin or eyes, wash water and seek medical advice.

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6.6.3. Low Level Greasing Option

This P2000T has low level greasing to some bearings. Grease pipes are
returned from the bearing to low level where maintenance can be performed
with ease.

All bearings must be lubricated in accordance with the maintenance schedule

otherwise your warranty will be effected.

1 2

Item Description Quantity Frequency

Feed Conveyor Tail Drum Bearing (Left) 4 Grams / 2 Pumps 50 Hours
Grease Feed Conveyor Tail Drum Bearing (Right) 4 Grams / 2 Pumps 50 Hours
Points 1
Incline Conveyor Tail Drum Bearing (Left) 4 Grams / 2 Pumps 50 Hours
Grade Incline Conveyor Tail Drum Bearing (Right) 4 Grams / 2 Pumps 50 Hours
EP2 Incline Conveyor Drive Drum Bearing (Left) 4 Grams / 2 Pumps 50 Hours
2
Incline Conveyor Drive Drum Bearing (Right) 4 Grams / 2 Pumps 50 Hours

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6.6.4. Pugmill Greasing

All bearings must be lubricated in accordance with the maintenance schedule

otherwise your warranty will be effected.

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not climb onto the machine. Always use a suitable platform.

1. Lower the incline conveyor fully.

2. Lock out, tag out, try-out your machine.
3. Remove guards and apply required grease.

1 2

Item Description Quantity Frequency

Grease Pugmill Non Drive Bearing (Left) 4 Grams / 2 Pumps 50 Hours
1
Points Pugmill Non Drive Bearing (Right) 4 Grams / 2 Pumps 50 Hours
Grade Pugmill Drive Shaft Bearing (Left) 4 Grams / 2 Pumps 50 Hours
EP2 2
Pugmill Drive Shaft Bearing (Right) 4 Grams / 2 Pumps 50 Hours

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6.7. Feed and Incline Conveyor Maintenance

6.7.1. Cleaning and Checking the Conveyor Belt

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not climb onto the machine to perform any maintenance tasks. Always use
a suitable maintenance platform.
Do not remove any guards while the machine is running or start the machine
while a guard is removed.
If any damage to the belt is found, do not operate the machine until it is
repaired or replaced.

1. Observe all safety warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Retract front telescopic hydraulic cylinders.
4. Shut down the machine and remove the ignition key.
5. Implement the lockout, tagout, try-out procedure.
6. Open the guard doors where necessary.
7. Clean the conveyor belt using a high pressure hose avoiding electrical
components where possible.
8. Check the belts for cuts, tears, rips or any other damage.

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6.7.2. Tensioning the Conveyor Belt

Feed Conveyor

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not climb onto the machine to perform any maintenance tasks. Always use
a suitable maintenance platform.

Do not over tension the belt as this will damage the drum bearings.

1. Observe all safety warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Start the conveyor.
4. Open the protective guard (1).
5. Tighten the belt by adjusting both belt adjusters (2) evenly, 2 turns at a
time until slippage stops.
6. Close the protective guard (1).

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Incline Conveyor

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not climb onto the machine to perform any maintenance tasks. Always use
a suitable maintenance platform.

Do not over tension the belt as this will damage the drum bearings.

1. Observe all safety warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Start the conveyor.
4. Tighten the belt by adjusting both belt adjusters evenly, 2 turns at a time
until slippage stops.

1 2

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6.7.3. Aligning the Conveyor Belt

In the event that a conveyor belt tracks off centre, the belt will need to be
adjusted to ensure it is running on the centre of the drums.
To check if the belt is aligned, visually inspect the belt position on the drum.
If the centreline of the belt is running in the centre of the drum then the belt is
perfectly aligned. If the whole belt is not on the centreline of the drum then the
belt needs to be aligned.
Make sure before aligning the belt that any deviation in belt travel is not due to
the build-up of material on the head or tail drums.
Remove build-up and observe the belt while running to ascertain if adjustment
is required.
If the centreline of the belt is located to the left or to the right side of the
centreline of the drum then it needs to be brought back to the centre. Make sure
to maintain correct belt tension when adjusting.

  
Belt to left of drum Belt centred on drum Belt to right of drum

In order to track the conveyor belt correctly, the following steps must be
followed.
 The conveyor structure must be straight.
 All pulleys, snub rollers, carrying idlers and return idlers must be square
with the frame and parallel to each other
 Belt tension must be great enough to prevent slippage at the drive pulley
and for the belt to conform to the crown of the pulleys.
 Cleanliness is essential to good tracking i.e. no foreign matter (Build-up)
on idlers etc.

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Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not climb onto the machine to perform any maintenance tasks. Always use
a suitable maintenance platform.

1. Observe all safety warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Start the conveyor.
4. For the feed conveyor open the protective guard (1).
5. Observe the belt for direction of tracking out of line.
6. If the belt is tracking off to the left, rotate the left adjuster (2) one full
rotation and observe the belt movement. Repeat until the belt is tracking
in line.
6. If the belt is tracking off to the right, rotate the right adjuster (3) one full
rotation and observe the belt movement. Repeat until the belt is tracking
in line.

Feed Conveyor Adjusters

2 3

Incline Conveyor Adjusters

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7. Make adjustments to the rollers by loosening the bolts attaching the
rollers to the conveyor and make small left or right adjustments until the
idlers are in the required position and the belt is running straight.

Direction
of Travel

8. Allow the belt to travel around at least three times and observe
alignment.
9. Repeat the above steps until the belt is running straight.

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6.7.4. Feed Conveyor Gearbox Oil Draining

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Oil can be hot and the operator should take care to avoid burns.
Dispose of oil safely and in an environmentally friendly manner.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Clean around plugs removing all potential contaminants.
6. Unscrew and remove the filler plug and the drain plug and allow the oil to
drain.
7. Wash inside the gearbox with a suitable liquid detergent.
8. Refit the filler and drain plug back into the gearbox.
9. Turn the unit for a few minutes in at high speed then drain the cleaning
liquid from the gearbox
10. Fill the oil as described in Gearbox Filling.

Oil Fill
Plug

Oil Level
Plug

Oil Drain
Plug
Oil Level
Plug

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6.7.5. Feed Conveyor Gearbox Oil Filling

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not fill oil in the track drive without checking oil level inside it.

When checking, filling or replacing oil in the gearbox the work area cleanliness
is essential. The gearbox operating life will be dramatically shortened if the oil
becomes contaminated. Only use new clean oil in clean containers and fillers.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Clean around plugs removing all potential contaminants.
6. Unscrew and remove the fill plug and the level plug.
7. Fill the oil through the filler hole until it runs out through the level hole.
8. Refit the filler and drain plug back into the gearbox.
9. Run the gearbox at low speed through several revolutions to remove any
trapped air and then re-check the level.
10. Add more oil if necessary.

Oil Fill
Plug

Oil Level
Plug

Oil Drain
Plug
Oil Level
Plug

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6.7.6. Incline Conveyor Gearbox Oil Draining

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Oil can be hot and the operator should take care to avoid burns.
Dispose of oil safely and in an environmentally friendly manner.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Clean around plugs removing all potential contaminants.
6. Unscrew and remove the filler plug and the drain plug and allow the oil to
drain.
7. Wash inside the gearbox with a suitable liquid detergent.
8. Refit the filler and drain plug back into the gearbox.
9. Turn the unit for a few minutes in at high speed then drain the cleaning
liquid from the gearbox
10. Fill the oil as described in Gearbox Filling.
Oil Fill
Plug

Oil Drain Oil Level

Plug Plug

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6.7.7. Incline Conveyor Gearbox Oil Filling

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not fill oil in the track drive without checking oil level inside it.

When checking, filling or replacing oil in the gearbox the work area cleanliness
is essential. The gearbox operating life will be dramatically shortened if the oil
becomes contaminated. Only use new clean oil in clean containers and fillers.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Clean around plugs removing all potential contaminants.
6. Unscrew and remove the fill plug and the level plug.
7. Fill the oil through the filler hole until it runs out through the level hole.
8. Refit the filler and drain plug back into the gearbox.
9. Run the gearbox at low speed through several revolutions to remove any
trapped air and then re-check the level.
10. Add more oil if necessary.

Oil Fill
Plug

Oil Drain Oil Level

Plug Plug

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6.8. Track Maintenance

In order to maintain the reliability of the tracks, regular maintenance is

essential.
Make certain the machine is tracked at least 10m in either direction on a daily
basis, to minimise risk of track chain seizure.
It should also be parked on level ground overnight and during periods to of
non-usage. It is imperative that the tracks are maintained as outlined within
this maintenance section.

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.

Always. .
 Perform maintenance on a level and solid surface.
 Ensure tracks is solidly supported if work is necessary under the tracks.
 Remove any build-up of grease, oil or debris.
 Repair all damage and replace worn or broken parts immediately.
 Check for oil leaks and damaged hydraulic hoses.
 Use only specified lubricants. Do not mix different brands or types.
 Use great care when maintaining the hydraulic system since oil may be
very hot when the machine has just been working.
 Dispose of lubricants in the proper manner.

6.8.1. Cleaning the Tracks

1. On a daily basis the tracks should be hosed down to dislodge any build-
up of material on the tracks.

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6.8.2. Checking Track Tension

Before attempting to manoeuvre the machine the tracks must be free of

obstructions, including material build-up.
It is important that the track is not tensioned too tightly as this places
excessive loads on the gearbox grease cylinder and idler bearings. It will also
lead to accelerated wear and premature failure.

1. Observe all Safety Warnings.

2. Position the machine on solid and level ground and drive 2 metres (2
yards) minimum in a forward direction, track idler roller leading.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout and try-out procedure.
5. One track at a time, measure the sag on the top part of the track on the
longest section of unsupported track by placing a ‘straight edge’ long
enough to reach from the drive sprocket to the nearest skid plate.
6. Measure the maximum amount of track sag from the high point of the
track to the bottom of the ‘straight edge’.

Sag of Track

7. The sag of the track must be between 5mm and 15mm.

8. Depending upon the sag you will need to either slacken or tension the
track.

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6.8.3. Adjusting the Track Tension

Track systems use a grease cylinder to keep each track chain in tension.
Screwed into the end of the grease cylinder is grease fitting, enabling grease
to be pumped into the grease chamber and released from it, tightening and
slackening the track.
Tensioner
Seals

Grease
Fitting

The grease inside the track tensioner is pressurised so care must be taken
when loosening the grease fitting. Grease coming out under pressure can
penetrate the body causing injury or death.

Wear personal protective equipment.

Injection hazard from high pressure fluid.
Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not climb onto the machine to perform any maintenance tasks. Always use
a suitable maintenance platform.
It is important that the track is not tensioned too tightly as this places
excessive loads on the gearbox grease cylinder and idler bearings. It will also
lead to accelerated wear and premature failure.

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1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Locate the access area on the side of the track frame.

Access
Area

Tightening the Track

6. Ensure the grease fitting and grease gun adaptor is clean; ingress of dirt
into the grease fitting can result in failure. Connect a grease gun to the
grease fitting and add grease until the track tension is within the
specified values given in Checking Track Tension.
7. Track the machine 50 metres (50 yards) forwards and 50 metres (50
yards) backwards, and repeat the procedure if the track slackens.

Slackening the Track

8. Loosen the grease fitting, by turning in an anti-clockwise direction, using
gradual increments until the grease begins to be expelled. Care must be
taken not to loosen the grease fitting too quickly.
9. When the correct track tension has been obtained, tighten the grease
fitting by turning in a clockwise direction and clean away all trace of
extruded grease. Be sure not to over tighten the grease fitting.

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If the track fails to slacken after grease fitting has been loosened; DO NOT
attempt to remove the tracks or disassemble the track tensioner, and DO NOT
remove the grease fitting from the tensioner. It is possible that running the
tracks a short distance in both directions with the grease fitting loosened may
help to expel the grease.

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6.8.4. Track Gearbox Oil Draining

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Oil can be hot and the operator should take care to avoid burns.
Dispose of oil safely and in an environmentally friendly manner.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface and bring the drain
holes to the required drain position shown below.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Clean around both plugs removing all potential contaminants.
6. Remove both plugs and allow the oil to drain.
7. Move the machine to bring the plugs to the fill position.
8. Fill the oil as described in Gearbox Filling.

Oil Plug Position Oil Draining 1 Oil Draining 2 Oil Draining 3

Oil
Drain

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6.8.5. Track Gearbox Oil Filling

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not fill oil in the track drive without checking oil level inside it.

When checking, filling or replacing oil in the gearbox the work area cleanliness
is essential. The gearbox operating life will be dramatically shortened if the oil
becomes contaminated. Only use new clean oil in clean containers and fillers.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface and bring the drain
holes to the required fill position shown below.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Clean around both plugs removing all potential contaminants.
6. Remove both plugs.
7. Fill the oil through the upper hole until it runs out through the lower hole.
8. Wait a few moments until any trapped air has escaped and then re-
check the level.
9. Add more oil if necessary.

Oil Plug Position Oil Filling 1 Oil Filling 2 Oil Filling 3

Oil
Fill 1

Oil
Level

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6.9. Pugmill Maintenance

6.9.1. Cleaning the Pugmill Box

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not climb onto the machine to perform any maintenance tasks. Always use
a suitable maintenance platform.
Do not remove any guards while the machine is running or start the machine
while a guard is removed.

By keeping the pugmill clean, maintenance will be easier and its overall life
will increase, resulting in a more efficient and productive blending plant.
Clean the pugmill box after every use.
If the pugmill isn’t cleaned after every use the material inside the pugmill
hardens, creating blockages in the feed and discharge chutes and water
nozzles.

1. Observe all safety warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Retract front telescopic hydraulic cylinders.

4. Shut down the machine and remove the ignition key.

5. Implement the lockout, tagout, try-out procedure.

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6. Open the pugmill guard doors.

Pugmill
Guards

7. Remove all hardened material around the guard doors, and on main
areas of the shaft, using a crowbar or similar tool. Avoid hitting delicate
components such as paddle arms and tips.
8. Wash out all loose material using a high pressure hose.
9. Manually rotate the shafts to locate any hidden material.
10. Check feed and discharge chutes for any blockages – remove and clean
accordingly.
11. Check the spray bars for any nozzle blockages.
12. Check and fix/replace any damaged, worn or missing components.
13. Close up guard doors and remove isolation.

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6.9.2. Pugmill Gearbox Oil Draining

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Oil can be hot and the operator should take care to avoid burns.
Dispose of oil safely and in an environmentally friendly manner.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Clean around plugs removing all potential contaminants.
6. Unscrew and remove the filler plug and the drain plug and allow the oil to
drain.
7. Wash inside the gearbox with a suitable liquid detergent.
8. Refit the filler and drain plug back into the gearbox.
9. Turn the unit for a few minutes in at high speed then drain the cleaning
liquid from the gearbox
10. Fill the oil as described in Gearbox Filling.

Oil Fill
Plug

Oil Drain Oil Level

Plug Plug

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6.9.3. Pugmill Gearbox Oil Filling

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not fill oil in the track drive without checking oil level inside it.

When checking, filling or replacing oil in the gearbox the work area cleanliness
is essential. The gearbox operating life will be dramatically shortened if the oil
becomes contaminated. Only use new clean oil in clean containers and fillers.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Clean around plugs removing all potential contaminants.
6. Unscrew and remove the fill plug and the level plug.
7. Fill the oil through the filler hole until it runs out through the level hole.
8. Refit the filler and drain plug back into the gearbox.
9. Run the gearbox at low speed through several revolutions to remove any
trapped air and then re-check the level.
10. Add more oil if necessary.

Oil Fill
Plug

Oil Drain Oil Level

Plug Plug

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6.9.4. Pugmill Gear Case Oil Draining

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Dispose of gear oil safely and in an environmentally friendly manner.

The gear case must be maintained in accordance with the maintenance

schedule.
Lubrication and Fluid Specifications. Only use a recommended fluid.
Always use the correct grade of gear oil.
If the gear case requires filling up on a regular basis, inspect the case for
leaks.
Always practice extreme cleanliness when servicing.

Volume:
5 Litres
1.33 US Gallons

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6.9.5. Checking the Gear Case Oil Level

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.

When checking, filling or replacing fluid in the gear case the area cleanliness
is essential.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Check the gear oil level by viewing the sight glass on the side of the gear
case shown below.
6. The gear oil level must be mid-way in the sight glass.
7. If necessary add gear oil, See Adding Gear Oil.

Gear Oil
Fill Level

Sight Glass

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6.9.6. Adding Gear Case Oil

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.

When checking, filling or replacing fluid in the gear case the area cleanliness
is essential.
Only use new clean fluid in clean containers and fillers.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Clean the area around the filler bung.
6. Remove filler bung.
7. Add gear oil of the correct grade to mid-way in the sight glass.
8. Fit the filler bung.

Gear Oil Sight Glass

Fill Level

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6.9.7. Changing Gear Case Oil

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Dispose of gear oil safely and in an environmentally friendly manner.

When checking, filling or replacing fluid in the gear case the area cleanliness
is essential.
Only use new clean fluid in clean containers and fillers.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Clean the area around the filler bung.
6. Unfastening the filler bung (1).
7. Ensure a suitable container is positioned under the drain point capable
of holding the full quantity of oil in the gear case.
See maintenance schedule for case volume.
8. Remove the drain plug (2) and allow the oil to drain into the container.

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9. Fit the drain plug.
10. Refill the gear case with new gear oil to mid-way in the sight glass.

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6.10. Hydraulic Tank

This is a high pressure system and only suitably qualified experienced

engineers should tackle any problems that may arise. Always relieve the
pressure from the hydraulic system before carrying out any kind of
maintenance or adjustment.
Never carry out any maintenance work without ensuring the hydraulic system
is depressurised.

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Hydraulic fluid can be hot and the operator should take care to avoid burns.
Dispose of hydraulic fluid safely and in an environmentally friendly manner.
Injection hazard from high pressure fluid.

All hydraulic functions are powered by pumps driven by the engine / electric
motors.
All relief valve pressures are factory set and should not be adjusted on site.
The hydraulic tank must be maintained in accordance with the maintenance
schedule.
Lubrication and Fluid Specifications. Only use a recommended fluid.
Always use the correct grade of hydraulic fluid.
If the hydraulic system requires filling up on a regular basis, all hydraulic parts
and hoses should be inspected for leaks.
Always practice extreme cleanliness when servicing.

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2
3
4

5
6

1. Gasket
2. Return Line Filter Volume:
480 Litres
3. Filler Cap 127 US Gallons
4. Air Filter/Breather
5. Fluid Level Gauge
6. Fluid Sensor
7. Suction Filter

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6.10.1. Checking the Hydraulic Fluid Level

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Operate the machine until the hydraulic fluid is at working operating
temperature.
4. Always have the cylinders retracted (where possible).
5. Shut down the machine and remove the ignition key.
6. Implement the lockout, tagout, try-out procedure.
7. Check the fluid level indicator, the fluid must be between the red and
black marks on the gauge.
8. If necessary add hydraulic fluid, See Adding Hydraulic Fluid.

Black Line

Fluid Level
Gauge

Red Line

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6.10.2. Adding Hydraulic Fluid

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.
Do not fill fluid in the hydraulic tank without checking fluid level inside it.
Never overfill the hydraulic tank, as it will cause leaks from the filler cap.

When checking, filling or replacing fluid in the hydraulic tank work the area
cleanliness is essential. Only use new clean fluid in clean containers and
fillers.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Operate the machine until the hydraulic fluid is at working operating
temperature.
4. Always have the cylinders retracted (where possible).
5. Shut down the machine and remove the ignition key.
6. Implement the lockout, tagout, try-out procedure.
7. Clean the area around the filler cap.
8. Remove the filler cap.
9. Add hydraulic fluid of the correct grade to mid-way between the red and
black marks on the gauge.
10. Fit the filler cap. It is recommended to always lock the filler cap after
adding fluid to prevent theft and tampering.

Black Line

Fluid Level
Gauge

Red Line

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6.10.3. Changing Hydraulic Fluid / Suction Filter / Return Filter

Injection hazard from high pressure fluid.

Wear personal protective equipment.
Switch off the machine and implement the lockout, tagout, try-out procedure.
Never overfill the hydraulic tank, as it will cause leaks from the filler cap.
Dispose of hydraulic fluid safely and in an environmentally friendly manner.
Injection hazard from high pressure fluid.

When checking, filling or replacing fluid in the hydraulic tank work the area
cleanliness is essential.
Only use new clean fluid in clean containers and fillers.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Operate the machine until the hydraulic fluid is at working operating
temperature.
4. Always have the cylinders retracted (where possible).
5. Shut down the machine and remove the ignition key.
6. Implement the lockout, tagout, try-out procedure.
7. Clean the area around the hydraulic tank
8. Remove the top guard (1).
1

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9. Release any pressure in the hydraulic tank by carefully unfastening the
filler cap (2).
10. Ensure a suitable container is positioned under the drain point capable
of holding the full quantity of fluid in the tank. See maintenance schedule
for tank volume.
11. Remove the drain plug (3).
12. Remove the cover plate and discard the gasket.
13. Remove the suction filters (4).
14. Flush out the tank with clean hydraulic fluid.
15. Fit replacement suction filters.
16. Fit the cover plate and the new gasket.
17. Fit the drain plug.
18. Remove and replace the return filter (5).

19. Refill the tank with clean hydraulic fluid to mid-way between the marks
on the oil level indicator.
20. Start the engine to circulate the fluid.
21. Operate the hydraulic controls to purge any air from the system.
22. Stop the engine and top up fluid to required level.

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6.11. Fuel System

Fire Hazard
Highly flammable substance. Avoid naked flames when working on the fuel
system.
Never remove the filler cap or refuel, with the engine running.
Never add gasoline or any other fuel mixes to diesel due to increased fire or
explosion risks.
Switch off your mobile phone when adding fuel.
Do not smoke while refilling or carrying out maintenance on the fuel system.
Do not carry out maintenance on the fuel system near naked lights or sources
of sparks, such as welding equipment.

Volume:
100 Litres
26.4 US Gallons:

1. Filler Cap
2. Fluid Level Gauge

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6.11.1. Checking the Fuel Level

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Check the fuel level indicator, the fuel must be between the red and
black marks on the gauge.
6. If necessary add fuel, See Adding Fuel.

Red Line

Fuel Level
Gauge

Black Line

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6.11.2. Adding Fuel

Wear personal protective equipment.

Switch off the machine and implement the lockout, tagout, try-out procedure.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Check the fuel level indicator, the fuel must be between the red and
black marks on the gauge.
6. Clean the area around the filler cap.
7. Remove the filler cap.
8. Add fuel.
9. Fit the filler cap. It is recommended to always lock the filler cap after
adding fuel to prevent theft and tampering.

Red Line

Fuel Level
Gauge

Black Line

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6.12. Battery

The battery contains sulphuric acid, electrolyte which can cause severe burns
and produce explosive gases. Avoid contact with the skin, eyes or clothing.
Always disconnect battery leads before carrying out any maintenance to the
electrical system.

6.12.1. Disconnecting the Battery

Wear personal protective equipment.

Electrocution hazard.
The battery contains sulphuric acid, electrolyte which can cause severe burns
and produce explosive gases. Avoid contact with the skin, eyes or clothing.
Switch off the machine and implement the lockout and tagout procedure.
Always disconnect battery leads before carrying out any maintenance to the
electrical system.
Before carrying out arc welding on the machine, disconnect the battery to
protect the electrical circuits and components. The battery must still be
disconnected even if a battery isolator is fitted.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Ensure all electrical circuits are switched off.
6. Disconnect the ground (-) lead from the battery.
7. Disconnect the positive (+) lead from the battery.
8. Lift the battery from the machine.

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6.12.2. Connecting the Battery

Wear personal protective equipment.

Electrocution hazard.
The battery contains sulphuric acid, electrolyte which can cause severe burns
and produce explosive gases. Avoid contact with the skin, eyes or clothing.
Switch off the machine and implement the lockout and tagout procedure.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Shut down the machine and remove the ignition key.
4. Implement the lockout, tagout, try-out procedure.
5. Ensure all electrical circuits are switched off.
6. Lift the battery onto the machine.
7. Connect the positive (+) lead to the battery.
8. Connect the ground (-) lead to the battery.

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6.12.3. Jump Starting the Battery

Wear personal protective equipment.

Electrocution hazard.
The battery contains sulphuric acid, electrolyte which can cause severe burns
and produce explosive gases. Avoid contact with the skin, eyes or clothing.
Switch off the machine and implement the lockout and tagout procedure.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface
3. Connect the positive (+) jump start cable to battery terminal and then
connect the ground (-).
4. Start the engine.
5. Disconnect the ground (-) jump start cable from the battery terminal and
then disconnect the positive (+).

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 MAINTENANCE
6.13. Hydraulic Ram Maintenance

This is a high pressure system. Never carry out any maintenance work without
ensuring the hydraulic system is locked out and depressurised.

Injection hazard from high pressure fluid.

Wear personal protective equipment.
Switch off the machine and implement the lockout and tagout procedure.

As part of the finish process in the chrome rod manufacturing a natural

lubricant is rolled into the surface. This lubricant helps prolong the life of the
hydraulic cylinder. We recommend that any cylinder exposed for more than
one week must have the rod coated with a good quality water resistant
grease.

1. Observe all Safety Warnings.

2. Manoeuvre the machine to a solid and level surface.
3. Always have the cylinders retracted (where possible).
4. Shut down the machine and remove the ignition key.
5. Implement the lockout, tagout, try-out procedure.
6. Clean dirt and dust from the exposed portions of the shaft using a dry
cloth.
Under no circumstances should sandpaper or other abrasive materials
be used to clean the surface. Plastic or copper wool can be used to
clean the surface and remove the dirt.
7. Apply a thin coating of solvent-diluted oil mixture to the exposed
surfaces of the chrome plated shafting. The mixture can be sprayed
directly onto the surface.

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 MAINTENANCE
8. Inspect the shaft surface after 1 month and apply additional corrosion
protection.
9. If the equipment is to be moved and then stored again for an extended
period of time, the steps above should be repeated for all shafts that
were stroked during the move.

Front Raise/Lower Pugmill

Hydraulic Rams Hydraulic Rams

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 TROUBLE SHOOTING

TROUBLE SHOOTING

7. TROUBLE SHOOTING ............................................................................ 2

7.1. INTRODUCTION ..................................................................................... 2
7.2. GENERAL ............................................................................................... 2
7.3. KNOWING THE SYSTEM ....................................................................... 2
7.4. RECOGNISING TROUBLE INDICATORS ............................................. 3
7.5. GUIDELINES FOR TROUBLESHOOTING CHARTS. ............................ 4
7.6. COMMON FAULTS AND CAUSES ........................................................ 5
7.7. ENGINE WILL CRANK BUT WILL NOT START .................................... 6
7.8. CONTROL PANEL WILL NOT SWITCH ON .......................................... 7
7.9. BATTERY GOES FLAT WHILE ENGINE IS RUNNING ......................... 8
7.10. TRACKS WILL NOT OPERATE ............................................................. 9
7.11. EXCESSIVE NOISE .............................................................................. 10
7.12. EXCESSIVE HEAT ............................................................................... 11
7.13. INCORRECT FLOW .............................................................................. 12
7.14. INCORRECT PRESSURE .................................................................... 13
7.15. ERRATIC OPERATION ........................................................................ 14
7.16. ELECTRICAL SYSTEM FAULT FINDING STEPS ............................... 17
DIGITAL MULTIMETER .................................................................. 17
TACHOMETER OR FREQUENCY METER .................................... 17

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 TROUBLE SHOOTING

TROUBLE SHOOTING
Before operating this machine the

WARNING safety instructions contained in

the Telestack Ltd Operation
Manual must be read & understood

INTRODUCTION

Only a qualified electrician should work on the electrical system of this machine.
Incorrect connections or modifications may cause the machine to operate in an
unsafe manner.

Any active fault will cause a relevant LED to illuminate on the front of the panel.

GENERAL
The troubleshooting charts that follow are of a general system nature. Effect
and probable cause charts are covered in this section.

A seemingly uncomplicated procedure such as relocating a system or changing

a component part can cause problems. Because of this the following points
should be considered:

 Each component must be compatible with and form an integral part of

the system. For example, an inadequate size filter on the inlet of a pump
can cause cavitation and subsequent damage to the pump.

 All hydraulic pipes must be of proper size and free of restrictive bends -
an undersized or restricted pipe results in a pressure drop in the pipe
itself.

 Some components must be mounted in a specific position with respect

to other components or the pipes. The housing of an in-line pump, for
example, must remain filled with fluid to remain lubricated.

KNOWING THE SYSTEM

Probably the greatest aid to troubleshooting is the confidence of knowing the
system. The construction and characteristics of each component should be
understood. For example knowing that a solenoid controlled directional valve

7-2

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 TROUBLE SHOOTING
can be manually actuated will save considerable time in isolating a defective
solenoid.

Some additional practices which will increase your abilities and also the useful
life of your system are outlined below:

 Know the capabilities of the system. Each component in the system has
a maximum rated speed, torque or pressure. Loading the system
beyond these specifications simply increases the risk of failure.

 Know the correct operating pressures. Always set and check pressures
with a gauge. The correct operating pressure is the lowest pressure
which will allow adequate performance of the machine and still remain
below the maximum rating of the components and the machine.

 Know the proper signal levels, feedback levels, dither and gain settings
in servo control systems. If they aren’t specified check them when the
system is functioning correctly and mark them on the schematic for
future reference.

RECOGNISING TROUBLE INDICATORS

The ability to recognize trouble indicators in a specific system is usually

acquired with experience. However a few general trouble indicators can be
discussed.

 Excessive heat is representative of misuse. A misaligned coupling

places an excessive load on bearings and can be readily identified by
the heat generated. A warmer than normal tank return line on a relief
valve indicates operation at relief valve setting. Hydraulic fluids which
have a low viscosity will increase the internal leakage of components
resulting in a heat rise. Cavitation and slippage in a pump will also
generate heat.

 Excessive noise usually means wear, misalignment, cavitation, or air in

the fluid. Contaminated fluid can cause a relief valve to stick and make
noise. These noises may be the result of dirty filters, or fluid, high fluid

7-3

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 TROUBLE SHOOTING
viscosity, excessive drive speed, low reservoir level, loose intake lines
or worn couplings.

GUIDELINES FOR TROUBLESHOOTING CHARTS.

The following charts are arranged in five main categories. The heading of each
one is an effect which indicates a malfunction in the system. For example if a
pump is exceptionally noisy refer to chart 1 titled excessive noise. The noisy
pump appears in column A under the main heading. In column A there are four
probable causes for a noisy pump. The causes are sequenced in order of the
likelihood of happening or the ease of checking it. The first cause is cavitation
and the remedy is ‘a’ if the first cause does not exist then check for the cause
number 2, etc.

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 TROUBLE SHOOTING
COMMON FAULTS AND CAUSES

Control Panel switches on but

engine will not start

Is the 15 second Check for battery

delay siren and voltage at terminal
beacon working? 50 on the ignition
switch when the
switch is in the
crank position.
NO

NO
YES
Replace
Check for ignition
Check the voltage at the
Check F8 switch
siren, beacon X3.SW terminal
fuse in the or loom for on controller
control damage. board
panel.

Check for voltage across coil of starter relay RL2 on the

controller board after 15 seconds when the switch is in the
crank position.

NO
YES
Check if fuse F1 is blown.
Check for voltage at the solenoid
engaging wire X3.ST at the starter
motor

Possible fault in the starter motor Replace the starter motor relay.

Check wire between Starter terminal Replace the engine controller board.
and the starter motor.

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 TROUBLE SHOOTING
ENGINE WILL CRANK BUT WILL NOT START

Engine will crank but will not

start.

Check to ensure that the green E- When turning the ignition switch to the
Stop healthy LED illuminates crank position check that the fuel solenoid
LED is illuminated.

YES Check that all other run warning

lamps are illuminated.
Is the red E-stop
activated, LED
staying illuminated?

Check if fuel
Ensure that all solenoid fuse
machine stops are F3, is blown
released and all and replace
cables are with correct
connected fuse rating.
correctly.

Replace the fuel solenoid

Check if fuel relay.
solenoid fuse
F3, is blown
and replace
with correct
fuse rating.

Check loom installation & fuel

solenoid for short to ground.

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 TROUBLE SHOOTING
CONTROL PANEL WILL NOT SWITCH ON

Control Panel will not switch on.

If battery voltage is suspect Check that battery voltage is

replace with good battery. above 12.6V

Check for battery voltage at

terminal 30 on ignition switch.

Ensure battery and ignition No battery voltage check FL1

terminals are clean and tight. 30amp main fuse on loom.

If blown replace with correct fuse Check for battery voltage at

specified. terminal 15 on ignition switch.

Ensure that there is a good

ground at terminal X3.5 on the
engine controller board.

Check for battery voltage on the

engine controller board at
terminal X3.3 when the ignition
key is switched on.

Check the engine controller board

and replace if necessary

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 TROUBLE SHOOTING
BATTERY GOES FLAT WHILE ENGINE IS RUNNING

Battery goes flat while engine is

running.

Check Battery Voltage

It should be between 13.6 & 14.5 volts.
with engine at high idle

NO Switch the ignition key to the “on” position

and check that the charge lamp on the
control panel is illuminated.
Check F12
fuse in the
control panel YES

Check for voltage at the D+ Terminal

Check lamp at the rear of the alternator.
and diode for
continuity

YES NO

Possible fault Check charge wire

in the between starter
alternator terminal and the
alternator.

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 TROUBLE SHOOTING
TRACKS WILL NOT OPERATE

Tracks will not operate

Check that the control lever is set to track

NO
Is the track siren and beacon operating?

Wait 15 seconds and try operating track Check fuse F2,

directional switches. timer SD3 and relay
RL3

Check fuse F4

FUSE OK – Check for battery voltage on

pin 7 in the track plug on the side of the Fuse Blown –
panel. Check for a short
NO to ground between
YES control panel track
junction box and
Check for battery voltage on the No. 4 handset.
wire inside the manual tracking handset.
Check connections
between the
YES
engine control Check connections
panel and tracks between the tracks
plug Switch the track switch to the track on
plug and manual
position and check for battery voltage on
handset.
the No.10 wire in the track junction box.

Check for voltage at No. 7 wire in the

manual handset

Check for battery voltage at wire No’s

5,6,8,9 in the track junction box. when
switches operated

YES NO
Check for battery voltage and ground Check connections
Check operation of connections at track solenoids. between handset &
track relays. Replace if track junction box.
necessary

RELAYS OK-Check
connection from
handset to track plug.

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 TROUBLE SHOOTING
EXCESSIVE NOISE

Excessive Noise

Pump Noisy Motor Noisy Relief Valve Noisy

Cavitation Coupling Misaligned Setting too low or too

close to another valve
setting
Remedy 1 Remedy 3 Remedy 4

Air in Fluid Motor or Coupling worn Worn Poppet

or Damaged And seat
Remedy 2 Remedy 2 Remedy 5

Coupling Misaligned

Remedy 3

Pump Worn or Damaged

Remedy 5

Remedies:
1. Any or all of the following:
2. Replace dirty filters, wash strainers in solvent compatible with system
fluid. Clean clogged inlet filters, clean or replace reservoir breather vent.
Change system fluid, change to proper pump drive motor speed. Hydraulic
oil temperature may be below the recommended operating range.
3. Any or all of the following: Tighten leaking connections Fill reservoir to
proper level .Bleed air from system, Replace pump shaft seal (and shaft if
worn at seal journal)
4. Align unit and check condition of seals, Bearings and Couplings.
5. Install pressure gauge and adjust to correct pressure(keep 3 bar
difference between valve settings)
6. Overhaul or replace.

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 TROUBLE SHOOTING
EXCESSIVE HEAT

Excessive Heat

Pump Heated Motor Heated Relief Valve Heated Fluid Heated

System Pressure too

See Fluid Heated on RHS
See Fluid Heated on RHS See Fluid Heated on RHS High
Remedy 4

Relief or Unloading Unloading valve set to

Cavitation Valve Setting Incorrect
Valve set too High high
Remedy 1,7 Remedy 4
Remedy 4 Remedy 4

Air in Fluid Excessive Load Fluid dirty or low supply

Remedy 2 Remedy 9 Remedy 1,2

Relief or Unloading
Worn or Damaged pump Incorrect fluid viscosity
Valve set to High
Remedy 5 Remedy 7
Remedy 4

Faulty Fluid cooling

Excessive Load
system
Remedy 9
Remedy 8

Worn Pump, Valve,

Worn or Damaged pump Motor, Cylinder or other
Remedy 5 component
Remedy 5

Remedies:
1. Check for damaged pump or pump drive, replace and align coupling
2. Change filters and system fluid if improper viscosity, fill to correct level.
3. Clean cooler and or cooler strainer, replace cooler fan or repair .Replace
cooler
4. Check for work load in excess of circuit design. Reduce load on machine

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 TROUBLE SHOOTING
INCORRECT FLOW

Incorrect Flow

No Flow Low Flow Excessive Flow

Relief or unloading valve RPM of pump drive motor

Pump not receiving fluid
set too low incorrect
Remedy 1,2
Remedy 4 Remedy 15

Pump drive motor not Flow by-passing through Improper sized pump
operating partially open valve used in replacement
Remedy 13 Remedy 4,5 Remedy 14

Pump to drive coupling External leak in the

sheared system
Remedy 5 Remedy 10

Pump to drive turning RPM of pump drive motor

wrong direction incorrect
Remedy 13 Remedy 15

Entire flow passing over Worn Pump ,Valve,

the relief valve Motor, cylinder or other
Remedy 4 Remedy 5

Damaged Pump
Remedy 5,6

Improperly assembled
pump
Remedy 5,6,14

Remedies:
1. Tighten leaking connections, fill reservoir to proper level and bleed air from
system.
2. On dual power machines, Check the emergency stop system and reset.
Check for damage to supply cable
3. Check position of manually operated controls, check electrical circuit on
solenoid operated controls.
4. Check for correct motor rotation on dual power machines. Reverse
Rotation if necessary
5. Replace with correct unit.

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 TROUBLE SHOOTING
INCORRECT PRESSURE

Incorrect Pressure

No Pressure Low Pressure Erratic Pressure Excessive Pressure

Pressure reducing relief

No Flow Relief Valve set too low Air in Fluid or unloading valve
See Incorrect Flow Chart Remedy 4 Remedy 2 misadjusted
Remedy 4

Releif valve damaged Worn Relief Valve

Remedy 5 Remedy 5

Damaged pump motor

Contamination in Fluid
or cylinder
Remedy 1,2,8
Remedy 5

Worn Pump Motor or

Cylinder
Remedy 5

Remedies:
1. Set appropriate engine speed for product being conveyed
2. Repair command console or interconnecting wires
3. Adjust repair or replace counterbalance valve
4. Locate bind and repair
5. Lubricate

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 TROUBLE SHOOTING
ERRATIC OPERATION

Fault
Operati
on Excessive
No Slow Erratic
movement Movement Movement speed or
movement

No flow or pressure Low flow Erratic Pressure

Excessive Flow
See incorrect flow and See erratic pressure chart
See incorrect flow chart Remedy reduce
pressure charts
engine speed

Fluid viscosity too high Air in fluid`

Pressure relief valves Remedy 7 Air in fluid`
inoperative or Remedy 1
misadjusted.
Remedy 1
Remedy 4 Low engine speed
No lubrication of machine
Remedy 15 ways or linkage
Mechanical bind
Remedy 19 Excessive load
Remedy 18
No lubrication of machine ways
Remedy 9
or linkage
Erratic command signal
No command signal to Remedy 19
CETOP valves Remedy 12,16

Remedy 16,12 Cylinders moving too fast

Sticking CETOP valve
Sticking CETOP valve
Remedy 5 Remedy 17
Remedy 5
Worn or damaged cylinder
or motor
Worn or damaged cylinder Worn or damaged cylinder or motor
or motor
Remedy 5
Remedy 5
Remedy 5

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 TROUBLE SHOOTING
Remedies:

1. Any or all of the following:

1.1. Replace dirty filters, wash strainers in solvent compatible with system
fluid. Clean clogged inlet filters, clean or replace reservoir breather vent.
Change system fluid, change to proper pump drive motor speed.
1.2. Hydraulic oil temperature may be below the recommended operating
range.
2. Any or all of the following:
2.1. Tighten leaking connections
2.2. Fill reservoir to proper level.
2.3. Bleed air from system,
2.4. Replace pump shaft seal (and shaft if worn at seal journal)
3. Align unit and check condition of seals, Bearings and Couplings.
4. Install pressure gauge and adjust to correct pressure (keep 3 bar
difference between valve settings)
5. Overhaul or replace.
6. Check for damaged pump or pump drive, replace and align coupling
7. Change filters and system fluid if improper viscosity, fill to correct level.
8. Clean cooler and or cooler strainer, replace cooler fan or repair .Replace
cooler.
9. Check for work load in excess of circuit design. Reduce load on machine
10. Tighten leaking connections, fill reservoir to proper level and bleed air from
system.
11. On dual power machines, Check the emergency stop system and reset.
Check for damage to supply cable
12. Check position of manually operated controls, check electrical circuit on
solenoid operated controls.
13. Check for correct motor rotation on dual power machines. Reverse
Rotation if necessary
14. Replace with correct unit.
15. Set appropriate engine speed for product being conveyed
16. Repair command console or interconnecting wires
17. Adjust repair or replace counter balance valve

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 TROUBLE SHOOTING
18. Locate bind and repair
19. Lubricate
20. Fluid may be too cold or should be changed to clean fluid of correct
viscosity.
21. Locate bind and repair.
22. Adjust repair or replace.
23. Clean and adjust or replace: Check condition of system fluid and filters.
24. Overhaul or replace
25. Repair command console or interconnecting wires
26. Lubricate.
27. Adjust repair or replace counterbalance valve.

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Electrical System Fault Finding Steps

To successfully carry out the various checks, certain test instruments are
essential. The following details the basic requirements in this respect. It should
be noted that in addition to these instruments a comprehensive kit of tools is
also essential. For fault finding purposes this need not include any specialised
tools.

Digital Multimeter

The Multimeter is a comprehensive test instrument for measuring voltage,

current and resistance. It should be capable of measuring the following ranges:

 Voltage DC 0-25-100-250 Volts

 Amperes DC 0-10 Amps
 DC Resistance 0-10k (ohms) or 0-2k (ohms)
 0-100k (ohms) or 0-20k (ohms)
 0-1M (ohms) or 0-200k (ohms)

Tachometer or Frequency meter

This instrument can be used for measuring the shaft speed of the alternator and
should be capable of measuring speeds between 0 and 5000 revolutions per
minute, (RPM).
An alternative to the tachometer is a frequency meter - however the alternator
must be generating its normal output voltage for this instrument to be accurate.

7-17

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 SPAREPARTS

SPAREPARTS

8. SPAREPARTS.................................................................................................... 2
8.1 MACHINE OVERVIEW ..................................................................................... 2
8.2 HOPPER OVERVIEW........................................................................................ 3
8.3 HOPPER EXTENSIONS AND FALLBREAK ..................................................... 4
8.4 HOPPER SKIRTING .......................................................................................... 5
8.5 HOPPER GUARDS ........................................................................................... 6
8.6 CEMENT HOPPER ............................................................................................ 7
8.7 JACKLEG RAMS .............................................................................................. 8
8.8 FEEDER CASSETTE ........................................................................................ 9
8.9 INCLINE CONVEYOR ..................................................................................... 10
8.10 CONVEYOR .................................................................................................... 12
8.11 PUGMILL FOLD RAM ..................................................................................... 13
8.12 PUGMILL......................................................................................................... 14
8.13 HEAD SECTION RAISE / LOWER TELESCOPIC ........................................... 15
8.14 CHASSIS ......................................................................................................... 16
8.15 CHASSIS COMPONENTS .............................................................................. 17
8.16 CAT C4.4 ATAAC ACERT ENGINE (96.5KW) 52.02.0085 ................................ 19
8.17 EXHAUST ........................................................................................................ 20
8.18 FUEL TANK ..................................................................................................... 21
8.19 HYDRAULIC TANK ......................................................................................... 22
8.20 TRACKS (21.17.0181) ..................................................................................... 23
8.21 TEDD ELECTRICAL SPARES ........................................................................ 25
8.22 ADDITIONAL COMPONENTS ........................................................................ 35
8.23 LOW LEVEL GREASE COMPONENTS .......................................................... 36

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 SPAREPARTS

8. SPAREPARTS

8.1 MACHINE OVERVIEW Pugmill

Incline Conveyor

Cement Hopper Telescopic

Hopper Canopy
Engine and Exhaust
Hydraulic Tank
Fuel Tank

Tracks

Item Part No. Description Qty

1 Hopper See Figure 8.2 1
2 Cement Hopper
3 Incline See Figure 8.8 1
4 Conveyor See Figure 8.9 1
5 Pugmill See Figure 8.10 1
6 Telescopic Head - See Figure 8.12 1
Chassis Guards + Internals See Figure 8.13 and 8.14
Engine and Exhaust See Figure 8.15 and 8.16
7 1
Fuel Tank See Figure 8.17
Hydraulic Tank See Figure 8.18
8 Tracks See Figure 8.19 1

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 SPAREPARTS

8.2 HOPPER OVERVIEW

Feeder Cassette

Item Part No. Description Qty

1 Hopper Extensions and Fall break See Figure 8.3 1
2 Hopper Guards See Figure 8.4 1
3 Cement Chute See Figure 8.5 1
4 Hydraulic Ram See Figure 8.6 1
5 Feeder Cassette See Figure 8.7 1

8-3

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 SPAREPARTS

8.3 HOPPER EXTENSIONS AND FALLBREAK

3
2

Item Part No. Description Qty

1 HF520-032-0050 Rear Extension 1
2 HF520-032-0044 Side Extension 2
3 HF520-032-0040 Front Extension 1
4 PM-HF520-031-0010 Fall Break 1

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 SPAREPARTS

8.4 HOPPER SKIRTING

Item Part No. Description Qty

1 HF520-027-0002 Rubber Skirting 2
2 HF520-022-0018 Rubber Clamp 2
3 HF520-022-0021 Side Rubber Clamp 6
4 HF520-027-0003 Side Rubber Skirting 2
5 HF520-022-0020 Rear Rubber Clamp 1
6 HF520-027-0004 Rear Rubber Skirting 1

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8.5 HOPPER GUARDS

Item Part No. Description Qty

1 HF520-020-0026 Guard 2
2 HF520-020-0024 Guard 4
3 HF520-020-0021 Guard 1
4 HF520-020-0020 Guard 2
5 44.11.0034 6" Galv Hinge - 2 Slots 14
6 44.11.0013 Drop T Handle 7

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8.6 CEMENT HOPPER

11

10

9
3
4
5
8 6

Item Part No. Description Qty

1 53.18.0106 Hopper Filter 1
2 53.18.0107 Hopper Relief Valve 1
3 19.25.1228 Rotary Valve Hydraulic Motor 1
4 009-PM-022-0016 Flange Plate 1
5 16.10.0165 Rotary Valve Gearbox 1
6 009-PM-022-0001 Flange Plate 1
7 009-PM-022-0003 Clamp 2
8 009-PM-027-0001 Rubber 1
9 53.18.0105 Rotary Valve 1
10 30.10.0007 Vibrating Hydraulic Motor 1
11 28.10.0010 Hopper Load Cell Kit 3
Hopper load cell junction box and
12 28.10.0011 1
amplifier (not shown)

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8.7 JACKLEG RAMS

Item Part No. Description Qty

1 Jackleg Ram 19.20.0068 2
2 Jackleg Ram Seal Kit 19.25.0389 2

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 SPAREPARTS

8.8 FEEDER CASSETTE

8 9 10

6
5
4
11
3
2
1
12

13

14

15

16
Item Part No. Description Qty
1 10.10.0006 Bearing 2
2 41.19.0129 Tail Drum 1
3 HF520-027-0010 Plough Scraper Rubber 1
4 15.50.0573 Rubber Covered Centre Roller 2
5 15.40.0002 Wing Roller 4
6 38.10.0003 Impact Bar 55mm 4
7 33.37.0195 Impact Bar 1400mm 4
8 16.10.0064 Motor 2
8 16.10.0078 Gearbox 2
9 41.19.0130 Feeder Head Drum 1
10 23.10.0041 Scraper 1
10 23.10.0025 Scraper Blade Only 5
11 15.40.0001 Centre Roller 1
12 HF520-022-0011 Nip Guard 1
13 15.40.0008 Disc Return Roller 1
14 15.40.0147 Impact Centre Roller 7
15 HF520-022-0007 Plough Scraper Rubber Clamp 2
16 HF520-022-0003 Guard 2
17 33.35.0048 Feeder Belt (Not Shown) 1

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8.9 INCLINE CONVEYOR

2 3
1

19

18
17

16

15

14

13
12
11
10

9 4

5
6
7

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 SPAREPARTS

Item Part No. Description Qty

1 38.10.0003 Impact Bars 4
2 15.40.0002 Wing Roller 4
3 15.40.0001 Centre Roller 2
4 HF520-020-0018 Guard 2
5 HF520-022-0003 Guard 2
6 HF520-022-0007 Plough Scraper Rubber Clamps 2
7 HF520-023-0030 Plough Scraper 1
8 HF520-020-0019 Tail Guard 1
9 10.10.0004 Bearing 2
10 41.19.0373 Tail Drum 1
11 HF520-022-0008 Plough Scraper 1
12 HF520-027-0001 Plough Scraper Rubber 1
13 HF520-023-0076 Tail End Piece 1
14 HF520-022-0036 Rear Skirting Clamp 1
15 HF520-027-0006 Rear Skirting Rubber 1
16 HF520-027-0005 Side Skirting Rubber 4
17 HF520-022-0037 Side Skirting Clamp 2
18 HF520-022-0038 Side Skirting Clamp 2
19 15.40.0147 Rubber Lagged Impact Centre 3
20 33.37.1027 Belt (Not Shown) 1

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8.10 CONVEYOR

3 4 5

2
8 7
1
9

10

11

Item Part No. Description Qty

1 15.40.0002 Wing Roller 14
2 15.40.0001 Centre Roller 7
3 12.13.0092 Gearbox- Motor Unit 1
3 12.10.0047 Motor Only 1
4 16.10.0159 Gearbox Only 1
5 23.10.0025 Scraper Blade Only 6
6 23.10.0035 Scraper 1
7 10.10.0065 Bearing 2
8 41.10.0009 Head Drum 1
9 47.41.1197 Water Meter 1
10 420.43.0603 Roller Baskets 2
11 15.40.0008 Disc Return Roller 2

8-12

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 SPAREPARTS

8.11 PUGMILL FOLD RAM

Item Part No. Description Qty

1 19.22.0036 Pugmill Fold Ram 2
1 19.25.0361 Seal Kit for 19.22.0036 2

8-13

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 SPAREPARTS

8.12 PUGMILL

1 2 3 4

15

5
6

14

13
9
12
11 10 8

Item Part No. Description Qty

1 12.10.0002 Motor 1
2 PM-HF520-143-0072 Guard 1
3 PM-HF520-143-2001 Gear Locking Collar 4
4 PM-HF520-143-0059 Guards 2
4 44.11.0034 6" Galv Hinge - 2 Slots 4
5 53.18.0064 Pugmill Gear 2
6 10.10.0086 Bearing 2
7 48.28.3313 Paddle Tips (Mild Steel) 36
7 48.28.3314 Paddle Tips (Hardox steel) 36
8 10.10.0065 Bearing 2
9 10.15.0110 Inlet End Seal 1
10 PM-HF520-143-0055 Rubber Clamp 2
11 PM-HF520-143-0054 Rubber Clamp 2
12 PM-HF520-027-0003 Outlet Rubber 1
13 PM-HF520-143-0070 Guard 1
14 PM-HF520-143-0071 Guard 1
15 12.10.0001 Gearbox 1

8-14

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 SPAREPARTS

8.13 HEAD SECTION RAISE / LOWER TELESCOPIC

1 2 3

Item Part No. Description Qty

1 19.22.0138 Telescopic Ram 2
1 19.25.0272 Seal Kit for 19.22.0138 2
2 HF520-024-0017 Pin 2
3 HF520-024-0012 Pin 2
4 HF520-024-0020 Pin 2
5 HF520-024-0016 Pin 2

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 SPAREPARTS

8.14 CHASSIS

9
8

7
6
5

2
4
3

Item Part No. Description Qty

1 031-HF520-020-0003 Guard 2
2 013-LF520-020-0002 Guard 4
3 HF520-020-0006 Guard 2
4 HF520-002-0004 Guard 1
5 023-TCL431-020-0002 Guard 1
6 HF520-020-0007 Guard 1
7 HF520-020-0001 Guard 2
8 031-HF520-020-0001 Guard 1
9 15.40.0141 Incline Tail Roller 3
10 44.11.0013 Drop T Handle 6
11 44.11.0034 6" Galv Hinge - 2 Slots 12

8-16

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 SPAREPARTS

8.15 CHASSIS COMPONENTS

Fuel Tank

Hydraulic Tank
Water Pump
Exhaust

Control Panel

Engine

Tracks

8-17

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 SPAREPARTS

Item Part No. Description Qty

1 Engine See 8.15 1
2 Exhaust See 8.16 1
3 Fuel Tank See 8.17 1
3 Hydraulic Tank See 8.18 1
4 Tracks See 8.19 1
5 Control Panel See 8.20 1
- Water Pump Kit Contact Spares for Breakdown 1
Additional Spares
6 52.03.0314 15mm fuel line (per Meter) 3
7 52.03.0312 10mm fuel line (per Meter) 2.5
8 52.03.0059 640 battery shd rated @115 ah and 1000cc 1
9 52.02.0184 Staged throttle cable 1
10 19.22.0527 Webtec 2
11 40.30.0607 Oil Cooler 2
12 19.22.0206-M 4 Bank Lever Valve 1
13 19.25.1247 High Pressure Carryover 1
14 19.25.0278 Ceetop 5 single manifold 1
DCV2 way HI flow P-T valve Ceetop 5 120
15 19.25.0931 1
litres /min
16 19.25.0267 Ceetop 5 3 station steel manifold block 1
17 19.25.0268 Ceetop 5 2 station open centre 12v Aron 2
18 19.25.0270 Ceetop 5 single solenoid A+ B-T 2
19 19.25.0269 Ceetop 5 3 station A + B - T 12v Aron 2
20 19.22.0064 3/8" Double body check valve 2
21 19.24.0057 11/2" Low Pressure Ball Valve 3
22 19.22.0029 1" Low Pressure Ball Valve 1
23 19.25.0750 1/2" NO 12 v solenoid valve 2 port 1
24 40.21.0244 3/4" Check Valve 1
25 40.30.0372 Quick Release Coupling ¾ Male 2
26 40.30.0373 Quick Release Coupling ¾ Female 2
27 40.30.0374 Quick Release Coupling 3/8 Male 1
28 40.30.0375 Quick Release Coupling 3/8 Female 1
29 19.25.1130 Cetop5-1bank-2 Way 1
30 40.30.0381 Pressure switch 20 - 200 bar 1
31 19.25.1230 Proportional valve 2
32 19.25.0319 Ctop 3 2 position P-T VALVE 1 1

8-18

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 SPAREPARTS

8.16 CAT C4.4 ATAAC ACERT Engine (96.5Kw) 52.02.0085

Item Part No. Description Qty

1 52.03.0064 Engine Oil Filter 1
2 24.10.0013 Engine Fuel Filter 1
3 53.03.0302 Engine Fuel Filter (Separator) 1
4 52.03.0074 Engine Air Filter Inner 1
5 52.03.0073 Engine Air Filter Outer 1
6 52.02.0091 Rubber Engine Mounts 1

7 33.33.0040 Blue silicone radiator hose 31mm ID. 1mtr long 1

8 19.25.0743 1/2" female to 5/8" tose tail swept 90 1
9 52.02.0090 CAT 4.4 Air Breather Pipe 1
10 19.25.0716 Quad Pump 1
11 19.25.0421 42cc clockwise pump 1
12 25.10.0043 Pump/Engine Adapter 1
13 19.22.0240 Pump Adaptor 2
14 19.22.0241 Pump Adaptor 2

8-19

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 SPAREPARTS

8.17 EXHAUST

10
9

Item Part No. Description Qty

1 53.03.0348 90 Degree Bend 1
2 52.02.0189 Radius Bend 1
3 52.02.0133 Exhaust 1
4 52.02.0156-2 Straight Pipe Extension 1
5 52.02.0134 Braided Flexi Pipe 1
6 52.02.0158 Clamp 1
7 52.02.0154 Pipe and Flange 1
8 52.02.0155 Exhaust Elbow with Cuff 1
9 52.02.0156-1 Radius Bend 1
10 52.01.0018 Ejector Pipe 1
11 52.02.0133 4.4 Silencer Reverse Mounted (Rev 1) 1
12 52.02.0153 3" Light Wall 65mm Radius Bend 1

8-20

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 SPAREPARTS

8.18 FUEL TANK

Item Part No. Description Qty

1 40.30.0017 Lockable Metal Filler Breather 1
2 40.21.0089 Level Temp Gauge 1

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 SPAREPARTS

8.19 HYDRAULIC TANK

4
6
3

1
7

Item Part No. Description Qty

1 40.21.0089 10” Tank Level Sight Gauge 1
2 40.30.0481 Breather Valve 1
3 40.30.0017 Lockable Filer Cap 1
4 40.30.0351 Float Switch – Oil Level 1
5 19.24.0080 Return Filter 1
5 19.24.0105 Return Filter Element 1
5 19.24.0131 O Ring Set 1
6 33.37.0250 Gasket 1
7 40.21.0127 In Tank Suction Filter 1 2
8 19.25.0248 In Tank Suction Filter 1 ½ 4

8-22

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 SPAREPARTS

8.20 TRACKS (21.17.0181)

Telestack Part
Item Code Description
010 21.17.0092 Gearbox
020 21.17.0093 Gearbox to Frame Bolt
090 21.17.0094 Sprocket
100 21.17.0036 Sprocket to Gearbox Bolt
110 21.16.0038 Lower Roller
120 21.17.0038 Roller to Frame Bolt
130 21.17.0039 Flat Washer (Roller to Frame)
140 21.17.0040 Idler
180 21.17.0139 Recoil Spring
185 21.17.0038 Recoil to Idler Bolt
186 21.17.0043 Spring Washer (Recoil to Idler)
190 21.17.0045 Grease Tensioner
200 21.17.0046 Tensioner to Frame Bolt
Spring Washer (Tensioner to
210 21.17.0047 Frame)
220 21.17.0048 Tensioner Grease Fitting
230 21.17.0049 Gasket For Grease Fitting
235 21.17.0050 Grease Gun Adaptor

8-23

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 SPAREPARTS

240 21.17.0244 Track Group

250 21.17.0052 Chain
260 21.17.0245 Track Shoe
270 21.17.0054 Track Shoe Bolt
280 21.17.0055 Track Shoe Nut
290 21.17.0056 Repair Link
300 21.17.0057 Master Pin
510 21.17.0229 Hose Kit
- Chainguard
- Chainguard to Frame Bolt
- Chainguard to Frame Washer

8-24

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 SPAREPARTS

8.21 TEDD ELECTRICAL SPARES

Image Part No. Description

20050569 DSE Panel

47.38.0135 Large Handset (Wired)

47.38.0134 Large Handset (Wireless)
47.38.0142 Handset Charger

47.38.0141 Small Handset

47.38.0142 Handset Charger

47.38.0165 Emergency Stop Box 500mm

47.38.0169 Siren/Buzzer 180mm

47.38.0127 Battery Isolator Switch

47.10.0164
Loom Clips
47.37.0249

47.38.0144 Spares Ignition Key

8-25

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 SPAREPARTS

AUX LOOM KIT – 47.38.0109

ITEM PART NUMBER DESCRIPTION

1 47.38.0146 TC AUX BREAKOUT LOOM
2 47.38.0167 TC E-STOP 2700MM
3 47.38.0165 TC E-STOP 500MM
4 47.38.0166 TC DOG LEASD ADD ON
5 47.38.0135 WIRED TRACKING REMOTE
6 47.638.0169 TC SIREN 700MM
7 47.38.0168 TC BEACON 1900MM

8-26

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 SPAREPARTS

HYDRAULIC LOOM KIT – 47.38.0110

ITEM PART NUMBER DESCRIPTION

1 47.38.0152 TC HYDRAULIC LOOM
2 47.38.0150 PUSH BUTTON DUMP LOOM
3 47.38.0145 HIRSHMAN SEALS AND SCREWS

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 SPAREPARTS

FEEDER ADD ON LOOM KIT – 47.38.0111

8-28

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 SPAREPARTS

47.38.0117 - TELESTACK OIL COOLER ADD ON LOOM

8-29

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 SPAREPARTS

47.38.0136 - TELESTACK FEEDER BEACON ADD ON KIT - KIT DIAGRAM

Item Part No. Description Qty

1 47.38.0168 TC Beacon 1900MM 1
2 TPN06844 Power Unit Beacon Tee Loom 1

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 SPAREPARTS

47.38.0224 – 2ND OIL COOLER LEAD

8-31

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 SPAREPARTS

47.38.0272 - CAT 4.4 T3 ELECTRIC ENGINE KIT

8-32

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 SPAREPARTS

ITEM PART NUMBER DESCRIPTION

1 47.38.0154 Loom Engine Cat 4.4
2 47.38.0131 Engine Fuse Module 12v
3 TPN6869 Starter-1400mm-70mm2M12 M8
4 TPN6860 Starter-1400mm-70mm2bolt on M12
5 TPN6288 Earth Strap-450mm-50mm2m12-m12
6 TPN6861 Red – 1100m-50mm2M8-M10Fuse
7 TPN6862 Red-Starter-1000mm-70mmM8-M8*90D
8 TPN6863 Red-1000mm-16mm2M8-M8
9 47.38.0126 Telestack Z Case Battery Fuse Kit
10 47.38.0127 Battery Isolator Switch
11 47.38.0144 Telestack- Ignition Key
12 47.38.0173 Loom Bracket
13 47.38.0145 Hirshmann Seals and Screws
14 47.38.0138 Coolant Sensor

8-33

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 SPAREPARTS

47.38.0273 - TELESTACK PUGMILL FORWARD & REVERSE OPTION ADD ON

ITEM PART NUMBER DESCRIPTION

1 TPN07385 Telestack Expanded IO power Loom
2 TPN07384 MH Feeder Fwd & Rev Loom
3 TPN08047 Pugmill Pressure Switch Lead
4 47.38.0145 Hirshmann Seals and Screws (MOQ10)
5 47.38.0227 Screener Expanded I/O Module

8-34

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 SPAREPARTS

8.22 ADDITIONAL COMPONENTS

Item Part No. Description Qty

29 39.10.0002 Grease Canister Adaptor 1/4 Female - 1/8 Male 6
30 39.10.0019 Grease Canister Adaptor 1/4 - 1/4 6
31 39.10.0003 1/4" Female / Male Elbow 6
32 37.30.0013 30mm Acme Bar Nut 4

8-35

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 SPAREPARTS

8.23 LOW LEVEL GREASE COMPONENTS

Item Part No. Description Length Location

1 39.10.0200 Grease Pipe Complete Kit
3/16” R7 Hose with 1/8” BSP Female
2 39.10.0172 1.8m Feeder Tail - LHS
90 & 1/8” BSP Female Straight Fittings
3/16” R7 Hose with 1/8” BSP Female
3 39.10.0173 1.8 Feeder Tail - RHS
90 & 1/8” BSP Female Straight Fittings
3/16” R7 Hose with 1/8” BSP Female
4 39.10.0174 5.3m Incline Tail LHS
90 & 1/8” BSP Female Straight Fittings
3/16” R7 Hose with 1/8” BSP Female
5 39.10.0175 5.3m Incline Tail RHS
90 & 1/8” BSP Female Straight Fittings
3/16” R7 Hose with 1/8” BSP Female Pugmill grease line
6 39.10.0201 10.5m
90 & 1/8” BSP Female Straight Fittings Incline head LHS
3/16” R7 Hose with 1/8” BSP Female Pugmill grease line
7 39.10.0202 9.3m
90 & 1/8” BSP Female Straight Fittings Incline head LHS

8-36

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 WARRANTY

WARRANTY

09. WARRANTY……………………………………………………………….9-2

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 WARRANTY

9. WARRANTY

Telestack Ltd (hereafter referred to collectively as “Seller”) warrants it’s new

machine and parts manufactured and sold worldwide, to be free, under normal use
and service, of any defects in manufacture or materials for a period of (i) 12 months
from date the machine is first placed into service, whether such machine is sold,
rented or leased or (ii) 2,000 hours of use, whichever first occurs; provided that in
no event shall this warranty extend beyond a period of 18 months from the date of
shipment from the factory; and further provided that (1) Seller receives written
notice of any defect within sixty (60) days of its discovery and Buyer establishes
that (i) the machine has been maintained and operated within the limits of rated and
normal usage; and (ii) the defect did not result in any manner from the intentional
or negligent action or inaction by Buyer, its agents or employees and (2) a Warranty
Validation Report has been completed, signed and returned to Seller within thirty
(30) days of the machines “in-service” date. If requested, by Seller, Buyer must
return the defective machine to Seller’s manufacturing facility, or other location
designated by Seller, for inspection, and if Buyer cannot establish those conditions
(1) (i) and (1) (ii) above have been met, then this warranty shall not cover the alleged
defect.

Seller’s obligation and liability under this warranty is expressly limited to, at Seller’s
sole option, repairing or replacing, with new or re-manufactured parts or
components, any part, which appears to Seller upon inspection to have been
defective in material or workmanship. Such parts shall be provided at no cost to the
owner. If requested by Seller, components or parts for which a warranty claim is
made shall be returned to Seller at a location designated by Seller at Buyer’s cost.
All components and parts replaced under this limited product warranty become the
property of Seller.

This warranty shall be null and void if parts (including wear parts) other than
genuine Telestack Ltd parts are used in the machine. This warranty shall be null
and void if any design and/or spec changes/upgrades have been made to the
machine without written, detailed, signed approval from an authorised officer of
Seller.
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 WARRANTY
Accessories, assemblies and components included in the Seller’s machine, which
are not manufactured by Seller, are subject to the warranty of their respective
manufacturers. Normal maintenance, adjustments, or maintenance/wear parts,
including without limitation, proper tightening of bolts, nuts and pipe fittings, adding
or replacing of fluids, filters, belts, skirting, chute linings and paint, are not covered
by this warranty and are the sole maintenance responsibility of Buyer.

SELLER MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND

MAKES NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE
No employee or representative is authorized to modify this warranty unless such
modification is made in writing and signed by am authorized officer of Seller. Seller’s
obligation under this warranty shall not include duty, taxes, environmental fees,
including without limitation, disposal or handling of tyres, batteries, petro-chemical
items, or any other charges whatsoever, or any liability for direct, indirect, incidental,
or consequential damages.

Improper maintenance, improper use, abuse, improper storage, operation beyond

rated capacity, operation after discovery of defective or worn parts, accident,
sabotage or alteration or repair of the machine by persons not authorized by Seller
shall render this warranty null and void. Seller reserves the right to inspect the
installation of the product and review maintenance procedures to determine if the
failure was due to improper maintenance, improper use, abuse, improper storage,
operation beyond rated capacity, operation after discovery of defective or worn
parts, or alteration or repair of the machine by persons not authorized by Seller.

Parts Warranty: Seller warrants the parts ordered from the Seller’s Spare Parts
Department to be free of defect in material or workmanship for a period of 12
months after date of shipment from the factory.

NO TRANSFERABILITY OF WARRANTY: This warranty is limited to the original

purchaser or original end-user if sold through a distributor, and is not assignable or
otherwise transferable without the written agreement of Seller. Please contact your
local distributor for additional details if needed.
9-3

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 WARRANTY

ITEMS NOT COVERED BY SELLER WARRANTY

The following items are NOT covered under the Seller Warranty (the
following list is not exhaustive):
1. Items sold by any individual, corporation, partnership or any other
organisation or legal entity that is not an authorized Seller distributor.
2. Components which are not manufactured by Seller are not covered by
Seller’s warranty. Such components are covered only by the warranty that
is provided by the manufacturer of such components. Such components
may include, but are not limited to, engines, engine components, and
customer supplied products.
3. Replacement of assemblies: Seller has the option to repair or replace any
defective part or assembly. It is Seller’s policy to refuse claims for the
replacement of a complete assembly that is field repairable by the
replacement or repair of defective part(s) within the assembly.
4. Normal Operational Maintenance Services and Wear Parts:
Maintenance services and wear parts are excluded from warranty claims.
Maintenance services and wear parts not covered include, but are not
limited to, such items as: proper tightening of bolts, nuts and pipe fittings,
adding or replacing of fluids, filters, belts, skirting, chute linings and paint.
5. Transportation cost and/or damage: Any damage caused by carrier
handling is a transportation claim and should be filed immediately with the
respective carrier.
6. Deterioration: Repairs, work required or parts exposed as the result of age,
storage, weathering, lack of use, demonstration use, or use for
transportation/movement of corrosive chemicals.
7. Secondary Failures: Should the owner or operator continue to operate a
machine after it has been noted that a failure has occurred, Seller will not be
responsible under the warranty for resultant damage to other parts due to
that continued operation.
8. Workmanship of Others: Seller does not accept responsibility for improper
installation or labour costs of any kind from personnel other than authorized
Seller distributor personnel.
9-4

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 WARRANTY
9. Stop and Go Warranty: Seller does not recognize “Stop and Go”
warranties.
10. Incidental or Consequential Damage: SELLER SHALL NOT BE LIABLE
FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY
KIND, INCLUDING, BUT NOT LIMITED TO, LOSS OF PROFIT, LOSS OF
PRODUCTION, INCREASED OVERHEADS, LOSS OF BUSINESS
OPPORTUNITY, DELAYS IN PRODUCTION, COST OF REPLACEMENT
COMPONENTS AND INCREASED COST OF OPERATION THAT MAY
ARISE FROM THE BREACH OF THIS WARRANTY. Buyer’s sole remedy
shall be limited to (at Seller’s sole option) repair or replacement of the
defective part.

THIS WARRANTY IS EXPRESSLY IN LIEU OF AND EXCLUDES ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED (INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) AND
ALL OTHER OBLIGATIONS OR LIABILITY ON SELLER’S PART. THERE ARE
NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY
OBTAINED HEREIN. Seller neither assumes nor authorizes any other person to
assume for Seller any other liability in connection with the sale of Seller’s machine.
This warranty shall not apply to any of the Seller’s machines or any part thereof
which has been subject to misuse, alteration, abuse, negligence, accident, acts of
God or Sabotage. No action by any party shall operate to extend or revive this
limited warranty, without the prior written consent of Seller. In the event that any
provision of this warranty is held unenforceable for any reason, the remaining
provisions shall remain in full force and effect.

IN THE EVENT OF ANY BREACH OF THE WARRANTY BY THE SELLER, THE

SELLER’S LIABILTY SHALL BE LIMITED EXCLUSIVELY TO THE REMEDIES
(AT SELLER’S SOLE OPTION) OF REPAIR, OR REPLACEMENT, OF ANY
DEFECTIVE MACHINE COVERED BY THE WARRANTY. IN NO EVENT SHALL
SELLER BE LIABLE FOR INCIDENTAL, INDIRECT, CONSEQUENTIAL OR
OTHER DAMAGES OR LOSSES RESULTING FROM A BREACH OF
WARRANTY INCLUDING, WITHOUT LIMITATION, LABOUR COSTS, LOSS
OF USE OF OTHER EQUIPMENT, THIRD PARTY REPAIRS, LOST PROFITS,
9-5

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 WARRANTY
LOST TIME, TOWING OR HAULAGE OF MACHINE, RENTAL COST,
PERSONAL INJURY, EMOTIONAL OR MENTAL DISTRESS, IMPROPER
PERFORMANCE OR WORK, PENALTIES OF ANY KIND, LOSS OF SERVICE
OF PERSONNEL, OR FAILURE OF MACHINE TO COMPLY WITH ANY
FEDERAL, STATE OR LOCAL LAW.

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 9.1 Vdation Report

TELESTACK LIMITED
WARRANTY DEPARTMENT ([email protected])
Bankmore Way East, Omagh, Co. Tyrone, N Ireland, BT79 0NZ,
Telephone: +44 (0) 2882 251100 Fax: +44 (0) 2882 252211

WARRANTY VALIDATION REPORT IMPORTANT!

This is your WARRANTY VALIDATION REPORT and it must be completed and returned to Telestack Limited within 5 days of the machine being put into
service in order to start warranty cover on your Telestack equipment. Please complete all information carefully and completely, then sign and return this
form to the above address or by e-mail to [email protected]

Model ________________________________ Serial Nr : ________________________________

Date Equipment Was Put into Service: ________________________________

CUSTOMER Name: ___________________________________ Address:____________________________________

City:_____________________________________ Country:_____________ Area Code: ________
Phone Nr:_________________________________ Contact:____________________________________
DEALER Name: ___________________________________ Address: ___________________________________
City:_____________________________________ Country:_____________ Area Code:________

START-UP PROCEDURE CHECK LIST

(To be completed by Dealer/Serviceman)

Please tick each Engine Make:- Engine Model: Engine Serial Nr:
box _____________________ ______________________ ________________
Customer has been instructed on operation and all safety aspects of operating and maintaining the equipment
Customer has been furnished with all Parts, Maintenance and Instruction Manuals
Customer has been instructed on equipment maintenance schedules and procedures
All Operation and Warning Decals are properly displayed on the equipment
Equipment was observed under actual working conditions for at least __________ hour(s)
Customer has been furnished with the Telestack Ltd’s “Limited Product Warranty” statement

Comments:________________________________________________________________________________________________________________
__________________________________________________________________________________________________________________________

I have inspected this equipment and find it in good working order; to the best of my knowledge, the customer and his personnel are well versed on the above
procedures.

Signed: _____________________________________________ NAME: _____________________________________

Dealer/ Serviceman (Print name)

CUSTOMER AGREEMENT
I agree the equipment has been thoroughly serviced and checked by the above named representative and I am satisfied with his instructions and
inspection. I have been provided with a copy of the Telestack Equipment Limited Product Warranty Statement and agree to its terms.

Signed: _____________________________________________ NAME: _____________________________________

Customer (Print name)

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 CE CERTIFICATE
Declaration of Conformity

Manufacturers Name: Telestack Ltd

Manufacturers Address: Bankmore Way East,

Omagh,
Co. Tyrone,
N. Ireland
BT79 0NZ

Declares that the following information in relation to this product is in conformity with the stated standards and
other related documents following the provision of the European Directive on Machinery Safety 2006/42/EC

Product Name: Mobile Hopper Feeder with Pugmill

Model: P2000T

Serial Nr: 85-0009

The following harmonised standards have been applied:

BS EN 618:2002 +A1:2010 Continuous handling equipment and systems. Safety and EMC requirements
for equipment for mechanical handling of bulk materials except fixed
conveyors
ISO 14120:2015 Safety of Machinery – Guards – General requirements for the design and
construction of foxed and movable guards
BS EN ISO 13857:2008 Safety of Machinery - safety distances to prevent hazard
zones being reached by upper and lower limbs
BS EN ISO 12100:2010 Safety of Machinery - General principles of design - Risk
assessment and risk reduction
BS EN ISO 13850:2015 Safety of Machinery – Emergency Stop Equipment

BS EN 60204-1:2018 Safety of Machinery – Electrical Equipment of Machines. General

requirements
AS/NZS 3000:2007 Australian Electrical Installation

This product must be installed, tested, commissioned and operated in accordance with Telestack’s
instructions. Only Telestack recommended spare parts must be used for maintenance purposes within the
warranty period.

Person authorized for compiling Technical File is as follows:

Mark Fisher *
Signed: ________________________________
Mark Fisher - General Manager

Date: ____________________________

Approved Electronic Signature * TC-007

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 TERMINOLOGY

TERMINOLOGY

11. TERMINOLOGY.....................................................................................11-2

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 TERMINOLOGY

11. TERMINOLOGY
The terms below are used throughout your TELESTACK LTD Operations
Manual:

Assemblies
Individual sections of the machine made up of different component parts.

Auxiliary Control Valve

A bank of hydraulic valves which carry out various movement functions
throughout the machine.

Belt Scraper
A device fixed or flexible mounted across the width of a belt of a conveyor for
removing adherent material.

Bogie
Undercarriage on chassis to which axles are bolted.

Centre Roller
A roller, which supports the loaded belt.

Control Panel
A panel that is situated alongside the Powerunit that houses the functions for
operating the machine.

Conveyor
A lattice structure which is split into a number of parts (for transport), that is
used to transport material from the point of loading to the stockpile location.

Conveyor belt
A belt used to carry materials and transmit the power required to move the
load being conveyed.

Dog Lead
A hand held device used to control the track movement.

Drum Adjusters
The apparatus used to adjust the tail drum so that the belt will run correctly
and smoothly along the conveyor (tracking).

Dust Covers
Sheet of metal or canvas that prevents, or limits the amount of dust produced
by the material transferred along the conveyor/machine.

Dust Cover Hoop

The device used to support the dust covers.

11-2

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 TERMINOLOGY
Feedboot
An external collecting device, which funnels material from the loading
apparatus unto the centre of the belt at a constant and steady rate.

Filler Cap
A cap used to seal a tank and is removed in order to fill the tank.

Guard
A covering, barricade, grating ,fence or other from of barrier, used to prevent
inadvertent physical contact with operating components such a gears,
sprockets, chains ,and belts.

Head Drum
A cylindrical steel pipe machined to give a raised centre (crown) and lagged
with rubber for grip.

Hardened Wear Plates

Durable material with high wear resistance, the plates are bolted inside the
feed boot to ensure a long service life of the feed boot.

Impact bars
These are placed under the feed boot and protect the belt from the impact of
the falling material.

Jacklegs
Hydraulic adjustable legs which raise or lower the back of the machine for the
purpose of coupling to the tractor unit.

Lockout
Procedure to be carried out to ensure the machine is safe for maintenance or
repairs.

Nip Point
A point at which a machine element moving in line meets a rotating element in
such a manner that it is possible to nip, pinch, squeeze, or entrap a person or
objects coming into contact with one or two of the members.

Platform
A working space for persons, elevated above the surrounding floor or ground
for the operation of machinery and equipment.

Plough Scraper
Rubber or plastic scraper mounted on top of the returning conveyor belt to
prevent material being trapped between the tail drum and belt.

Power unit
An enclosed unit situated under the main conveyor which houses the
component parts which together drive the machine.

11-3

THE POWER TO MOVE MATERIALS

 TERMINOLOGY
Reject Grid
An arrangement of equally spaced grid bars which is used to separate the
large stones before the material enters the feed hopper.

Remote control
Any system of controls in which the actuator is situated in a remote location.

Retract
Withdraw or fold up conveyor.

Return Roller
Roller which is used to support an un-laden belt, on the underside of the
conveyor.

Scraper
A device fixed or flexibly mounted across the width of a belt of a conveyor for
removing adherent material.

Side Roller
Roller used to create arc on the belt to reduce spillage.

Sprocket
A toothed wheel arranged to fit into the links of a chain.

Telescopic Section
Section of the machine that extends telescopically, in order to alter the
discharge height and distance of the conveyor.

Tracks
Driven tracks to move the machine. The beams, shapes, or formed section on
which trolleys, roller, shoes, or wheels roll or slide while propelled.

Transport Bracket
A bracket used to hold an assembly in place whilst in transport.

Transport Position
The position of the machine when conveyors are folded.

Variable Speed Flow Control

A device which is used to hydraulically vary the speed of the conveyor belt.

Vulcanized Belt
A conveyor belt that has been joined seamlessly using a special treatment.

Wing Roller
The roller used to arc the belt to reduce material spillage.

11-4

THE POWER TO MOVE MATERIALS

This page was intentionally left blank
 HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM

12. HYDRAULIC CIRCUIT DIAGRAM ............................................................12-2

12-1

THE POWER TO MOVE MATERIALS

This page was intentionally left blank
 25.10.0043
Engine Bell housing

Clamp Hub, PB-BS, z=15, 16/32 DP &

41cc 41C 11CC 11CC
52.02.0085 SAE3S/9/12-162x4xM12/127
Cat 4.4 ACERT 96 kw

19.22.0716 - Quad Pump

42cc C/W flanges.

19.25.0589

feeder

19.24.0080 - Return Filter 1

Ports, COLOUR CODED GAUGE

This page was intentionally left blank
 ELECTRICAL SCHEMATICS

ELECTRICAL SCHEMATICS

13. ELECTRICAL SCHEMATICS ....................................................................13-2

13-1

THE POWER TO MOVE MATERIALS

This page was intentionally left blank
 F
E
D
C
B
A
Modem and Lead Add-On
Modem
3/6 3/6

Rev: 1.4
Rev: 1.3

Rev: 1.2
3/14 4/6 4/6 Brown/Black 22/35 22/35 Modem Power
6/14 5/6 5/6 Yellow/Purple 25/35 25/35 Modem CAN H

1
1

10/14 6/6 6/6 Blue 24/35 24/35 Modem CAN L

4/14 1/6 1/6
5/14 2/6 2/6
Keyswitch+

14/35 14/35
White 13/35 13/35 Keyswitched Power

Optional pullcord added

Collision Switch Corrected

Tipping Grid Add-on added

1 3
Telestack Panel (2 of 3)

1/4 1/4
4/4 4/4 /2.E2 GND

2
2

3/4 3/4 /2.E2 Keyswitch+

2 4

Pullcord 2*
2/4 2/4 /2.E2 CAN L Yellow 30/35 30/35 CAN L
/2.E2 CAN H Yellow/White 31/35 31/35 CAN H

/2.E2 Dual Power Inhibit Crank Green 26/35 26/35 Dual Power Inhibit Crank
/2.E2 EStop+ In

Purple/Black 2
1 3 1/4 1/4 EStop- In

Green/Yellow 2

Drawn By: JRD

Drawn By: JRD
Drawn By: JRD
/2.E2
4/4 4/4
3/4 3/4

Slate
Slow track/Radio/Dual Power Options
2 4

Pullcord 1*
2/4 2/4

White/Purple

Date:
Date:
Date:
EStop+ In

Blue/Slate
3

3
Connector
35 Way

Blue Key

Yellow/Brown
1 3 1/4 1/4

Cross-section of all wires can be assumed to be 1sq.mm unless otherwise indicated in brackets ()
Loom*
4/4 4/4

Junction

2/6/20

5/8/19
19/8/20
3/4 3/4 1/4 1/4 White/Purple 4/35 4/35 EStop+ In
2 4

EStop 2
2/4 2/4 Slate 4/4 4/4 Slate 3/35 3/35 EStop- In
Purple/Black 1 3/4 3/4
Green/Yellow 1 2/4 2/4

1 3 1/4 1/4 Green/Yellow

4/4 4/4 Purple/Black
3/4 3/4 Black
2 4 -F6

EStop 1
2/4 2/4 White/Black White/Black 10/35 10/35 EStop+ Out

Project Name:

4
4

*Optional pullcord kit; otherwise EStop 2 connects directly to Aux Breakout Loom
10A

28/35 28/35
Siren 29/35 29/35
Pwr 1/2 1/2 Orange Orange 1/35 1/35 Siren 32/35 32/35
GND 2/2 2/2 Black 33/35 33/35

-F2
Beacon 20A

Tracked Stockpiling Conveyor

Pwr Black 2/2 2/2
GND Red 1/2 1/2 White/Red 2/35 2/35 Beacon

5
5

Feeder Beacon Add-On

Beacon Beacon Tee Loom
PCB Power

Pwr Red 1/2 1/2

GND Black 2/2 2/2

Sheet Name:
Black 2/2
Beacon Orange 1/2
Pwr Red 1/2 1/2
GND Black 2/2 2/2

6
6

Black 21/35 21/35 GND

Aux Breakout Loom

Doglead Handset
1/10 1/10 Black 1/6 1/6
-F5
Panel Power

2/10 2/10 Red/White 2/6 2/6 Red/White 11/35 11/35 Doglead Power
3/10 3/10 Yellow/Slate 3/6 3/6 Yellow/Slate 17/35 17/35 Doglead CAN L 5A
4/10 4/10 Brown/Orange 4/6 4/6 Brown/Orange 18/35 18/35 Doglead CAN H
5/10 5/10 Orange 5/6 5/6 White/Orange 20/35 20/35 Doglead Stop
6/10 6/10
20A

Greaser+ Fused 14/19 14/19 Brown/White 5/35 5/35 Auto Greaser+ -F11
-F7

/3.B1 -F12
/3.A1 Belt scale+ Fused 12/19 12/19 Brown/Yellow 6/35 6/35 Belt Scale+ 10A
7

/3.B1 Sensor Power 3/19 3/19 White/Brown 7/35 7/35 Sensor Power 10A
/3.A1 Working Lights Power 16/19 16/19 Purple 12/35 12/35 Working Lights Power
18/19 18/19 23/35 23/35 Working Lights Power
/3.A1 LH Limit Switch 6/19 6/19 Green/Blue 27/35 27/35 LH Limit Switch
/3.A1 RH Limit switch 4/19 4/19 Orange/Black 8/35 8/35 RH Limit Switch
control

Collision Switch 13/19 13/19 Red/Yellow 9/35 9/35 Collision Switch

Module

/3.A1
/3.B1 Conveyor Speed Input 11/19 11/19 Slate/White 19/35 19/35 Conveyor Speed Input
/3.B1 Downstream+ 7/19 7/19 Blue/Yellow 15/35 15/35 Downstream+
/3.B1 Downstream- 19/19 19/19 Green/Brown 16/35 16/35 Downstream-
/3.B1 Upstream Output 9/19 9/19 Pink 34/35 34/35 Upstream
2/19 2/19 35/35 35/35 Upstream
Sheet
To Option Add-On Loom

1/19 1/19
10/19 10/19
1 of 4

8
8

5/19 5/19
/3.B1 GND 8/19 8/19
15/19 15/19
17/19 17/19
A3

Black
C

F
E
D
B
A
 1 2 3 4 5 6 7 8

Radio & I/O Module

Radio & I/O Module
A standard on CAT 4.4 T3,
optional on other variants
A

12/12 RH Slow Track

2/12 LH Slow Track
B B

9/12 Grid Down

Black 12 Way
I/O Module Slow Track Loom

8/12 Grid Up
Grey 12 Way
12/12 CAN H
1/12 CAN L
7/12 Power
6/12 Power
standard on CAT 4.4 T3,

Connector

Connector
5/12 GND
8/12 GND

GND
GND
Deutsch

Deutsch
optional on other variants

10/12
11/12

10/12
11/12
2/12

4/12

4/12
3/12

9/12

5/12

3/12
7/12

6/12

1/12
2/12

2/12
7/12
6/12
5/12
8/12
1/12
12/12

3/12
4/12
9/12
10/12
11/12

4/12
5/12

7/12

3/12
6/12

10/12
1/12
11/12
12/12
8/12
9/12
Green
White

Yellow/White
Black

Black
Orange

Purple
Blue
Yellow
C C

Purple
Black

Black
Blue
A/3
C/3

B/3
2/2

2/2

2/2

2/2
1/2

1/2

1/2

1/2
B/3
A/3
C/3
1/2
2/2

2/2
1/2

1/2
2/2

1/2
2/2
RH Slow Track
LH Slow Track
Coil+

Coil+

Coil+

Coil+
Black

Purple
Blue
Coil-

Coil-

Coil-

Coil-
Grid Down
Grid Up
D D

I/O Module Slow Track Loom Tipping Grid Add-on Loom

To Aux.Breakout Loom TC I/O Module Power Loom

/1.D2 Keyswitch+ White 1/8 1/8 White 1/8

/1.D2 GND Black 2/8 2/8 Black 2/8
/1.D2 CAN L Yellow 3/8 3/8 Yellow 3/8
E /1.D2 CAN H
Dual Power Inhibit Crank
Yellow/White
Green
4/8
6/8
4/8
6/8
Yellow/White
Green
4/8
6/8
Dual Power Option
E
/1.D2
/1.D3 EStop- In Slate 7/8 7/8 Slate 7/8
/1.D2 EStop+ In White/Purple 8/8 8/8 White/Purple 8/8
5/8 5/8 5/8

TC I/O Module Power Loom

standard on CAT 4.4 T3,
optional on other variants

F F
Rev: 1.3 Collision Switch Corrected Drawn By: JRD Date: 2/6/20 Project Name: Sheet Name:
Sheet
Rev: 1.4 Optional pullcord added Drawn By: JRD Date: 19/8/20
Tracked Stockpiling Conveyor Slow Track/Radio/Dual Pwr
Rev: 1.2 Tipping Grid Add-on added Drawn By: JRD Date: 5/8/19
2 of 4 A3
1 2 3 4 5 6 7 8
 F
E
D
C
B
A

Rev: 1.4
Rev: 1.3

Rev: 1.2
/1.D8
/1.D8
/1.D8
/1.D7
/1.D7
/1.D8
/1.D7
/1.D7
/1.D7
/1.D7
/1.D7
/1.D7

1
1

GND
Downstream-
Downstream+
Sensor Power
Collision Switch
RH Limit switch
LH Limit Switch

Greaser+ Fused

Upstream Output
Belt scale+ Fused
To TC Aux.Breakout Loom

Working Lights Power

Conveyor Speed Input

Optional pullcord added

Collision Switch Corrected

Tipping Grid Add-on added

Upstream Machine Link Lead Rear Interlink Chassis Loom
Brown 7/8 7/8 Pink
1/6 Brown (2.5) 1/6 1/6 Purple 8/8 8/8 Pink

2
2

Purple

3/6 3/6 3/6

4/6 4/6 4/6 30 86 3/8 3/8 Green/Brown
Red/Yellow

Green/Blue

Slate/White
Blue/Yellow

5/6 5/6 5/6 87 85 Black

Brown/White

White/Brown

87a
Orange/Black

Brown/Yellow

6/6 6/6 6/6 Black 4/8 4/8 Black

2/6 Blue (2.5) 2/6 2/6 Black 5/8 5/8 Black

Drawn By: JRD

Drawn By: JRD
Drawn By: JRD
Proximity Sensor
M30 Blue B/3 B/3 Black
Black C/3 C/3 Red Red 6/8 6/8 Slate/White
Brown A/3 A/3 White

Date:
Date:
Date:
3

3
Dummy Plug
1/2 1/2 White White 1/8 1/8 White/Brown

Cross-section of all wires can be assumed to be 1sq.mm unless otherwise indicated in brackets ()
2/2 2/2 Blue Blue 2/8 2/8 Blue/Yellow

2/6/20

5/8/19
19/8/20
Front Interlink Add-On
Dummy Plug Downstream Lead
1/6 11/6 Brown 1/2
2/6 2
2/6 Blue 2/2
3/6 3
3/6
4/6 4
4/6
5/6 5
5/6 1/2 Brown/White
6/6 6
6/6 2/2 Black

Project Name:

4
4

Auto Greaser

1/2 Brown/Yellow
2/2 Black
Power
Belt Scale

Tracked Stockpiling Conveyor

5
5

Worklights Loom
Work Light
1/2 1/2
2/2 2/2

Sheet Name:
Red 1/4 1/4 Purple
Red 2/4 2/4
Work Light 3/4
Black 3/4
1/2 1/2 Black 4/4 4/4 Black
2/2 2/2

6
6

Tracked Radial Sensor Loom

Option Add-On Loom

LH Limit Switch

3/4 3/4
1/4
22
21

1/4 Black
2/4 2/4
4/4 4/4 Green/Blue
14
13

1/6 1/6 Black

2/6 2/6 Green/Blue
7

3/6 3/6 Orange/Black

RH Limit Switch 4/6 4/6 Red/Yellow
5/6 5/6
3/4 3/4 6/6 6/6 White/Brown
1/4
22
21

1/4 Black
2/4 2/4
4/4 4/4 Orange/Black
14
13

Collision Switch
Sheet

'2' Signal Slate C/3 C/3 Red/Yellow

3 of 4

8
8

'1' +12V Brown A/3 A/3 White/Brown

'3' GND Black B/3 B/3 Black
A3
C

F
E
D
B
A
 F
E
D
C
B
A
All GND wires joined
at ring crimp to chassis
Black
3/35 3/35 GND

Rev: 1.4
Rev: 1.3

Rev: 1.2
4/35 4/35 GND
Oil Cooler Add-On Loom 7/35 7/35 GND

1
1

Stat Switch 8/35 8/35 GND

Hyd.Oil Stat 1/2 1/2 White/Red 5/8 5/8 White/Red 30/35 30/35 Hydraulic Oil Stat
GND 2/2 2/2 Black Blue 1/8 1/8 (2) 9/35 9/35 Oil Cooler 1
-F3
Panel Power

1st Oil Cooler Blue 2/8 2/8 (2) Blue/Brown 10/35 10/35
Pwr 1/2 1/2 (3) (2) 6/8 6/8 (2) 20/35 20/35 15A
GND 2/2 2/2 (3) Black (2) 7/8 7/8 (2) 21/35 21/35 control
Module

2nd Oil Cooler (2) 8/8 8/8 (2)

GND 2/2 2/2 (2) Black 3/8 3/8 5/35 5/35 Oil Cooler 2

Optional pullcord added

-F13

Collision Switch Corrected

Pwr 1/2 1/2 (2) Red/White Red/White 4/8 4/8 Red/White 6/35 6/35

Tipping Grid Add-on added

15A
control
Module
Telestack Panel (3 of 3)

2
2

Feeder On/Off Loom

Feeder
Coil- 2/2 2/2 Blue 2/2 2/2 Black
Coil+ 1/2 1/2 Brown 1/2 1/2 Orange/Black 18/35 18/35 Feeder

LH Conveyor
Coil+ 1/2 1/2 Green Green 33/35 33/35 LH Conveyor Run

Drawn By: JRD

Drawn By: JRD
Drawn By: JRD
Coil- 2/2 2/2 Black
LH Track Forward
Coil+ 1/2 1/2 Yellow Yellow 34/35 34/35 Track L Forward
Coil- 2/2 2/2 Black
26/35 26/35

Date:
Date:
Date:
29/35 29/35
3

3
LH Track Reverse

Cross-section of all wires can be assumed to be 1sq.mm unless otherwise indicated in brackets ()
Coil- 2/2 2/2 Black

2/6/20

5/8/19
19/8/20
LH Dump Valve Coil+ 1/2 1/2 Blue Blue 22/35 22/35 Track L Reverse
Coil-2/2 2/2 Black
Coil+1/2 1/2 Slate Slate 12/35 12/35 LH Track/Conv. Dump Valve

RH Conveyor
Coil+ 1/2 1/2 Pink Pink 32/35 32/35 RH Conveyor Run
Coil- 2/2 2/2 Black
RH Track Forward
Coil+ 1/2 1/2 Purple Purple 35/35 35/35 Track Right Forward

Project Name:

4
4

Coil- 2/2 2/2 Black

RH Track Reverse
Coil- 2/2 2/2 Black
RH Dump Valve Coil+ 1/2 1/2 Brown Brown 23/35 23/35 Track Right Reverse
Coil- 2/2 2/2 Black
Coil+ 1/2 1/2 Orange Orange 11/35 11/35 RH Track/Conv. Dump Valve

Hyd.Tank Sensor

Tracked Stockpiling Conveyor

1/3 1/3 Green/White Green/White 31/35 31/35 Hydraulic Oil Temperature
2/3 2/3 Blue/White Blue/White 27/35 27/35 Hydraulic Oil Level

5
5

3/3 3/3 Black

Fuel Level Sender
B/3 B/3 Black
C/3 C/3 Purple/Black Purple/Black 19/35 19/35 Fuel Level
A/3 A/3 White/Purple
24/35 24/35 Sensor Power

Sheet Name:
White/Purple 25/35 25/35 Sensor Power
Pushbutton & Dump Loom
Aux Dump 1/4 1/4 White/Purple
Coil+ 1/2 1/2 White/Brown White/Brown 4/4 4/4 White/Brown White/Brown 17/35 17/35 Aux. Dump
Coil- 2/2 2/2 Black Slate/White 2/4 2/4 Slate/White Slate/White 28/35 28/35 Aux. Dump Switch
4
3

Black 3/4 3/4 Black

6
6

Hydraulic Loom

2/12 2/12
TC Add-On 360/Front Rear Raise Lower Loom 4/12 4/12
35 Way Connector
White Key

360/Radial LH 6/12 6/12

Coil- 2/2 2/2 Black 8/12 8/12 Black
Coil+ 1/2 1/2 Blue/Yellow 10/12 10/12
Rear Lower 12/12 12/12
Coil+ 1/2 1/2 White
Coil- 2/2 2/2 Black 5/12 5/12 Blue/Yellow 13/35 13/35 360/Radial LH
7

Front Lower White 1/12 1/12 White 2/35 2/35 Rear Lower
Coil+ 1/2 1/2 Brown/Yellow 9/12 9/12 Blue/Yellow 15/35 15/35 Front Lower
Coil- 2/2 2/2 Black

Front Raise
Coil- 2/2 2/2 Black
Rear Raise Coil+ 1/2 1/2 Red/Blue 11/12 11/12 Red/Blue 16/35 16/35 Front Raise
Coil- 2/2 2/2 Black
Coil+ 1/2 1/2 Green/Purple Green/Purple 3/12 3/12 Green/Purple 14/35 14/35 Rear Raise
Sheet

360/Radial RH
4 of 4

8
8

Coil+ 1/2 1/2 Brown/Purple 7/12 7/12 Brown/Purple 1/35 1/35 360/Radial RH
Coil- 2/2 2/2 Black
A3
C

F
E
D
B
A
 1 2 3 4 5 6 7 8
Black
64 Way ECU Connection

Ignition Switch/EStop Input

Engine Fuse Module

Glow Plug Switched+

A 17/39 17/39 A

Remote Stop Input

8V Sensor Power

Blocked Air Filter

18/39 18/39

Low Idle Input

Water In Fuel
Coolant Level
ECU Fused+
ECU Fused+
ECU Fused+
ECU Fused+

Sensor GND

J1939 High
8/39 8/39

J1939 Low
10/39 10/39

Screen
Return
11/39 11/39

GND
GND
GND
GND
GND
12/39 12/39

43/64
47/64

23/64
44/64
24/64
25/64
26/64
27/64
28/64
29/64

20/64
21/64
22/64

40/64

48/64

45/64

41/64
42/64
46/64
49/64
57/64

33/64

38/64
35/64
30/64
31/64
32/64

34/64

36/64

37/64

39/64

50/64
51/64
52/64
53/64
54/64
55/64
56/64
58/64
59/64
60/64
61/64
62/64
63/64
64/64
10/64

15/64
16/64

11/64
12/64
13/64

14/64
17/64
18/64
19/64
-FM15

4/64

2/64
3/64
9/64

7/64
8/64

5/64

6/64
1/64
25/39 25/39 Brown/Black
25A 26/39 26/39
28/39 28/39

4/64
1/64
2/64
3/64
9/64

43/64
47/64

23/64
44/64
24/64
25/64
26/64
27/64
28/64
29/64

20/64
21/64
22/64

40/64

48/64

45/64

41/64
42/64
46/64
49/64
10/64
7/64
8/64
15/64
16/64
5/64
57/64
6/64
11/64
12/64
13/64

33/64
14/64
17/64
18/64
19/64

38/64
35/64
30/64
31/64
32/64

34/64

36/64

37/64

39/64

50/64
51/64
52/64
53/64
54/64
55/64
56/64
58/64
59/64
60/64
61/64
62/64
63/64
64/64
B 1/39 1/39(2) Black
B

Black/Green

Black/Green
White

White

White
Green/White

White/Orange

Red/Black
White/Purple

Orange
Black/White
Black/Yellow

White/Black
2/39 2/39(2) Brown/Black
3/39 3/39(2)

Red
Black
4/39 4/39(2) Glow Plugs
5/39 5/39(2) (via adapter loom)
-FM11 6/39 6/39(2) Red (10+10) Red 1/1 1/1
50A

A/3
C/3
B/3

2/3

2/2
3/3

1/2
13/39 13/39

1/3
To next sheet (Panel)
15/39 15/39 Orange Low Idle Input /2.D5
Drive circuit 16/39 16/39

B/3

2/3

1/2
2/2
A/3
C/3

3/3
1/3
19/39 19/39 Red/Black Engine Stop /2.C5
20/39 20/39

Signal
GND
Power
Coolant Level Sensor
21/39 21/39 White/Black EStop Relay O/P

Water In Fuel Sensor

/2.D5
C 22/39 22/39 C

Air Filter Switch

Black J1939 Low /2.D5
14/39 14/39 Black/Yellow Red J1939 High /2.D5

9/39 9/39 White/Slate

87a

-K11 Black (2) 2/4

-FM14
30

29/39 29/39 (2) 3/4 I/O Module

20A 30/39 30/39 Red/Brown Red/Brown (2) 1/4 Connection
87

(2) 4/4
Red/Yellow Glow Plug Drive- /2.C5
85
86

7/39 7/39 White/Slate White/Slate Keyswitch+

D /2.D5
D
-FM12 34/39 34/39 Brown Brown Panel Power /2.D5
80A 35/39 35/39
36/39 36/39 White/Red Starter Crank /2.D5
37/39 37/39
38/39 38/39
39/39 39/39 Engine Start/Charge Brown/Yellow Alternator Excite /2.D5

24/39 24/39
-FZCASE3
200A Alternator
32/39 32/39 -FZCASE2 W+ B+ D+
E -FM13 23/39 23/39
400A
+ve crank
From Deutz E
loom
5A
-FZCASE1
200A

33/39 33/39 W
LEAD-ACID
BATTERY G V (25)
27/39 27/39 U
31/39 31/39
M
Red
-ve Starter Motor
-ve
Black Black GND /2.F5

F Cross-section of all wires can be assumed to be 1sq.mm unless otherwise indicated in brackets () F
Rev: 1.0 Initial Release Drawn By: JRD Date: 15/11/19 Project Name: Sheet Name:
Sheet
Rev: 1.1 Water In Fuel & Glow Plug changes Drawn By: JRD Date: 18/2/20
Tracked Stockpiling Conveyor CAT 4.4 T3 Engine Loom
Rev: Drawn By: Date: 1 of 2 A3
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 Ignition Key Switch 8

Telestack Panel (1 of 3)
Panel Power
Panel Power
30
A A
EStop+ In 0,1

-S1
210

50 15
F11 Glowplugs -K1 86 30
50A 85 87a
87

-F9
10A
20A
-F4
35 Way Connector - Black Key Keyswitch+
B B
Module

EStop Relay Output

control

Glow Plug Drive-

Alternator Excite
Low Idle Enable

Crank Request
Panel Power
Engine Stop

Keyswitch+
J1939 High
F13 Modem

J1939 Low

GND
5A

GND
28/35

29/35

23/35
22/35
21/35

27/35

24/35
25/35
26/35

20/35
30/35

31/35
32/35
33/35
34/35

35/35
11/35

16/35
17/35
18/35
19/35
12/35

13/35
14/35

15/35
10/35
4/35

2/35

3/35

5/35
6/35
8/35

7/35

9/35
1/35
F15 Engine ECU
25A

28/35

29/35

23/35
22/35
21/35

27/35

25/35
26/35
30/35

11/35

4/35
8/35
16/35
17/35
18/35
19/35
12/35
31/35
32/35
33/35
34/35
7/35

1/35
2/35

24/35
13/35
14/35

35/35
3/35
15/35
10/35
9/35
5/35

20/35
6/35
C C

Brown

White/Red
Red

White/Slate
Black

Orange

Black
Brown/YEllow
White/Black
From previous sheet
/1.D8 Glow Plug Drive- Red/Yellow

/1.C8 Engine Stop Red/Black

F14 I/O Module /1.C8 J1939 Low Black

20A K11 I/O Module /1.C8 J1939 High Red

/1.C8 Low Idle Input Orange

EStop Relay O/P White/Black

D /1.C8
/1.D8 Panel Power Brown D
/1.D8 Starter Crank White/Red
/1.E8 Alternator Excite Brown/Yellow
/1.D8 Keyswitch+ White/Slate

F12 Panel
80A

E CAT 2.2 T3/4.4 T3 E

Engine Fuse Module

/1.F8 GND Black

F Cross-section of all wires can be assumed to be 1sq.mm unless otherwise indicated in brackets () F
Rev: 1.0 Initial Release Drawn By: JRD Date: 15/11/19 Project Name: Sheet Name:
Sheet
Rev: 1.1 Water In Fuel connector changed Drawn By: JRD Date: 18/2/20
Tracked Stockpiling Conveyor CAT 4.4 T3 Engine Loom
Rev: Drawn By: Date: 2 of 2 A3
1 2 3 4 5 6 7 8
 F
E
D
C
B
A

Rev:
Rev:
Rev: 1.0

1
1

GND
GND
GND
CAN L
CAN H

EStop- In

I/O Power
I/O Power
EStop+ In
Keyswitch+

From Engine Loom

Initial Release
Expanded I/O Module

From Aux.Breakout Loom

Dual Power Inhibit Crank

Grey
Black

Green
Brown

Slate

Black
Black
Black
White

Green
Yellow
Keyways

Red/Brown
Red/Brown
White/Purple
Yellow/White

(2)
(2)
(2)
(2)

2
2

4/4
3/4
5/8
8/8
4/8
3/8
1/8

7/8
6/8

2/8

1/4 (2x2)1/4
1/8

3/4
5/8
8/8
3/8

7/8
6/8

4/4
4/8

2/4 (2x2)2/4
2/8

Drawn By:
Drawn By:
Black 12 Way Deutsch Connector
11/12 11/12

Drawn By: JRD

3/12 3/12
Yellow 2/12 2/12 CAN L
Yellow/White 1/12 1/12 CAN H
4/12 4/12
(2x2) Black 5/12 5/12 GND

Date:
Date:
Date:
6/12 6/12 GND
3

3
(2x2) Red/Brown 8/12 8/12 I/O 12V

Power Loom
Expanded I/O
7/12 7/12 I/O 12V
9/12 9/12

16/2/21
10/12 10/12
12/12 12/12

Left Track / 360 Grey 12 Way Deutsch Connector

Divert Coil+ 1/2 1/2 Green/Orange 9/12 9/12 Left Track/360 deg Divert
Coil- 2/2 2/2 Black/White 5/12 5/12 GND

Project Name:

4
4

Black 6/12 6/12 GND

7/12 7/12 GND
Left Track Rev.
Coil+ 1/2 1/2 Yellow/Slate 2/12 2/12 Left Track Reverse
Coil- 2/2 2/2 Black

3/12 3/12
4/12 4/12

Telemix Add-on Kit

Left Track Fwd.
Coil- 2/2 2/2 Black
Coil+ 1/2 1/2 Yellow/Red 1/12 11/12 Left Track Forward

Slow Track
& Dump Loom

5
5

Right Track Rev.

Coil+ 1/2 1/2 Brown/Blue 11/12 1/12 Right Track Reverse
Coil- 2/2 2/2 Black

8/12 8/12
10/12 10/12

Sheet Name:
Right Track Fwd.
Coil- 2/2 2/2 Black
Coil+ 1/2 1/2 White/Green 12/12 12/12 Right Trackl Forward

6
6

Green 12 Way Deutsch Connector

2/12 2/12
Forward 3/12 3/12
Coil+ 1/2 1/2 Brown/Pink 1/12 1/12 Forward
Coil- 2/2 2/2 Black 4/12 4/12
5/12 5/12
6/12 6/12 GND
7/12 7/12 GND
Reverse 8/12 8/12
Forward

Coil- 2/2 2/2 Black 9/12 9/12

Feeder/Pugmill

& Reverse Loom

Coil+ 1/2 1/2 Yellow/Brown 12/12 12/12 Reverse

10/12 10/12
11/12 11/12
7

Brown 12 Way Deutsch Connector

1/12
3/12
4/12
5/12
Pugmill Pressure 7/12
Switch 8/12
Signal 1/2 Yellow/Red 2/12 Signal
+12V 2/2 White 6/12 +12V
Sheet

9/12
10/12
1 of 1

8
8

11/12
12/12
A3
C

F
E
D
B
A
This page was intentionally left blank
 APPENDIX

APPENDIX

14. APPENDIX……………………………………………………………….14-2

14-1

THE POWER TO MOVE MATERIALS

This page was intentionally left blank
 APPENDIX

Storage and Preservation

Short-term storage (up to 3 mths)
For short-term storage before commissioning, please observe the
following:

 Where possible, store parts in the fitting position and secure against falling

 Lightly grease bare metal housing surfaces, shafts, rods, metal fitting, and
all other potentially corrosive parts

 Store in dry rooms

 Temperature must not fluctuate beyond the range of –5 ºC to +50 ºC

 Relative humidity less than 60%

 No direct exposure to sunlight or UV light

 No aggressive, corrosive substances (contaminated air, ozone, gases,

solvents, acids, alkalis, salts, radioactivity etc.) in the immediate vicinity

 No vibration or oscillation

Long-term storage (3mths or more)

For storage or standstill periods in excess of 3 months, we recommend our

long-term storage option. With the long-term storage option and the use
of the measures listed below, storage for up to 2 years is possible. As the
actual influences on the parts greatly depend on the local conditions, these
times should only be regarded as guide values.

14-2

THE POWER TO MOVE MATERIALS

 APPENDIX
Conditions of the machine and parts for long-term storage prior to
commissioning:

 Where possible, store in the fitting position and secure against falling

 Transportation damage any external paint must be repaired. Check that a

suitable rust inhibitor is applied to the damaged paint area. If necessary
apply a suitable rust inhibitor to the surfaces

 Store in a dry place

 Temperature must not fluctuate beyond the range of –5 ºC to +40 ºC

 Relative humidity less than 60%

 No direct exposure to sunlight or UV light

 No aggressive, corrosive substances (contaminated air, ozone, gases,

solvents, acids, alkalis, salts, radioactivity etc.) in the immediate vicinity

 No vibration or oscillation

 Where applicable, parts be covered adequately with petrolatum tape (e.g.

Denso tape) for corrosive protection

Additional requirements for long term storage of gears

 It is required the units are completely filled with lubricant or have VCI

 Corrosion protection agents need to be added to the gear oil. (See label
on gear unit for details)

 The sealing band in the vent plug must not be removed during storage.
The gear unit must remain sealed tight

 In tropical regions, the drive unit must be protected against damage by

insects

 If the storage or standstill period exceeds 2 years or the temperature

during short-term storage greatly deviates from the standard range, the
lubricant in the gear units must be replaced before commissioning

 If the gear unit is completely filled, the oil level must be reduced before
commissioning

14-3

THE POWER TO MOVE MATERIALS

 APPENDIX
Storage of electrical components

Storage refers to putting components in safe keeping for future use.

There may be many reasons to store electrical components for use at a later
date. There are also many types and sizes of storage facilities, but all must
provide the same environment for the proper storage of electronic
components:

THE ELECTRIC CONTROL PANEL MUST BE

STORED INDOORS AT ALL TIMES

Outside Storage: Storage grounds should be free of litter, debris, and

sheltered from possible adverse weather conditions.
Inside Storage: The building, its floors and the shelves on which components
are stored need to be electrically grounded. Smoke detectors are also highly
recommended.
Climate Control: To remain in proper operating condition, and to prevent
possible damage, all electronic components should be stored in a climate
controlled facility. Climate controlled means that the temperature and humidity
levels are monitored to ensure that they are stable and within recommended
range. Air-conditioned storage is recommended, along with humidification and
dehumidification capabilities. Simply limiting access to a storage facility can
assist in maintaining proper temperature and humidity levels:
Ideal Storage Temperature Range: 15ºC to 27ºC
Ideal Storage Humidity Range: 30% to 60% relative humidity (RH)

Air Quality: Proper ventilation is recommended. Air should circulate freely

throughout the storage facility. Ventilation can be achieved with a simple fan or
an air conditioning system.

14-4

THE POWER TO MOVE MATERIALS

 APPENDIX
 Before any power is applied all electrical components must be completely
dry and free from dust

 After transport or storage all electrical terminals (this means any screw or
bolt that has an electric wire attached to it) must be checked for tightness

 Control panel sockets most have their lids locked in the closed position

 All other sockets most have their lids locked in the closed position

 Plugs without lids must be tied down with their pins pointing down

 All Motor terminal boxes, limit switches, junction boxes, sensors, plugs
and sockets, should be inspected for moisture ingress due to
condensation, before any power is applied

 Control panel and terminal junction boxes should have a suitable quantity
off anti-condensation bead bags installed in them. These must be replaced
when necessary.

 Control panels and all other electrical components must be stored indoors.

 If there is power available, the heaters inside the control panel could be
switched on (this is thermostatically controlled and will maintain a constant
temperature)

 Each motor terminal block must be covered (not with a plastic bag as this
creates condensation) if left outside for long periods of time

 All electrical circuits to be tested by a competent Electrician, as per

current regulations, before power is applied taking into consideration and
protecting Electronic / PLC equipment.

Disclaimer: This information is provided for guidance purposes only, based on

generalised assumptions of typical storage conditions. It is the owner’s
responsibility to ensure storage preservation is adequate, based on actual
storage conditions. Telestack will not be held responsible for any issues arising
from long term storage.
Telestack recommends that regular inspection of the stored items should be
undertaken to ensure that adequate steps have been made to ensure full
protection during long term storage.

14-5

THE POWER TO MOVE MATERIALS

Bankmore Way East | Omagh
Co.Tyrone | Northern Ireland
BT79 ONZ

T :+44 (0) 28 8225 1100

E : [email protected]

THE
POWER
TO MOVE
MATERIALS