ManualArchive 390600522 Operating Instructions

Operating Instructions
TB110
390600522
A820143 L
Table of Contents
1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Safety Alert Icons & Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Serial Number/Machine Rating Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.4.1 Standard Telebelt Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4.2 Pro-Vantage Warranty Plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4.3 Conditions of Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Customer Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.5.1 On-Call Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 Technical Service Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 Additional Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.8 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.9 Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.9.1 Travel Position Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.9.2 Operating Position Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.10 Boom Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.11 Overall Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.12 U. S. / Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
2.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Operating Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Cold Weather Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2 Pre-Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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2.4 Hydraulic Control Valves, Oil Cooler, High Pressure Filter,

Suction Filters, and Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 Boom and Outrigger Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.6 Electric Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.7 Radio Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.8 Radio Remote Control Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.9 Cable Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.10 Radio Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.11 Emergency Cab Lift System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.12 Power Take-Off (PTO) Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.12.1 PTO Switch-Manual Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.12.2 PTO Switch-Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.13 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2.13.1 Outrigger Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.13.2 Outrigger Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.13.2.1 Standard Outrigger Set-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
2.13.2.1 Special Outrigger Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
2.13.3 Outrigger Pads (Blocking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.14 Machine Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
2.15 Conveyors Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

2.15.1 Feed Conveyor Raise/Lower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.15.2 Feed Conveyor Swing (Slewing). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2.15.3 Feed Conveyor Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2.15.4 Main Conveyor Raise/Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
2.15.5 Conveyor Boom Swing (Slewing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2.15.6 Conveyor Telescoping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2.16 Main Conveyor Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

2.16.1 Setting-Up Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2.17 Conveyor Belt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

2.17.1 Belt Speed Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
2.18 Conveyor Belt Speed Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
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2.18.1 Belt Speed Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

2.18.2 Belt Speed/Capacity Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Table 1: Telebelt Speeds and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-49
Table 2: Speeds and Capacities for an 18-Inch Wide Belt (U. S.) . . . . . . . . . . . . . . . . . . . . .2-51
Table 3: Speeds and Capacities for an 18-Inch Wide Belt (Metric) . . . . . . . . . . . . . . . . . . .2-52
2.19 Placing Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

2.19.1 Low Slump (Dry) Concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
2.19.2 High Slump (Wet) Concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
2.19.3 Dry Materials (Rock, Sand, Backfill, or Landscaping Material) . . . . . . . . . . . . 2-54
2.19.4 Maintenance During a Pour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
2.20 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
2.21 Water Tank and Pressure Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

2.21.1 Operating the Pressure Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
2.21.2 Winterizing the Pressure Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
2.21.3 Preparing Pressure Washer for Use After Winterizing . . . . . . . . . . . . . . . . . . 2-60
2.21.4 Optional Water Tank and Oil Tank Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
2.22 Tear-Down (After Cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
3.0 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Travel Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Highway Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 Pusher Axle Control (TB110) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Interaxle Lock Switch (Mack Truck Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.4.1 Engaging the Interaxle Lockout (Sterling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5 Job Site Travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.5.1 Boom Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5.2 Feed Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5.3 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5.4 Gear Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5.5 New Job Site Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
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4.0 Preventative Maintenance . . . . . . . . . . . . . . . . . . . 4-1

4.1 Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Table 1: Recommended Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Table 2: Recommended Oils and Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.2 Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Table 3: Recommended Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.3 Quick Reference of Adjustment Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Table 4: Component Adjustment Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.4 Hydraulic System Oil Tank, Fluid Level Gauge, Thermometer, and
Air Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.5 Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.5.1 Replacing the Suction Oil Filter Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5.2 Replacing the High Pressure Oil Filter Element . . . . . . . . . . . . . . . . . . . . . . . .4-11
4.6 Lubricating the Telebelt (TB110) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.6.1 Outrigger Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.6.2 Boom Arm Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.6.3 Conveyor Sheave and Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.7 Maintaining the Conveyor Slewing Gear Reducer . . . . . . . . . . . . . . . . . . . 4-17

4.7.1 Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.7.2 Changing Reducer Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.7.3 Changing Brake Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.7.4 Feed Conveyor Slewing Gear Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.7.4.1 Changing Reducer Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
Changing Lower Reservoir Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Changing Upper Reservoir Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.8 Tensioning the Feed Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.9 Training (Aligning) the Feed Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.10 Adjusting U-Roller (Feed Conveyor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.11 Replacing the Feed Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

4.11.1 Removing the Old Feed Conveyor Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.11.2 Installing the New Feed Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
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4.12 Replacing the Feed Conveyor Motor Collet . . . . . . . . . . . . . . . . . . . . . . . . 4-31

4.12.1 Removing the Old Collet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4.12.2 Installing the New Collet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4.13 Tensioning the Telescope Traction Drive Cable. . . . . . . . . . . . . . . . . . . . . 4-33
4.14 Replacing the Telescope Traction Drive Cable . . . . . . . . . . . . . . . . . . . . . 4-35
4.15 Adjusting the Equalizer (Helper) Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4.16 Tensioning the Main Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

4.16.1 Tensioning Belt Using Hydraulic Jack Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4.17 Training (Aligning) the Conveyor Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

4.17.1 Training (Aligning) Main Conveyor Belt at Head Section . . . . . . . . . . . . . . . . 4-41
4.17.2 Main Conveyor Belt Training (Alignment) at Drive Pulley . . . . . . . . . . . . . . . . 4-42
4.18 Replacing the Main Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.19 Torquing the Feeder Turntable Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . 4-47
4.20 Checking the Main Conveyor Turntable Bearing Bolts . . . . . . . . . . . . . . . 4-49

Table 5: Bolt Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-50
4.21 Telebelt Belt Splicing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

4.21.1 Belt Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
4.21.2 Belt Length Determination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4.21.3 Belt Rolling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4.21.4 Belt Splicing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4.21.4.1 Working Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52
4.21.4.2 Material Required (for Standard Telebelt Belt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.21.4.3 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53
4.21.4.4 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54
4.21.4.5 Inch to Millimeter Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.21.4.6 Belt Splicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55
4.22 Checking and Adjusting Hydraulic Pump Pressures . . . . . . . . . . . . . . . . 4-62

4.22.1 Checking and Adjusting Feeder Belt Pump Low Pressure Setting . . . . . . . . . 4-63
4.22.2 Checking and Adjusting Feeder Belt Pump High Pressure Setting . . . . . . . . 4-66
4.22.3 Checking and Adjusting Main Conveyor Belt Pump Low Pressure Setting . . 4-68
4.22.4 Checking and Adjusting Main Conveyor Belt Pump High Pressure Setting . . 4-70
4.22.5 Checking and Adjusting Boom/Outrigger Pump Low Pressure Setting . . . . . 4-73
4.22.6 Checking and Adjusting Boom/Outrigger Pump High Pressure Setting . . . . . 4-74
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5.0 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 General Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Safe Operating Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.3 Range Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.3.1 Range Diagram Horizontal Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3.2 Range Diagram Vertical Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.4 Special Outrigger Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Scenario 1 – Two Rear, One Front Extended Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Scenario 2 – One Rear Outrigger in Rear Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Scenario 3 – Two Rear Outriggers Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.5 Lock Out – Tag Out Procedure

Lock Out - Tag Out Procedure Where Contact With Moving Parts is Possible . . . . . . . . . . . . . . . . . 5-10
Lock Out - Tag Out Procedure Where Contact With Moving Parts is Not Possible. . . . . . . . . . . . . . 5-10
Appendix A: Glossary/
Abbreviations and Technical Terms. . . . . . . . . . . . . . . . A-1
Appendix B: Index of Key Words . . . . . . . . . . . . . . . . . B-1
VI Putzmeister America, Inc. A820143_TOC_0702K

1.0 Introduction
1.1 Scope
These operating instructions provide information on the Putzmeister Telebelt® and its safe operation.
Read and follow all instructions to avoid hazards, reduce repair costs/downtime, and increase the reliability
and service life of the machine.
These operating instructions are supplemented by all local, state, and federal laws and regulations for
accident prevention and environmental protection.
Keep these operating instructions with the machine at all times. In the event of damaged or missing pages,
reprints are available. Contact the Putzmeister Customer Support Team for additional copies.
WARNING
Do not operate this machine
without training.
Understand the warnings in
safety manuals and on decals.
TB1.1
Illustration 1-1: Read All Operating Instructions Before Operating Machine

Ensure that these operating instructions are read and applied by any person in charge of carrying out work
with (and on) this machine, such as:
• Operation (set-up, troubleshooting in the course of work, or tearing down the machine).
• Service (maintenance, inspection, and repair).
• Transporting machine.
Should you have any questions regarding the operation of the machine or any of its components, please
contact your dealer or the Putzmeister Customer Support Group at (1-800-890-0269) or reference the
Customer Support Card at the front of this manual.
When calling, please have the machine information handy in order for us to assist you as quickly as possible.
The most important information is the model number and machine serial number.
These operating instructions provide a description of the machine superstructure only. Please refer to the
vehicle/carrier manufacturers manual for specific instructions that apply to the chassis itself.
A820143_01_0702K Putzmeister America, Inc. 1–1

Introduction
Putzmeister America is committed to product quality, innovation, and service excellence. Component
modifications are made periodically that may or may not be included in these operating instructions at the
time of printing.
Contents of this publication (except where granted) may not be copied or reproduced without prior consent
from Putzmeister America.
1.2 Safety Alert Icons & Symbols

The following icons and symbols are used throughout these operating instructions:
NOTE:
This icon represents specific information regarding the proper use of the machine and
is introduced with the symbol shown (blue), the word “Note” printed in bold, and the
associated text in italics.
IMPORTANT:
This safety alert icon represents information or precautions intended to alert a
specific condition or action regarding an individual component or system on
the machine and is introduced with the symbol shown, the word “Important”
printed in bold, and the associated text in bold italics.
CAUTION:
This icon represents information, rules, or precautions intended to alert
against potentially hazardous situations which, if not avoided, could result in
minor or moderate equipment damage. It is introduced with the symbol shown
(yellow), the word “Caution” printed in bold and the associated text in bold
italics.
WARNING:
This icon represents information, rules, or precautions intended to alert
against unsafe practices or potentially hazardous situations which, if not
avoided, could result in personal injury and equipment damage. It is introduced
with the symbol shown (orange), the word “Warning” printed in bold, and the
associated text in bold italics.
DANGER:
This icon represents specific information, rules, or precautions intended to
alert against an imminently hazardous situation which, if not avoided, will
result in death or serious personal injury and equipment damage. It is
introduced with the symbol shown (red), the word “Danger” printed in bold, and
the associated text in bold italics.
1–2 Putzmeister America, Inc. A820143_01_0702K

Introduction
1.3 Serial Number/Machine Rating Plate
EXAMPLE 3906XXXXX
1
2
3 5
4
TB1.3
1. Model number
2. Serial number
3. Model year
4. Hydraulic pressure max. (bar) - main and feed conveyor hydraulic pump
5. Gross Vehicle Weight (GVW) Rating
Illustration 1-2: Machine Serial Number and Rating Plate

The machine serial number and all other vehicle information is stamped on the Machine Rating Plate as
shown in Illustration 1-2. It is located next to the filter gauges on the operator’s pedestal on driver’s side of
the machine.
1.4 Warranty
1.4.1 Standard Telebelt Warranty
Putzmeister, Inc. warrants each new machine to be free of defects in material and workmanship under
normal use and service for a period of twelve (12) months from date of delivery to initial user, or 2,200
operating hours, whichever comes first. If the machine is delivered from Putzmeister to a distributor rather
than the initial user, this warranty shall run for a period of twelve (12) months from the date of shipment to
the distributor, unless the distributor has promptly provided a written statement to Putzmeister advising their
date of delivery to the initial user.
1.4.2 Pro-Vantage Warranty Plan

In addition to the standard warranty, the Pro-Vantage extended warranty applies to this product. Pro-
Vantage extends the initial coverage on ‘major components’ to 36 months or 6600 hours. Components
covered by this plan include booms (provided annual inspections have been documented to Putzmeister);
hydraulic pumps (main, accumulator, boom); hydraulic valves; hydraulic cylinder (drive, boom); hydraulic
motors (agitator, water pump); and planetary reduction boxes.

Introduction
1.4.3 Conditions of Warranty

For this warranty to apply, the product must be maintained as outlined in this manual. This warranty is issued
only to the initial user. This warranty is void if the machine is subjected to misuse, neglect, accident, or
abuse.
Putzmeister’s obligation under this warranty is limited to repair or replacement of any part(s) found to be
defective. All parts are to be returned freight prepaid to Putzmeister, Inc. or its authorized distributor. Final
warranty disposition will be based on result of the factory’s inspection. Repair or replacement of defective
parts FOB the initial users premises, shall constitute fulfillment of all warranty obligations by Putzmeister,
Inc. This warranty does not include labor or transportation charges nor shall it apply to a machine upon
which repairs or alterations have been made, unless authorized by Putzmeister, Inc.
This warranty does not apply to normal maintenance service or to normal replacement of certain machine
parts (such as belts, hoppers, tremies, etc.) which are subject to normal wear. Putzmeister makes no warranty
in respect to trucks, trade accessories, or outside purchased components, such being subject to the warranties
of their respective manufacturers.
THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTIES EXPRESSED OR IMPLIED,

INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. Putzmeister shall not be liable for any consequential loss, damage, or expense resulting from
the use of its products. No person, firm, or corporation is authorized to make warranty judgements on behalf
of Putzmeister, Inc.
1.5 Customer Support

1.5.1 On-Call Support
Putzmeister provides a 24/7 Emergency Customer Support Hotline at 1-800-890-0269. Trained
technicians are always available to resolve emergency situations, provide advice, or answer technical
inquiries.
1.6 Technical Service Training

Regularly scheduled service training seminars for customers and dealers include:
• Hands-on training
• Problem-solving exercises
• Exclusive working models
• Dynamic graphic presentations
• Safety training
For more information contact the toll-free Customer Support line at 1-800-890-0269.

Introduction
1.7 Additional Standard Features

Each new Telebelt comes complete with a transfer chute, aluminum diamond deck work platforms, large
side-mounted aluminum tool boxes, emergency stop button, and a high quality paint finish.
In addition, each machine comes with a ship-away kit; a package of tools and/or extras customized for each
model.
1.8 Optional Equipment

There are several Telebelt hopper options available for different material placement needs. Each hopper has
been designed and manufactured to handle the most harshest materials and concrete slumps:
• Rock hopper (Illustration 1-3)
• Front-end loader hopper (Illustration 1-4)
• California hopper (Illustration 1-5)
• Low profile hopper (Illustration 1-6)
TB1.8-1
Illustration 1-3: Rock Hopper

Introduction
TB1.8-2
Front View Side View
Illustration 1-4: Front-End Loader Hopper
TB1.8-3
Illustration 1-5: California Hopper

Introduction
TB1.8-4
Top View Side View
Illustration 1-6: Low Profile Hopper

Additional options and accessories available are:
• Side loading channels
• Boom lights
• Oil and water tank heater
• Additional oil cooler
• Tow package
• Custom paint schemes
Contact the Putzmeister Customer Support Group for additional options not listed.
1.9 Component Locations

1.9.1 Travel Position Diagram
The Telebelt component locations for travel mode are shown in Illustration 1-7 (Appearance and location
may vary depending on model – TB110 shown here for illustrative purposes):

Introduction
1 2
TB1.9.1c
3
TB1.9.1a
10 9 8 7 6 5 4
11
12
13
TB1.9.1b
14 15 16 17 18 19
Illustration 1-7: Travel Position

1. Feed conveyor
2. Conveyor: four-section telescopic boom
3. Boom rating plate
4. Water tank
5. Pressure washer system
6. Hydraulic system oil tank
7. Electric control box, air pressure regulator, and pusher axle pressure regulator
8. Modular Boom and outrigger control valves
9. Machine rating plate
10. Radio and/or cable remote control
11. Transfer swivel
12. Upper turntable
13. Outriggers (4)
14. Reducers (2)
15. Pusher axle
16. End hoses
17. Hydraulic jack set

Introduction
18. Hydraulic oil cooler, high pressure filter, and belt speed control valves
19. Truck cab controls
1.9.2 Operating Position Diagram

The Telebelt component locations in the operating position is shown in Illustration 1-8:
11
12
TB1.9.2
13
2
10
3
9
8
360° Continuous Rotation
7
4
5
6
Illustration 1-8: Operating Position

1. Right front and rear outriggers
2. Left front and rear outriggers
3. Feed conveyor
4. Pedestal, containing hydraulic oil tank and water tank
5. Transfer swivel and transfer chute
6. Conveyor telescopic boom
7. Base or truss section (Arm “A”)
8. Inner-mid section (Arm “B”)
9. Outer-mid section (Arm “C”)
10. Head section (Arm “D”)
11. Discharge boot
12. Reducer (tremie)
13. End hose (delivery trunk)

Introduction
1.10 Boom Rating Plate

The boom rating plate (located on the upper turntable on driver’s side) provides information on the
telescopic boom as shown in Illustration 1-9:
1
2
3
4
5
6
7
8 9
TB01.10
Illustration 1-9: Boom Rating Plate

1. Boom model
2. Boom serial number
3. PN or arm assembly – arm assembly part number
4. Year of manufacture
5. Horizontal reach max. – maximum horizontal reach of boom
6. Vertical reach max. – maximum vertical reach of boom
7. End hose length max. – maximum end hose length allowed
8. Max. hydr. pressure – maximum hydraulic fluid pressure in the hydraulic system
9. Maximum weight per feet of belt to be conveyed – maximum weight of material allowed to be
conveyed

Introduction
1.11 Overall Dimensions

Illustration 1-10 shows the overall machine and vehicle dimensions:
Total Height =
13.5 ft (4.11 m)
Wheelbase =
23.92 ft (7.3 m)
Overall Length =
40 ft (12.2 m)
TB1.11
Not shown: width = 8.ft (2.6m)
Illustration 1-10: TB110 Overall Dimensions

Introduction
1.12 U. S. / Metric Conversions
Metric Conversions
To Convert Into Multiply By

Linear Measurement Miles Kilometers 1.609
Yards Meters 0.9144
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Millimeters 25.4
Kilometers Miles 0.622
Meters Yards 1.094
Meters Feet 3.281
Centimeters Feet 0.033
Meters Inches 39.37
Centimeters Inches 0.394
Millimeters Inches 0.039
Area Square Inches Square Centimeters 6.452

Square Feet Square Meters 0.0929
Square Miles Square Kilometers 2.59
Acres Hectares 0.4047
Square Centimeters Square Inches 0.155
Square Meters Square Feet 10.763
Square Kilometer Square Miles 0.386
Hectares Acres 2.471
Volume Cubic Inches Cubic Centimeters 16.39

Cubic Feet Cubic Meters 0.02832
Cubic Yards Cubic Meters 0.7646
Cubic Centimeters Cubic Inches 0.061
Cubic Meters Cubic Feet 35.318
Cubic Meters Cubic Yards 1.308
Weight Ounces Grams 28.3495

Pounds Kilograms 0.4536
Tons (short) Metric Tons 0.9078
Grams Ounces 0.0352
Kilograms Pounds 2.205
Metric Tons Tons (short) 1.102
Pressure Pounds / Sq. Inch Kilopascals 6.895

Pounds / Sq. Inch Bars 0.069
Kilopascals Pounds / Sq. Inch 0.145
Bars Pounds / Sq. Inch 14.493
Work Inch-Pounds Kilogram-Centimeters 1.152144

Foot-Pounds Kilogram-Meters 0.1383
Foot-pounds Newton-Meters 1.356
Kilogram-Centimeters Inch-pounds 0.868
kilogram-Meters Foot-pounds 7.230
Newton-Meters Foot-pounds 0.7374
Continued on next page

Introduction
Metric Conversions (Continued)
To Convert Into Multiply By

Liquid Volume Quarts Liters 0.9463
Gallons Liters 3.785
Liters Quarts 1.057
Liters Gallons 0.2642
Liquid Flow Gallons / Minute Liters / Minute 3.785

Liters / Minute Gallons / Minute 0.2642
Temperature Farenheit Celsius 1. Subtract 32

2. Multiply by 5
3. Divide by 9
Celsius Farenheit 1. Multiply by 9

2. Divide by 5
3. Add 32

Introduction
This Page Intentionally Left Blank

2.0 Operation
2.1 Operating Tips
DANGER:HAZARDOUS CONDITIONS.
Whenever problems with machine arise or hazardous situations occur,
ALWAYS push the nearest Emergency Stop button on the machine to halt
operation immediately.
PUSH ANY ONE OF THREE EMERGENCY STOPS LOCATED ON THE MACHINE!
E-Stop Located on Operator’s Platform of Pedestal next to the Modular

Boom Control (MBC) Valve
E-Stop Located on Electric Control Box Cover
E-Stop Located on Cable or Radio Remote Control Unit
.1
4-2
62
00
A8
IMPORTANT:
To clear the E-stop, twist the E-stop button that was pushed until it pops out.
Next, turn the power switch ‘Off’ then back ‘On’. Then, clear E-stop mode by
pressing the reset/horn switch on electric control box or on the radio (cable)
remote control.
DANGER:PINCH POINT.
Do not stand in the working area between the conveyors when slewing either
the conveyor boom or feed conveyor or the potential for personal injury could
occur.
To ensure the safe and proper operation of the Telebelt, follow these tips:
• It is best to run belts only as fast as the job requires. For example, it is not recommended to run the
belts at 900 ft./minute (274.3 m/minute) to pour walls (unless high slump/wet concrete requires it).
The belts should be run fast enough for optimum production without causing rock bounce. Refer to
the belt speeds and capacities charts in Section 1 and working speeds in Section 6.
• Spray areas of machine which are subject to concrete splatter with an adhesion-resistant agent. This
will prevent concrete from sticking to the machine and make cleanup easier.
• Maintain hopper and transfer skirt lengths so they can contain material being placed without causing
the following restrictions:
• If skirt length is too long, capacity is decreased.
• If skirt length is too short, the skirt will leak.

Operation
• Ensure that scrapers are properly maintained. Rotate scraper blades that are rounded and not working
properly. Replace blades after all four edges are rounded.
• The operator should stay as close as possible to the hopper to control material supply and observe
machine operation.
• Ensure that adequate clearance is always maintained between the feed and conveyor boom.
• Use the Telebelt set-up label (shown in Ill. 2-1) affixed to the machine as a quick reference guide in
addition to reading all relevant instructions in this manual to assist in safely setting-up the machine:
OPERATING INSTRUCTIONS
TELEBELT ® TB 110 - Set-up
Preliminary Setup
1. Monitor all machine gauges to ensure that pressures, temperatures and fluid (i.e., fuel, oil and
water) levels are at recommended readings.
2. Inspect job site to determine safest access and setup areas.
3. Determine with job superintendent where best setup locations are, based on details of pour.
4. Position Telebelt truck in a safe, open area for setup. Keep in mind that machine may require
one or more moves during pour.
5. With truck engine running, transmission in neutral and parking brake on, engage boom /
outriggers / feeder power take-off (PTO) ONLY. Leave conveyor belt PTO disengaged.
Cable Remote Control System Setup
6. If using a cable remote control system, perform the following steps:
A. Verify that remote cable is attached to right side of electric control box.
B. At cable remote control, perform the following steps:
! Twist emergency stop (E-stop) button to allow it to pop out.
! Verify that all function switches are off.
C. Ensure electric control box and stack valve E-stops are released.
D. Clear E-stop mode.
Radio Remote Control System Setup
7. If using a radio remote control system, perform the following steps:
A. Verify that radio receiver is attached to right side of electric control box.
B. Ensure radio transmitter has charged battery inserted.
C. Release E-stop button by twisting button to pop it out.
D. Ensure control box and stack valve E-stops are released.
E. Turn radio transmitter power switch on.
F. Clear E-stop mode.
Outrigger Setup
8. With truck engine running, transmission in neutral and parking brake on, engage
boom/outriggers power take-off (PTO) ONLY. Leave conveyor belt PTO disengaged.
9. Remove outrigger safety chains.
10. Pull spring loaded locking pins with “D” rings and manually swing two rear outriggers until they
lock in their working position.
11. Repeat step 8 for two front outriggers.
12. Lower outrigger pads so that truck is level.
Conveyors Setup
13. Remove ratchet safety strap that secures the main and feed conveyors.
14. Fully raise feed conveyor out of its cradle.
15. On cable or radio remote control, place function selector switch in “main boom” position.
16. Fully raise transfer swivel.
17. On cable or radio remote control, place function selector switch to “outrigger/feeder” position.
18. Slew feed conveyor to desired position at side or rear of truck.
19. Lower feed conveyor until feed conveyor feet are firmly on ground and pressure is off from feed
conveyor elevate cylinder.
20. On cable or radio remote control, place function selector switch in “main boom” position.
21. Raise main conveyor out of boom rest.
22. Slew main conveyor next to a clear location.
23. Attach reducer (tremie) and end hose (delivery trunk) to end of main conveyor.
24, Raise feed conveyor hopper side panels and pin in place. Then istall feed conveyor front and
rear panels and pin in place. Pin side skirts to rear panel.
25. Inspect head scraper blades at discharge end of both conveyors. If scraping edge is worn,
rotate or replace blade. Head scraper condition and cleanliness are essential to clean
conveyor operation.
26. Make sure transfer skirts and boots are free of concrete buildup.
27. Every day before operation, grease the feed conveyor drive pulley bearings.
28. Engage conveyor belt power take-off (PTO).
29. Test run belts to check for proper belt tension (i.e., no slippage) and belt alignment (i.e., belt
running to center of the conveyor rollers).
30. Raise engine speed to full operating RPM using throttle switch on the remote control.
31. Adjust belt speeds to suit requirements of the pour.
32. Ensure that hopper skirts, transfer skirts, discharge boots and scrapers are adjusted to handle
the requirements of the pour.
A800815-2.1
Illustration 2-1: Telebelt set-up

Operation
2.1.1 Cold Weather Startup

To operate the Telebelt during cold weather, perform the following steps:
1. Ensure that the hydraulic oil cooler fan is turned off by switching the hydraulic oil cooler fan switch
(located on the electric control box; item 10 of Illustration 2-6) to the ‘off’ position.
2. Engage PTO’s and run hydraulic oil pumps for 15 minutes to circulate and warm hydraulic oil.
3. Start conveyor belts at a reduced speed and run for a few minutes while gradually increasing belt
speed. Monitor the filter gauges making sure they do not read in the red zone. Reduce conveyor speed
if gauges approach the red zone.
4. With belts running, test each function for proper operation.
5. When the hydraulic oil has reached 40° F (4.4° C), turn the hydraulic oil cooler fan switch to the ‘on’
position. The oil cooler fan is now set to come on ‘automatically’ when the temperature of the hydrau-
lic oil reaches approximately 131° F (55° C).
6. Proceed with normal machine operation.
2.2 Pre-Operational Checks

At the job site and before operating machine, perform the following final checks to ensure the safe operation
of machine:
CAUTION: EQUIPMENT DAMAGE.
Operating the Telebelt without air pressure on the hydraulic reservoir or
insufficient oil can cause damage to the hydraulic system.
1. Monitor the following machine gauges to ensure that pressures, temperatures, and fluid levels are at
the recommended readings:
• Air pressure is turned on to hydraulic oil tank.
• Hydraulic oil level and temperature. If oil temperature is below 40° F, perform “Cold Weather Star-
tup” procedure.
• Water tank level.
• Truck fuel level.
• Hydraulic filter gauges
• High pressure filter ‘pop-up’ indicators
• All vehicle gauges
2. Inspect area around machine and ensure that ground is capable of supporting machine. Look for clues
of possible ground defects such as:
• Recently moved or piled soil
• Leaking source of water
• Utility work (electric or water)
• Vent for underground tank

Operation
3. Determine job site strategy with job superintendent, based on the following information:
• Progression of pour (where pour is to start).
• Access (where machine is able to reach).
• Access for ready-mix trucks.
• Moves necessary to complete pour.
• Minimum slewing radius of the Telebelt conveyor.
• Machine dimensions and weight (refer to Specifications section)
NOTE:
As a rule, the site management determines the set-up site for the machine and
prepares the site accordingly. However, the machine operator is responsible for
setting up the machine safely. The site must be suitable for machine access and
set-up. The ground must be level enough for outriggers to be able to level the
machine. Inspect the proposed site carefully and reject the set-up site if there is any
doubts about the safety of the site.
4. Ensure that all personnel have the proper tools required for the job and are wearing the appropriate per-
sonal protective equipment.
5. Ensure that all personnel can communicate with each other by using the following hand signals or
other means of communication.
2.3 Hand Signals

CAUTION: SAFETY HAZARD.
Establish a set of hand signals such as the American Society of Mechanical
Engineers (ASME) recommended signals (shown in Illustration 2-2) with a
designated spotter whenever the visibility of the machine (front, sides, and
rear), telescopic boom, conveyors, or end hose is obstructed.
SAFETY INSTRUCTIONS
A800021 Rev. 1
Illustration 2-2: ASME Hand Signals (Per ASME B30.27)

Operation
Before beginning machine operation, the machine operator, end hose operator (if applicable), and spotter
should agree on the hand signals or other communication method to be used during the pour.
2.4 Hydraulic Control Valves, Oil Cooler, High Pressure Filter, Suc-
tion Filters, and Pumps
Illustration 2-3 shows the component locations of the hydraulic system:
14
3 5
1
6
15
7
7
8
9
10
11
12
13
13
TB2.4-1
Illustration 2-3: Hydraulic Control Valves, Oil Cooler, High Pressure Filter, Inlet Filters, and Pumps
1. Oil cooler – All hydraulic oil, except case drains and feeder belt circuit, flows through this cooler
before returning to the hydraulic tank. In extreme cold conditions, it may be necessary to cover the oil

Operation
cooler with a removable cover. The electric fan on the oil cooler is automatically controlled and can be
manually operated by using the on/off switch located on the electric control box.
2. Belt speed control valves.
3. Feed conveyor/outrigger 6-section control valve.
4. Modular boom control (MBC) valve.Modular boom control (MBC) valve.
5. Emergency stop – This is one of three E-stops located on the machine. The other E-stops are located on
the electric control box and on the radio (or cable) remote control units. To permit remote control sys-
tem operation, twist this button to allow it to pop up and then clear the E-stop mode using the E-stop
reset/horn switch on the electric control box, radio, or cable remote control. Push in this button to dis-
able the remote control system in emergency situations. Pressing this button will stop all machine
functions except the cooling fan and cause engine throttle to go to idle. If the machine does not shut
down, the machine must be disabled by truck engine shutdown or PTO disengagement.
NOTE: The E-stop will not reset unless the radio or cable remote controls are connected and switched ‘On’
and all three E-stop buttons are ‘Out.’
6. High pressure filter housing with “pop-up” indicator on its top – When the pop-up button appears,
push it back down. If it will not stay down at normal operating temperature (104° F / 40° C), replace
the filter element. The bypass for this filter goes to the hydraulic tank. Operating a machine with a fil-
ter in bypass will cause the boom and outrigger functions to slow down. This filter is in line between
the boom pump and the boom control valves.
7. Suction filters and gauges – When machine is turned off, these gauges should normally be in the Green
Area. However, if the truck’s air supply is low the gauge may also show in the red area. Always check
truck air pressure before changing filters. Under operating conditions, replace filters when the gauges
are in the Red Area (as shown in Illustration 2-4):
Green Area
Filter OK
Red Area
Replace Filter
TB2.4-2
Illustration 2-4: Suction Filter Gauges

8. Hydraulic pump for feed conveyor.
9. Hydraulic pump for main conveyor.

Operation
10. Hydraulic pump for pressure washer.

11. Hydraulic pump for boom and outriggers.
12. Road drive shaft.
13. PTO drive shafts.
14. Feeder lift pressure switch – This switch will disable main boom slewing when pressure is sensed in
the feeder elevate circuit.
15. Oil temperature sensor – Turns on oil cooler fan when the oil reaches 122° F (50° C) and shuts the con-
veyor down if oil temperature reaches 195° F (90° C).
2.5 Boom and Outrigger Control Valves

DANGER:TIPPING HAZARD.
Do not attempt to reposition any outrigger unless the main conveyor telescope
is fully retracted, lowered, and centered to the front or rear of the truck.
NOTE:
The boom/outriggers/feeder PTO must be engaged or the boom and outrigger valves
will not work. This PTO engages a piston-type pump that provides hydraulic fluid for
the outrigger, boom and feeder functions.
Normally, the electrical controls are used to position both conveyors and the
outriggers. In the event of an electrical failure, the main conveyor, feed conveyor, and
outrigger control valves can be operated manually to position the conveyors and
outriggers.

Operation
Illustration 2-5 below shows the boom and outrigger control valve functions:
E MODULE
ELEVATE TELESCOPE SWING SWIVEL SET UP OUTRIGGER OR BOOM TB2.5b
3 4 5 6 1
8
9
10 11 12 13
7
TB2.5c
A800812 TB2.5a
Illustration 2-5: Boom and Outrigger Control Valves

The boom and outrigger control valves are located at center of operator’s platform on pedestal.
1. Operating Mode Valve (OMV) – Push to engage boom functions or pull to engage outriggers.
2. Decal – Depicts Modular Boom Control (MBC) valve functions.
3. Elevate – While pushing the OMV valve, push lever up to lower conveyor boom or pull down to raise
conveyor boom.
4. Telescope – While pushing the OMV valve, push lever up to extend conveyor mid and head sections or
pull down to retract conveyor sections.
5. Swing – While pushing the OMV valve, push lever up to swing conveyor boom clockwise or pull
down to swing conveyor boom counter-clockwise.
6. Feed conveyor swivel set-up – While pushing the OMV valve, push lever up to raise feed conveyor
turret or pull down to lower feed conveyor turret.
7. Feed conveyor and outrigger 6-section valve decal.
8. Feed conveyor slewing – While pulling the OMV valve, push lever up to slew feed conveyor clock-
wise or pull down to slew feed conveyor counter-clockwise.

Operation
9. Feed conveyor elevate – While pulling the OMV valve, push lever up to lower feed conveyor or pull
down to raise feed conveyor.
10. Outrigger left front (LF) – While pulling the OMV valve, push lever up to raise LF outrigger or pull
down to lower LF outrigger.
11. Outrigger right front (RF) – While pulling the OMV valve, push lever up to raise RF outrigger or pull
down to lower RF outrigger.
12. Outrigger left rear (LR) – While pulling the OMV valve, push lever up to raise LR outrigger or pull
down to lower LR outrigger.
13. Outrigger right rear (RR) – While pulling the OMV valve, push lever up to raise RR outrigger or pull
down to lower RR outrigger.
2.6 Electric Control Box

Whenever boom functions, conveyors, or accessories are operated, 3/4 to full
engine RPM should be used. Engine speed should not be used to “feather”
operating functions. Operating at low engine speeds can cause lack of
lubrication and overheating; resulting in damage to hydraulic components and
PTO drives. DO NOT use foot throttle to exceed maximum PTO throttle settings.
NOTE:
Maximum PTO RPM settings vary according to truck and transmission options.
Engine speed can be adjusted using any of the following throttle controls:
• Cruise control in truck cab.

• Throttle control switch on the electric control box
• Throttle control switch on the cable or radio remote control
When the cable remote control or radio remote control transmitter is not in use, it
should be stored in a dry location such as the truck cab. Use the cable reel to store
the cable in the electric control box compartment.

Operation
Illustration 2-6 shows the electric control box as viewed from the front, left and right sides:
13 12 14 15 1 2 3 4 7 18
5 6
TB2.6
16 17 7 8 9 10 11
Left Side Front Side Right Side
Illustration 2-6: Electric Control Box (“Combi” Box)

1. Panel power indicator (green) – When illuminated, power is on to control box. Power will remain on
only if truck parking brake is set and the boom/outrigger/PTO is engaged.
2. Emergency stop (E-stop) indicator (red) – When illuminated, control box is in E-stop mode.
3. Hydraulic oil over-temperature indicator (red) – Illuminates when hydraulic oil temperature reaches
195° F (90° C).
4. Hour meter – Indicates the time that the main conveyor belt has been on.
5. Throttle switch – Move up to increase or down to decrease engine throttle speed. Engine speed is
maintained when this toggle switch is released.
6. Oil cooler fan on indicator (green) – Illuminates when oil cooler relay is ‘On.’
7. Control box key and keyhole – Insert key (stored on right side of panel) in keyhole and turn to open or
lock hinged cover.
8. Emergency stop (E-stop) – This is one of three E-stops located on the machine. The other E-stops are
located next to the modular boom control (MBC) valve (at rear of pedestal), and on the radio (or cable)
remote control unit. To permit remote control system operation, twist this button to allow it to pop up
and then clear the E-stop mode using the E-stop reset/horn switch (item 9). Push in this button to dis-
able the remote control system in emergency situations. Pressing E-stop button will stop all machine
functions except cooling fans and cause the engine throttle to go to idle. If the machine does not shut
down the machine must be disabled by truck engine shutdown or PTO disengagement.

Operation
9. E-stop reset/horn switch – Push to clear the E-stop mode and/or blow the horn. The first press clears
the E-stop. The second press and subsequent presses blow the horn.
10. Manual hydraulic oil cooler fan switch – Turn on to manually activate hydraulic oil cooler fan.
11. Hydraulic oil temperature gauge – Receives signal from thermo-probes at bottom of hydraulic oil
cooler.
12. Work light switch #1 – Turns the work light that is connected to work light receptacle #1 on or off.
13. Work light receptacle #1 – This is where the work light that is attached to the conveyor support plugs
in.
14. Work light switch #2 – Turns a work light that is connected to work light receptacle #2 on or off.
15. Work light receptacle #2 – An accessory light can be plugged in here. Boom lights are connected here
if so equipped at the factory.
16. X2 connector – For specific wire colors, size, etc., refer to the Electric Control Box Schematic Dia-
gram.
17. X88 connector – For specific wire colors, size, etc., refer to the Electric Control Box Schematic Dia-
gram.
18. X81 connector – The radio receiver or cable remote plugs in here. For specific wire colors, size, etc.,
refer to the Electric Control Box Schematic Diagram.
2.7 Radio Remote Control

Illustration 2-7 shows the components for the radio remote control transmitter:
4
1 5
3
6
On HF Si1 Si2
7 TB2.7
Illustration 2-7: Radio Remote Control

1. Electric control box.
2. Radio receiver cable.
3. Radio receiver with antenna.

Operation
4. Radio frequency (RF) link.

5. Radio remote control transmitter.
6. Battery charger (located in truck cab on center console).
7. Radio receiver status panel:
• On (yellow): Illuminates when operating voltage is present at receiver.
• HF (red): Illuminates whenever the transmitter is switched off.
• Si1(green): Illuminates when radio remote control transmitter is switched on.
• Si2 (green): Illuminates when a movement command (e.g., boom joystick movement) is understood
by the receiver, otherwise it is off.
2.8 Radio Remote Control Transmitter

Illustration 2-8 shows the functions for each switch and button on the radio remote control transmitter:
Horn + E=stop Boom + Swivel Feeder

Reset Outriggers
Boom Speed Boom Slow Boom Speed

Program 100%
Water Pump Engine Stop Feeder Up

On
Feeder Down Boom Elevate Boom Elevate

Up Down
Throttle Up Throttle Down Conveyors 1&2

Radio Remote
Conveyor 1 On Conveyor 2 On
Control Icon
Volume/Speed Volume/Speed
Swivel Up Legend
Conveyor 1 Conveyor 2 Swivel Down
Feeder Swing Feeder Swing
Left Right Telescope In
Boom Swing Boom Swing

Telescope Out
Left Right
TB2.8b
12 13
11 1
2
10 3
9 8 7 6 5 4
TB2.8a
Illustration 2-8: Radio Remote Control Transmitter and Icons

Operation
1. Power switch – Turns radio remote transmitter on or off. The radio remote transmitter is powered by a
battery that inserts in the pocket on the bottom of the transmitter. Nickel Cadmium (NiCd) batteries
should be used (fully discharge before charging to prevent building a memory effect). To conserve bat-
tery power, ensure this switch is off when radio remote is not in use. After turning this switch on,
Function Selector Switch (item 11) must be activated to reset the system.
2. Engine stop and pressure washer switch – Lift and push up to turn on pressure washer or down to
remotely stop engine.
3. Boom control joystick – Move to the “out” or “in” position to telescope conveyor mid and head sec-
tions out or in. Move to the “left” or “right” position to swing the conveyor boom or feed conveyor to
the left or right. Move to the “up” or “down” to raise or lower the conveyor boom or feed conveyor.
Move back to center position to stop moving the conveyors. The farther the joystick is moved in any
position, the faster the function will operate. The function selector switch (item 11) allows you to
select either the feed conveyor or main conveyor boom operation. There is a pressure switch that pre-
vents the conveyor boom from being slewed left or right unless there is no pressure on the feed con-
veyor elevate cylinder (feed conveyor is set-up with its feet on the ground).
4. Rabbit/snail/program switch – Place in middle “snail” position to have all boom functions operate at
a slower programmed speed or in “rabbit” position to have all boom functions operate at normal speed.
To program the “snail” speed, temporarily hold this switch in the upper “snail” position, place desired
joystick to its “maximum desired” position (between 0% and 100% speed), and then release the
switch.
5. Transmit indicator light (green) – Blinks green to indicate that power is on and it is transmitting a
signal to the radio receiver.
6. Low battery indicator light (red) – Blinks red when battery is low.
8. Feed conveyor belt speed potentiometer – Turn clockwise (CW) to increase or counter-clockwise
(CCW) to decrease feed conveyor belt speed. The conveyor switch (item 9) must be in (I+II) position
for feed conveyor belt to operate.
9. Conveyor switch – Lift switch and push up to 1st position (I) to turn main conveyor belt on. Lift
switch and push up to 2nd position (I+II) to turn feed conveyor belt on. The conveyor belt speed poten-
tiometers (items 8 and 10) must be greater than zero (off) for the conveyor belts to operate. If the con-
veyors switch is left on during E-stop activation, a 194° F (90° C) hydraulic oil over-temperature
condition or remote engine stop, this switch must be turned off and then back on (after E-stop has been
reset) to reactivate conveyor belts.
10. Main conveyor belt speed potentiometer – Push in and turn (CW) to increase or (CCW) to decrease
conveyor belt speed. The conveyor switch (item 9) must be in either (I) or (I+II) position for the con-
veyor belt to run.
11. Function selector switch – Push up to reset Emergency stop (E-stop) or blow horn. Once E-stop is
reset, pushing up will blow horn. This switch will not reset E-stop unless the pressure washer switch is
off and all joysticks are in their neutral position. Leave switch in the middle position to operate con-

Operation
veyor boom and swivel. Lift switch and pull down to activate outriggers or feed conveyor boom. The
conveyor boom and swivel will not operate when outriggers or feed conveyor boom are activated.
12. Feed conveyor swivel set-up switch – Lift and push up to lower or down to elevate the feed conveyor
turret. Please note that the swivel will not operate if the conveyor switch is ‘On.’
13. Emergency stop – This is one of three E-stops located on the machine. One E-stop is located next to
the modular boom control (MBC) valve (operator’s platform on pedestal) and another one is located
on the electric control box cover. To permit remote control system operation, ALL THREE E-stops
must be out. To release E-stop, twist the button to allow it to pop up and then clear the E-stop mode by
using the horn/outrigger/reset switch (item 11). Push in this button to disable the remote control system
in emergency situations. Pushing in ANY E-stop button will stop all machine functions except the
hydraulic oil cooling fan and cause the engine throttle to go to idle. If the machine does not shut down,
the machine must be disabled by truck engine shutdown or PTO disengagement.
Note: The E-stop will not reset unless the radio or cable remote controls are connected and switched ‘On’
2.9 Cable Remote Control

Illustration 2-9 shows the components of the cable remote control:
1 2 3
TB2.9-1
1. Electric Control Box
2. Cable Harness and Connectors
3. Cable Remote Control
Illustration 2-9: Cable Remote Control

Operation
Illustration 2-10 shows the functions for each switch and button on the cable remote control:
Horn + E=stop Boom + Swivel Feeder

Reset Outriggers
Boom Slow Boom Slow Boom Speed

Adjust 100%
Water Pump Engine Stop Feeder Elevate

On Up
Feeder Elevate Boom Elevate

Up
Boom Elevate
Down
Cable Remote
Down
Control Icon
Conveyors 1&2
Throttle Up Throttle Down
Legend
Conveyor 1 On Conveyor 2 On
Swivel Up
Volume/Speed Volume/Speed
Conveyor 1 Conveyor 2 Swivel Down
Feeder Swing Feeder Swing
Left Right Telescope In
Boom Swing Boom Swing

Telescope Out
Left Right
TB2.9-2b
12 1
2
11
10
3
4
8 7 6 5
9 TB2.9-2a
Illustration 2-10: Cable Remote Control and Icons

1. Emergency stop (E-stop) – This is one of three E-stops located on the machine. The other E-stops are
located next to the modular boom control (MBC) valve (operator’s platform on pedestal) and on the
electric control box cover. To permit remote control system operation, ALL THREE E-stop buttons
must be out. Twist the button to allow it to pop up and then clear the E-stop mode using the horn/out-
rigger/reset switch (item 11). Push in this button to disable the remote control system in the event of an
emergency. Pushing in ANY E-stop button will stop all machine functions except the hydraulic oil
cooler fan and cause the engine throttle to go to idle. If the machine does not shut down, the machine
must be disabled by either truck engine shutdown or PTO disengagement.

Operation
2. Boom speed potentiometer – Sets the boom speed when the boom speed toggle switch (item 3) is in
the “snail” position.
3. Boom speed toggle switch – Move to “snail” position to have all boom functions operate between 0%
and 100% speed using boom speed potentiometer (item 2), or move to “rabbit” position to have all
boom functions operate at 100% speed.
NOTE: All boom functions are non-proportionate when operating at 100% speed (rabbit) position.
4. Telescope out/in or swing (slew) left/right joystick– To extend and retract the conveyor mid and
head sections, place the selector switch (item 11) in the ‘upper’ position. Move the joystick to the ‘out’
or ‘in’ position to move the mid and head sections out or in. Move the joystick to the ‘left’ or ‘right’
position to swing the conveyor boom to the right or left. To swing the feed conveyor, place the selector
switch (item 11) in the ‘lower’ position. Move the joystick to the left or right to swing the feed con-
veyor to the left or right. There is a pressure switch that prevents the conveyor boom from being
slewed left or right unless there is no pressure on the feed conveyor elevate cylinder.
5. Engine stop and pressure washer switch – Push up to turn on pressure washer or down to remotely
stop engine.
6. Elevate up/down joystick – Place the selector switch (item 11) in the ‘upper’ position to operate the
conveyor boom or in the ‘lower’ position to operate the feed conveyor. Then, move the joystick to the
‘up’ or ‘down’ position to raise or lower the conveyor boom or feed conveyor.
8. Feed conveyor belt speed potentiometer – Turn clockwise (CW) to increase or counter-clockwise
(CCW) to decrease feed conveyor belt speed. The conveyor switch (item 9) must be in the (I+II) posi-
tion for the feed conveyor belt to run.
9. Conveyor switch – Lift switch and push up to 1st position (I) to turn conveyor belt on. Lift switch and
push up to 2nd position (I+II) to turn both conveyor and feeder belt on. The conveyor belt speed poten-
tiometers (items 8 and 10) must be greater than zero (off) for the conveyor belts to operate. If the con-
veyor switch is left on during E-stop activation, a 194° F (90° C) hydraulic oil over-temperature
condition or remote engine stop, this switch will have to be turned off and then back on (after E-stop
has been reset) to reactivate the conveyor belts.
10. Conveyor belt speed potentiometer – Push in and turn (CW) to increase or (CCW) to decrease con-
veyor belt speed. The conveyor switch (item 9) must be in the (I) or the (I+II) position for the conveyor
belt to run.
11. Function selector switch – Push up to reset Emergency stop (E-stop) or blow horn. Once E-stop is
reset, pushing up will blow horn. This switch will not reset E-stop unless the pressure washer switch is
off and all joysticks are in their neutral position. Leave switch in middle position to operate conveyor
boom and swivel. Lift switch and pull down to activate outriggers and feed conveyor boom. Conveyor
boom and swivel will not operate when outriggers are activated.
12. Feed conveyor swivel set-up switch – Push up to lower or down to elevate the feed conveyor turret.
This function will not work if conveyor switch is on or if function selector switch (item 11) is in feeder
position.

Operation
2.10 Radio Battery Charging

Observe the following radio battery charging cautions:
• Do not charge a hot battery. Attempting to charge a hot battery may damage it, allow battery
to cool before charging.
• Keep battery contacts clean.
• Periodically lubricate contact spring posts in the battery charger (and radio transmitter) with
a non-conductive contact cleaner to ensure that they move freely.
• Remove battery from charger after its charging cycle is complete.
• Only use batteries that are approved for the application and electrical requirements.
• Do not attempt to use special Tele-Teach battery to program the “Snail” settings
TB2.10
Illustration 2-11: Radio Remote Control Battery Charger

1. Single-battery charger – Located on center console in truck cab next to driver’s seat.
2. Nickel Cadmium (NiCd) battery – NiCd batteries are charged by placing them in the receptacle of the
charger assembly with battery label up. Charging begins automatically.
• Length of battery charge is approximately 3 hours at 100% duty cycle. Times vary depending on age
of battery and ambient temperature. Older batteries lose capacity over time. Temperatures under 32°
F (0° C) have a negative effect on battery charge.
• Battery can exceed 500 charging cycles if handled properly.
• Recharge battery only when it is empty (red LED on radio transmitter blinks).
• Always store the battery at room temperature (if possible).

Operation
• Never store battery in a tool box or in pants pockets.

• Protect battery contacts from short circuits. Always use the protective cap provided.
• Recharge batteries that have not been in use for a period of time.
3. Discharge button – used to fully discharge the battery before charging to minimize the “Memory
Effect”.
4. The four LED indicators on the charger indicate one of the following conditions:
1. Battery is defective (red LED).
2. Battery is charging (yellow LED).
3. Battery is charged (green LED).
4. Battery is discharging (yellow LED).
2.11 Emergency Cab Lift System

DO NOT SLEW MAIN CONVEYOR TO THE LEFT OR RIGHT. This could result in
an unstable tipping condition which will cause death, personal injury, and
damage to machinery.

The truck cab cannot be tilted to access the truck engine with the feed and main
conveyor booms in the stowed position. The emergency cab-lift system can be
used to raise the feed and main conveyor booms for a MAXIMUM OF 10
MINUTES at a time so that the truck cab can be tilted to access the truck engine.
Damage to this electric motor may occur, if it is run for more than 10 minutes
at a time or not allowed to cool down to ambient temperatures after each use.
If the truck engine cannot be started, the emergency cab-lift system can be used to lift the feed and main
conveyor booms so that the truck cab can be tilted to access the truck engine. Perform the following steps:

Operation
2
1
3
4
1. Control Box: On/Off Switch TB2.11-1a
2. Emergency Cab-Lift Pump and Electric Motor

3. Battery Cable (Located in battery box on passenger’s side,
Mack)
4. Hand Pump (Located behind passenger door next to muffler,
Mack)
Illustration 2-12: Emergency Cab-Lift System

To use the emergency cab-lift system, refer to Illustrations 2-12 & 2-13 and perform the following steps:
1. Connect the cable clamp (item 3, Ill. 2-12) to the positive (+) terminal on the truck battery.
2. Flip the switch on the control box located next to the high pressure oil filter (item 1, Ill. 2-12) to the
“On” position.
3. The green indicator will illuminate.

Operation
TB2.11-2
Illustration 2-13: Modular Boom Controls

Refer to Illustration 2-13 when performing the following steps:
4. Pull back and hold the selector lever (item 4, Illustration 2-13).
5. While holding the selector lever back, push down on the feed conveyor elevate lever (item 1, Ill. 2-13).
6. Next, push the feed conveyor swivel set-up lever (item 3, Ill. 2-13) up to fully raise feed conveyor tur-
ret.
7. Push and hold the selector lever (item 4, Ill. 2-13) forward.
8. While holding the selector lever in the forward position, pull down the boom elevator lever (item 2, Ill.
2-13) to raise the boom high enough so the truck cab can be raised.
9. Turn switch on control box to the “Off” position.
10. Disconnect the cable clamp (item 3, Ill. 2-12) from the positive (+) terminal on the truck battery.
11. When servicing of truck engine is done, lower the cab.
12. Start the engine and use normal control functions to lower boom and feeder to the stored position.

Operation
2.12 Power Take-Off (PTO) Switches

2.12.1 PTO Precautions
WARNING:PERSONAL INJURY HAZARD.
Power Take-Off (PTO) units are powered by engine or drivetrain components
(flywheel, crankshaft, or transmission). Do not service the PTO and related
components unless the engine is shut down and a lockout, tag out procedure
is being used.
Always keep body parts and loose-fitting clothing away from PTO and
drivetrain components, or personal injury may result.
Always be aware of PTO status (engaged or disengaged – red LED light on or
off). Ensure to disengage the PTO when not in use.
NOTE:
PTO’s will not engage if the parking brake is not applied. PTO’s will only operate with
truck transmission in neutral.
2.12.2 PTO Switch – Manual Transmission

Some Telebelt models equipped with manual transmissions have two PTO switches located on the rear panel
of the center console next to the driver’s seat in the truck cab as shown in Illustration 2-14. Illustration 2-15
shows the PTO switch and “Operating Instructions” label that can be found in other Telebelt models
equipped with manual transmissions:

Operation
TB2.12.2-1d APPLY
PULL TO
G
U
IN
N L
1 INTER
6
K
E
RELEASE
L O
AK
R
O C
AXLE
PA
BR
C K
K
PUSH TO
1 2 O
F
P.T.O. O
N
F
5
2
6
5 3 O
3 F
P.T.O. O
N
F
4
! CAUTION TB2.12.2-1a
TB2.12.2-1d
Avoid equipment damage.
Before turning on PTO, stop 4
PTO Switches Panel on Center Console
vehicle and
push in clutch pedal.
TB2.12.2-1b
Illustration 2-14: PTO Switches for Telebelts with Manual Transmissions (Mack Chassis)
1. Inter-axle lockout switch – This switch locks or unlocks the inter-axle lockout. A red LED lamp illu-
minates when the switch is in the “Locked” (engaged/on) position. Refer to “Inter-Axle Lock Switch”
in Section 3. Refer also to ‘Truck Owners Manual.’
2. Boom/outrigger/feeder PTO switch – Located on switch panel, this switch engages a piston pump and
a gear pump. The piston pump provides hydraulic power for the outrigger, boom, and feed conveyor
functions. The gear pump provides hydraulic power for the pressure washing system. A red LED lamp
illuminates when this PTO switch in the “On” (engaged) position.
3. Conveyor belt PTO switch – Located on switch panel, this switch engages the two hydraulic pumps
that power the conveyor and feed conveyor belt hydraulic motors. A red LED lamp illuminates when
this PTO switch is in the “On” (engaged) position.
4. Hazard label for PTO switches (located near PTO switches) – Stop vehicle and/or push-in the clutch
pedal before turning on PTO’s.
5. Pilot light (green) – This light illuminates whenever a PTO switch is turned on to show that power is
being supplied to the electric control box.

Operation
6. Parking brake – This switch applies or releases the parking brake. Pulling the switch out engages the
parking brake. Pushing the switch in releases the parking brake. The parking brake must be engaged
before PTO’s will work.
1. To operate PTO’s (with manual transmissions), perform the following steps:
2. Start engine (if not running).
3. Push in clutch (shift gear lever of transmission into neutral if not already done so).
4. Release clutch pedal.
5. Pull out parking brake switch to engage parking brake.
6. Push in clutch pedal.
7. Turn PTO switches to the “On” position (red LED lamps illuminate).
8. Release clutch pedal.
9. PTO’s are ready for operation of conveyor belt, boom, outrigger, or swivel functions.
PUMP
SHIFTING PTO WITH MANUAL TRANSMISSION
“DRIVE TO PUMP”: - Position Unit on Job Site
- Set Parking Brake “ON”
- Shift Transmission to “Neutral”
-“Pump-Drive” Switch to “Pump”
(Green Pump Light On)
- Depress Clutch
- Shift Transmission to “Operating Gear”
- Release Clutch Slowly
“PUMP TO DRIVE”: - Depress Clutch
DRIVE TB2.12.2-2a
- Shift Transmission to “Neutral”
- Release Clutch
PTO Switch & Operating Instructions for - “Pump-Drive” Switch to “Drive”
- Release Parking Brake
Telebelts with Manual Transmissions TB2.12.2-2b A800252
Illustration 2-15: PTO Switch for Telebelts with Manual Transmissions (Other than Mack)

Operation
2.12.3 PTO Switch – Automatic Transmissions

Illustration 2-16 shows the PTO switch and “Operating Instructions” label used for Telebelts equipped with
automatic transmissions:
PUMP OPERATING INSTRUCTIONS

SHIFTING PTO WITH AUTOMATIC TRANSMISSION
“DRIVE TO PUMP”: - Position Unit on Job Site
- Set Parking Brake “ON”
- Shift Selector to “N” (Neutral)
- “Pump-Drive” Switch to “Pump”
(Green Pump Light On)
- Shift Selector to “D” (Display Indicates “4”)
CAUTION: If engine is switched off or transmission shifted to

Neutral, repeat “DRIVE TO PUMP” procedure to reset
interlocks for 4th Gear Lock-up PTO operation.
DRIVE TB2.12.3-1b “PUMP TO DRIVE”: - Shift Selector to “N” (Neutral)

- “Pump-Drive” Switch to “Drive”
PTO Switch & Operating Instructions label for - Shift Selector to “D” (Display Indicates “1”)
TB2.12.3-1a A800251
Telebelts with Automatic Transmissions
Illustration 2-16: PTO Switch for Telebelts with Automatic Transmissions (Other than Mack)
To operate PTO’s (with automatic transmissions), perform the following steps:
1. Start engine (if not running)
2. Set parking brake to “On”
3. Press gear selector switch (shown in Illustration 2-17) to “N” (Neutral)
2
PUMP 1 2 3
R
N
DRIVE
D
3
MP
PU
R
E
IV
DR
N
TB2.12.3-2a
Sterling Acterra, L-Line Cab

1. Gear Selector D
2. PTO Switch
TB2.12.3-2c
Sterling Condor Cab

3. Parking Brake TB2.12.3-2b
Illustration 2-17: Gear Selector for Telebelts with Automatic Transmissions (Sterling Chassis)
4. Place PTO switch to “Pump” position or “Drive to Pump” (green pump light illuminates)

Operation
5. Press gear selector “D” then “Up” arrow until display indicates “4”
If engine is switched off or transmission is shifted to Neutral, repeat “Drive to
Pump” procedure to reset interlocks for 4th gear lock-up PTO operation.
6. Proceed to “Pump to Drive” (disengaging PTO)

7. Place PTO switch to “Drive” position
8. Press gear selector “D” then “Down” arrow until display indicates “1.”
2.13 Outriggers
Never attempt to reposition any outrigger leg unless the main conveyor is fully
retracted, lowered, and centered to the front or rear of the vehicle

Each outrigger leg can be raised or lowered by using its built-in outrigger up/
down switch or the appropriate outrigger stack valve. Use caution when raising
or lowering outriggers over fenders. Outriggers move quickly and can crush
fenders. Ensure that outrigger switches are kept clean, sand and debris in the
switch can cause it to stick. Ensure that outrigger drain holes (Illustration 2-18)
are kept free of debris.
NOTE:
When the radio (or cable) remote outrigger switch is activated, the outrigger up/down
control switches become active. When the radio/cable remote outrigger switch is
deactivated, the outrigger up/down control switches are locked out to prevent
accidental raising or lowering of the outriggers.

Operation
2.13.1 Outrigger Control Switch

Each of the four outrigger legs has a built-in control switch as shown in Illustration 2-18:
1
UP
DOWN
2
Drain Hole
Illustration 2-18: Built-In Control Switch on Each Outrigger Leg

1. Outrigger up/down control switch – Push the “up” button, on top, to raise outrigger or “down” button,
on bottom, to lower outrigger. These outrigger controls operate the same regardless of whether a radio
or cable remote control unit is used.
2. Swing-out handle – Use handle to swing outrigger leg to working position.
2.13.2 Outrigger Set-Up

DANGER:CRUSHING HAZARD.
There is a danger of crushing in the swing-out and extension zone for the
outriggers. Ensure that this area is secure and observe at all times. Press the
EMERGENCY STOP button if anyone enters this danger zone.
DANGER
Keep clear
of moving
outriggers.
TB2.13.2-1
Illustration 2-19: Keep Clear of Outrigger Danger Zone

Operation
Observe ground conditions (especially tripping hazards) before swinging outriggers.

Always use the handle and keep to the outside when swinging the outrigger leg. Watch for and ensure that
body parts and other objects are not underneath outrigger pad when lowering the outrigger leg.
Make sure to maintain a safe distance from pits, slopes, trenches, etc., when setting up. Check the condition
of the soil or flooring where the machine will be positioned. As shown in Illustration 2-20, the force
transferred into the ground by each outrigger is distributed through the ground in a conical pattern at a 45°
angle. This imaginary cone must not exit through the wall of the pit. Make sure to maintain a safe distance
from any pits (at least “a”), as shown in Illustration 2-20:
A. If the ground has good load-bearing capacity, maintain a minimum clearance of “(a)” from a pit of:
• (a1) = 6.6 ft. (2m) if pit is 0 to 6.6 ft. (0 to 2 m) deep
• (a2) = 1 x T if pit is > 6.6 feet (2m) deep
(a) = 6.6 ft (2 m)
(a)
Good Load-bearing Soil

45°
TB2.13.2-2
Illustration 2-20: Minimum Clearance “(a)” from a Pit 0 to 6.6 feet (0 to 2 meters) Deep
B. If the ground does not have good load-bearing capacity, maintain an additional safety clearance
“A” from a pit. Such that (as a minimum):
• (A1) = 13.2 ft. (4m) if pit is 0 to 6.6 ft. (2m) deep
• (A2) = 2 x T if pit is > 6.6 ft. (2m) deep
Illustration 2-21 below is an example of the required additional safety clearance from a pit:
A=2xT
T
TB2.13.2-3
Illustration 2-21: Additional Safety Clearance “A” from a Pit

Operation
2.13.2.1 Standard Outrigger Set-Up

It is recommended to set up the Telebelt with all four outriggers fully extended and locked in the operating
position. When placing the machine, ensure that there is adequate clearance to fully extend the outrigger
legs (as shown in Illustration 2-22).
TB2.13.2-4
Illustration 2-22: Outrigger Legs Must Always Be Fully Swung Out and Locked
2.13.2.2 Special Outrigger Set-Up

In special cases, obstructions may create a situation where it is not possible to extend all four outriggers to
their ‘standard’ locked operating position. In these special situations extreme care must be taken to avoid
an unsafe condition. There are three acceptable ‘Special Outrigger Set-Up’ configurations that can be used
in restricted areas. Please refer to section 5.4 for an explanation of the three Special Outrigger Configura-
tions and range diagrams.
NOTE:
In all Special Outrigger Configurations, the outriggers must be locked in position. If these
scenarios still do not allow set-up or if the outriggers cannot be locked in position, it is
unsafe to operate and other means of moving the material should be used.

Operation
2.13.3 Outrigger Pads (Blocking)

Do not bridge voids or other ground irregularities with support blocks or timber
blocks, since these blocks may break if a point load is applied to them. If these
blocks break, the machine will not have the necessary stability and may tip
over.
As shown in Illustration 2-23, check for voids or other ground irregularities under the outrigger pads:
TB2.13.3-1
Illustration 2-23: No Voids or Other Ground Irregularities Under the Outrigger Pad
Ensure that the outrigger pads are set-up on level supporting ground (as shown in (A) of Illustration 2-24):
(A)
TB2.13.3-2
Illustration 2-24: Outrigger Pads Should Be Set-up on Level Supporting Ground

Operation
Verify that the machine is supported sufficiently by comparing the corner bearing loads and the load-bear-
ing capacity of the supporting ground (permissible ground pressure) by performing the following steps:
A. Ask site management (or determine) the maximum permissible ground pressure (load-bearing ca-
pacity of the supporting ground).
B. Calculate the maximum possible ground pressure that each outrigger leg can exert using the follow-
ing equation:
Maximum possible ground pressure = Machine corner bearing load ÷ Support area
Ground Ground
Pressure Pressure
30,398 lbs 34,311 lbs
135.0 kN 153.0 kN
TB2.13.3-3a TB2.13.3-3b
Illustration 2-25: Example of Outrigger Leg Front and Outrigger Leg Rear Decal
NOTE: The Corner Bearing Load is stated on each outrigger leg. Please refer to the decal
affixed to each leg for the loads specific to your machine.
C. Compare A. and B. – If the possible ground pressure is less than the maximum permissible ground
pressure, support is adequate for the job. However, if the maximum possible ground pressure is
greater than the maximum permissible ground pressure, then it is necessary to increase the support
area under the outrigger pads, this is typically done with timber blocks or other structurally sound
support materials.
TB2.13.3-4
Illustration 2-26: Telebelt Outrigger Pads are 27.2 in. x 19.5 in. (690 mm x 495 mm) in Size

Operation
Make sure to always use at least 4 timber blocks with a cross-section of 6 in. x
6 in. (15 cm x 15 cm) each and lengths shown in the examples below. Place the
4 timber blocks together and level beneath the outrigger pad as shown in
Illustration 2-27. The outrigger pad and the timber blocks must always be free
from grease, oil, ice, etc., to avoid the support leg from slipping off and causing
machine to tip. During the course of a material placement, check to ensure that
the outriggers are not sinking into the ground.
TB2.13.3-5
Illustration 2-27: Length of the Timber Blocks Required

Illustration 2-28 shows examples of the front and rear outrigger leg decals affixed to the machine regarding
the leg load limits, safety clearances, and the minimum length of the timber blocks required for blocking
the outrigger pads safely:

Operation
6"
30,398 lbs
Leg 6"
34,311 lbs
Load
6"
Limits 6"
135.0 kN 153.0 kN
Permissible Ground Lb/in? L = Timber Block Length with Cross Permissible Ground Lb/in? L = Timber Block Length with Cross
Pressure (kN/m?) Section of 6" X 6" (15cm X 15cm) Pressure (kN/m?) Section of 6" X 6" (15cm X 15cm)
Undisturbed Soil 14.5 87" Permissible Undisturbed Soil 14.5 Supporting Ground is Not
(100) (225cm) (100)
Ground Suitable for Outriggers
Asphalt 29 44" Asphalt 29
(min 8" thick) (200) (113cm) Pressures (min 8" thick) (200)
49"
(127cm)
Hardcore
(Compacted)
36.3
(250)
35" and Hardcore 36.3 39"
(90cm) (Compacted) (250) (102cm)
Clay, Coarse 43.5 29"
Length of
Clay, Coarse 43.5 33"
Clay (Firm) (300) (75cm) Timber Blocks Clay (Firm) (300) (85cm)
Mixed Stone (Firm) 50.8
(350)
25" Required Mixed Stone (Firm) 50.8
(350)
28"
(64cm) (73cm)
Layered Gravel 58 Layered Gravel 58 25"
(Firm) (400) No Timber Required
(Firm) (400) (64cm)
72.5 72.5
(500) No Timber Required No Timber Required
(500)
109 109
(750) No Timber Required No Timber Required
(750)
Rock (fractured, 145 Rock (fractured, 145
weathered) (1000) No Timber Required weathered) (1000) No Timber Required
Safety
Clearance from
Pit
A800818-2.13.3 A800819-2.13.3
Illustration 2-28: Example of Outrigger Leg Front Decal and Outrigger Leg Rear Decal

Operation
2.14 Machine Set-Up

When the material placement area of the job site has been determined (access, safety, etc.), begin machine
set-up as follows:
DANGER:EXHAUST FUME HAZARD.
Vehicle exhaust fumes contain gases which can be lethal or carcinogenic. Set
the machine up in an adequately ventilated site or vent exhaust gases away
from work area.
1. Ensure that the setup site is adequately ventilated. Exhaust gases can be fatal.
2. Position the Telebelt in a safe and open area. Keep in mind that the machine may require additional
moves during material placement.
3. Check the clearance for extending the telescopic boom.
IMPORTANT:
Leave the main conveyor belt PTO disengaged (off) at this time to prevent
accidental operation of belts during setup.
NOTE:
The truck engine will automatically throttle up approximately 200 RPM when the
PTO’s are engaged.
4. With the truck engine running, transmission in neutral (manual transmission), and parking brake on,
engage boom/outriggers/feeder power take-off (PTO) only, by performing the following steps:
A. Push in clutch pedal (clutch disengaged).
B. Ensure that truck transmission is in neutral.
C. Position PTO switch (for boom/outriggers/swivel) to “On” position (PTO engaged).
D. Let clutch pedal out (clutch engaged).
For Telebelts with automatic transmissions follow these steps to engage PTO:
A. Set parking brake “On.”
B. Press gear selector switch to “N” (Neutral).
C. Place PTO switch to “Pump” position or “Drive to Pump” (green pump light illuminates).
D. Press gear selector “D” then “Up” arrow until display indicates “4.”
NOTE: For more information on PTO switch location and operation, please see “PTO
Switch – Manual Transmissions” or “PTO Switch – Automatic Transmissions
sections.

Operation
NOTE:
The function selector switch on the remote controls (horn/outrigger & feeder reset
switch) is used to clear the E-stop mode by pushing this switch up two times. The first
press clears the E-stop. The second and subsequent presses blow the horn. If the
horn will not blow, recheck cable connections, E-stop buttons, parking brake, and
power supplied to the electric control box.
If an E-stop button is depressed, release it and turn radio transmitter power switch off and
back on. The horn/outrigger/reset switch (on the radio) will not reset E-stop unless pressure
washer switch is off and all joysticks are in their neutral position.
5. If using a radio remote control system, perform the following steps:

A. Verify that radio receiver is connected to right side of electric control box.
B. Ensure that radio transmitter has a charged battery inserted.
C. Release E-stop button, by twisting button to allow it to pop out.
D. Ensure that control box and stack valve E-stops are released.
E. Turn radio transmitter power switch on.
F. Clear E-stop mode (refer to note above).
6. If using a cable remote control system, perform the following steps:
A. Verify that remote cable is attached to right side of electric control box.
B. At cable remote control, perform the following steps:
• Twist emergency stop (E-stop) button to allow it to pop out.
• Verify that all function switches are off.
C. Ensure that electric control box and stack valve E-stops are released.
D. Clear E-stop mode.
All four outriggers must be used and locked into working position to stabilize
the Telebelt conveyor through slewing, telescope, and elevate functions.
Do not attempt to reposition any outrigger unless main conveyor is fully retracted, lowered,
and centered to the front or rear of truck. The boom will not operate when the outriggers
are activated.
NOTE:
Each outrigger leg can be raised or lowered by using its built-in outrigger up/down
switch or the appropriate outrigger stack valve.

Operation
Boom and outrigger stack valves can be operated manually. In the event of an
electrical failure, pull and hold the boom/outrigger selector valve to operate the
outrigger stack valves. Push in and hold the boom/outrigger selector valve to operate
the boom stack valves.
7. On radio or cable remote control, place horn/outrigger/reset switch to outrigger position.

8. Remove outrigger safety chains.
9. Pull spring-loaded locking pins with wire rope (as shown in Illustration 2-29) and manually swing the
two rear outriggers until they lock into their working position.
1. Wire rope
TB2.14
2. Spring-loaded locking pin
Illustration 2-29: Rear Outrigger Leg (Left Side Shown)

10. Repeat step 9 for the two front outriggers.
11. Lower the outrigger pads until the truck and machine is completely raised and level. Use the bubble
level located by the stack valve for leveling the unit. Truck should be level within 3°.
12. After outriggers are positioned, on either the radio or cable remote control, return the horn/outrigger/
reset switch to its center (off) position.
2.15 Conveyors Set-Up

NOTE:
The main conveyor boom can be slewed left/right, elevated up/down, or telescoped
in/out by using the appropriate joystick on the radio (or cable) remote control
transmitter. In the event of an electrical failure, use the appropriate stack valve (along
with the boom/outrigger selector valve).
The boom/outrigger/feeder PTO switch must be engaged (on) or the main boom,
outrigger, feeder boom and pressure washer control valves will not work.
The main conveyor boom cannot be slewed left/right unless all pressure from the
feed conveyor elevate cylinder is relieved (the feed conveyor is on its support feet on
ground). When slewing the main conveyor, the feed conveyor slewing brake is
released so that the feed conveyor will not move with the main conveyor.

Operation
IMPORTANT:
The Function selector switch on both the cable and radio remote control (item
(A) in the following diagram), must be pushed up to reset Emergency stop (E-
stop) or blow horn. Leave switch in middle position to operate main conveyor
boom and swivel. Lift switch and pull down to activate outriggers and feed
conveyor boom. Main conveyor boom and swivel will not operate when
outriggers are activated.
Always double check that conveyor ratchet strap has been removed prior to
attempting feed conveyor movements.
TB2.15
Illustration 2-30: Cable and Radio Remote Control Function Selector Switch
A. Function selector switch – Use the function selector switch to determine if you want the elevate or
telescope joystick to operate the conveyor boom, feed conveyor or outrigger.
2.15.1 Feed Conveyor Raise/Lower

First, place the Function Selector Switch to the ‘Feeder/Outrigger’ position. Raising or lowering the feed
conveyor can then be accomplished by using one of the following three methods:
1. Radio remote control – Left diagram in Illustration 2-31 shows the joystick (item 1) that is used to
raise/lower the feed conveyor using the radio remote control transmitter. Twisting the joystick clock-
wise or counterclockwise will raise and lower the feed conveyor.
2. Cable remote control – Right diagram in Illustration 2-31 shows the joystick (item 3) that is used to
raise/lower the feed conveyor using the cable remote control.
Elevate (slew) up/down joystick (item 3, Ill. 2-31) – Move joystick to the “up” position to raise the
feed conveyor or move to the “down” position to lower the feed conveyor. Move back to center to
stop moving feed conveyor.

Operation
3. Feed conveyor control valves – Standing at the operator’s platform on the pedestal, Illustration 2-32
shows the valve levers used to raise or lower the feed conveyor (normally only used when radio or
cable remote control is inoperable).
Feed conveyor elevate (item 5, Ill. 2-32) – While pulling the selector handle on the Modular Boom
Control (MBC) valve (item 6, Ill.2-32), push lever up to lower the feed conveyor or pull down to
raise the feed conveyor.
TB2.15.1-1a
Radio Remote Control
Cable Remote Control TB2.15.1-1b
Illustration 2-31: Radio and Cable Remote Controls
4
5
TB2.15.1-2
Illustration 2-32: Feed Conveyor (Outrigger) Control Valve

Operation
2.15.2 Feed Conveyor Swing (Slewing)

Feed conveyor swing (slewing) is done using the following three methods:
1. Shift the function selector switch to the ‘Feeder/Outrigger’ position.

2. Radio remote control transmitter – Use the slew left/right joystick (item 1, Ill. 2-31) by moving stick to
the “left” position to slew the feed conveyor to the left or move joystick to the “right” position to slew
the feed conveyor to the right. Move back to center to stop moving the feed conveyor.
3. Cable remote control – Use the slew left/right joystick (item 2, Ill. 2-31) by moving stick to the “left”
position to slew the feed conveyor to the left or move joystick to the “right” position to slew the feed
conveyor to the right. Move back to center to stop moving the feed conveyor.
4. Feed conveyor control valve – Use the feed conveyor slewing control valve lever (item 4, Ill. 2-32)
while pulling selector valve on MBC (item 6, Ill. 2-32), push slewing control lever up to slew feed
conveyor in a clockwise (CW) direction or pull lever down to slew feed conveyor in a counterclock-
wise (CCW) direction.
2.15.3 Feed Conveyor Set-Up

Use only hoppers approved by Putzmeister for use with the Telebelt. Use of
unapproved extended capacity hoppers may cause damage to feed conveyor
and other Telebelt components.
1. Remove ratchet strap that secures feeder and main conveyor to the transport brackets.
2. Completely raise hopper end of feed conveyor.
3. Completely raise swivel.
4. Slew feed conveyor to desired position on side or rear of truck.
5. Lower feed conveyor to shoulder height. Remove pins from feeder leg pivots and swing legs down.
Re-pin pivots.
6. Lower feed conveyor until the feed conveyor feet are firmly on ground.

Operation
7. Assemble feed conveyor hopper as shown in the illustration and steps that follow:
Hopper Grate
Rear Panel Gate & Front

C Panels
D
Side Skirt
Pin to Rear E
Panel
Side Panel
B Brackets
A Side Panel
Hinges
TBE2.15.3
Illustration 2-33: Feed Conveyor Hopper
NOTE:
Feeder legs are adjustable in length for uneven ground. Legs can also be extended
to decrease angle when placing wet concrete.
Refer to Illustration 2-33 when performing the following procedures:

A. Remove pins holding side panel down, fold side panels up, and re-pin side panels in working position.
B. Install front and rear panels and pin in place.
C. Pin rear of side skirts to rear panel.
D. Install hopper grate

Operation
2.15.4 Main Conveyor Raise/Lower

The conveyor boom is raised or lowered using any one of the following three methods:
1. Shift the function switch to ‘Boom’ operation.
2. Radio remote control – Left diagram of Illustration 2-34 shows the joystick (item 1) that is used to
raise/lower the conveyor boom using the radio remote control transmitter. Twist joystick clockwise to
raise, counterclockwise to lower.
3. Cable remote control – Right diagram of Illustration 2-34 shows the joystick (item 3) is used to raise/
lower the conveyor boom using the cable remote control.
Elevate (slew) up/down joystick – Move joystick to the “up” position to raise the conveyor boom.
Move joystick to the “down” position to lower the conveyor boom. Move back to center to stop
moving the conveyor boom.
4. Modular Boom Control (MBC) – Standing at the operator’s platform on the pedestal, Illustration 2-35
shows the MBC valve levers used to raise/lower and swing the conveyor boom (normally used when
the radio or cable remote control is inoperable).
Elevate (item 4, Ill. 2-35) – While pushing on the selector valve lever (item 6, Ill. 2-35), push lever
(item 4) up to lower conveyor boom or pull down to raise conveyor boom.
1
3
TB2.15.4-1
Radio Remote Cable Remote Control
Illustration 2-34: Radio and Cable Remote Control

Operation
4
6
ELEVATE
SWING
TB2.15.4-2
Illustration 2-35: Modular Boom Control (MBC)
2.15.5 Conveyor Boom Swing (Slewing)

Conveyor boom swing (slewing) is done using the same three methods:
1. Radio remote control transmitter – Use the swing left/right joystick (item 1, Ill. 2-34) by moving stick
to the “left” position to swing conveyor boom to the left or move stick to the “right” position to slew
the conveyor boom to the right. Move back to center to stop moving the conveyor boom. The farther
the joystick is moved either “left” or “right” the faster the conveyor boom will swing left or right.
2. Cable remote control – Same as radio remote, using item 3 in Illustration 2-34. However, the cable
remote control is non-proportional.
3. Modular Boom Control (MBC) – Use the conveyor boom swing lever (item 5, Ill. 2-35) as shown to
swing the boom:
Conveyor swing – While pushing and holding the selector valve (item 6, Ill. 2-35), move conveyor
boom in a (CW) direction by pushing the conveyor swing lever up. To swing the conveyor boom
in a (CCW) direction pull the conveyor swing lever down.
2.15.6 Conveyor Telescoping

Telescoping the conveyor mid and head sections is also accomplished using these three methods: Radio
Remote, Cable Remote, and Modular Boom Control (MBC).

Operation
1. Radio remote control – Use the Telescope Out/In joystick (item 1, Ill. 2-34) by moving stick to the
“out” or “in” position to telescope the conveyor out or in. Move back to center to stop telescoping the
conveyor. The farther the joystick is moved toward the “out” or “in” position, the faster the mid and
head sections will telescope.
2. Cable remote control – Same as Radio Remote, using item 3 in Illustration 2-34, but is non-propor-
tional.
3. Modular Boom Control (MBC) – While pushing and holding selector valve lever (item 6, Ill. 2-36),
push lever (item 7, Ill. 2-36) up to extend conveyor boom mid and head sections or pull lever down to
retract conveyor boom mid and head sections.
6
7
TELESCOPE
TB2.15.6
Illustration 2-36: Modular Boom Control
2.16 Main Conveyor Set-Up

DANGER:PINCH POINT HAZARD.
The working area between the two conveyors is a potential pinch point. Do Not
Allow any personnel to stand in the area between the conveyors when either
are being moved.
WARNING:
Adhere to the following guidelines when attaching reducer (tremie) and end
hose to end of conveyor boom:
• DO NOT use screw-type clevises to attach the reducer to the end frame. The rocking mo-
tion of the reducer can unscrew the pins.
• Be sure safety hooks have spring-loaded latches that work freely.

Operation
• DO NOT use nylon ratchet straps for securing end hoses, since they are subject to failure
(rot) caused by a reaction with the chemicals in concrete.
• DO NOT exceed maximum end hose length of 15 feet (5 m).
2.16.1 Setting-Up Conveyor

1. On cable or remote control, place function selector switch in middle or “conveyor boom” position.
2. Raise conveyor out of boom rest.
3. Slew conveyor out to a clear location.
4. As shown in Illustration 2-37, attach reducer (tremie) and end hose (delivery trunk) to end of conveyor
head section by performing the following steps:
A. Attach reducer (5) to conveyor head section end frame (1) using a pin-type clevis (2) on each side.
B. As a backup to each clevis, attach safety hook of end frame chain (3) to reducer mounting loop (4)
on each side.
C. Attach short end of chain binder assembly (6) to lug on reducer, using screw-type clevis.
D. Ensure that end hose (7) is pushed on to the reducer completely.
E. Wrap the chain around the end hose, above the bottom ring of the reducer, and secure tightly with
the chain binder.
1. End frame of conveyor head section
Complete Assembly 2. Pin-type clevis (one on each side)
3. Safety hook of end frame chain (one

2 on each side)
1
4
3 4. Reducer mounting loop (one on
each side)
5 5. Reducer (tremie)
6. Chain, binder, and clevis
6 7. End hose (delivery trunk)
TB2.16.1-1b
TB2.16.1-1a
Illustration 2-37: Attaching Reducer and End Hose to End of Conveyor

Operation
CAUTION:
DO NOT use a hammer to clean the head scraper blades. A hammer blow will
fracture the tungsten carbide blades.
Correct tension of the head scraper is made at the time of the pour. Create
enough tension to keep the belt clean but not enough to actually start to
remove belt material. Be careful not over tension. Over-tensioning will shorten
the belt life and damage the splice. As a rule of thumb, with new blades and
springs, pull enough tension to be able to slip a credit card in between spring
coils.
NOTE:
T-handles or chains provided at the conveyors discharge end section, are connected
to the head scraper by way of springs. Pulling up on the T-handles or chains increases
head scraper tension on the belt. If increased tension does not improve scraper
operation, rotate or flip the blade to a new edge. Replace blades when all four
edges are worn.
5. As shown in Illustration 2-38, inspect head scraper blades and discharge end of both conveyors.
If scraping edge is worn, rotate or replace blade.
1. Head Scraper Assembly

7
2. Arm (RH, LH)

1
3. Clamp, Inner
4
4. Blade (Rotalloy)
5
5. Clamp, Outer
3
2
6. Skirt
6
7. T-Handle Adjuster
TB2.16.1-2
Illustration 2-38: Head Scraper Assembly

6. Ensure that transfer skirts and boots are free of concrete buildup.
7. Engage conveyor belt power take-off (PTO).
8. Test run belts to check for proper belt tension (no belt slippage) and belt alignment (belt running to
center of the conveyor rollers).
9. Raise engine speed to full operating RPM using throttle switch on the remote control.

Operation
2.17 Conveyor Belt Operation

CAUTION:
All conveyor operations should be made with the engine speed at 3/4 to full
operating RPM. Engines speeds should NOT be used to “feather” operating
functions. Operating at low engine speeds can cause lack of lubrication and
overheating, resulting in damage to hydraulic components and PTO drives.
Keep the following points in mind when operating conveyors with manual bypass:
• Two manual bypass valves, which are located next to the oil cooler, can be used to turn the
belts on in the event of an electrical failure. Remove coil caps from load sense shutoff valves.
Open brass stems fully and replace caps. Partially open round top manual control knob
approximately five turns (these knobs are hard to turn when oil is flowing through the bypass).
Push levers down fully to turn the belts on and adjust belt speeds with the round knobs on top
of valves.
• Main “ON” First and “OFF” Last. When using manual controls, make sure to turn the
conveyor off after turning off the feed conveyor.
WARNING:
If conveyor belts are started using the manual bypass valves, they cannot be
turned off with the remote controls or E-stops. DO NOT leave these valves
unattended when using them to operate the conveyor belts. Turn speed control
valves off and screw brass stems of load sense valves back in after completing
manual operation.
NOTE:
Engine speed can be adjusted using any of the following throttle controls:
• Cruise control in truck cab
• Throttle control switch on the electric control box
• Throttle control switch on the radio or cable remote control.
Conveyor and feed conveyor belt speeds are independently adjusted using the
conveyor speed controls located on the radio (or cable) remote control or manual
bypass valve speed controls.
2.17.1 Belt Speed Control Valves
NOTE:
The conveyor belt PTO must be engaged or the conveyor belts will not run. This PTO
engages two hydraulic pumps that provide hydraulic pressure to the feed and
conveyor belt hydraulic motors.
Illustration 2-39 shows the component locations of the belt speed control valve (located next to Hydraulic
Oil Cooler):

Operation
6 8
7
! WARNING
5
2
RPM RPM
1 3
CONVEYOR FEED
4
EMERGENCY STOPS WILL NOT
OPERATE WHEN BELT ON/OFF
MANUAL OVERRIDES ARE USED
ON MANUAL OVERRIDES OFF
TB2.17.1 A800357 Rev . 1 TB2.17.1
Illustration 2-39: Belt Speed Control Valves

1. Conveyor belt manual bypass speed control – When the conveyor belt manual bypass valve is turned
on (by pushing lever down) and the conveyor load sensing shutoff valve (item 7, Ill. 2-39) is either
energized or bypassed, turn this knob to adjust conveyor belt speed clockwise (CW) to decrease speed
or counter-clockwise (CCW) to increase speed.
2. Feed conveyor belt manual bypass speed control – When the feed conveyor belt manual bypass valve
is turned on (by pushing the lever down), and the feed conveyor load sensing shutoff valve (item 8, Ill.
2-39) is either energized or bypassed, turn this knob to adjust feed conveyor belt speed (CW) to
decrease speed or (CCW) to increase speed.
3. Feed conveyor belt manual bypass valve – Normal position for this valve is off (lever is pulled up). If
radio or cable remote control is not working, this valve can be turned on (by pushing lever down) to
manually bypass the electric control.
4. Conveyor belt manual bypass valve – Normal position for this valve is off (lever is pulled up). If radio
or cable remote control is not working, this valve can be turned on (by pushing lever down) to manu-
ally bypass the electric control.
5. Conveyor proportional belt speed control valve – The cable or remote control sends signals to this
valve to increase or decrease conveyor belt speed by adjusting the hydraulic oil flow inside valve.
6. Feed conveyor proportional belt speed control valve – The radio or cable remote control sends signals
to this valve to increase or decrease feed conveyor belt speed by adjusting the oil flow.
7. Main conveyor load sensing shutoff valve – This valve closes when an E-stop is pressed, which
ensures that the conveyor belt hydraulic pump shuts off even if the conveyor belt speed control valve is
stuck open. In the event of a total loss of electrical power, the conveyor belt manual bypass speed

Operation
control can not be used unless this valve is bypassed. This valve can be bypassed by performing the
following steps with the feed conveyor belt off:
1. Remove the plastic cap that covers the knurled knob
2. Turn knurled knob fully counter-clockwise
3. Screw plastic cap back on.
NOTE: To return to normal operation of this valve (unbypassed), remove the plastic cap, turn
knurled knob fully clockwise, and screw plastic cap back on.
8. Feed conveyor load sensing shutoff valve – This valve closes when an E-stop button is pressed, which
ensures that the feed conveyor belt hydraulic pump shuts off even if the feed conveyor belt speed con-
trol valve is stuck open. In the event of a total loss of electrical power, the feed conveyor belt manual
bypass speed control cannot be used unless this valve is bypassed. This valve can be bypassed by per-
forming the steps given in (7) above.
9. Initially adjust belt speeds (refer to the belt speeds and capacities charts and graphs in 2.18.1 and
2.18.2 below).
2.18 Conveyor Belt Speed Settings

All conveyor operations should be made with the engine speed at 3/4 to full
operating RPM. Engine speed should NOT be used to adjust conveyor belt
speed. Operating at low engine speeds can cause lack of lubrication and
overheating, resulting in damage to hydraulic components and PTO drives.
NOTE:
There are many variables that determine belt speed setting such as type of material,
water content, desired placement rates, supply rate to the conveyor, conveyor angle,
etc. The following suggestions may be used as a starting point from which
adjustments can be made, as needed:
– Each conveyor has its own hydraulic pump and control valve, and can be set to run at dif-
ferent speeds. The conveyor motor controls are located next to the oil cooler. Speed poten-
tiometer settings are located on the radio or cable remote control.
– Conveyor belt speed settings (0-10) refer to the indicator dial on the individual speed
potentiometers.
– Belt speed does not always change output. A common mistake is when an operator slows a
belt to top off a wall. If the mixer is not slowed, the belt will just run fuller and deliver the
same volume. Conversely, speeding belts up will not increase output or volume if the mixer
discharge is not increased.
– Some materials may require slower belt speeds and/or lower elevation angle to deliver
higher production.
– Some materials such as wet sand may bridge in hopper or transfer. Usually this can be
corrected by trimming hopper and transfer skirts, but external vibration may be necessary.

Operation
To have properly adjusted conveyor belt speeds, adjust belt speeds according to the type of material that will
be placed:
• Low slump (dry) concrete
• High slump (wet) or plasticized concrete
• Dry materials (rock, sand, backfill, or landscaping materials)
2.18.1 Belt Speed Determination

The capacity of the conveyor belts can be affected by increasing or decreasing conveyor belt speed. Belt
speed can be determined by performing the following steps:
1. Mark reference points on the belt and conveyor with a piece of chalk, marker, etc.
2. Note the time it takes the belt to travel one loop using a watch or count off in seconds.
3. Determine the corresponding belt speed using chart in Illustration 2-40 and graph in Illustration 2-41
below:
OPERATING INSTRUCTIONS
TELEBELT - BELT SPEED CHART
Loop time (sec’s)
Belt speed (ft/min)
Feed Conveyor
400 11.25 36.00

500 9.00 28.80
600 7.50 24.00
700 6.40 20.60
800 5.60 18.00
900 5.00 16.00
1000 4.50 14.40
Belt speed can be determined by marking the belt and

conveyor and timing the belt travel for one loop through
the conveyor. Use a piece of chalk to mark reference
points on the belt and conveyor. Use a watch to note the
time it takes the belt to travel one loop. Refer to the chart
above for the corresponding belt capacity.
TB2.18.1 A800305
Illustration 2-40: Telebelt Belt Speed Chart

Operation
Conveyor Belt Speed Determination Graph

Feed Conveyor Belt Speed Determination Graph 40
39
15 38
37
14 36
Example: 35 Example:
13 34
If belt completes 33 If belt completes
12 32 one loop in 22.5 sec.,
one loop in 9.5 sec.,
belt speed is 31 belt speed is approx.
11 30 640 feet per minute.
Loop Time in Seconds
Loop Time in Seconds

approx. 475 feet
29
10 28
27
9 26
25
8 24
23
7 22
21
6 20
19
5 18
17
4 16
15
14
0
0 100 200 300 400 500 600 700 800 900 1000
0
Belt Speed in Feet Per Minute 0 100 200 300 400 500 600 700 800 900 1000
Belt Speed in Feet Per Minute TB2.18.1-2
Illustration 2-41: Belt Speed Determination Graph
2.18.2 Belt Speed/Capacity Charts

Table 1, shows the conveyor speeds for optimum performance and capacity with the feed conveyor in
normal operating position (support legs resting on ground):
NOTE:
18-inch wide Telebelts can deliver up to 6 yd3/min at 0 degree boom angle and 4-inch slump.
Production is affected by variables such as slump, aggregate size and type, weather
conditions (rain, wind, temperature), boom angle, and belt speeds. In many circumstances,
slower belt speeds can result in higher production.
Make sure to run belt fast enough to move the material, but slow enough to prevent material
slippage or rock bounce.
The following charts are guidelines based on optimum conditions, results will vary.
Table 1: Telebelt Speeds and Capacities
Feed Conveyor Belt Conveyor Angle and Working Speed (ft/min)

Speed (ft/min) at 20°
“Normal” Working Slump Capacity
0° 5° 10° 15° 20° 25° 30°
Angle (inches) (yd3/min)
2 2.54
4 3.82
900 575 630 700 780 900 - -
6 3.39
8 2.97

Operation
Table 1: Telebelt Speeds and Capacities
Feed Conveyor Belt Conveyor Angle and Working Speed (ft/min)

Speed (ft/min) at 20°
“Normal” Working Slump Capacity
0° 5° 10° 15° 20° 25° 30°
Angle (inches) (yd3/min)
2 2.12
4 3.18
750 475 525 580 650 750 900 -
6 2.83
8 2.47
2 1.70
4 2.54
600 385 420 465 525 600 720 900
6 2.26
8 1.98
2 1.41
500 320 350 390 435 500 600 750
4 2.12

Operation
Table 2 shows conveyor capacities for an 18-inch wide belt at a given speed and angle:
Table 2: Speeds and Capacities for an 18-Inch Wide Belt
Capacities (yd3/min) at Conveyor Angle

Conveyor Belt Speed
(ft/min) Slump
0° 5° 10° 15° 20° 25° 30°
(inches)
2 4.00 3.65 3.29 2.93 2.54 2.13 1.69
4 6.00 5.48 4.94 4.39 3.82 3.20 2.54

900
6 5.30 4.87 4.39 3.90 3.39 2.85 2.25
8 4.67 4.26 3.84 3.42 2.97 2.49 1.97
2 3.33 3.04 2.75 2.44 2.12 1.78 1.41
4 5.00 4.56 4.12 3.66 3.18 2.67 2.11

750
6 4.44 4.06 3.66 3.25 2.83 2.37 1.88
8 3.89 3.55 3.20 2.85 2.47 2.08 1.64
2 2.67 2.43 2.20 1.95 1.70 1.42 1.13
4 4.00 3.65 3.29 2.93 2.54 2.13 1.69

600
6 3.56 3.24 2.93 2.60 2.26 1.90 1.50
8 3.11 2.84 2.56 2.28 1.98 1.66 1.31
2 2.22 2.03 1.83 1.63 1.41 1.19 .94

500
4 3.33 3.04 2.75 2.44 2.12 1.78 1.41

Operation
Table 3 is identical to Table 2, except it uses metric units of measure:
Table 3: Speeds and Capacities for an 18-Inch (457.2 Millimeter) Wide Belt
Capacities (m3/min) at Conveyor Angle

Conveyor Belt
Speed (m/min) Slump
0° 5° 10° 15° 20° 25° 30°
(mm)
50 3.06 2.79 2.52 2.24 1.95 1.63 1.29
100 4.59 4.19 3.78 3.36 2.92 2.45 1.94

275
150 3.65 3.72 3.36 2.99 2.59 2.18 1.72
200 3.57 3.26 2.94 2.61 2.27 1.90 1.51
50 2.55 2.33 2.10 1.87 1.62 1.36 1.08
100 3.82 3.49 3.15 2.80 2.43 2.04 1.62

230
150 3.40 3.10 2.80 2.49 2.16 1.81 1.44
200 2.97 2.71 2.45 2.18 1.89 1.59 1.26
50 2.04 1.86 1.68 1.49 1.30 1.09 .86
100 3.06 2.79 2.52 2.24 1.95 1.63 1.29

180
150 2.72 2.48 2.24 1.99 1.73 1.45 1.15
200 2.38 2.17 1.96 1.74 1.51 1.27 1.01
50 1.70 1.55 1.40 1.24 1.08 .91 .72

150
100 2.55 2.33 2.10 1.87 1.62 1.36 1.08

Operation
2.19 Placing Material

At start of concrete pour or material placement, perform the following procedures to adjust the conveyor
belt speeds according to the type of material being placed. Use the belt speed potentiometers on the radio or
cable remote control as shown in Illustration 2-42:
Main Conveyor
1 Belt Speed
Potentiometer
3
Feed Conveyor
2
Belt Speed
Conveyors
Potentiometer
Switch
TB2.19
Illustration 2-42: Radio or Cable Remote Control Belt Speed Potentiometers

1. Main conveyor belt speed potentiometer - Push in and turn clockwise (CW) to increase or
counter-clockwise (CCW) to decrease conveyor belt speed. The conveyors switch (item 3 in
Illustration 2-42) must be in (I) or (I+II) position for conveyor belt to run.
2. Feed conveyor belt speed potentiometer - Turn (CW) to increase or (CCW) to decrease feed con-
veyor belt speed. The conveyors switch (item 3 in Illustration 2-42) must be in the (I+II) position for
feed conveyor belt to run.
3. Conveyors switch - Lift switch and push up to 1st position (I) to turn conveyor belt on. Lift switch
and push up to 2nd position (I+II) to turn feed conveyor belt on.
2.19.1 Low Slump (Dry) Concrete

1. If conveying low slump (dry) concrete (stays in place on the feed conveyor when the belt is stopped)
use the following suggested settings:
• Feed conveyor – 6
• Main conveyor – 5
• Feed conveyor hopper gate – Fully open (up)
2. While pouring, check hopper gate, transfer, and boom discharge for overfill. Also check transfer for
splatter. Make adjustments as required for maximum production with minimum splatter and overfill.

Operation
2.19.2 High Slump (Wet) or Plasticized Concrete

1. If conveying high slump (wet) or plasticized concrete (will slide back down the feed conveyor, when
belt is stopped), use the following settings:
• Feed conveyor hopper gate – Fully closed (down)
2. Make sure to follow these recommendations:
• Run feed conveyor fast enough to prevent concrete from sliding back down the belt.
• Run main conveyor fast enough to keep transfer clear, without creating splatter.
• Keep hopper gate low to help keep a low cross-section of material on belt and reduce wave action.
• Keep truck hopper level low to allow for concrete sliding back down when feed conveyor belt is
turned off.
• If possible, run feed conveyor belt empty before stopping to prevent concrete from sliding back down
the belt.
2.19.3 Dry Materials (Rock, Sand, Backfill, or Landscaping Materials)

1. If conveying rock, sand, backfill, or landscaping materials use the following settings:
• Feed conveyor hopper gate – Fully open (up)
2. Make sure to follow these recommendations:
• Run feed conveyor slow enough to maintain a fully loaded belt with minimal rock bounce and roll-
back.
• Run main conveyor fast enough to keep transfer clean, with minimal rock bounce.
2.19.4 Maintenance During a Pour

The operator should always stand as close as possible to the feed conveyor
hopper in order to be able to monitor gauges, scrapers, supply, and operation.
NEVER stand at the discharge end of the conveyor, as the machine cannot be
monitored from there which could lead to personal injury or equipment
damage.
The oil cooler fan automatically turns on when the hydraulic fluid temperature
reaches 131° F (55° C). A switch on the electric control box is provided to turn
the oil cooler fan on manually if necessary.

Operation
NOTE:
Leaking scrapers accelerate scraper wear. Material that passes over the scrapers is
abrasive and will wear down the scraper material. Leaking scrapers also cause
splatter and unwanted grout collection in critical areas of the boom.
Sensors in hydraulic system will shut the conveyor belt off if the hydraulic oil reaches 194° F
(90°C). This is not an E-stop, since the boom functions will continue to operate. After the oil
has cooled, the belt circuits can be reset by turning the belt switch to “off” and then back to
“on” again. When this happens, always determine and correct the cause of overheating.
WARNING:PERSONAL INJURY.
Turn belts off before making any adjustments or repairs to any components.
Failure to do so may cause personal injury or equipment damage.
To maintain the Telebelt during a concrete pour or material placement, perform the following steps:
1. Check the transfer between feed and conveyor for concrete or material build-up. It should be discharg-
ing an even flow of material on the conveyor belt.
2. Check the connection between the scraper arms and the scraper blade clamp. Make sure that all four
bolts are tight. Ensure that head scraper is clean and tensioned enough to keep belt black without
taking off belt material:
• Tighten if necessary to eliminate grout “carry-back.”
• Loosen if belt material is observed on scraper arms.
3. Check all rollers and pulleys. They should be turning freely without concrete build-up.
4. Continuously monitor belt training (alignment) and tensioning. Shut down and re-tension or train
(align) as required (refer to Preventative Maintenance section of this manual). Keep in mind that:
• A loose belt will wear prematurely.
• A belt improperly trained (aligned) could run off the pulleys causing damage to belt edges and other
conveyor components.
• Always tension the belt before attempting to train (align) belts.
5. Frequently monitor engine gauges in truck cab.
6. Frequently monitor the following gauges and control lights for the truck and the conveyors:
• Hydraulic fluid level and oil temperature gauge (194° F or 90° C maximum). The hydraulic oil tem-
perature gauge is part of the fluid level gauge.
• Oil temperature gauge, hydraulic oil over-temperature indicator (red), and oil cooler fan on indicator
(green) on the electric control box.
7. Observe the overall general operation and condition of the conveyors by keeping these questions in
mind:
• Are the scrapers operating properly?
• Is the conveyor boom telescoping smoothly?

Operation
• Are the conveyor mid and head section stops in place and properly secured?
• Are the conveyor belts running at the proper speed?
• Is there build-up at the transfer points?
• Are there leaks at any transfers or skirts?
• Are there any unusual noises, squeaks, squeals, thumps, etc.?
2.20 Cleaning
Clean the Telebelt after each concrete pour or material placement using the following equipment:
• Wire brush
• Scraper
• High-pressure washer
Clean the machine thoroughly by performing the following steps:
1. Remove feed conveyor hopper. Completely clean belts, discharge boots, head scrapers, transfer chute,
and transfer skirts.
2. Wash all material off both conveyors. Ensure that drive pulley areas, turntable, and area under feed
conveyor hopper is thoroughly cleaned.
3. Run both conveyors until they are clean and dry.
4. Clean tail and “V” scrapers.
5. Remove any material build-up from telescope pulleys.
When cleaning machine, make sure to clean the following seven specific areas where material build-up can
cause problems:
A. Hopper or Hopper Transfer Skirts
If concrete or other material is allowed to build-up on the feed conveyor hopper or hopper
transfer skirts, the concrete/material covered skirts will cut their way into and eventually
through the conveyor belt resulting in premature belt failure.
B. Conveyor Rails
Thoroughly clean conveyor rails to remove useless dead weight, and to keep safety and oper-
ating information decals clean.
C. Hydraulic Cylinders
Clean any splatter from hydraulic cylinder rod ends to prevent seals from being destroyed or
hydraulic fluid from being contaminated. Rod wipers on cylinders will not remove hardened
concrete build-up.
D. Conveyor Cross Frames

Make sure to completely clean cross frames underneath conveyor belts to prevent concrete or
material build-up from cutting into the belt surface, and added weight that will cause the

Operation
hydraulic cylinders to work harder.
E. Hydraulic Hose Assemblies and Valves

Clean all hydraulic hoses of concrete splatter that can cause hose failure. Make sure to clean
the hydraulic valves to keep concrete and material from contaminating hydraulic fluid.
F. Rollers and Pulleys

Clean all material build-up away from roller assemblies that can cause excessive belt wear and
increased power requirements needed to run the belt. Build up on rollers and pulleys also af-
fect belt training (alignment).
G. Other Areas to Consider

Make sure to completely clean the following areas to maintain long service:
• Conveyor belts
• Head and V-scrapers
• Discharge boots
• Reducer (tremie)
• Also clean loose rocks and material from booms, decks, axles, frame, wheels, etc. to prevent
debris from coming off of unit during transport.
2.21 Water Tank and Pressure Washer

WARNING:EQUIPMENT DAMAGE.
When operating water pump, ensure that the valve is in the normal operating
position or damage to the pump may occur.

The pressure washer or water pump may freeze in very cold weather due to
close tolerances. To protect washer or water pump from freezing, perform the
winterizing procedures.

Operation
EXAMPLE
3
1
TB2.21-1a TB2.21-1B
1. Water Tank 3. Water Level Indicator
2. Water Tank Filler Cap 4. Water Tank Clean-Out Covers

Illustration 2-43: Water Tank Components
! WARNING
5 WINTERIZING OPERATION
NOT NORMAL
OPERATION -
6 MAY DAMAGE
PUMP!
A800431 NORMAL OPERATION
4
2
7 3
TB2.21-2
Illustration 2-44: Pressure Washer (Viewed from left side of truck)

Operation
1. Pressure washer water pump suction selector valve – When valve lever is down the pressure
washer pump is in normal operating position. When valve lever is up, the pressure washer pump is
in the winterize operation mode.
2. Pump suction selector valve hose – Insert open end in 50/50 mix of antifreeze solution (5 gal., 19
liter bucket).
3. Water tank drain – When valve lever is up (normal operating position) the water tank drain plug is
“closed”. When valve lever is down the drain plug is “open” and water tank will drain.
4. Pressure washer pump
5. Pressure washer control valve – Solenoid-operated valve controlled by cable remote control or
radio transmitter. If cable or radio remote control fails, this valve can be manually operated by turn-
ing screw clockwise until the pressure washer starts.
6. Hose reel lock
7. Wand
2.21.1 Operating the Pressure Washer

WARNING:WATER UNDER HIGH PRESSURE
When operating the pressure washer, always wear eye protection. Pressurized
water and debris may fly in different directions and could cause personal injury.
Ensure that all bystanders are at a safe distance from machine to avoid
physical contact by water or debris.
To operate the pressure washer perform the following procedures:

1. Open water tank filler cap (item 2, Ill. 2-43) and fill water tank (item 1, Ill. 2-43) to upper level of
water level indicator (item 3, Ill. 2-43) with water. Replace filler cap.
2. Ensure that water pump selector valve (item 1, Ill. 2-44) is down or in “Normal” operating position and
water tank drain (item 3, Ill. 2-44) is “closed” (lever is in ‘up’ position).
3. Unlock hose reel (item 6, Ill. 2-44).
4. Start the pressure washer pump by lifting and pushing up the switch on the radio or cable remote con-
trol (item 1, Ill. 2-45) or manually by turning screw on pressure washer control valve (item 5, Ill. 2-44)
clockwise until pressure washer starts.

Operation
tb2.21.1
Illustration 2-45: Pressure Washer Pump Switch

5. Use the wand (item 7, Ill. 2-44) attached to the pressure hose to clean the Telebelt.
WARNING:WATER UNDER HIGH PRESSURE.
Never tie open the spray gun trigger or start the machine with the spray gun
unattended. High pressure flow could cause the gun and wand to fly around
causing personal injury or property damage.
6. Do not run acids, petroleum based solvents, highly chlorinated materials or insecticides through this
pump. Damage to internal parts could result.
2.21.2 Winterizing the Pressure Washer

To winterize the pressure washer perform the following steps:
A. Drain water tank by opening the tank drain valve (item 3, Ill. 2-44).
B. Place suction hose (item 2, Ill. 2-44) from water pump suction selector valve (item 1, Ill. 2-44) in a 50/
50 mix of antifreeze solution (a 5 gallon, 19 liter bucket works well for this purpose). Position water
pump suction selector valve lever in the “up” position to open suction line.
C. Remove wand from pressure hose, turn on pressure washer. Operate pump until antifreeze reaches
nozzle.
D. Drain wand and store in cab to keep from freezing.
2.21.3 Preparing Pressure Washer for Use After Winterizing

A. Move water pump selector valve down.
B. Turn pressure washer ‘On’ and pump the antifreeze into a bucket.
C. Turn pump off when antifreeze has been purged.
D. Attach wand.

Operation
2.21.4 Optional Water Tank and Oil Tank Heaters

Failure to turn ‘Off’ water tank ball valves during warm weather conditions, will
result in the continual heating of the water and/or oil and may result in
premature wear of the oil cooler fan and damage to the pressure washer pump
and/or other hydraulic components.
There are two optional tank heaters available for the water tank and hydraulic reservoir for use in cold
climate conditions. There is a 110 volt electric heater, as well as, an engine manifold heater.
1. Electric 110 volt heater – The electric heater uses an electric element that is inserted into the tank. The
heater can be plugged into any standard 110 volt receptacle. If heaters are used in both the water tank
and the hydraulic reservoir, there will be two separate 110 volt heating elements each having its own
electrical plug.
2. Engine manifold heater – The engine heater circulates warm coolant from the engine manifold through
a heating element that is inserted into the water tank, then back to the engine manifold (as shown in
Illustration 2-46). For this reason there are two coolant lines (outlet and return) that run from the
engine manifold to the heating element. Each coolant line has a manual shut off valve that is used to
turn the tank heater on or off. To turn the heater ‘on’ rotate the valve handles to the horizontal position.
To turn the heater ‘off’ rotate the handles to the vertical position. When in the ‘On’ position, the heater
will continue to heat as long as the engine is running.
OFF 1. Valve lever ‘up’ (vertical) - heater is ‘Off’

OPEN
2. Valve lever ‘down’ (horizontal) - heater is ‘On’
C
ON
OPEN
C
O
Return to Engine Manifold OFF

Heater Core
OPEN
C
ON
OPEN
Using One Engine

Manifold Heater in TB2.21.4-1
Water Tank or
From Engine Manifold Hydraulic Reservoir
Illustration 2-46: Single Engine Manifold Heater
If manifold heaters are used in both the water tank and the hydraulic reservoir there will be a “tee” in the
line coming from the engine manifold (as shown in Illustration 2-47). After the “tee” there are two separate
ball valves. One valve controls the flow of warm engine coolant to the water tank heater (‘A”, Ill. 2-47) the
other valve controls the flow of engine coolant to the hydraulic reservoir (‘B’, Ill. 2-47). The manifold outlet
and return lines each have two ball valves. While each heater can be controlled separately, the individual
ball valves controlling each heater should be either turned ‘ON’ or ‘OFF’ together at the manifold outlet and
return lines.

Operation
OFF Shift both levers ‘A’ or both levers ‘B’ to independently control each heater
B
OPEN
C
ON
OPEN
OFF
OPEN
A Using Two Engine
C
Manifold Heaters
ON
OPEN
Return to
Engine Manifold
OFF Water Tank
A
OPEN
C
ON
OPEN
OFF Oil Reservoir

B
OPEN
C
ON
OPEN
TB2.21.4-2
C
From
Engine Manifold
Illustration 2-47: Two Engine Manifold Heaters

3. Heater operation in warm conditions – The tank heater is intended to keep the water from freezing or
to ease oil flow during cold climate conditions. The tank heater should not be used during warm
weather conditions. On units with engine heaters, the coolant line valves must be turned off when the
risk of freezing conditions has ended. Failure to turn the valves off will result in continual heating of
the water and/or oil. As a result, premature wear to the oil cooler fan as well as, damage to the pressure
washer pump and other hydraulic components could occur if subjected to continuous heat.
2.22 Tear-Down (after Cleaning)

All four outriggers must be locked in their storage position, with safety chains
attached, before driving away from job site.
The ratchet strap is a safety device that prevents damage to the feed and
conveyor rails due to bounce during road travel.
To tear down the Telebelt after material placement and to prepare it for travel, perform the following steps:
1. Disengage belt conveyor PTO to prevent accidental belt movement during tear-down.
2. Remove reducer (tremie) and end hose (delivery trunk, if used) from end of conveyor head section and
store.
3. Disassemble and fold feed conveyor hopper and store front and rear panels.
4. Move conveyor boom to its stowed (transport) position.

Operation
5. On the radio or cable remote control, move the function selector switch to the “outrigger/feeder” posi-
tion.
6. Raise feeder enough to allow for storage of feeder legs, then fully raise feed conveyor and move it to
its transport position.
7. Next, move function selector switch to the “conveyor boom” position.
8. Fully lower transfer swivel.
9. On the radio or cable remote control, move the function selector switch to the “outrigger & feeder”
position.
10. Lower feed conveyor to storage position.
11. Attach ratchet strap that secures main conveyor boom and feed conveyor to transport saddle brackets.
12. On the radio or cable remote control, move the horn/outrigger/reset switch to the outrigger position.
13. Fully raise front outrigger pads off ground.
14. Pull spring-loaded locking pins with “D” rings and manually swing the two front outriggers until they
lock in their travel storage position. DO NOT apply pressure when placing pads on deck. Leave slack
in the pad mounting links (as shown in Illustration 2-46)–this will allow for frame twist and reduces
the chance of bending the decks.
TB2.22
Illustration 2-48: Outrigger Pad Mounting Links

15. Repeat Step 14 for the two rear outriggers.
16. Attach outrigger safety chains to rear outrigger rings.
17. On the radio or cable remote control, return the horn/outrigger/reset switch to the center position and
perform the following steps:
• Push in E-stop button (cable only).
• Turn power switch to “off” position (radio only).

Operation
18. If using a cable remote control, roll up cable and store cable in a secure compartment.
19. Store cable remote control head (or radio remote control transmitter) in a dry, protected location, pref-
erably in the truck cab.
20. Disengage boom/outriggers PTO.
21. Ensure that pressure washer hose is rolled up and all toolbox doors are closed and latched.
22. Perform final walk-around and ensure all reducers (tremies), end hoses, and accessories are stored.
Check all lights and make sure no obstructions are in the travel path.

3.0 Transport
3.1 Travel Safety Information
• Inspect the truck daily, per state and federal Department of Transportation guidelines.
• Disengage all PTO’s before travel.
• Before driving the truck, check suitability of proposed route with regard to height, width, weight, and
length of the Telebelt.
• The Telebelt may not be used to transport goods except for accessories used with the machine, such
as hydraulic jack set, hoses, etc. The maximum loading or the maximum permissible gross weight
must not be exceeded.
• Get to know the job site area. Become familiar with work site obstructions and other potential hazards
in the area.
• When moving in tight quarters, post a spotter to help guard against collisions or bumping into struc-
tures.
• Watch clearances when traveling. Do not take a chance of running into overhead or side obstructions.
• Before pulling off the road onto “untested” ground, always walk the area to visually inspect for areas
where tires might sink.
• Never move truck unless:
• Boom is fully retracted
• Boom is centered over rear or front of truck
• Outriggers are raised and pinned
• Do not drive truck on road unless:
• Boom strap is holding both conveyors in place
• Swivel is down all the way
• All toolbox doors are locked
• Outrigger safety chains are in place
• All accessories and attachments are secured

Transport
3.2 Highway Travel

The side panels of the feed conveyor folding hopper must be folded down and
pinned (in their flat position) prior to highway travel. This is necessary to
prevent exceeding maximum permissible truck height during highway travel.
Prepare the truck and the machine for highway travel as shown in Illustration 3-1:
! CAUTION
PRIOR TO ROAD TRAVEL MAKE SURE
OF THE FOLLOWING:
1. SWIVEL TRANSFER IS DOWN. TB3.2a
2. OUTRIGGERS ARE PINNED OR CHAINED.
3. BOOM STRAP IS IN PLACE.
4. ALL LOOSE ITEMS ARE REMOVED OR
5.
SECURED.
COMPARTMENT DOORS ARE LOCKED.
Secure both conveyors
6. REMOTES, CLEVIS, BINDERS, TREMIES, to transport bracket
TOOLS AND TRUNK HOSES ARE SECURED.
TB3.2b A800453 Rev. 1 with ratchet strap
Illustration 3-1: Prepare Telebelt for Highway Travel

Perform the following steps before driving the Telebelt on the highway:
1. Ensure that both conveyors are properly secured:
• Conveyor is resting over truck cab in its transport brackets.
• Feed conveyor is in its travel position (transfer swivel fully lowered).
• Feed conveyor folding hopper is in its transport position.
• Both conveyors are properly secured with a ratchet strap.
2. Ensure that the outriggers are folded in, pinned in place, and secured with safety chains.
3. Verify that the Telebelt is equipped with the following items and that all items are secured:
• Reducers (tremies), end hoses (delivery trunks), chain binder, and clevises.
• Front and rear panels for feed conveyor folding hopper.
• Hydraulic jack set for tensioning conveyors and telescope cable.
• Tools, rain gear, shovels, etc.
• Feed conveyor standard hopper.
• Operating instruction manuals.
• Safety equipment: personal protection equipment, reflectors, fire extinguisher.
• Remote controls and batteries.
4. Ensure that the two PTO switches located in truck cab, are in “Off” position.
5. Lower the pusher axle as described below:

Transport
3.3 Pusher Axle Control (TB110)

In some conditions a pusher axle may be required to maintain legal axle weight limits. The pusher axle
works by air being exhausted from the front lift air springs and allowed to flow to the rear load air springs.
The pusher axle control switch is located on the center console next to the driver’s seat. The pusher axle air
pressure regulator is located on the driver’s side, in the electric control box compartment, and works by
turning the regulator knob to increase or decrease the air pressure. Refer to Illustration 3-2 below:
Air Pressure Regulator

3
Center Console Pusher Axle
PUSHER
UP
2
PUSHER
DOWN
1
TB3.3-1b
TB3.3-1a
Electric Control Box – Located Below Left Front Outrigger
Illustration 3-2: Pusher Axle Controls

1. Pusher axle control switch - To lower the axle, flip switch to the “down" position. To raise axle, flip
switch to “up" position. Axle is automatically raised when truck is put in reverse or when PTO's are
engaged.
2. Pusher axle pressure regulator - Turn knob to increase or decrease air pressure on pusher axle’s
rear load air springs to setting on factory rating plate (Each machine has a rating plate that notes
the proper air pressure setting for the regulator as shown in Illustration 3-3).
3. Pressure gauge - Displays air pressure in rear load air springs. The rear load air springs pressure
should be sufficient to cause the pusher axle to carry 10,000 lbs (4536 kg).

Transport
!
DO NOT EXCEED XX PSI
FOR TAG OR PUSHER AXLE
ORIGINAL ADJUSTMENT WAS MADE TO
TECHNICAL REQUIREMENTS. EXCEEDING
RECOMMENDED PSI SETTING MAY VIOLATE
TB3.3-2b
03_003 FEDERAL OR STATE LAWS OR AXLE RATING!
Pusher axle air pressure setting stamped on rating plate
located on operator’s pedestal next to serial number. A800243
TB3.3-2a
Illustration 3-3: Pusher Axle Air Pressure Rating Plate

WARNING: PERSONAL INJURY.
When raising or lowering the pusher axle, ensure that all personnel are at a safe
distance from the actuating suspensions. Failure to do so can result in bodily
injury or death.
WARNING: EQUIPMENT DAMAGE.

Do not travel at greater than 15 mph (24.14 kmh) when raising or lowering the
pusher axle.
CAUTION:
Improper pusher axle pressure settings can cause overload on the front or rear
axles resulting in illegal axle weights.

Pusher axle must be lowered for transport. Failure to do so will cause improper
axle loading and may cause equipment damage.
NOTE:
To comply with state and federal Department of Transportation regulations, the
pusher axle regulator and gauge can not be mounted in the cab.
Axle can only be pressurized when truck brake air is above 90 PSI (6.20 BAR).

Transport
3.4 Interaxle Lock Switch (Mack Truck Only)

WARNING: PERSONAL INJURY AND PROPERTY DAMAGE.
Do not engage the interaxle lockout unless the vehicle is standing still or is
moving less than 30 mph (48.3 km/h). This could damage the differential or lead
to loss of vehicle control, causing personal injury, and property damage.
The interaxle lockout switch is located on the center console or control panel near the PTO switches
(depending on Telebelt model) as shown in Illustrations 3-4 & 3-5 (for more information, refer to the truck
chassis owner’s manual):
Interaxle Lockout Switch

APPLY
PULL TO
G
U
IN
N L
INTER
K
E
RELEASE
L O
AK
R
O C
AXLE
PA
BR
C K
K
PUSH TO
O P.T.O. O
F
N
F
O P.T.O. O
F N
F
TB3.4-1a
TB3.4-1b
Illustration 3-4: Interaxle Lockout Switch – Center Console (Mack Chassis)
A
R
X
N L
D E
L
O
C
TB3.4-2a K
TB3.4-2b
Illustration 3-5: Axle Lock – Control Panel (Sterling Chassis)

When the interaxle lockout switch is flipped to the “lock” or “up” position, a red LED illuminates informing
the driver that the lock is “On”. When the lockout is engaged, both of the tandem axles are locked together
(positive through-drive) for maximum traction with no differential action between axles. It is not necessary
to stop the vehicle to engage the interaxle lock switch so long as the vehicle is not traveling over 30 mph
(48.3 kmh) or if the wheels are not slipping.

Transport
3.4.1 Engaging the Interaxle Lockout (Sterling)
NOTE:
The red LED light remains lit as long as the inter-axle lockout is engaged. This is to
remind the driver to release the lockout as soon as normal traction is regained. On
some units, an audible buzzer stays on when the lockout is engaged.
During normal vehicle operation, the interaxle lockout is in the “Unlocked” (disengaged) position. When
poor traction conditions are encountered, it may be necessary to provide a positive through-drive to both
axles by flipping the interaxle lockout switch to the “Locked” or “Up” (engaged) position. To engage inter-
axle lockout, perform the following steps:
1. Push switch to “Lock” or “Up” position to engage (red LED light illuminates).
2. Briefly release accelerator pedal to allow gear shift to take place, then proceed to drive through the
slippery area.
3. When normal driving conditions are regained, unlock the interaxle by flipping the switch to the
“Unlocked” or “Down” (disengaged) position (red LED light is off). Then release the accelerator pedal
momentarily (to shift out of the locked position) and proceed to drive normally.
3.5 Job Site Travel

Ensure that both conveyor belts are empty before attempting to move machine.
To drive the Telebelt in the job site travel mode with the feed conveyor in its rest, perform the following
steps:
1 2 3
TB3.5a
1. Retaining pin and hair pin
2. Feed conveyor resting on its support bracket.
TB3.5b
3. Main conveyor fully retracted and level to rear of truck.
Illustration 3-6: Using the Feed Conveyor Support Bracket for Job Site Travel

Transport
3.5.1 Boom Position

1. With all four outriggers fully deployed and feed conveyor support legs resting on the ground, fully
retract conveyor mid and head sections, and swing conveyor directly over rear of truck (item 3 in Illus-
tration 3-6).
3.5.2 Feed Conveyor

2. Remove the retaining pins (item 1 in Illustration 3-6) from the lower hole in feed conveyor support
bracket (item 2, Ill. 3-6). Raise the bracket and replace clevis pin in upper support hole and lock clevis
pin in place with the hair pin. It may be necessary to fold the hopper panels down.
3. Raise the feed conveyor and position over support bracket, then lower the feed conveyor onto pads of
support bracket.
4. If driving through area with low clearance (14 feet or less), it may be necessary to lower the swivel.
5. Lower feed conveyor onto pads of support bracket as shown in Illustration 3-6.
3.5.3 Outriggers
WARNING: PERSONAL INJURY OR EQUIPMENT DAMAGE.
Use caution when raising or lowering outriggers to prevent personnel injury or
property damage. Ensure that outrigger switches are kept clean because sand
and debris in the switch can cause it to stick.
4. Raise outriggers fully.

5. Fold front outriggers to deck.
6. Fold rear outriggers to deck or straight to rear.
7. Turn remote ‘Off.’
3.5.4 Gear Selection

DANGER: TIPPING HAZARD.
When traversing over rough terrain of job site, use the lowest transmission
gear to avoid possible tipping of machine when driving over ruts or potholes.
1. In truck cab, flip PTO switches to the “Off” position to turn off PTO’s. Release the parking brake by
pushing in the parking brake knob. Engage clutch and place shift lever into first (or lowest) gear.
2. Carefully drive machine to new job site location.

Transport
3.5.5 New Job Site Location

After machine is safely positioned at new job site location, perform the following steps to resume machine
operation:
• Place transmission into neutral gear.
• Pull-out parking brake knob to set parking brake.
• Engage PTO per instructions for unit.
• If E-stop on remote control unit was used, twist E-stop button until it pops out, then clear the E-stop
mode by using the horn/outrigger/reset switch.
• Fully deploy all four outriggers until machine is raised off the ground.
• Raise feeder and swivel as necessary and place feeder in position.

4.0 Maintenance
4.1 Recommended Lubricants
Never mix different types of hydraulic oils together (such as mixing
biodegradable hydraulic oils with mineral hydraulic oils).
Hydraulic Oils
To assure efficiency and long component life of your Putzmeister product, always use the correct hydraulic
oil that has been tested and proven for your product’s application. While there may be oil suppliers that can
supply a similar oil, we strongly recommend using only the hydraulic oil that has been tested and has a
proven history of success. Hydraulic components are expensive to replace. Components that become pre-
maturely worn or damaged from the using of incorrect oil are not covered by Putzmeister’s warranty. Please
provide your local oil supplier with the specific grade, i.e., (HLP VG46) as well as, the required
specifications (from the following charts) that the oil must contain. Request your supplier to provide written
confirmation stating that their oil meets these specifications.
Putzmeister installs HLP VG46 mineral based oil as the standard hydraulic oil at the factory. This oil meets
the majority of temperature requirements in the vast majority of applications. In extremely warm or
extremely cool temperature applications, approved HLP VG68 or HLP VG46 oils may be used. In limited
applications, biodegradable oil may be used. However, caution should be used because of the reduced
acceptable operating temperature range. Contact the factory first before switching to biodegradable oil.
Oil / Filter Change Intervals
Maintaining clean hydraulic oil is critical to the performance and life of the equipment’s hydraulic system.
As oil is initially pumped through a new system and as hydraulic components complete their initial ‘wear-
in’ cycle, the fine impurities that result are deposited in the oil and captured by the filters. For this reason,
the hydraulic filter vacuum meter should be monitored closely, and the filters should be changed as required.
The hydraulic oil should be changed every 500 hours of operation. Likewise, using the correct hydraulic
oil that has been designed for this unit will provide optimum performance and long life. Using other than
the recommended hydraulic oil may result in poor performance and premature wear or failure to
components.
Please refer to the following charts when replacing the hydraulic oil. The ‘standard’ oil installed at the
factory is HLP VG46 Mineral oil. This oil has been proven to function well in a wide variety of applications
and temperature ranges. For units operating in extremely cool, or extremely hot conditions, optional oils
may be substituted during the normal oil change intervals.
A820143_04_0809L Putzmeister America, Inc. 4–1

Maintenance
Table 1 below, provides technical information and numeric designations for the recommended hydraulic oils
to use with the Telebelt..
Table 1: Recommended Hydraulic Oils
Standard Hydraulic Oil (Installed at Factory)

Oil Operating Temperature Range: 14°F (-10°C) – 194°F (90°C)
Grade: HLP VG46 Mineral
Specifications:
Properties Putzmeister Spec
Demulsifying power < 20 min
Air release properties < 6 min
Viscosity Index > 97
Pour point < 11°F (-12°C)
FZG gear test SKS 12
Foaming power @75°F (24°C) < 100 / 0
Foaming power @199°F (93°C) < 50 / 0
Hot Climate Applications

Specifications:
Properties: Putzmeister Spec
Foaming power @75°F (24°C) < 100 / 0
Foaming power @199°F (93°C) < 50 / 0
4–2 Putzmeister America, Inc. A820143_04_0809L

Maintenance
Table 1: Recommended Hydraulic Oils (Continued)
Cold Climate Applications

Specifications:
Foaming power @75°F (24°C) < 100 / 0
Foaming power @199°F (93°C) < 50 / 0
Biodegradable Oil (Contact Factory)

Grade: HEES 46
Specifications:
Iodine value < 10
Gear test SKS 12
Foaming power @75°F (24°C) < 100 / 0
Foaming power @199°F (93°C) < 50 / 0

Maintenance
Table 2 below, shows the recommended engine and transmission oils and greases to use with the Telebelt.
For more information, please refer to the chassis manufacturer’s owners manual for engine, transmission
and chassis recommended lubricants.
Table 2: Recommended Oils and Greases

Engine Oil Transmission Oil Gear Greasing Centralized
Boxes (Manual) Lubrication
System
Marking in
Accordance with HD HYP – K2K-30 K1K-30
DIN 51502
Requirements
API CH-4/SJ API GL$ – DIN 51825 DIN 51825
Standard
Mineral, Multi-purpose, Lith-

Characteristics Mineral –
ium Grease
Viscosity Grade, SAE 90 SAE 80 NLGI NLGI Class

NLGI Class SAE 20 DIN 51517 DIN 51512 SAE 90 Class 2 1 DIN 51818
DIN 51511 Standard Winter DIN 51818

Maintenance
4.2 Maintenance Intervals

Do Not use any lubricant product that contains graphite for lubricating the
telescope slides or damage can occur to the UHMW slide pads.
Table 3 below, shows the service intervals for various maintenance tasks to be performed upon reaching the
designated hours of operation. The hour meter on the control panel should be used to determine intervals.
Table 3: Recommended Maintenance Intervals
Every ___ Hours of Operation

Other
Assembly Action
Intervals
Daily 50 200 500 1000
Lubricate unit superstructure • Weekly
Visual and function check on all

•
safety equipment
Check welds •
General
Check threaded unions •
Overall unit inspection • Annually
Inspect electrical cables, wires •
Check hydraulic fluid level •
Drain off condensed water •
Check hydraulic hoses and lines

Hydraulic •
(damage/leaks)
System
Full fluid change •
Clean hydraulic fluid tank •
Check hydraulic unions •

Maintenance
Table 3: Recommended Maintenance Intervals (Continued)
Every ___ Hours of Operation

Other
Assembly Action
Intervals
Daily 50 200 500 1000
Check contamination indicator

•
on the filters
Hydraulic Oil Replace high and low pressure

• As required
Filter filter elements
Replace suction filter elements

• As required
(three)
Water Tank Check water level •
Full oil change PTO gearbox •

Transmission Full oil change slewing gear First 100, 2000,
reducer and annually
Pedestal Check slewing head bolts •
Lubricate feed conveyor roller

See Lubricating the Telebelt
axle shafts
Lubricate the telescope cable See Lubricating the Telebelt

Conveyors
Telescopic section rails that con-
See Lubricating the Telebelt
tact wear slides
Check conveyor rollers •
Engine
In accordance with the engine/transmission manufacturer’s maintenance information
Transmission
NOTE:
In the interest of safety and OSHA requirements, an annual inspection should
NOTICE be performed by a qualified inspector or technician to certify that the
outriggers, turret, and conveyors are in safe and optimal working condition.

Maintenance
4.3 Quick Reference Of Adjustment Values

Use Table 4 below as a quick reference for component adjustment values:
Table 4: Component Adjustment Values
Item Adjustment Value
Air pressure is adjusted to a factory set level. Ensure air regulator is turned on dur-
ing operation. A pressure of approximately 5 psi (0.345 BAR) will show on the
Air Pressure, Hydraulic three suction filters when the reservoir is pressurized and the unit is at rest. The res-
Reservoir ervoir filler cap is vented at 12 psi (0.83 BAR); check cap for proper operation by
pressing release valve in center of cap. Pressures higher than 15 psi (1.03 BAR)
can cause damage to the reservoir.
Pusher axle air pressure should be set to ensure that the axle is loaded to 10,000 lbs.
Air Pressure, Pusher Axle
Air pressure settings for individual units are noted on their rating plates.
Belt Tension, Feeder 1,500 - 1,800 psi (103 - 120 BAR), using gauge on portable hydraulic jack set.
Belt Tension, Main 1,000 - 1,200 psi (68 - 81 BAR), using gauge on portable hydraulic jack set. Main-
Conveyor tain enough tension to keep belt from wandering from side to side on the pulleys.
Cable Tension, Equalizer Snug only, do not over tighten or main conveyor may not fully extend or retract. A
(Helper) Cables sag of 1" to 1 1/2" in the center of a fully extended cable is acceptable.
Cable Tension, Telescope 2,500 psi (170 BAR), using gauge on portable hydraulic jack set.
Pump Pressure, Accessory

2,500 psi (170 BAR), this is the gear pump that operates the pressure washer.
Pump
Pump Pressure, Conveyor/ 319 psi (22 BAR) Standby (LOW) pressure adjustment.
Outrigger 4,000 psi (280 BAR) Full compensated (HIGH) pressure adjustment.
Pump Pressure, Feeder 218 - 232 psi (15 - 16 BAR) Standby (LOW) pressure adjustment.
Belt 4,000 psi (280 BAR) Full compensated (HIGH) pressure adjustment.
203 - 290 psi (14 - 20 BAR) Standby (LOW) pressure adjustment.

Pump Pressure, Main Belt
4,000 psi (280 BAR) Full compensated (HIGH) pressure adjustment.
Throttle Setting, Electric

Factory set according to engine transmission option.
Remote

Maintenance
4.4 Hydraulic System Oil Tank, Fluid Level Gauge, Thermometer, and
Air Pressure Regulator
Components of the hydraulic system oil tank, fluid level gauge and thermometer ar shown in Illustration
4-1 below:
6
2 TB4.4c
3 7
8
TB4.4a TB4.4b
Illustration 4-1: Hydraulic System Oil Tank, Fluid Level Gauge, and Thermometer
1. Oil tank filler cap with manual vent and pre-set pressure relief.
2. Hydraulic system oil tank – 150 gallon capacity, located on front part of pedestal, provides oil
for the hydraulic system.
3. Oil tank clean-out – Used to clean out debris inside of tank. Please refer to ‘Recommended
Maintenance Intervals’ table in 4.2 Maintenance Intervals section.
4. Oil tank fluid level gauge and thermometer – If oil temperature is below 40°F (4°C), perform
the “Cold Weather Startup” procedure. Oil cooler electric fan will automatically turn on at 131°F
(55°C). With unit in level position, check and ensure hydraulic fluid level is 2 inches from top of
sight glass with conveyors and outriggers in travel position.
5. Oil tank pressure regulator and water trap – This air pressure regulator is located in the elec-
tric control box compartment. It is not adjustable and will maintain 5 psi (0.345 bar) with the red
tab in the “up” position.
6. Tank pressurization valve red tab – For normal operation tab should be in “Up” position. For
maintenance/service of the hydraulic system, tab should be in the “Down” position (as shown).
7. Relief valve – Used to relieve pressure from hydraulic tank along with hydraulic filter cap vent.
8. Water trap – Any water that accumulates in the water trap should be drained as necessary.

Maintenance
4.5 Filter Element Replacement

Hydraulic oil becomes Very Hot at working temperature and may cause severe
burns. It is recommended to change filters when oil is at ambient temperature.
CAUTION: UNSAFE PRACTICES, COULD RESULT IN MINOR/MODERATE

DAMAGE.
Observe the following general instructions when replacing filter elements:
• Cleanliness is important in the maintenance of hydraulic systems. Ensure that no dirt or oth-
er impurities enter the system. Even very small particles can cause valves to be scored,
pumps to seize and choke, and control bores to become blocked.
• If possible, use a filler unit to fill up the hydraulic system. Never leave the tank lid open
longer than necessary.
• Always replace filter elements. As previously recommended in ‘Recommended Mainte-
nance Intervals’ table.
• Before installing new filters, check all O-rings and other seals and replace if damaged.
NOTE:ENVIRONMENTAL PROTECTION:
Dispose of old filter elements and any drained oil in appropriate containers or
NOTICE receptacles.

Maintenance
4.5.1 Replacing the Suction Oil Filter Elements
If a suction oil filter gauge is in the red range at operating temperature, replace the filter element by
performing the following steps:
11 1. Suction filter housing

1”
2. Set screw (bar magnet)

SAE 2”
2
1
3. O-ring (2) – 3.5” x 0.2” (90mm
3 x 5mm)
1 1/2”
4
1” 4. Hex nut (M6)
5
5. Valve disc
6. Seal
10
7. Filter lid stop and hex nut (2)
8. O-ring – 4.75” x 0.14” (120.25
6 mm x 3.53mm)
9
7 (A) 9. Filter cartridge
TB4.5.1-1a 8
10. Ball valve & hose assembly
11. Screw plug
TB4.5.1-1b
Illustration 4-2: Suction Oil Filter Assembly

1. Stop engine and disengage PTO's.
2. Push the red button on the hydraulic tank filler cap vent (item 1, Illustration 4-1), and open filler cap to
half-lock position to relieve air pressure from the reservoir before opening any part of the hydraulic
system.
3. Place a container under the ball valve and hose assembly (item 10, Ill. 4-2) to catch the hydraulic fluid.
4. Loosen and unscrew the hex nuts on the stops (item 7, Ill. 4-2).
5. Pull straight out and withdraw the filter element lid to the stops WITHOUT turning it.
NOTE: A foot valve in the base of the filter housing interrupts the fluid supply automat-
ically.
6. Wiggle the filter element loose to provide an air supply.
7. Open the ball valve to drain the hydraulic fluid.
8. Turn the filter lid to the left and pull out the filter element (as shown in (A)).
9. Unscrew the hex nut (item 4, Ill. 4-2) from the set screw (item 2, Ill. 4-2) on bar magnet. Do not loosen
set screw.

Maintenance
10. Remove the filter cartridge and dispose of properly.

Some filter elements available have too low of a flow rate and if used could
cause damage to the hydraulic system. It is recommended that only original
Putzmeister filter elements be used in order to prevent damage to the machine.
11. Thoroughly clean the filter housing and wipe down the bar magnet with a clean cloth.
12. Install new O-rings (item 3, Ill. 4-2) and put new filter element in place. Replace the retaining hex nut
(item 4, Ill. 4-2) onto set screw (item 2, Ill. 4-2) on bar magnet.
13. Check and adjust the set screw to achieve the correct element dimension. The correct dimension is
measured from the inner face of element lid to end of threaded stud at end of element. This stud opens
the foot valve disc (item 5, Ill. 4-2) as previously mentioned. Distance must be 13.6 inches (346 mm) ±
.02 inches (0.5 mm) for proper operation (shown in Illustration 4-3):
13.6 inches ± 0.02 (346 mm ± 0.5 mm)

13
.6”
±.
02
(34
6m
m
±0
.5)
TBE4.5.1-2
Illustration 4-3: Correct Length for Filter Element

The filtering process causes dirt particles to accumulate in the filter housing.
Therefore, the filter housing should be thoroughly cleaned before installing a
new filter cartridge or else the new filter cartridge will become dirty quickly and
decrease its life expectancy.
14. Clean and replace the filter lid O-ring (item 8, Ill. 4-2).
15. Install the filter element into the filter housing and turn the filter lid to the right until the two slots on
lid are installed all-the-way onto the stops (item 7, Ill. 4-2).
16. Close the ball valve.
17. Re-tighten the hex nuts on the stops to secure lid to filter housing.
18. Check oil level. Top off as necessary.
19. Start engine.
20. Check for leaks.

Maintenance
21. If any leaks are detected, go to steps 4-9 to remove element and check the O-rings.
22. If no leaks are detected, remove the container and properly dispose of the used hydraulic filters and
fluid.
4.5.2 Replacing the High Pressure Oil Filter Element

Do Not start the hydraulic pumps until the hydraulic system is re-pressurized
to 5 psi (0.35 BAR). A safety valve on the chassis air tank prevents supply to
this system if brake pressure is below 90 psi (6.2 BAR).
The high pressure filter has a bypass indicator on the valve assembly that indicates when the filter is in the
bypass mode. To replace the high pressure filter element, refer to Illustration 4-4 and perform the following
steps:
2
7
35 - 40 ft. lbs. (50 Nm)
1. Bypass indicator
2. Protecting cap
3. O-ring – 0.864” x 0.07”
3
(21.95 mm x 1.78 mm)
4. Filter element
5. Filter casing
5
6. Back-up ring
7. O-ring – 2.17” x 0.10”
(55.25 mm x 2.62 mm) 4
TB4.5.2-1
Illustration 4-4: High Pressure Filter Element

1. In cold conditions, the red bypass indicator (item 1, Ill. 4-4) may pop-up during initial startup. When
the hydraulic oil is at operating temperature (122°F, 55°C) and engine is at maximum RPM, check the
condition of the filter by pressing the red bypass indicator. The filter is OK if the indicator remains
depressed. If the indicator pops-up again, the filter needs to be replaced.
2. Stop engine and disengage PTO’s.

Maintenance
3. Push red tab on tank pressurization valve (item 6, Ill. 4-1) down to vent the tank.
4. Push the red button on the hydraulic tank filler cap vent, and open filler cap to half-lock position to
relieve air pressure from the reservoir before opening any part of the hydraulic system.
NOTE: This prevents leakage from the filter bypass hose.
5. Place a container under the filter casing (item 5, Ill. 4-4).
6. Loosen the filter casing using the hex nut (shown in Illustration 4-5) and allow the hydraulic oil to
drain.
EXAMPLE
Filter
Casing
Hex Nut
TB4.5.2-2
Illustration 4-5: High Pressure Oil Filter
7. Remove the filter element (item 4, Ill. 4-4) from the filter casing and dispose of properly.
Some filter elements available have too low of a flow rate and if used could
cause damage to the hydraulic system. It is recommended that only original
Putzmeister filter elements be used in order to prevent damage to the unit.
8. Thoroughly clean the filter casing with a clean cloth.
9. Clean and inspect O-rings and back-up ring (items 3, 6 and 7, Ill. 4-4). Replace as necessary.
10. Install a new filter element into the head of the filter assembly.
11. Install the filter casing and tighten using the hex nut to 35 - 40 ft. lbs (50 Nm).
12. Refill the hydraulic oil tank (up to maximum level) with previously recommended hydraulic oil.
13. Close filler cap.

Maintenance
14. Push red tab on tank pressurization valve ‘up’ to pressurize tank.
15. Start the engine.
16. Engage conveyor/outrigger PTO.
17. Check for leaks around the filter casing.
18. If no leaks are detected, remove the container and properly dispose of the used hydraulic oil.
19. If any leaks are detected, switch conveyor/outrigger PTO OFF and STOP engine.
20. Repeat steps 4-10 and inspect casing, O-ring, and back-up ring. Repeat steps 12-17.
4.6 Lubricating the Telebelt (TB110)

Before lubricating the Telebelt, refer to the “Recommended Oils and Greases”
table on page 4-3 for the recommended grease, hydraulic fluid, or gear oil to
use.
NOTE:
Lubrication points are indicated by decals affixed to the machine as shown in
NOTICE Illustration 4-6:
EXAMPLE
Decals Indicating
Lubrication Points
TB4.6-1
Illustration 4-6: Lubrication Points

Maintenance
To properly lubricate the Telebelt, perform the steps outlined in the diagrams that follow:
18 17 16 15 14
13
12
TELEBELT TB110 11
10
TB4.6-2 8
1 2 3 4 5 6 7
Illustration 4-7: Telebelt Truck Lubrication Points
Lubricate after every 50 hours of operating time or as otherwise indicated. Use appropriate grease for all locations,
except as noted:
1. 6 @ PTO drive shafts

2. 12 @ each outrigger
3. Daily – Check and fill hydraulic tank to maximum level with appropriate hydraulic oil
4. 2 @ main conveyor lift cylinder rod end (1 on each side)
5. 2 @ main conveyor lift cylinder base end (1 on each side)
6. 2 @ main conveyor pivot pin (1 on each side)
7. 1 @ conveyor turntable bearing and pinion gear teeth with open gear lubricant spray (NAPA
Chain & Cable Spray)
8. Check and fill conveyor slewing gear transmission and brake to mark with appropriate gear oil
9. 2 @ conveyor turntable ball bearings lube manifold
10. Check and fill telescope gear reducer to mark with appropriate gear oil
11. Every 200 hours – chain on conveyor telescope drive assembly with “NAPA Chain & Cable
Spray”
12. 4 @ telescope drive sheave bearings lube manifold
13. 2 @ conveyor drive pulley bearings
14. Check feed conveyor bearing and pinion gear teeth and lubricate with open gear lubricant
spray (NAPA Chain & Cable Spray)
15. 1 @ rear of transfer for feeder turntable bearing:
16. 2 @ feed conveyor drive pulley bearings. Lubricate every 8 hours of operating time.
17. 1 @ feed conveyor lift cylinder base end and 1 @ feed conveyor lift cylinder rod end
18. 2 @ feeder hinge (1 on each side)

Maintenance
4.6.1 Outrigger Lubrication
Illustration 4-8 shows the lubrication points for the front and rear outriggers (TB110 only):
2 1
5 4
TB0085 TB4.6.1a
Illustration 4-8: TB110 Outrigger Lubrication Points
Lubricate each outrigger after every 50 hours of operation using NLGI Class 2 grease.
1. Lock pin – 2 grease fittings

2. Cylinder pin – 2 grease fittings
3. Cylinder eye and pin – 3 grease fittings
4. Hinge pin (below) – 1 grease fitting
5. Lower hinge pin – 2 grease fittings
6. Pivot pin and cylinder eye – 2 grease fittings

Maintenance
4.6.2 Conveyor Arm Lubrication

DO NOT use any product containing graphite when lubricating the conveyor
arm slide rails. Damage to slide rails will occur due to softening of the UHMW
slide pads.
Illustration 4-9 shows the lubrication points for the conveyor arms:
1 2 3 4 5
TB4.6.2
Illustration 4-9: Conveyor Arm Lubrication Points
Lubricate after every 50 hours (or as indicated) of operation using “NAPA Chain and Cable Spray” or equivalent
1. Arm 1 top rails inside

2. Arm 2 top rails (inner and outer sides)
3. Arm 3 top rails (inner and outer sides)
4. Arm 4 top rails (outer side only)

Maintenance
4.6.3 Conveyor Sheave and Wire Rope Lubrication
The lubrication points for the conveyor sheaves and wire rope are shown in Illustration 4-10:
2 1
4 5
6 9
8
TBE4.6.3
7
Illustration 4-10: Conveyor Sheave and Wire Rope Lubrication Points

1. Conveyor Arm 1 – 2 @ head sheaves and 2 @ tail sheaves (total = 4)
4. Conveyor Arm 4 – 4 @ tail sheaves (total = 4)
5. Telescope traction drive cable (wire rope) – Lubricate with NAPA Chain and Cable Spray or
equivalent.
6. Traction drive sheave sets – Two grease fittings per set
7. Equalizer cable (wire rope) – Lubricate with NAPA Chain and Cable Spray or equivalent.
8. Sheave – There are a total of 20 sheaves with one fitting per sheave. Lubricate the sheave
bearings with NLGI Class 2 grease.
9. Telescope traction drive chain – Lubricate with NAPA Chain and Cable Spray or equivalent.
4.7 Maintaining the Conveyor Slewing Gear Reducer

To check the oil level, drain off water condensate, and change the oil in the conveyor slewing gear reducer,
perform the following steps:
NOTE:
Carry out the full oil change with the unit at operating temperature. This allows
NOTICE the reducer oil to flow out more easily. It is recommended that the reducer be
flushed out with a small quantity of oil to ensure that wear particles and
contamination are washed out.

Maintenance
Illustration 4-11 provides component locations for the conveyor slewing gear reducer, brake and motor:
OIL
SAE 90 1
MAX
MIN
TB4.7c
3a
3b
3c
4
8 5
Note:
Reducer oil drain plugs,
7 brake drain plug, and
brake oil filler shown 90°
6 from their original
TB4.7a positions for clarity.
TB4.7b
Illustration 4-11: Conveyor Slewing Gear Reducer, Brake, and Motor

1. Reducer oil breather
2. Reducer
3. Reducer oil drain plugs
4. Brake
5. Brake oil drain plug
6. Hydraulic motor
7. Screw plug for checking oil level
8. Brake oil breather
9. Inspection glass/sight gauge

Maintenance
4.7.1 Checking Oil Level
Check the oil level once a week when the engine is off, the reducer is idle, and the unit is level. The oil level
should not be below the lower edge of the inspection glass (item 9, Ill.4-11) or 1.2 inches (30 mm) below
the top of the oil breather (item 1, Ill. 4-11). To change oil, proceed as follows:
4.7.2 Changing Reducer Oil
The first full oil change should be carried out after the first 100 operating hours, and then thereafter after
every 2000 operating hours or annually.
1. Place an oil pan underneath gear reducer assembly to catch draining oil.
2. Remove the plug from the oil breather pipe (item 1, Ill. 4-11).
3. Remove the bottom oil drain plug (item 3c, Ill. 4-11).
4. After oil has stopped draining, replace the oil drain plug and hand-tighten.
5. Refer to Illustration 4-12 for procedures to refill the reducer with gear oil (SAE 90) up to the upper
edge (maximum level) of the sight gauge.

Maintenance
Oil Canister (1 Gal (3.78 L) Procedure for Refilling Reducer:

Filled 3/4 Full (approx. 3 qt./2.84 L)
of SAE 90 Gear OIl 1. Ensure that the ball valve is closed
before filling the oil canister.
2. Fill the oil canister with (3 qt./2.84 L)
Oil Breather SAE 90 gear oil.
Plug
3. Install the 3/8” straight pipe fitting into
the drain plug hole (item 3b) of the gear
OIL reducer and tighten until snug.
SAE 90
MAX 4. Open the ball valve.
MIN
5. Hold the oil canister up so that the bot-

Hose
(3-4 feet) tom of canister is above the sight gauge.
6. Allow oil to flow into reducer until oil is
Drain Plug visible in the center of the sight gauge.
(item 3b)
7. Close ball valve.
8. Remove the 3/8” straight pipe fitting
and re-install oil drain plug.
9. Re-install plug in breather pipe.
Hydraulic Fittings Used:
(1) 3/8” Straight Pipe Fitting
(Parker #6 HP5ON-SS)
(1) 3/8” FxF, Ball Valve
TB4.7.2 (Parker MV609-6)
(1) 1/2” to 3/8” Hose Barb
Fitting
(Parker 125HBL-8-6)
Illustration 4-12: Changing Reducer and Brake Oil

Maintenance
4.7.3 Changing Brake Gearbox Oil

1. Remove the plug from the brake oil breather (item 8, Ill. 4-11).
2. Remove the brake oil drain plug level (item 5, Ill. 4-11) and allow all oil to drain. Replace plug.
3. Remove oil level plug (item 7, Ill. 4-11).
4. Install the oil canister fittings as shown in Illustration 4-13.
5. Fill the oil canister with one quart (.95 L) of SAE 90 gear oil.
6. Using the oil canister and following the procedures in Illustration 4-13, fill the gearcase with gear oil
(SAE 90).
Oil Canister (1 Gal (3.78 L)

Procedure for Refilling Brake Gearbox:
Filled with (1 qt./.95 L) SAE 90 1. Ensure that the ball valve is closed
Gear Oil
before filling the oil canister.
2. Fill the oil canister with (1 qt./.95 L)
SAE 90 gear oil.
3. Install the 3/8” straight pipe fitting into
OIL the drain plug hole (item 3c) of the
SAE 90
MAX
brake gearbox and tighten until snug.
MIN
4. Open the ball valve.
Hose 5. Hold the oil canister up so that the bot-
(3-4 feet)
tom of canister is above the sight gauge.
6. Allow oil to flow into gearbox until oil
begins to flow out of oil level plug (item
Oil Breather 7, Ill. 4-11). Close ball valve.
Plug
7. Remove the 3/8” straight pipe fitting
Oil Level and re-install oil drain plug.
Plug Hydraulic Fittings Used:
8. Re-install oil level plug.
(Parker #6 HP5ON-SS) 9. Re-install plug in oil breather.
(1) 3/8” FxF, Ball Valve
(Parker MV609-6)
(1) 1/2” to 3/8” Hose Barb
TB4.7.3
Fitting
(Parker 125HBL-8-6)
Illustration 4-13: Changing Brake Gearbox Oil

Maintenance
4.7.4 Feed Conveyor Slewing Gear Reducer
The feed conveyor slewing gear reducer is located on the underside of the feeder base assembly (feeder
turntable bearing) on the driver’s side.
To check the oil level and change the oil in the feed conveyor slewing gear reducer, perform the following
steps:
NOTE:
Carry out the full oil change with the unit at operating temperature. This allows
NOTICE the reducer oil to flow out more easily. It is recommended that the reducer be
flushed out with a small quantity of oil to ensure that wear particles and
contamination are washed out.
Illustration 4-14 provides component locations for the feed conveyor slewing gear reducer and brake:
1. Vent
2
2. Vent tube
3. Reducer breather tube

3
4. Cap plug
9 5. Brake breather
4
6. Brake drain plug
5 7. Cap plug for checking oil level

8
8. Brake oil level
7
9. Reducer oil level
6
TB4.7.4
Illustration 4-14: Feed Conveyor Slewing Gear Reducer and Brake

Maintenance
4.7.4.1 Changing Reducer Oil

The first full oil change should be carried out after the first 100 operating hours, and then thereafter after
every 2000 operating hours or annually. The reducer has two separate reservoirs within the gearbox. Each
reservoir must be drained and filled separately.
Changing Lower Reservoir Oil
1. Place an oil pan underneath gear reducer assembly to catch draining oil.
2. Remove the brake drain plug (item 5, Ill. 4-14).
3. After oil has stopped draining, install oil canister fittings as shown in Illustration 4-15.
4. Refer to Illustration 4-15 for procedures to refill the lower reducer gearbox with SAE 90 gear oil up to
reducer oil level.
Oil Canister (1 Gal. (3.78 L) Procedure for Refilling Reducer:

Filled 1/2 Full (approx. 2 qt./1.9 L)
of SAE 90 Gear Oil 1. Ensure that the ball valve is closed before
filling the oil canister.
2. Fill the oil canister approximately 1/2 full

(2 qt.) of SAE 90 gear oil.
3. Install the 3/8” x 1/4” pipe nipple on 3/8”

straight pipe fitting.
4. Install 1/4” end of pipe nipple to drain plug

port on gear reducer brake and tighten un-
Hose
(3-4 feet) til snug.
Drain Plug Port 6. Hold the oil canister up so that the bottom
On Brake
of canister is above the reducer oil level
(item 6, Ill. 4-13).
7. When oil has stopped draining from the

canister into the reducer, set the canister
Hydraulic Fittings Used:
(1) 3/8” x 1/4” Pipe Nipple, Hex
down and close the ball valve (make sure to
TB4.7.4.1-1
(Parker 216P-6-4) have the drain plug ready to install).
(Parker #6 HP5ON-SS) 8. Remove the pipe nipple and straight pipe
(1) 3/8” FxF, Ball Valve fitting.
(Parker MV609-6)
(1) 1/2” to 3/8” Hose Barb
Fitting 9. Re-install the drain plug.
(Parker 125HBL-8-6)
Illustration 4-15: Changing Feed Conveyor Reducer Lower Reservoir Oil

Maintenance
Changing Upper Reservoir Oil
1. Remove the cap plug (item 4, Ill. 4-14) allowing oil to drain.
2. Remove the reducer oil level plug (item 9, Ill. 4-14).
3. After oil has stopped draining, install the oil canister fittings as shown in Illustration 4-16.
4. Using the oil canister and following the procedures in Illustration 4-16, fill the brake with SAE 90 gear
oil.
5. Replace the drain plug and hand-tighten.
Procedure for Refilling Reducer:

Oil Canister (1 Gal. (3.78 L)
Filled with (1 qt./.59 L) of 1. Ensure that the ball valve is closed before
SAE 90 Gear Oil
filling the oil canister.
2. Fill the oil canister with (1 qt./.95 L) of SAE

90 gear oil.
3. Install the 3/8” x 1/4” pipe nipple on 3/8”

straight pipe fitting.
4. Install 1/4” end of pipe nipple to cap plug

Hose port on gear reducer and tighten until
(3-4 feet)
snug.

Cap Plug
Port
6. Hold the oil canister up so that the bottom
of canister is above the reducer oil level
(item 9, Ill. 4-14).
7. Allow oil to flow into reducer housing until

oil begins to flow from the oil level tube
Hydraulic Fittings Used: (item 3, Ill. 4-14).
(1) 3/8” x 1/4” Pipe Nipple, Hex
(Parker 216P-6-4)
(1) 3/8” Straight Pipe Fitting 8. Close ball valve.
(Parker #6 HP5ON-SS)
TB4.7.4.1-2 (1) 3/8” FxF, Ball Valve 9. Remove the pipe nipple and straight pipe
(Parker MV609-6) fitting and re-install cap plug.
(1) 1/2” to 3/8” Hose Barb
Fitting
(Parker 125HBL-8-6) 10. Re-install the reducer oil level plug.
Illustration 4-16: Changing Feed Conveyor Reducer Upper Reservoir Oil

Maintenance
4.8 Hydraulic Jack Set

All Telebelts are shipped with a hydraulic jack set (P/N A311810). The hydraulic jack set is used to tension
the main and feed conveyor belts, and to tension the telescope traction drive cable.
4
6
3
7
5
2 11
10
9
12
TB0010-13-8
Illustration 4-17: Hydraulic Jack Set
1.Retracting chain 7.Coupler

2.Pressure gauge tee with 2 8.Pin and chain
needle valves
3.Ram end 9.Hand pump
4.Cylinder 10.Pump needle valve
5.Ram collar 11.Fitting
6.Hydraulic hose 12.Hydraulic jack set tray

Maintenance
CAUTION:
When the hydraulic jack set is assembled, the ram ends need to be tightly
screwed into the ram ends. If they come loose, the threaded end of the ram end
will bend when pressure is applied, and the threads will be damaged.
Ram End
Pressure Gauge
Tee with Needle
Valves
Hand
Pump
Illustration 4-18: Hydraulic Jack Set
To prevent damage to the ram end threads, follow the procedure below:
A. Connect the pressure gauge tee to coupling on the hand pump.

B. Connect the hydraulic hoses to the cylinders and the needle valves on pressure gauge tee.
C. Screw the ram ends into the cylinders – hand tight.
D. Close the needle (relief) valves and pump both rams out fully.
E. Continue pumping until there is about 2000 psi showing on the gauge.
F. Hold one cylinder at a time with one hand and sharply strike the side of the ram end with a 4-pound
hammer.
The preceding procedures both seats the threads of the ram ends and checks for fitting leaks.

Maintenance
4.9 Tensioning the Feed Conveyor Belt

To adjust the tension of the feed conveyor belt by extending hopper end section, perform the following steps:
NOTE:
NOTICE The tension of the feed conveyor belt is adjusted by extending the hopper end
section.
Retaining Bolt & Nut

Guide Block on
ti
ec
i nS
Ram End Ma
4.8
TB
Retaining Bolt & Nut
Guide Block
Ram End
n
c tio
d Se Pump Needle
En Valve
Ram Needle
Valves
Illustration 4-19: Tensioning Feed Conveyor Belt

1. Using the hydraulic jack set, fit collars over rams and pin rams to end section top flange so that ram
ends make contact with main section guide blocks (as shown in Illustration 4-17).
2. Connect hand pump and both rams to pressure gauge tee.
3. Remove nuts from retaining bolts that connect the end section to the main section.
4. With pump needle valve closed and both ram needle valves open, operate pump to extend ram ends
against end section guide blocks. Apply enough pressure to remove the end section retaining bolts.
5. Extend end section further until gauge on jack reads 1500-1800 psi (103-120 Bar) or until ram ends
are fully extended.
NOTE:
If one side of the end section starts to bend or bind, close the ram needle valve
NOTICE that is feeding pressure to the ram on the side of the bind. Then gradually pump
to push on the other side until both sides can slide into the conveyor rails
evenly.

Maintenance
6. If belt tension is sufficient (i.e., at 1500-1800 psi), perform the following steps:
A. Secure end section to main section with retaining bolts. Adjust ram strokes as required to align bolts
to holes in take-up rails.
B. Release pressure from ram ends by opening pump needle valve.
C. Remove rams from take-up rails.
7. If belt tension is NOT sufficient with ram ends fully extended, install retaining bolts, retract ram ends,
move rams toward main section, pin rams to end section top flange, and repeat above steps.
4.10 Training (Aligning) the Feed Conveyor Belt

To adjust the training (aligning) of the feed conveyor belt, refer to Illustration 4-18 and perform the
following steps:
Belt travel –
Either direction
1
If belt runs to-

ward this side
of tail pulley
2
3
TB4.9b
TB4.9a Then tighten the adjusting bolt on

1. Feed conveyor belt this end of the tail pulley
2. Tail pulley
3. Adjusting bolt – Used to train (align)
conveyor belt
Illustration 4-20: Feed Conveyor Belt Training (Aligning) at Tail Pulley

1. If the belt tends run to one side of the pulley, tighten tail pulley adjusting bolt (item 3, Ill. 4-18) on that
side one turn at a time.

Maintenance
NOTE: The feed conveyor belt may have to be run for several complete loops before a
full response to belt training adjustments occurs.
4.11 Adjusting a U-Roller (Feed Conveyor)

If belt runs true at head and tail pulleys but runs to one side of U-rollers, one or more U-rollers located near
the area of run-off may require adjustment.
1. Center line of U-rollers

2. Side idler brackets, which are always
after U-rollers
3. Arrow painted on belt
4. Direction of travel
5. To move belt to right. . .
6. Move U-roller forward on this side. . .
1
2
3 4
0-1
TB4.1
6
5
TB4.10-1a
Illustration 4-21: Feed Conveyor Belt Training at U-Roller

1. To adjust a U-roller, move it one or more holes forward in the conveyor rails, as shown (item 6, Ill. 4-
19).

Maintenance
4.12 Replacing the Feed Conveyor Belt

To replace the feed conveyor belt, refer to Illustration 4-20 and perform the following steps:
4.12.1 Removing the Old Feed Conveyor Belt

1. Lower feed conveyor down so that feet are touching the ground. Refer to the “Feed Conveyor Setup”
procedure.
2. Disengage conveyor belt and conveyor/outrigger/feeder PTO’s and turn the engine off.
3. Remove hairpins from boot pins and chains and pull boot/deflector assembly from discharge end sec-
tion.
4. Release tension on head scraper. To release tension, pull up on T-handles, remove hairpins and allow
T-handles to drop down through slotted holes into the end section. Remove head scraper assembly.
5. Using portable hydraulic jack set, release tension of the belt at hopper end section by performing the
following steps:
A. Fit collars over rams and pin rams to end section top flange so that ram ends make contact with main
section guide blocks (as shown in Illustration 4-17).
B. Connect hand pump and both rams to pressure gauge tee.
C. With pump needle valve closed and both ram needle valves open, operate hand pump to extend ram
ends against end section guide blocks. Apply enough pressure to remove the end section retaining
bolts.
D. Slowly release pressure from ram ends by opening pump needle valve. Allow ram ends to retract
easing conveyor belt tension. As tension is eased, end section will retract somewhat.
6. Move the hopper end section further into the main section to allow removal of pulley assemblies. Man-
ually push in end section or use hydraulic jack set to pull end section in by performing the following
steps:
A. Fit collars over rams and pin rams to end section top flanges so that ram ends will extend away from
main section (as shown in Illustration 4-20).
B. Use retracting chains to grab main section with chain links. Pull chain over to pinned ram end and
fasten chain to ram end.
C. With pump needle valve closed and both ram needle valves open, operate hand pump to retract main
section as required.

Maintenance
NOTE: If one side of the main section starts to bend or bind, close the ram needle valve
that is feeding pressure to the ram on the side of the bind. Then gradually pump
to pull on the other side until both sides can slide into the main section guide
blocks.
D. When ram ends are fully extended, release pressure from ram ends by opening pump needle valve.
E. Reposition chains and repeat this step if end section requires further retracting.
Retracting Chain
4.1
Ram TB
Retracting Chain
Ram Needle
Valve
Ram
Illustration 4-22: Removing the Old Feed Conveyor Belt

7. Remove bolts and retainers and pull tail pulley out of bracket.
8. Remove V-scraper mounting brackets from hopper end section.
9. Remove all U-rollers and upper side idlers. Do not remove any return rollers.
NOTE:
Before removing these roller assemblies, note their locations and orientation
NOTICE for re-assembly.
10. Remove torque arm pin from drive motor bracket at end section.

Maintenance
11. Loosen collet tension bolt at discharge end section. Tap collet tension bolt to disengage hydraulic
motor. Remove motor, unscrew bolt completely and remove collet. Refer to “Removing the Old Col-
let” procedure.
12. Remove pulley bearing box bolts and remove drive pulley and bearing boxes from end section as one
piece.
13. Remove old belt.
4.12.2 Installing the New Feed Conveyor Belt

1. Unroll new belt in conveyor laying belt on bottom rollers.
NOTE:
When installing new belt, ensure that:
NOTICE – Belt is the correct size for your conveyor (18” x 76’ for TB110 feed conveyor).
– Belt is positioned with the thickest layer (wear layer) up and splice
orientation as shown in Illustration 4-21 below.
– The arrow painted on the new belt points in the direction of travel.
1 3
2
6
5
TB4.11.2
4
1. Thick rubber cover to the outside (or load side) of the belt
2. Thin rubber cover runs on the pulleys
3. Direction of travel (yellow arrow is painted on top)
4. Head scraper
5. Correct direction of splice
6. Direction of travel
Illustration 4-23: Feed Conveyor Belt Installation
2. Install head and tail pulleys. Installation is the opposite of disassembly.
3. Install hydraulic motor, collet, and torque arm pin.
4. Install U-rollers and upper side idlers.
5. Install V-scraper mounting brackets and V-scraper.

Maintenance

The V-scraper must be installed correctly to prevent material from being caught
between the belt and pulley, which will damage the belt. After installing V-
scraper, check clearance between scraper blade and conveyor belt. Blade edge
should be positioned just above but not touching the belt. If necessary, tap V-
scraper brackets using a hammer and pin driver to affect positioning of scraper
blade.
6. Tension feed conveyor belt. Refer to “Tensioning the Feed Conveyor Belt” procedure.
NOTE:
Tension the belt by extending tail end section until pressure gauge on portable
NOTICE hydraulic jack reads 900 psi (62 BAR). Replace tail section retaining bolts after
correct tension has been achieved.
7. Install head scraper.
8. Apply tension to head scraper. Pulling up on T-handles draws the head scraper blade to the belt. After
applying tension, reinstall hairpins through holes in T-handles to hold scraper against the belt.
NOTE:
Correct tension of head scraper is made at time of pour. At that time, apply
NOTICE enough tension to keep the belt clean and ‘black’ but not enough tension to
actually remove belt material. At initial installation and when testing the belt,
apply light tension only.

Over-tightening the head scraper will shorten belt life and damage the splice.
9. Install boot/deflector assembly.

10. Test run conveyor and check belt training.

Initial start-up should be made with extreme care. Run the belt (jog the belt) for
approximately 100 feet and check belt training (alignment). If the belt tracks to
one side of conveyor or pulleys, adjust training (aligning) as required. If belt
trains (aligns) properly, repeat trial run a few times to be sure training
(alignment) is correct.

Maintenance
4.13 Replacing the Feed Conveyor Motor Collet

To replace the feed conveyor motor collet, perform the following steps:
6
5
4
1 2
TB4.12
7
8
Illustration 4-24: Replacing the Feed Conveyor Motor Collet

1. 18 mm ribbed lock washer
2. 3/4-inch washer SAE
3. Collet tension bolt
4. Collet
5. Collet key (1/4 inch x 2 inch)
6. Torque arm pin
7. Feed conveyor drive pulley
8. Hydraulic motor
4.13.1 Removing the Old Collet

1. On end of pulley opposite motor, unscrew collet tension bolt a few turns.
2. Strike bolt head with a hammer to force collet out of its taper.
3. Remove torque arm pin and hydraulic motor.
NOTE:
It is not necessary to disconnect hydraulic hoses when pulling out the
NOTICE hydraulic motor during collet replacement. However, it is recommended that
the motor be supported by chain, cable, etc., to avoid damage to hose
connections.
WARNING:
Do not disconnect hydraulic hoses from motor unless hydraulic pumps are
disengaged.
4. Fully unscrew collet tension bolt and remove collet, being careful not to lose collet key.

Maintenance
4.13.2 Installing the New Collet

1. Check collet key and bore for damage. Replace defective parts.
2. Apply lubricant to the following areas:
• Outside of collet
• Inside of pulley opening
• Collet tension bolt threads
3. Install collet and key in pulley bore. Hold collet in place and start threads of collet tension bolt (with
flat washer and lock washer installed properly) in threads of collet. Screw collet tension bolt in hand
tight. Refer to Illustration 4-22.
4. Insert motor shaft in collet splines. Push motor in until it bottoms against collet. Collet tension bolt and
collet will pull motor up against the rail when tightened. Refer to Illustration 4-22.
5. Hold motor in position and slowly tighten collet tension bolt while rocking the motor by hand, up,
down and side-to-side. This ensures that motor shaft splines are properly seated in collet splines so that
motor wobble and collet wear are reduced.
6. Re-install torque arm pin.

Do not use bolts in place of torque arm pin.
7. Torque collet tension bolt to 120-160 ft.-lb. (162 to 216 N-m). To prevent drive pulley from rotating
while tightening bolt, retain pulley with a chain wrench or have an assistant hold the belt.
8. Strike end of collet tension bolt a few times with a heavy hammer an re-torque bolt. Repeat once or
twice more to ensure that bolt is fully and properly tightened.
9. To be sure that collet is properly ‘seated,’ check collet tension bolt torque/tightness:
• After first 30 minutes of operation
• On a daily basis for the first five days of operation
Damage to collet and/or motor shaft splines can occur if collet tension bolt
becomes loose during operation.
NOTICE
Some wobble in the feed conveyor motor is normal.

Maintenance
4.14 Tensioning the Telescope Traction Drive Cable

IMPORTANT:
The traction drive cable should not sag more than 6 inches at end of truss when
main conveyor is fully extended.
To adjust the tension of the main conveyor traction drive cable, refer to Illustration 4-23 and perform the
following steps:
1 2
1. Tight cable (reference)
TB4.13-1
2. 6 inches maximum deflection
Illustration 4-25: Traction Drive Tensioning

Do not attempt to make any adjustments to the traction drive cable unless the
electrical control system and the engine are off and lock out - tag out procedure
is used.
1. Remove cover that protects traction drive cable tensioning cylinder on base section of main conveyor.
2. Attach hydraulic hose at rod end port of cable tensioning cylinder to hydraulic jack set pressure gauge
tee and hand pump as shown in Illustration 4-24.
3. Open cylinder needle valve feeding tensioning cylinder and close pump needle valve.
4. Operate pump to retract tensioning cylinder. If cable is under tension, apply enough hydraulic pressure
to cable tensioning cylinder rod end to remove pins that secure cable anchor to take-up rail. See Illus-
tration 4-24:

Maintenance
1 2 6 1. Tensioning cylinder
TB4.13-2
2. Conveyor (take-up) rail
3. Tensioning cylinder anchor and pins
3 4. Piston head side vent
5 7
4 5. Cylinder rod end port (apply pump pres-
sure here to tension rope by retracting
8 cylinder)
6. Cable anchor and pins
9
7. Traction drive cable
8. Pressure gauge tee
9. Hydraulic jack
Illustration 4-26: Traction Drive Cable Tensioning

5. Retract cable tensioning cylinder rod until gauge on jack reads 2500 psi (170 BAR) or until cylinder
rod is fully extended.
6. If cable tension is sufficient (i.e., at 2500 psi) or cylinder rod is fully retracted, perform the following
steps:
A. Secure cable anchor to take-up rail with pins. Adjust cylinder stroke as required to align pins to
holes in take-up rail.
B. Release pressure from cable tensioning cylinder by opening pump needle valve. This causes the ca-
ble anchor to take the load of the cable.
7. If cable tension is NOT sufficient with cylinder rod fully retracted, perform the following steps:
A. Secure cable anchor to take-up rail with pins. Adjust cylinder stroke as required to align pins to
holes in take-up rail.
B. Remove pins to free cylinder anchor from take-up rail.
C. Open pump needle valve, manually extend cylinder, and pin cylinder anchor to take-up rail.
D. Repeat above steps 3 through 5.
8. Disconnect hydraulic pump and pressure gauge tee.
NOTE:
Each end of the traction drive cable is secured by three cable clamps.
NOTICE Periodically check that these clamps are tight.

Maintenance
4.15 Replacing the Telescope Traction Drive Cable

To replace the telescope traction drive cable, refer to Illustration 4-25 and perform the following steps:
1. Release tension at take-up cylinder.

2. As shown in Illustration 4-25 below, remove the old cable and install the new cable:
13 12
Arm 1
11 10
Arm 2
Telescope Drive Group
Horizontally mounted
sheaves stacked vertically 9
Arm 3 8
22 20 18 16 14
X 7 25 Arm 4
Fly Section Group
Horizontally mounted
Driver’s side
sheaves stacked vertically 6 24 Arm 4 Passenger’s side
23 21 19 17 15
Arm 3 5
4
Arm 2
2 3
Arm 1 Take-up Cyl. X

1 X = Cable end with thimble, clamps,
and clevis OR cable with swaged socket
TB4.14-1
The numbers 1 through 25 correspond with the 25 sheaves used by the telescope cable assembly.
Illustration 4-27: Telescope Cable Reeving
NOTE:
As shown in Illustration 4-25:
NOTICE
– All vertically mounted sheaves are reeved counterclockwise.
– Looking down on horizontally reeved sheaves, 6 & 7 reeve clockwise and all
others reeve counterclockwise.
When installing a new cable, please remember the following points:
– The current production telescope cable has a swaged socket on the end that
connects to the telescope drive assembly dead head. This cable is designed
to be pulled through from the telescope drive assembly to the tension
cylinder. If it is not practical to pull the cable through in this direction, then
cut the swaged end off and use cable clamps and thimbles on both ends.

Maintenance
– The telescope cable may be pulled in from either end. The easiest way to pull
a new cable in is to attach the new cable to the old cable and pull the new
cable through while pulling the old cable out. Attaching to the old cable is
made by butt welding, or creating a four foot long flat splice. If there are any
broken strands on the old cable, cut them off and secure the cut strands to
avoid catching as the old cable is pulled out.
3. As shown in Illustration 4-26, ensure that the cable clamps are properly installed.
4 5
TB4.14-2
As shown, the cable clamps are directional. Ensure that the saddle of the clamp is on the ‘live’ end and the U-bolt
compresses the cut end. Leave a 4 ft. (1.2m) “tail” beyond cable clamps and tie it out of the way.
1. Teledrive assembly
2. Swaged socket – on end of cable that attaches to teledrive assembly
3. Cable clamp saddle – on ‘live’ end of cable
4. Cable clamp U-bolt – on cut end of cable
5. 4 ft. (1.2m) “tail”
6. Take-up cylinder
Illustration 4-28: Telescope Cable Ends

4. Re-tension cable to 2500 psi (170 BAR).
5. Check cable tension regularly using the “Tensioning the Telescope Traction Drive Cable” procedure.

Maintenance
4.16 Adjusting the Equalizer (Helper) Cables

To adjust the equalizer (helper) cables, use Illustration 4-27 and perform the following steps:
There are four equalizer (helper) cables used on

5 the TB110. These cables are 9/16-inch in diam-
eter, 35 feet in length, and have a swaged pin
3 clevis on one end. These cables ARE NOT part
of the main telescope cable reeving arrange-
4 9 ment.
1. Arm 1
5 2. Arm 2
3. Arm 3
2 4. Arm 4 (head)
6 5. Telescope stop
6. Anchor
7. Anchor and adjustment
7 8. Extend equalizer cable (one on each side) –

Runs from anchor (item 6) on Arm 3,
around sheave on inner end of Arm 2, and
ends at anchor on Arm 1 (item 7).
1 8 9. Retract equalizer cable (one on each side) –
Runs from anchor on Arm 3, around sheave
on outer end of Arm 2, and ends at anchor
on Arm 1.
TB4.15
Illustration 4-29: Equalizer (Helper) Cables

Maintenance
NOTE:
Equalizer cable operation:
NOTICE
– The main telescope drive cable (not shown in Illustration 4-27) moves the
conveyor head section (Arm 4) in and out. When the head section (Arm 4)
reaches full extension or retraction, it acts against stops on Arm 3.
– Arm 3 is pulled or pushed by Arm 4 (head section). As Arm 3 moves, it pulls
the equalizer cables with it. The cables, in turn, act against the ends of Arm
2 to extend it or retract it. The equalizer cables extend Arms 2 & 3 equally. The
cables also reduce the torque requirement of the telescope drive motor.
Equalizer cable adjustment:
– Tension on the main telescope cable is important, since it is a traction
(friction) drive and low tension causes slippage. Tension of the equalizer
cables is not as important. A fully extended equalizer cable can have 1 to 1 1/
2 inches of sag in the center and not create a problem. Equalizer cables do
not rely on tension or friction.
– Equalizer cables that are too tight can cause problems. Over-tightened
extend equalizer cables will make boom retraction impossible. The same is
true for over-tightened retract equalizer cables, full extension is limited.
1. With boom fully retracted, snug the retract (outer) pair of equalizer cables.
NOTE:
All adjustments are made at the anchors (item 7, Ill. 4-27) on the conveyor base
NOTICE section (Arm 1), using the nuts on the cable anchors. Ensure that each anchor
has a jam nut that is tightened after adjustments are made. Also, periodically
check that the three securing cable clamps are tight.
2. With main conveyor fully extended, snug the extend (inner) pair of equalizer cables.

Maintenance
4.17 Tensioning the Main Conveyor Belt

To adjust the tension of the conveyor belt, refer to Illustrations 4-28 & 4-29 and perform the following steps:
Conveyor Arm 1 Conveyor
Drive
Pulley Secondary
Take-Up
Pulley
Adj.
Conveyor
Belt Adj. Primary Take-Up Pulley
TB4.16-1
NOTE:
Move the primary and secondary take-up pulleys away from drive pulley to tension belt.
Illustration 4-30: Tensioning the Conveyor Belt
1 8
7 1. Ram end
2
6 2. Ram with collar, pins and hydraulic hose
2
16-
TB4. 3. Take-up rails – Primary-conveyor arm 1,
secondary-conveyor arm 4
4. Pressure gauge tee with 2 needle valves
5. Hydraulic jack (Hand pump)
2
1 6. Take-up pulley
7. Belt
3
8. Pulley bracket
4
9. Pulley bracket retaining bolts (and nuts)
5
Illustration 4-31: Tensioning Belt with Hydraulic Jack Set

Maintenance
4.17.1 Tensioning Belt Using Hydraulic Jack Set

1. Locate the primary take-up pulley at the head end of conveyor arm one (shown in Illustration 4-28).
2. Pin each ram (item 2, Ill. 4-29) to the take-up rails (item 3, Ill. 4-29) of either the conveyor base or
inner-mid section so that the ram heads (item 1, Ill. 4-29) make contact with the take-up pulley bracket
(item 8, Ill. 4-29).
3. Connect the couplers of the rams to the pressure gauge tee (item 4, Ill. 4-29) and hand pump (item 5,
Ill. 4-29).
4. Ensure that pump needle valve is closed and both gauge needle valves open, then operate hand pump
to extend ram ends against the pulley bracket. Apply enough pressure to remove the pulley bracket
retaining bolts (item 9, Ill. 4-29).
5. Continue to operate pump extending ram ends until the pressure gauge reads 1000–1200 psi (68– 81
BAR) or until ram ends are fully extended.
NOTE: If one side of the pulley bracket starts to bend or bind, close the needle valve that
is feeding pressure to the ram on the side of the bind. Then gradually pump to
push on the other side until both sides can slide into the conveyor rails evenly.
6. If belt tension is sufficient at 1000 – 1200 psi (68 – 81 BAR), perform the following steps:
A. Secure pulley bracket to take-up rails with retaining bolts. Adjust ram strokes as required to align
bolts to holes in take-up rails. Count the bolt holes to ensure that the pulley bracket is square in the
rails.
B. Release pressure from ram ends by opening pump needle valve.
C. Remove rams from take-up rails.
7. If belt tension is still NOT sufficient with ram ends fully extended, pin pulley bracket in place, retract
ram ends, and re-pin rams closer to the pulley bracket on the take-up rails and repeat above steps.
8. If end of arm one is reached and belt tension is NOT sufficient, perform these steps:
A. Release belt tension at take-up pulley and slide pulley toward tail of arm one.
B. At secondary take-up pulley bracket, in tail of arm four, remove retainer bolts in rail slides.
C. Pull secondary take-up bracket toward tail end of arm four. Count holes to ensure that take-up
bracket is square with rails and replace bolts.
9. If end of truss section is reached and belt tension is NOT sufficient, perform the following steps:
A. Release belt tension at take-up pulley and slide pulley toward tail of truss section.
B. At secondary take-up bracket, in tail of head section, remove retainer bolts in slide rails.
C. Pull secondary take-up bracket toward tail end of head section and replace bolts. Count holes to en-
sure that take-up is square with rails and replace bolts.
D. Re-tension belt at main take-up by repeating above steps.

Maintenance
4.17.2 Secondary Belt Take-Up Adjustment

CAUTION:
Read and follow all procedures. Use a ‘Lock out - Tag out’ procedure and
observe all safety rules when working on the TelebeltTM
CAUTION:
Do not place hands, arms or any body parts into the main conveyor or
telescoping sections without first ensuring that the engine is off.
CAUTION:
When the belt is re-spliced or replaced, make sure to position the secondary
take-up first. This will prevent the take-up bracket from hitting the end frame of
the next section.
Secondary take-up is in the heel

Main Take-Up of the tip section. The next sec-
tion overlaps this area and hides
it from view.
Illustration 4-32: Main and Secondary Take-Up
As the main belt stretches, it can be adjusted by both the main and a secondary belt take-up. There is
approximately five feet of main belt take-up and four feet of secondary take-up which equals 9 feet of take-
up or equivalent to 18 feet of belt length to tighten the belt.
The secondary take-up is located in the heel of the tip section of the main conveyor. Using the secondary
take-up reduces the expense of re-splicing a belt sooner than necessary.

Maintenance
NOTE:
Both of the take-ups must be fully retracted before re-splicing or replacing the
NOTICE main belt.
The following procedures applies to Telebelt models TB 80, TB 105, TB 110,

TB 130, and TB 600.
4.17.2.1 Adjustment of Secondary Take-Up
If the end of the truss section take-up is reached and the belt tension is NOT sufficient, perform the following
steps:
CAUTION: Personal Injury Hazard
To avoid personal injury, place a bolt into the last hole of the main conveyor
take-up rail so that the take-up bracket does not slide back and fall out.
Adjustment
Track
Take-Up
Bracket
Illustration 4-33: Secondary Take-Up Bracket

Maintenance
CAUTION:
Only tighten the secondary take-up enough to remove the slack. Do final
tensioning with the hydraulic jack set at main take-up.
Put a bolt into the first hole of the main take-up track.
E. Release belt tension at take-up and slide pulley toward tail of truss section.
F. At the secondary take-up bracket, in the tail of the tip section, remove retainer bolts in rail slides.
1 9
4
4 4
8
3
3
S 2 7
2 2
1 1 1 6
3
5 TB4.18-1
4
Illustration 4-34: Main Conveyor Belt Reeving
1.Conveyor belt 6.Inner midsection (I)

2.Drive pulley 7.Outer midsection (O)
3.Snub pulley (S) 8.Tip or head section (H)
4.Main or base section (B) 9. Tip section or secondary take-up
(approx 4 ft.)
5. Main or base section take-up
(approx 5 ft.)
NOTE: The main belt is tightened when the secondary take-up is tightened from right to
left and the main take-up is tightened from left to right.
G. Pull secondary take-up bracket toward the tail end of tip section and replace the bolts. Count the num-
ber of holes to ensure that the take-up is square with the rails, and replace the bolts. Only pull the belt
snug – do not stretch the belt at this time.
H. Re-tension the belt at main take-up using the hydraulic jack set as provided in the Telebelt Operating
Instructions “Maintenance” chapter.

Maintenance
--5
Secondary -13
010
Take-Up Rail TB0
9
8 Adjustment Track
1
2
7
6
4 5
3
8 Rail
Illustration 4-35: Arm 4 / Tip Section Secondary Take-Up
1.Secondary take-up bracket 6.Lock nut

2.Pulley (5 in.) 7.Flat washer
3. Hexagon-head cap screw 8.Flat washer
4.Flat washer 9. Hexagon-head cap screw
5.Pulley retainer
Tip for Adjusting the Secondary Take-Up
Using the hydraulic jack set on the secondary take-up to tension belt can be cumbersome, instead use a

Maintenance
heavy bar or pipe to hold the take-up bracket in place.
Put a heavy bar or pipe through the

conveyor sections behind the
take-up bracket
Illustration 4-36: Use a Heavy Bar or Pipe Behind Take-Up Bracket
Fully extend the head / tip section and half of the next section.
I. Retract tip section approximately 10 feet.

J. Slide a heavy bar or pipe through the conveyor behind the tip side of secondary take-up bracket (see
Illustration 5).
K. Loosen take-up bracket with hammer and remove retaining bolts from adjustment track.
L. Telescope tip section out slowly until belt is snug, not tight.
M. Replace bolts and ensure that bracket is square by counting the number of bolt holes on both sides.
N. Retract tip section slightly and remove the heavy bar or pipe.
NOTE:
Run belt slowly and check for run-off at the main and secondary take-ups. Use
NOTICE a single jack to correct the run-off.

Maintenance
4.18 Training (Aligning) the Conveyor Belt

4.18.1 Training (Aligning) Main Conveyor Belt at Head Section
IMPORTANT:
Belts should run in center of all pulleys. Belts that are properly trained
(centered) generally will not “de-train” on their own. Belts that start to wander
on the pulleys indicate improper tension (loose belt).
Ensure that belt is properly tensioned before attempting to re-train the belt.
During the course of operation, if the conveyor belt appears to be running to one side or another adjust the
training (alignment) of the conveyor belt by performing the following steps:
1. If the conveyor belt tends to run to one side of a pulley (except drive pulley), tighten the pulley adjust-
ing bolt on that side, one turn at a time (refer to Illustration 4-30).
NOTE:
When telescoping the main conveyor with the belt turned ‘off’, the belt may run
NOTICE to one side of a pulley. Once the belt is engaged, it should return to center.
If belt runs toward this side, If belt runs toward this side,
tighten this adjusting bolt. tighten this adjusting bolt.
One turn at a time. One turn at a time.
TB4.17.1
Illustration 4-37: Main Conveyor Belt Training (Aligning) at Head Section
NOTE: The conveyor belt may need to run for several complete loops before a full re-
sponse to belt training adjustments occurs.
2. Carefully restart the conveyor at a slow speed and observe effect of adjustments.
3. If the belt requires further adjustment, repeat step one.

Maintenance
4.18.2 Main Conveyor Belt Training (Alignment) at Drive Pulley
If belt runs to one side of drive pulley, refer to Illustrations 4-31 & 4-32 and perform the following steps:
8 1
Steel Cross member
2
TB4.17.2-1b
7
6
4
TB4.17.2-
TB4.17.2-1c
Illustration 4-38: Main Conveyor Belt Training (Alignment) at Drive Pulley

1. Drive pulley adjusting bolt
2. Snub pulley
3. Conveyor belt
4. Pulley retainer (adjusting) bolt
5. 5” (127 mm) pulley (roller)
6. Distance between drive pulley bearing block and mounting plate
7. Distance between drive pulley bearing block and snub pulley
8. Drive pulley bearing block
A. Check belt centering on the 5 inch (127 mm) pulley (item 5, Ill. 4-31) located at rear bottom of base
section. Centering belt on this roller will usually center the belt on the drive pulley as well. Adjustments
to this pulley are made using either of the two pulley retainer bolts (item 4, Ill. 4-31). Tightening the
bolt causes the belt to move away from bolt.
B. If belt is still not centered on drive pulley, check and verify that the drive pulley is square to frame and
steel cross member. Refer to Illustration 4-31. Check and make sure that ends of the drive pulley are
equal distance from the steel crossbreed. If not, adjust using bolts (item 1, Ill. 4-31). Check that the snub
pulley (item 2, Ill. 4-31) is parallel to the drive pulley. If not, use slotted holes in sub pulley brackets to
adjust.

Maintenance
5 Inch (127 mm) Pulley
If belt runs to-

ward this side
of drive pulley
TB4.17.2-2
Then tighten the adjusting bolt on this
end of the 5 in. (127 mm) pulley
Illustration 4-39: Belt Training Using 5 Inch (127 Millimeter) Pulley
NOTE: The conveyor belt may need to run for several complete loops before a full re-
sponse to belt training adjustments occurs.
C. Carefully restart the conveyor at a slow speed and observe effect of adjustments.
D. If the belt requires further adjustment, repeat step A.

Maintenance
4.19 Replacing the Main Conveyor Belt

To replace the main conveyor belt, refer to Illustrations 4-33 & 4-34, and perform the following steps:
1
9
4
4 4
8
2 3
3
S 2 7
2
1 1 1 6
3
4 5 TB4.18-1
1. Conveyor Belt 4. Arm 1 7. Arm 3
2. Drive Pulley 5. Arm 1 take-up (5 feet) 8. Arm 4
3. Snub Pulley 6. Arm 2 9. Arm 4 take-up (4 feet)
Illustration 4-40: Main Conveyor Belt Reeving

1. For ease of installation, extend conveyor fully.
2. Remove head scraper and V-scrapers.
9 1. Ram end
8
1
7 2. Ram with collar, pins and hydraulic hose
2
6
3. Take-up rails – Conveyor arm 1 primary
TB4
.18-2 take-up pulley at head end
4. Pressure gauge tee with 2 needle valves
5. Hydraulic jack (hand pump)

2
1 6. Primary take-up pulley
7. Belt
3 4
8. Pulley bracket
5
9. Pulley bracket retaining bolts (and nuts)
Illustration 4-41: Using Hydraulic Jack to Replace Main Conveyor Belt

Maintenance
3. Using portable hydraulic jack set, release tension on the belt by performing the following steps:
A. Fit collars over rams (items 1&2, Ill. 4-34) and pin rams to take-up rails on Arm 1 so that ram ends
make contact with pulley bracket (item 8, Ill. 4-34).
B. Connect hand pump (item 5, Ill. 4-34) to both rams to the couplers on pressure gauge tee (item 4,
Ill. 4-34).
C. Ensure that pump needle valve is closed and both gauge needle valves are open, then operate hand
pump to extend ram ends against the pulley bracket. Apply enough pressure to remove the pulley
bracket retaining bolts (item 9, Ill. 4-34).
D. Slowly release pressure from ram ends by opening pump needle valve. As ram ends retract, the pul-
ley bracket will retract and belt tension will be eased.
E. Disconnect pressure gauge tee from rams and remove rams from take-up rails.
F. Fully retract take-up pulley (item 8, Ill. 4-34) along the take-up rails. Create as much belt slack as
possible by fully retracting take-up pulley.
4. Remove snub pulley from conveyor.
5. Remove old belt and install new belt by performing these steps:
• Cut old belt at truss section.
• Tie new belt to old belt.
• Pull new belt in by pulling old belt out in normal direction of travel. It may be necessary to idle the
main drive pulley if it resists belt travel.
6. If old belt has already been removed, reeve new belt through conveyor sections as shown in Illustration
4-33.
NOTE:
When installing new belt, ensure that:
NOTICE
– Belt length is > 235 feet.
– Belt is positioned with the thickest layer (wear layer) to the outside as shown
in Illustration 4-35.
– The arrow painted on the new belt points in the direction of travel.
– Belt ends meet on top of conveyor to ease vulcanizing.

Maintenance
1 3
2
6
4 5
TB4.18-3
1. Thick rubber cover to the outside (load side) 4. Head scraper
of belt
5. Correct direction of splice
2. Thin rubber cover runs on the pulleys
6. Direction of belt travel
3. Direction of travel (arrow painted on top)
Illustration 4-42: Main Conveyor Belt Installation

7. Slice (vulcanize) new belt as shown in “Telebelt Splicing Procedure” section.
IMPORTANT:
Pay close attention to the way the belt is cut to produce the splice. If the splice
NOTICE is made improperly, the head scraper will catch and open the splice the first
time that the belt is run with the head scraper installed.
8. Replace snub pulley.

9. Replace head and “V” scrapers.
10. Manually extend head section take-up pulley. Refer to the “Tensioning the Main Conveyor Belt” pro-
cedure.
11. Train (align) the belt. Refer to the “Training (Aligning) the Main Conveyor Belt” procedure.
12. At time of material placement, tension head scraper.
Insert TB0010-5 Replacing Guide Blocks Here

Maintenance
4.20 Torquing the Feeder Turntable Bearing Bolts

Maintaining proper torque values for bolts is very important for structural
strength, performance, and reliability of the Telebelt unit. Variations in torque
can cause distortion, binding, or complete separation of the feed conveyor
base from turret. Failure to maintain proper torque of the turntable bearing
attaching bolts will result in damage to the unit structure and possible injury to
personnel.
CAUTION:
Proper identification of bolt grade is important. When marked as a high
strength bolt (grade 10.9), all personnel working on the unit must be aware of
bolt classifications and that ONLY high strength heat-treated tempered bolts
are installed. The fasteners must be installed according to specifications.
Special attention should be given to the existence of lubricant and plating that
will cause variation from dry torque values. When a high strength bolt is
removed, or un-torqued, the bolt MUST be replaced with a new bolt of the same
classification, along with a new high strength hardened flat washer.
NOTE:
If while checking the inner and outer race bearing bolts, one or more is found
NOTICE to be loose, it is likely that the bolt has stretched and will require replacement.
When replacing bolts, be sure to replace the high strength hardened flat
washers.
To torque the feeder turntable bearing bolts, refer to Illustration 4-36 for proper bolt tightening sequence
and perform the following steps:

Maintenance
Feeder Turntable Bearing Bolts &

Hardened Flat Washers
Feeder Turntable Bearing
Feeder Base
TB4.19b
31 35 1 5
35 1 5 27 9
27 31 9 13 23 13
23 19 17
19 17 15 2
21
15 1 21
25 11 25
11
29 7 29
7
3 33 3 33
34 4 34 4
30 8 30 8
26 12
16 26 12
22
18 20 22 16
14 24 18 20
10 6 28 14 24
2 36 32 10 6 28
TB4.19a
2 36 32
Torque inner race and outer race bolts to 310 pounds-foot (420 newton-meters). Torque inner race bolts first, then
torque outer race bolts using sequence shown.
1. Inner race of feeder turntable bearing bolts – (36) M18 x 2.5, grade 10.9 bolts and hardened flat
washers. These bolts secure the feeder turntable bearing to the feeder base.
2. Outer race of feeder turntable bearing bolts – (36) M18 x 2.5, grade 10.9 bolts and hardened flat
washers. These bolts secure the feeder turntable bearing to the feeder base.
Illustration 4-36: Feeder Turntable Bearing Bolt Tightening Pattern

Maintenance
4.21 Checking the Main Conveyor Turntable Bearing Bolts

CAUTION:
This inspection should be carried out by qualified personnel.
Do not tighten loose bolts, but replace them with new ones. In addition, the two
bolts to the left and the two bolts to the right of the loose bolt must be replaced.
Use only original spare parts as listed in Table 5.
NOTE:
NOTICE The main conveyor turntable bearing bolts must be checked every 500 hours of
operation or at least once a year.
To check and replace the main conveyor turntable bearing bolts, perform the following steps:
31 35 1 5
35 1 5 27 9
27 31 9 13 23 13
23 19 17
19 17 15 2 21
15 1 21 4
25 11 25
11
29 7 3 29
7
3 33 3 33
4
34 4 34 4
30 8 30 8
26 12
16 26 12
22
18 20 22 16
14 24 18 20
10 6 2 28 14 24
36 32 10 6 28
TB4.20 2 36 32
1. Inner race of main conveyor turntable bearing bolts – (36) M24 x 130, grade 12.9 bolts and
hardened flat washers. These bolts secure the main conveyor turntable bearing to the ped-
estal.
2. Outer race of main conveyor turntable bearing bolts – (36) M24 x 130, grade 12.9 bolts,
hardened flat washers, and spacer sleeves (26.9 x 44.5 x 48.0). These bolts secure the main
conveyor turntable bearing to the turntable assembly.
3. Loose connecting bolt (example) – Loose bolt(s)
4. Connecting bolts that must also be replaced.
Illustration 4-37: Main Conveyor Turntable Bearing Bolts

1. Replace the loose bolts and the two neighboring bolts on each side.

Maintenance
2. Oil the thread and the head bearing surface with SAE 30 oil and tighten the replacement bolts in accor-
dance with the torque specification table below.
Bolt Tightening Torques
Tightening torques
Size Part number (AN)
Ft. lbs (Nm)
066560005
M12 81 (110)
M12 x 50 912-12.9U130
042568005
M24 DIN934-10 Hex Nut
M24 553 (750)
042969002
M24 x 75 DIN931-10.9 HT BLK
043133002
M24 x 130 912-12.9U130
231468000
M24 x 150 912-12.9U130
M24 650 (880)
043134001
M24 x 170 912-12.9U130
043135000
M24 x 250 912-12.9U130
222770008
M30 x 170 912-12.9U130
M30 1290 (1750)
223045004
M30 DIN934-12 Hex Nut

Maintenance
4.22 Telebelt Belt Splicing Procedure

This belt splicing method has been developed for the following reasons:
• To achieve full tensile strength through splice area
• To prevent the scraper blade from opening the splice
• To obtain longer service life of the belt
• To prevent moisture and small particles from reaching the belt core.
The following Telebelt belt splicing procedures are applicable to 18” wide belts. They must be followed
exactly for maximum conveyor performance.
4.22.1 Belt Characteristics
The standard 7/16”-thick Telebelt belt is made up of three layers (plies) as shown in Illustration 4-38. The
top ply (the thicker one) is the load carrying side. The middle ply (tensile part) of belt is constructed of fab-
ric ply. The bottom ply (the thinnest one) is the non-load carrying side. The Telebelt belt is special for these
reasons:
• High strength, will not wear unevenly
• Tracks true without riding up idlers
• Troughs evenly with 45 degree idlers
• Resists stretching, tearing, fraying, impact, abrasion, and cutting
• Resists chemicals, rot, mildew, and delamination
3
TB4.21.1
1. Layer (ply) I: top cover – load carrying side (width = 3/16”)
2. Layer (ply) II: fabric ply – core (width = 3/16”)
3. Layer (ply) III: bottom cover – non-load carrying side (width = 1/16”)
Illustration 4-38: Belt Layers (Total Width = 7/16”)

Maintenance
4.22.2 Belt Length Determination
The belt length to cut is shown in Table 6:
Belt Length
TB110 Main Conveyor 247 ft. NEL (Net Endless Length)
TB110 Feed Conveyor 76 ft. NEL
4.22.3 Belt Rolling
During belt rolling, ensure to not damage belt with chains, cables, forklifts, or any handling equipment the
belt may come in contact with.
4.22.4 Belt Splicing Procedure
NOTE:
Careful and accurate work is required for belt splicing. Experience in handling various
tools, such as knives, ply lifters and ply knives, is important for successful results in
belt splicing. Personnel without previous experience, should practice the procedure
on scrap belts until familiarization with tools is obtained. Best results will be achieved
by following the instructions carefully.
4.22.4.1Working Area
Use a worktable that is flat, smooth, and stable, and is at least 6” wider than the belt width and is about 6’
in length. If possible, an extension table can be used for extra working area and convenience. For proper
drying and bonding of the cement, room temperature should be at 70° F (22° C).
4.22.4.2Material Required (for Standard Telebelt Belt)
Materials for splicing TB110 belts should be compatible with RMA (Rubber Manufacturer’s Association)
Grade 1 rubber compounds, and should include the following:
• Solvent
• Cement
• .020 tie gum
• Cover gum
• Light breaker fabric
• Release paper

Maintenance
4.22.4.3Tools Required
Illustration 4-39 shows the tools required for belt splicing.
04_039
Illustration 4-39: Belt Splicing Tools
Tools required for belt splicing procedure:

1. C-clamps (4 required)
2. Cross bar (4 required)
3. Carpenter’s square
4. Carpenter’s plier
5. Ply lifter
6. Pliers
7. 2” roller
8. 1/2” roller
9. 1/8” roller
10. One polisher/grinder 4” or 6”
11. Grinding disc – 24 grit
12. Buffing brush
13. Pencil
14. Hand brushes (large and small)
15. One ply knife
16. Flat knife

Maintenance
17. Flat knife sharpener

18. Utility knife
4.22.4.4Precautions
The following precautions should be taken:

• The cutting edge of the one ply knife should be sharp and the knife should be held 45° to the belt sur-
face so that the land of the knife will be flat on the ply.
• Do not cut deeper than required with the one ply knife. (If the knife cuts through the second ply, the
ply is ruined).
• Brush and clean all surfaces with solvent before applying cement on them.
• Keep cement and repair gum cans tightly sealed and stored in a dry place.
• Stir cement thoroughly before and during use.
• The cement and solvent should be allowed to dry thoroughly.
• Splices must be accurately aligned and matched.
• Surfaces with cement and gum applied are to be kept clean.
• Make a trial fit of the spliced ends when they are dry to be sure about the splice. Align both edges and
check each step or skive for fit. A slight gap is permissible, but edges must not lap.
A splice is ruined if:

• A knife cuts through two plies.
• Air bubbles are left in the splice.
• Splices do not align correctly.
• Spliced area is not cleaned thoroughly.
• Fabric is damaged while buffing bevels on the load carrying side.
• The splice is not vulcanized at the correct temperature, correct pressure, or for the correct amount of
time.
4.22.4.5Inch to Millimeter Conversion
Table 7 provides inch to millimeter conversions, additional conversions are also available in “U.S./Metric
Conversions” section.
Inch to Millimeter
Inch 1/64 1/32 1/16 1/8 3/16 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1
MM .397 .794 1.588 3.175 4.763 6.350 7.938 9.525 12.7 15.875 19.05 22.225 25.4

Maintenance
4.22.4.6Belt Splicing
To splice a belt, perform the following procedures:

1. Stretch out right end of belt on table with the load carrying side (top cover layer) on top and strap it
down with a cross bar and a pair of C-clamps. As shown in Illustration 4-40, draw the following lines
using a pencil and a square:
• Base line #1
• Base line #2
• Ply 1 cut
• Ply 2 cut
• End cut
• Top cover bevel cut
REMOVE TOP COVER TO

3“
FABRIC PLY BEVEL CUT COVER
17.5” 1.5” REMOVE BOTTOM COVER TO
18” STEP TO A FABRIC FABRIC PLY BEVEL CUT COVER
REINFORCEMENT 16”
STEP TO A FABRIC 51”
REINFORCEMENT
TRAVEL
45°
TOP COVER
B
THIS SIDE TOP COVER
THIS SIDE
18”
45°
A TRAVEL
3“
51” BEVEL TO FRAY/BREAK CORDS
16” 17.5”
STEP TO A FABRIC
18”
STEP TO A FABRIC
GRIND TAPER ON REINFORCEMENT REINFORCEMENT
TOP COVER
1.5”
51”
1. Base line #1
6
TRAVEL 7 2. Base line #2 (51”
from base line #1)
18”
45°
3. Ply 1 cut
2 4 5 4. Ply 2 cut
3 1 5. End cut
16” 17.5” 18” 6. Top cover bevel cut
TB4.21.4.6-1
1.5”
7, Bottom cover cut
3“
Illustration 4-40: Drawing “Cut Lines” on Right End of Belt

Maintenance
2. Flip belt over so that non-load carrying side (bottom cover layer) is on top. As shown in Illustration 4-
41, draw the following lines using a pencil and a square:
• Base line #1
• Base line #2
• Bottom cover bevel cut
TB4.21.4.6-2
TOP VIEW
TRAVEL
18”
45°
16” 17.5” 18”

6
1.5” 3 3“
7 9 5
11 2
8 4
10
12 1
Refer to this Illustration while performing steps 3 to 12 of this procedure
1. Bottom cover bevel cut

2. End cut
3. Top cover bevel cut
4. Ply 1 cut
5. Ply 2 cut
6. Top cover rubber layer
7. Ply 1 fabric layer
8. Skim coat rubber layer #1
10. Skim coat rubber layer #2
12. Bottom cover rubber layer
Illustration 4-41: Performing Cuts on Right End of Belt

3. Along “bottom cover bevel cut” line, perform a 45° slant cut (skive) through the bottom cover layer
of rubber only with a sharp hand knife. Ensure that you do not cut into ply 3.

Maintenance
4. Using ply lifter and carpenter’s pliers, pull from ply 3 the first three inches of the bottom cover rubber
next to the bottom cover bevel cut. This will expose the ply 3 layer 1.5 inches further from where the
end cut will be made.
5. Flip belt over so that the top cover is on top and along the “end cut” line, cut through all layers of the
belt with a sharp knife.
6. Along “top cover bevel cut” line, perform a 45° slant cut through the top cover layer of rubber only
with a sharp knife. Ensure that you do not cut into ply 1.
7. Using ply lifter and carpenter’s pliers, pull from ply 1 the first 2.5 inches of the top cover rubber next
to the top cover bevel cut. This will expose the ply 1 layer one inch further from where the ply 1 cut
will be made.
8. Along “ply 1 cut” line, cut through the ply 1 layer only with a sharp knife. Ensure not to cut into ply 2
layer.
9. Remove ply 1 layer from the “ply 1” cut line to the end of the belt. This will expose the ply 2 layer.
10. Redraw the “ply 2 cut” line on ply 2.
11. Along “ply 2 cut” line, cut through the ply 2 layer only with a sharp knife. Ensure that you do not cut
into ply 3 layer.
12. Remove ply 2 layer from the “ply 2 cut” line to the end of the belt. This will expose the ply 3 layer.
13. Stretch out left end of the belt on the table with non-load carrying side (bottom cover rubber layer) on
top and strap it down with cross bar and a pair of C-clamps. As shown in Illustration 4-42, draw the
following lines using a pencil and a square:
• Base line #1
• Base line #2
• End cut
• Ply 2 cut
• Ply 3 cut
• Bottom cover bevel cut

Maintenance
1.5”
3“
51”
18” 17.5” 16”
45° TRAVEL
TRAVEL
18”
45°
16” 17.5” 18”

51”
1.5” 3“
1. Base line #1
3“ 1.5” 2. Base line #2 (51 inches

from base line #1)
18” 17.5” 16”
3. End cut
45° 7 TRAVEL 4. Ply 2 cut
3 4 5 6
5. Ply 3 cut
1
2
6. Bottom cover bevel cut
TB4.21.4.6-3 51”
7. Top cover bevel cut
Illustration 4-42: Drawing “Cut Lines” on Left Side of Belt

14. Flip over belt so that load carrying side (top cover rubber layer) is on top. As shown in Illustration 4-
43, draw the following lines:
• Base line #1
• Base line #2
• Top cover bevel cut

Maintenance
3“ 1.5”
18” 17.5” 16”
TRAVEL
45°
TOP VIEW
51”
1 6
SIDE VIEW
2
8
5 4 10
TB4.21.4.6-4 7
9
3 12
11
1. Top cover bevel cut 7. Ply 1 fabric layer

2. End cut 8. Skim coat rubber layer #1
3. Bottom cover bevel cut 9. Ply 2 fabric layer
4. Ply 3 cut 10. Skim coat rubber layer #2
5. Ply 2 cut 11. Ply 3 fabric layer
6. Top cover rubber layer 12. Bottom cover rubber layer
Illustration 4-43: Performing Cuts on Left End of Belt – Refer to this diagram while performing Steps 12 to 24.
15. Along “top cover bevel cut” line, perform a 45° slant cut through the top cover layer of rubber only
with a sharp knife. Ensure that you do not cut into ply 1.
16. Using ply lifter and pliers, pull from ply1 the first three inches of the top cover rubber next to the top
cover bevel cut. This will expose the ply 1 layer 1.5 inches further from where the end cut will be
made.
17. Flip over belt so the bottom cover is on top and along the “end cut” line, cut through all layers of belt
with knife.
18. Along “bottom cover bevel cut” line, perform slant cut through the bottom cover layer of rubber only
with knife. Ensure not to cut into ply 3.

Maintenance
19. Using ply lifter and pliers, pull from ply 3 the first 2.5 inches of the bottom cover rubber next to the
bottom cover bevel cut. This will expose ply 3 layer one inch further from where the ply 3 cut will be
made.
20. Along “ply 3 cut” line, cut through the ply 3 layer only with knife. Ensure not to cut into ply 2 layer.
22. Redraw the “ply 2 cut” line on ply 2.
23. Along “ply 2 cut” line, cut through the ply 2 layer only with knife. Ensure not to cut into ply 1 layer.
25. On both ends of the belt, use wire wheel brushes to remove any loose rubber from the entire splice
area.
26. Buff approximately 2 inches beyond the top and bottom bevel cuts on both ends of the belt.
NOTE:
Start at Step 27 in this procedure if you have purchased a belt with its ends already
prepared.
27. Align the belt splice to make sure all ply’s, cuts, and edges are square and do not overlap.
TB4.20.4.6-5
2 1
6
6
4
5
3
1. Left end of belt
2. Right end of belt
3. Splice area
4. Step area – This is the area between ply 1 cut (on right end of belt) and ply 3 cut (on left end of belt).
Cement and tie gum are applied to this area.
5. Cover strip area – Breaker fabric and cover gum are applied to this area
6. Ply 2 cut – This is the alignment point for the belt ends
Illustration 4-44: Splicing the Belt Ends (Side View)

Maintenance
NOTE:
Perform Steps 28 through 42 for top cover, flip belt over, and then repeat Steps 28
through 42 for bottom cover.
28. Wash complete splice area with solvent and clean rag.
29. Apply cement to any exposed cords. Let dry.
30. Apply 2 coats of cement on step area of both ends of splice.
NOTE:
Allow cement to dry between coats. Ensure not to cement cover strip area.
31. Put tie gum on one end of cemented splice area, and remove any air pockets.
32. Poke tie gum with a sharp object to allow any trapped air to escape. Ensure not to damage the fabric
when doing this.
33. Lay the splice together making sure all edges and ply’s are square, straight, and not overlapped.
34. Roll the splice to remove any air.
35. Trim excess fabric (approximately 1.5 inches of 3-inch flap on top or bottom cover rubber) at cover
strip area.
36. Wash buffed cover strip area and allow to dry completely.
37. Apply 2 coats of cement, and allow to dry completely.
38. Put approximately 1-inch wide strip of breaker fabric over ply seam.
39. Roll cover gum into cover strip area (3/16-inch top, 1/16-inch bottom).
40. Trim excess cover with knife.
41. Put narrow (approximately 1/2-inch) 1/16-inch cover gum strip on center of cover strip at fill area.
42. Place release paper that has been coated with cement on cover strip area.
43. Put belt in Vulcanizer with 5/16-inch thick steel edge irons held in place with pipe clamps.
44. Cure belt at 290° F (143° C) for 30 minutes at 100 psi (6.9 BAR).
45. Cool belt quickly to between 100° F and 150° F (38° – 65° C) while still at 100 psi (6.9 BAR).
46. Remove belt from press. Trim and clean edges.

Maintenance
4.23 Checking and Adjusting Hydraulic Pump Pressures

This section contains procedures for checking and adjusting the main, feeder, and boom/outrigger hydraulic
pump pressure settings. All three hydraulic pumps are pressure-compensated variable displacement axial
piston pumps wit a swash plate design. A test gauge kit must be attached to the appropriate test port while
performing these procedures:
NOTE:
A gauge assembly kit is included with the Telebelt Ship-Away Kit.
1
2
TB4.22-1
1. Gauge assembly #1 - This gauge consists of a hydraulic hose with a 400
mm minimess fitting on one end and a 1/4” fitting on the other end for a
0-60 BAR (0-882 psi) hydraulic pressure gauge (P/N 016372007).
2. Gauge assembly #2 - This gauge consists of the same set up as gauge as-
sembly #1 except a 0-400 BAR (0-5880 psi) hydraulic pressure gauge is
used (P/N 017250005).
Illustration 4-45: Gauge Assembly Kit
High and low pressure adjustment screws are on the compensator valve block of each hydraulic pump.
They have an acorn nut cover, a 3/4 in. hex socket adjustment screw and a lock nut. The adjustment screws
are next to each other; the smaller one controls standby (low) pressure (item 1, Ill. 4-46) and the larger con-
trols compensator (high) pressure (item 2, Ill. 4-46). Turning them in clockwise (CW) increases pressure.
Turning them out counterclockwise (CCW) decreases pressure. If any adjustment is made to the standby
(low) pressure setting, make sure to re-check the compensator (high) pressure setting, as these settings
interact.

Maintenance
Illustration 4-46 shows the location of the two pressure adjustment screws on the hydraulic pump:
3
1
TB4.22-2
1. Standby (low) pressure adjustment screw (3/4 in. / 20 mm)
2. Compensator (high) pressure adjustment screw (3/4 in. / 20 mm)
3. Main belt, feeder belt, or boom/outrigger hydraulic pump

Illustration 4-46: Location of High and Low Pressure Adjustment Screws
4.23.1 Checking and Adjusting Feeder Belt Pump Low Pressure Setting
To check or adjust the standby (low) pressure setting for the feed conveyor belt hydraulic pump, refer to
Illustration 4-47 & 4-48 and perform the following steps:
6
5
OFF
2
1
ON
TB4.22.1/2
Illustration 4-47: Feed Conveyor Belt Test Port (M2A)

Maintenance
1. 60 BAR test gauge

2. Feed conveyor belt test port (M2A)
3. Feed conveyor belt manual bypass valve
4. Feed conveyor belt manual bypass speed control - This knob should be opened or closed only
when the bypass valve (item 3, Ill. 4-47) is OFF (handle in up position as shown). This knob is
very difficult to turn when the bypass valve is on. This control knob should be left closed when
not in use. This protects the plastic indicator stem that comes up when the valve is opened.
These control knobs should be opened and closed once a month to prevent any buildup of
corrosion in the valves (caused by cleaning water seeping down in the valve stems).
5. Feed conveyor belt proportional valve
6. Feed conveyor load-sensing shutoff valve
1. Connect 60 BAR test gauge (item 1, Ill. 4-47) minimess fitting to feed conveyor belt test port (M2A).
2. Disconnect electrical connector on feed conveyor belt proportional valve (item 5, Ill. 4-47).
3. Reset E-stop (so that load-sensing shutoff valve is energized) or manually bypass feed conveyor load-
sensing shutoff valve (item 6, Ill. 4-47) by turning its knurled knob (beneath plastic cap) fully (CCW).
NOTE:
This procedure cannot be performed unless the feed conveyor load sensing shutoff
valve is either energized or bypassed.
2
Feed Conveyor
Manual Bypass
in ON position
60 BAR
Test Gauge
TB4.22.1-2
Illustration 4-48: 60 BAR Test Gauge Connected to Test Port

Maintenance
4. Ensure that feed conveyor belt manual speed bypass control (item 1, Ill. 4-48) is turned all of the way
in (CW). With the feed conveyor belt manual bypass valve in the ON position (item 2, Ill. 4-48), this
knob (item 1, Ill. 4-48) adjusts the feed conveyor belt speed.
5. Turn ON feed conveyor belt manual bypass valve (item 2, Ill. 4-48) by pushing its valve lever down.
This manually bypasses the radio or cable remote control.
6. Read standby (low) pressure at test gauge.
NOTE:
All pressure readings and adjustments must be made at maximum RPM.
7. If necessary, adjust standby (low) pressure to 20 BAR using standby (low) pressure adjustment screw
(item 1, Ill. 4-46) on feed conveyor belt hydraulic pump compensator valve block.
8. Disconnect 60 BAR test gauge minimess fitting from feed conveyor belt test port (M2A) and recon-
nect electrical connector on feed conveyor belt proportional valve (item 5, Ill. 4-47).
9. Turn OFF feed conveyor belt manual bypass valve (item 2, Ill. 4-48) by pulling its valve lever up.
10. If the feed conveyor load-sensing shutoff valve (item 6, Ill. 4-47) was manually bypassed in Step 3,
turn its knurled knob (beneath the plastic cap) fully (CW). This returns the load-sensing shutoff valve
to its normal position (unbypassed).
11. If adjustments are made, re-check high pressure setting, since these settings interact. Proceed to proce-
dure for checking and adjusting feeder belt pump high pressure setting in section 4.22.2.
12. If no adjustments are made, test is complete.

Maintenance
4.23.2 Checking and Adjusting Feeder Belt Pump High Pressure Setting
To check or adjust the compensator (high) pressure setting of the feed conveyor belt hydraulic pump, refer
to Illustrations 4-49 & 4-50 and perform the following steps:
6
5
OFF
2
ON
TB4.22.1/2
Illustration 4-49: Feed Conveyor Belt Test Port (M2A)

2. Feed conveyor belt test port (M2A)
3. Feed conveyor belt manual bypass valve
4. Feed conveyor belt manual bypass speed control - This knob should be opened or closed only
5. Feed conveyor belt proportional valve
6. Feed conveyor load-sensing shutoff valve
1. Connect 400 BAR test gauge (item 1, Ill. 4-49) minimess fitting to feed conveyor belt test port (M2A).
2. Reset E-stop (so that load-sensing shutoff valve is energized) or manually bypass feed conveyor belt
load-sensing shutoff valve (item 6, Ill. 4-49) by turning its knurled knob (beneath plastic cap) fully
(CCW).

Maintenance
NOTE:
This procedure cannot be performed unless the feed conveyor load-sensing shutoff valve
is either energized or bypassed.
3. Disconnect and cap feeder hoses at feeder motor.
1 Feed Conveyor Belt Manual

Speed Control (turned fully
counterclockwise)
2
Feed Conveyor
Manual Bypass
in ON position
400 BAR
Test Gauge
TB4.22.1-2
Illustration 4-50: 400 BAR Test Gauge Connected to Test Port (M2A)
4. Ensure that feed conveyor belt manual speed bypass control (item 1, Ill. 4-50) is turned all the way out
(CCW). With the feed conveyor belt manual bypass valve lever pushed down (item 2, Ill. 4-50), this
knob (item 1, Ill. 4-50) adjusts the feed conveyor belt speed.
5. Turn ON feed conveyor belt manual bypass valve (item 2, Ill. 4-50) by pushing its valve lever down.
6. Read compensator (high) pressure at test gauge.
NOTE:
7. If necessary, adjust compensator (high) pressure to 280 BAR using taller screw (item 2, Ill. 4-46) on
feed conveyor hydraulic pump compensator valve block.

8. Turn off feed conveyor belt manual bypass valve (item 2, Ill. 4-50) by pulling its valve lever up.
9. Disconnect 400 BAR test gauge minimess fitting from feed conveyor belt test port (M2A).
10. Remove the caps previously installed on the two feed conveyor motor hoses and re-connect them to
the feed conveyor motor.
11. If adjustments are made, re-check low pressure setting, since these settings interact (use procedure for
checking and adjusting feeder belt pump low pressure setting in section 4.22.1).
12. If the feed conveyor load-sensing shutoff valve (item 6, Ill. 4-49) was manually bypassed in Step 2,
turn its knurled knob (beneath plastic cap) fully (CW). This returns the load-sensing shutoff valve to
its normal position (unbypassed).
13. Turn manual bypass speed control (item 1, Ill. 4-50) off by turning knob fully (CW).
4.23.3 Checking and Adjusting Main Conveyor Belt Pump Low Pressure Setting
To check or adjust the standby (low) pressure setting of the main conveyor belt hydraulic pump, refer to
Illustrations 4-51 & 4-52 and perform the following steps:
2 1
OFF
3
ON
TB4.21.1.3/4
Illustration 4-51: Main Conveyor Belt Test Port (M1A)

Maintenance

2. Main conveyor belt test port (M1A)
3. Main conveyor belt manual bypass valve
4. Main conveyor belt manual bypass speed control - This knob should be opened or closed only
5. Main conveyor belt proportional valve
6. Main conveyor load-sensing shutoff valve
1. Connect 60 BAR test gauge (item 1, Ill. 4-51) minimess fitting to main conveyor belt test port (M1A).
2. Disconnect electrical connector on main conveyor belt proportional valve (item 5, Ill. 4-51).
3. Reset E-stop (so that load-sensing valve is energized) or manually bypass main conveyor load-sensing
shutoff valve (item 6, Ill. 4-51) by turning its knurled knob (beneath plastic cap) fully (CCW).
NOTE:
This procedure cannot be performed unless the main conveyor load-sensing shutoff
Main Conveyor Belt

Manual Speed Control
(turned fully clockwise)
2
3
60 BAR
Test Gauge
Main Conveyor
Manual Bypass
in ON position
TB4.21.3/4-2
Illustration 4-52: 60 BAR Test Gauge Connected to Test Port (M1A)

4. Ensure that main conveyor belt manual speed bypass control (item 1, Ill. 4-52) is turned all of the way
in (CW). With the main conveyor belt manual bypass valve in the ON position (item 2, Ill. 4-52), this
knob adjusts the main conveyor belt speed manually.
5. Turn ON main conveyor belt manual bypass valve (item 2, Ill. 4-52) by pushing valve lever down.
6. Read standby (low) pressure at test gauge.
NOTE:
All pressure reading and adjustments must be made at maximum RPM.
7. If necessary, adjust standby (low) pressure to 20 BAR using shorter screw (item 1, Ill. 4-46) on main
conveyor hydraulic pump compensator valve block.
8. Disconnect 60 BAR test gauge minimess fitting from main conveyor belt test port (M1A) and recon-
nect electrical connector on main conveyor belt proportional valve (item 3, Ill. 4-52).
9. Turn OFF main conveyor belt manual bypass valve (item 2, Ill. 4-52) by pulling its valve lever up.
10. If the main conveyor load-sensing shutoff valve (item 6, Ill. 4-51) was manually bypassed in Step 3,
11. If adjustments are made, re-check high pressure setting, since these settings interact. Proceed to proce-
dure for checking and adjusting main conveyor belt pump high pressure setting in section 4.22.4.

Maintenance
4.23.4 Checking and Adjusting Main Conveyor Belt Pump High Pressure Setting
To check or adjust the compensator (high) pressure setting of the main conveyor belt hydraulic pump, refer
to Illustrations 4-53 & 4-54 and perform the following steps:
4
2 1
TB4.22.1.3/4
Illustration 4-53: Main Conveyor Belt Test Port

2. Main conveyor belt test port (M1A)
3. Main conveyor belt manual bypass valve
4. Main conveyor belt manual bypass speed control - This knob should be opened or closed only
5. Main conveyor belt proportional valve
6. Main conveyor load-sensing shutoff valve
1. Connect 400 BAR test gauge (item 1, Ill. 4-53) minimess fitting to main conveyor belt test port
(M1A).
2. Reset E-stop (so that load-sensing shutoff valve is energized) or manually bypass main conveyor load-
sensing shutoff valve (item 6, Ill. 4-53)

NOTE:
This procedure cannot be performed unless the main conveyor load-sensing shutoff
1 1
2
3
3
TB4.22.4
Illustration 4-54: Main Conveyor Belt Hydraulic Motor Hoses and Manifold Block
1. Main conveyor belt hydraulic motor (2)
2. Main conveyor belt
3. Main conveyor belt hydraulic motor hoses and connections (4)
4. Manifold block, main conveyor anti-cavitation

Maintenance
3. Cap off the two main conveyor belt motor hoses before the manifold block (item 4, Ill. 4-54) in the
boom head or cap off all four main conveyor belt motor hoses (Item 3, Ill. 4-54).
Main Conveyor Belt

Manual Speed Control
(turned fully clockwise)
3 2
400 BAR
Main Conveyor Test Gauge
Manual Bypass
in ON position
TB4.22.3/4-2
Illustration 4-55: 400 BAR Test Gauge Connected to Main Conveyor Belt Test Port (M1A)
4. Ensure that main conveyor belt manual speed bypass control (item 1, Ill. 4-55) is turned all of the way
out (CCW). With the main conveyor belt manual bypass valve in the ON position (item 2, Ill. 4-55),
this knob adjusts the main conveyor belt speed.
5. Turn on main conveyor belt manual bypass valve (item 2, Ill. 4-55) by pushing its valve lever down.
6. Read compensator (high) pressure at test gauge.
NOTE:
7. If necessary, adjust compensator (high) pressure to 280 BAR using taller screw (item 2, Ill. 4-46) on
main conveyor hydraulic pump compensator valve block.
8. Turn off main conveyor belt manual bypass valve (item 2, Ill. 4-55) by pulling its valve lever up.

9. Remove 400 BAR test gauge from main conveyor test port (M1A).
10. Uncap and re-install hose connections that were disconnected and capped in Step 3.
11. If adjustments are made, re-check low pressure setting, since these settings interact (use procedure for
checking and adjusting main conveyor belt pump low pressure setting in section 4.22.3).
12. If the main conveyor load-sensing shutoff valve (item 3, Ill. 4-55) was manually bypassed in Step 2,
13. Turn manual bypass speed control (item 1, Ill. 4-55) OFF (turn fully CW).
14. If no adjustment is made, test is complete.

4.23.5 Checking and Adjusting Boom/Outrigger Pump Low Pressure Setting
To check or adjust the standby (low) pressure setting of the boom/outrigger hydraulic pump, refer to Illus-
trations 4-56 and perform the following steps:

Maintenance
TB4.22.5
4 3
1. Modular boom control (MBC) valve

2. Boom/outrigger selector valve lever (push up for Boom position)
(P) Test Port
3. Boom/outrigger (P) test port (located beneath MBC valve on driver’s
side)
4. 60 or 400 BAR test gauge assembly
TB4.22.5
Illustration 4-56: Boom/Outrigger (P) Test Port
1. Connect 400 BAR test gauge (item 4, Ill. 4-56) minimess fitting to boom/outrigger (P) test port on
MBC valve.
2. On MBC valve, push up boom/outrigger selector valve lever (item 2, Ill. 4-56) to boom position and
continue to hold in boom position for remainder of this procedure.
WARNING:
The boom/outrigger selector valve must be held in the boom position
throughout the entire procedure and when switching pressure gauges.
If the boom/outrigger selector valve is not held in the boom position, the
pressure at the boom/outrigger (P) test port will spike higher than 60 BAR and
damage the 60 BAR test gauge.

NOTE:
3. Read the standby (low) pressure at test gauge. After at least 30 to 60 seconds, only approximately 22
BAR should be shown on 400 BAR test gauge.
4. Continue to hold the boom/outrigger selector valve in boom position. When the 400 BAR pressure
gauge reads approximately 22 BAR, have an assistant or use free hand to disconnect the 400 BAR
pressure gauge minimess fitting from test port, then connect minimess fitting for the 60 BAR pressure
gauge to boom/outrigger (P) test port on MBC valve.
5. If adjustment is required, continue to hold the boom/outrigger selector valve lever in boom position,
have an assistant or use free hand to adjust the standby (low) pressure to 22 BAR using shorter screw
(item 1, Ill. 4-46) on boom/outrigger hydraulic pump control valve.
NOTE: If necessary, remove the diamond plate cover from operator stand to access the
adjustment screw on the hydraulic pump control valve.
6. Disconnect the 60 BAR test gauge minimess fitting from boom/outrigger (P) test port.
7. Release the boom/outrigger selector valve lever.
8. If adjustment was made, re-check the high pressure setting, since these settings interact. Proceed to
procedure for checking and adjusting boom/outrigger pump high pressure setting in section 4.22.6.
9. If no adjustment was made, test is complete.

Maintenance
4.23.6 Checking and Adjusting Boom/Outrigger Pump High Pressure Setting
To check or adjust the compensator (high) pressure setting of boom/outrigger hydraulic pump, refer to
Illustration 4-57 and perform the following steps:
1. Connect the 400 BAR test gauge (item 4, Ill. 4-57) minimess fitting to boom/outrigger (P) test port
(item 3, Ill. 4-57) on MBC valve.
TB4.22.6
4 3
1. Modular boom control (MBC) valve

2. Boom/outrigger selector valve lever (push up for Boom position,
pull down for Outrigger position) (P) Test Port
3. Boom/outrigger (P) test port (located beneath MBC valve on
driver’s side)
4. 400 BAR test gauge assembly TB4.22.6
Illustration 4-57: Boom/Outrigger (P) Test Port
2. While holding the boom/outrigger selector valve lever (item 2, Ill. 4-57) in either the up (boom) posi-
tion or down (outrigger) position, engage a boom or outrigger function to the end of its travel (e.g.,
outrigger up); read compensator (high) pressure at test gauge.

NOTE:
All pressure readings and adjustments must be made at maximum RPM. A boom or
outrigger function must be at the end of its travel (i.e., fully up or fully down, etc.) to read
compensator (high) pressure.
3. If required, adjust the compensator (high) pressure to 280 BAR using taller screw (item 2, Ill. 4-46) on
boom/outrigger hydraulic pump compensator valve block.
NOTE: If necessary, remove the diamond plate cover from operator stand to access the
adjustment screw on the hydraulic pump control valve.
4. Disconnect the 400 BAR test gauge minimess fitting from boom/outrigger (P) test port.
5. Release the boom/outrigger selector valve lever.
6. If adjustments are made, re-check the low pressure setting, since these settings interact. Proceed to pro-
cedure for checking and adjusting boom/outrigger pump low pressure setting in section 4.22.5.

Maintenance
This Page Intentionally Left Blank

5.0 Safety Instructions
5.1 General Safety Guidelines
Putzmeister America has made every attempt to anticipate all possible circumstances that might involve a
potential hazard. However, the warnings in this manual are therefore not all inclusive. In addition, while
Putzmeister America has made every attempt to produce a safe and reliable product, it is the responsibility
of the owner/operator to keep the machine in a safe operating condition and to use the machine in a safe and
effective manor. If an unsafe condition exists, DO NOT operate the machine until it has been made safe to
operate or until the job site issue has been fully resolved.
If a procedure, tool, device, or work method is used that is not specifically recommended by Putzmeister,
you must ensure that it is safe for you and other persons nearby. You should also ensure that the machine
will not be damaged or made unsafe by the procedures and methods you choose.
All persons operating, assembling, transporting, and maintaining this machine should be aware of and
comply with the following safety rules and recommendations:
• The Telebelt is a concrete/material placing machine. It is not designed for use as a crane. To use it as
such could cause damage to the machine and cause injury or death to personnel.
• Unless authorized and approved by Putzmeister, do not make any modifications, alterations, or
changes to a Telebelt that could in any way affect its original design. Doing so will void the Warranty
of the machine.
There are several publications available that go into great detail on how an operator and job site personnel
can work safely with (and around) material placement equipment. Some of these are listed below. Since
these publications are reviewed and edited on a regular basis by experts in the industry, Putzmeister America
strongly suggests reading them and incorporating their message into one’s daily practices.
In addition, there are certain safety topics and recommendations that are either unique to this Putzmeister
America product or are of such importance that they need to be included in this section of the manual
regardless of duplication with other publications. It is strongly suggested that everyone who will be working
with or around this piece of equipment be knowledgeable of this section’s contents.
Safety Standards
– ASME B30.27 Safety Standard (www.asme.org)

The operator and anyone near the machine must wear appropriate clothing and protective equipment as
required by local, state, federal, and job site regulations. Never operate the Telebelt without clearly
understanding the safety requirements of the job.

Safety Instructions

DO NOT OPERATE Telebelt if wind speed is greater than 31 miles per hour
(14.14 meters/second). High winds may cause erratic movement of conveyor
leading to center of gravity shifts that may cause the machine to tip over.
• Read and make note of any defaced or missing safety and hazard alert decals located on the machine
and replace as soon as possible.
Illustration 5-1 shows the name, quantity and location of the safety and hazard alert decals that are affixed
to the machine:
25 (On the Inside of the Outriggers 41

38 29
(Both Sides) 5 37 (Next to Rubber)
16, 28
38 26 24 (On the tank

(Both Sides) next to press.
20, 27 26
regulator)
16
9, 15
(Below the bottom
of the door) 12, 13 16, 18 11 35 33 34 3, 16
19
(On the left side Inside (Both Sides)
at the bottom 1, 6, 7, 8, 17, 21, (All decals placed on
of the pedestal 22, 23, 28, 30 tank wall driver side)
29 41 25 (On the Inside of the Outriggers

(Next to
38 5
Rubber)
16, 28
26 4, 12, 39, 40
(On top of 24, 36
20, 27 pedestal) (On dashboard
above PTO switch)
16
9, 15
(Below the bottom
33 32 14 12 of the door)
35 11 33
(On top of (On the fuel tank)
1, 6, 7, 21, 22,
manual
23, 28, 30, 42 10
speed control
(All decals placed on (On side of equipment
valves)
tank wall passenger side) box)
Item # QTY / per Decal # Decal Description Item # QTY / per Decal # Decal Description
1 2 A800017 Qualified Operator 22 2 A800319 Danger Moving Machine
2 2 A800018 Electrical Hazard 23 2 A800320 Danger Shut Off Machine
3 4 A800086 Do Not Climb 24 2 A800323 Air Regulator
4 1 A800117 Disengage A/C 25 10 A800324 Danger Pinch Point
5 2 A800144 Use Boom Strap 26 1 A800325 Danger Pressurized Tank
6 1 A800146 Important Order 27 2 A800326 Danger Hyd. Leaks
7 2 A800147 Warning Icons 28 4 A800327 Danger Turn Off Engine
8 1 A800186 Do Not Operate 29 2 A800330 Danger Electrocution
9 2 A800203 Fire Ext. Inside Cab 30 2 A800331 Warning Radio Remote
10 2 A800213 Danger PTO Shaft 31 14 A800346 Danger Do Not Walk
11 2 A800214 Do Not Reuse Fastener 32 1 A800357 Warning Manual Overrides
12 1 A800235 Warning Battery Cables 33 4 A800415 Danger Clear Stabilizers
13 1 A800236 Caution Battery Switch 34 1 A800431 Warning Normal/Winter
14 2 A800237 Vented Cap Only 35 2 A800443 Frame Warning-No Weld
15 2 A800238 Slip Resistant Surface 36 1 A800453 Caution Travel Mode
16 6 A800313 Watch Step 37 2 A800496 Do Not Use Boom as Crane
17 1 A800314 Safety Instructions 38 4 A800692 Danger Pinch Point
18 1 A800315 Caution Reservoir Air 39 1 A800704 Warning Min. 13’ 6” Height
19 1 A800316 Caution Protect Press. Washer 40 1 A800719 Caution Battery Charger
20 2 A800317 Caution Cyl. Interference 41 2 A800729 Interference Warning
21 2 A800318 Danger Oil Coated/Slippery 42 2 A800823 End Hose Instructions
Illustration 5-1: Safety Decal Locations

Safety Instructions
• Do not allow any persons to ride on conveyors.

• Make sure that the area directly under and around the conveyors is kept clear of personnel.
• Do not overload conveyors. Falling materials can be hazardous to nearby personnel.
• Keep hands, clothing and tools away from moving belts and pinch points.
• If operating in cold weather, allow ample time for hydraulic oil to warm up.
• Do not bypass any safety inter-lock systems and/or circuits.
DANGER: ELECTROCUTION HAZARD.

If any portion of the Telebelt truck and conveyor contacts or becomes too close
to an electrical power source, all equipment and persons on or around them are
in serious danger of injury, damage or death (as shown in Illustration 5-2
below):
This Area Should Be Avoided
Danger Zone Area Table 1: Minimum Required Clearances

See Table 1 (Per ASME B30.27)
Voltage, kV Min. Required Clearance
(Phase to Phase) ft (m) [Note: 1]
Operation Near High Voltage Power LInes
to 200 17 (5)
Over 200 to 350 20 (6.10)
Over 350 to 500 25 (7.62)
Over 500 to 750 35 (10.67)
Over 750 to 1000 45 (13.72)
Operation in Transit with Conveyor Lowered

to 0.75 4 (1.22)
Over 0.75 to 50 6 (1.83)
Over 50 to 345 10 (3.05)
Over 345 to 750 16 (4.87)
Over 750 to 1000 20 (6.10)
Note:
(1) Environmental conditions such as fog, smoke,
TB5.1-2 or precipitation may require increased clearances.
Illustration 5-2: Minimum Safe Distance from Electrical Power Source

• Avoid potentially dangerous electrical hazards by maintaining a safe distance between conveyor and
any electrical power source. For lines rated at or below 200 kV minimum clearance of at least 17 feet
(5 m) shall be kept. For higher voltages see Table 1 in Illustration 5-2.
Depending on the circumstances, one or more of the following precautions must be taken while working in
the proximity of any electrical power source:

Safety Instructions
• Contact those in charge of the power source and have the power turned off and lines grounded.
• Use of an additional “spotter” person to watch for the boom’s proximity to the power source.
• Provide a physical means to prevent the boom from being able to come within 17 feet of the power
source.
For further information on electrical hazards and precautions, please consult additional sources on the
subject. One example is the ASME (American Society of Mechanical Engineers) B30.27 Manual for
Material Placement Systems.
5.2 Safe Operating Zones

Setting up the machine using LESS THAN ALL FOUR OUTRIGGERS FULLY
EXTENDED, will greatly reduce stability in portions of the normal operating
range and may cause the machine to tip over. Putzmeister America will not be
held responsible for any injuries or equipment damage incurred as a result of
improper machine setup and use.
For stability and the safe operation of the machine in all working positions, ALL FOUR OUTRIGGERS
must be completely extended and locked in place to avoid hazardous tipping conditions. See Section 5.4
(Special Outrigger Configurations) for limited restricted use of the machine.
Use the model-specific range diagrams as a reference when setting up outriggers for normal horizontal and
vertical operation.
• Depending on the model, outrigger pad loads can exceed 45,000 pounds ON ONE PAD. Tires,
springs, and axles cannot be expected to carry these loads for a missing outrigger. Illustration 5-3
shows the magnitude of load that is applied to the supporting ground surface by the outrigger with the
conveyor fully extended:
27”x19” PAD AREA = 513 SQ.IN.
MAX. GROUND PRESSURE:

34,311LB
= 66.9 PSI
513 SQ.IN EXAMPLE:
34,311LBS (153 kN) Rear Outrigger Leg Load Limit
MAX OUTRIGGER PAD REACTION DUE TO
OVERTURNING MOMENT FROM CONVEYOR
FULLY EXTENDED & LOADED TB5.2
Illustration 5-3: Example of Outrigger Pad Ground Pressure

The actual center of gravity (CG) of the machine is a combination of the loaded conveyor CG and the carrier
CG. It moves, depending on conveyor angle, loads and extension. This combined CG point must be within
the outrigger pads.

Safety Instructions
• The truck must be level, from front to rear and from side-to-side (within three degrees). An out of
level vehicle can cause a runaway conveyor, undue side loads, and the movement of the center of
gravity that can cause stability problems.
• Outrigger’s that are not pinned are NOT considered deployed. Unpinned outriggers can be used for
leveling, or for removing “bounce”, but they cannot be used to increase permissible slewing angles.
Side loading an unpinned outrigger (slewing the conveyor) can cause the outrigger to pivot.
5.3 Range Diagrams

Operating outside the range limits the machine was designed for can cause
damage to machine components and cause personal injuries.
The following example range diagrams are for normal outrigger setup and machine operation. Please refer
to the machine specifications provided for the range diagrams that relate to your specific vehicle.
5.3.1 Range Diagram Horizontal Limits

Illustration 5-4 shows the range for safely slewing the main conveyor using ALL FOUR outriggers extended
with pins locked. The conveyor boom can rotate and operate in a 360° radius. The feed conveyor can also
rotate 360°.
EXAMPLE
360° Operation Zone for
Feed & Main Conveyor
106’ 1” (32.34 m)
35’ 1”
(10.72 m)
16° FEEDER
NO OPERATION
24’ 2”
16° FEEDER (7.37 M)
25’ 2 1/2”
NO OPERATION (7.68 m)
Main Conveyor
Feed Conveyor 27’ 5”

(8.38 m)
TB5.3.1
Illustration 5-4: Range Diagram Horizontal Limits

Safety Instructions
5.3.2 Range Diagram Vertical Limits

Illustration 5-5 shows the minimum and maximum range of operation for horizontal, vertical and side reach
of both conveyors.
Max. Horizontal Reach at 30°

EXAMPLE 91’ 6” (27.92 m)
360° Continuous Rotation

Feeder & Conveyor Boom
Max. Vertical Reach

60’ 2” (18.35 m)
7°
Feed
Conveyor 30°
Limits
Min. Vertical Reach
Min. Side Reach 20’ 0” (6.11 m)
35’ 1” (10.72 m) Max. Net Side Reach
100’ 6” (30.64 m)
TB5.3.2
Max. Side Reach
106’ 1” (32.34 m)
Illustration 5-5: Range Diagram Horizontal, Vertical and Side Reach Limits
5.4 Special Outrigger Configurations

Setting up the machine using less than all four outriggers fully extended must
be done only with an elevated level of caution. Removal of the standard support
configuration greatly decreases the stability in portions of the operating range.
The modified range diagrams that follow must be adhered to if setting up in the
described manner. It is the responsibility of the operator to decide the best
method of ensuring that the boom does not enter the unacceptable zone by
allowing the side face of the boom to pass by the outrigger foot. It is
Putzmeister’s recommendation that a spotter (secondary operator) be
assigned to the task with proper training and a method for giving the operator
a warning when necessary.
It is stressed that full deployment of all outriggers is always the best practice and must be done if reason-
ably possible. However, location configurations can occur that will not permit full deployment yet can be
safely worked if proper precautions and procedures are followed. Putzmeister limits these acceptable
exceptions to the following three scenarios:

NOTE:
In all Special Outrigger Configurations, the outriggers must be locked in position. If
these scenarios still do not allow set-up or if the outriggers cannot be locked in
position, it is unsafe to operate and other means of moving the material should be
used.
Scenario 1 – Two Rear, One Front Extended Outriggers
In this set-up, both of the rear outriggers and one of the front outriggers are fully deployed. The remaining
front outrigger is either stored or unpinned (shown in stored position).
EXAMPLE
ACCEPTABLE
Range
Do not slew boom beyond the

rear outrigger foot on the short
rigged side
Do not slew boom beyond

the front outrigger foot
DANGER
NOT ACCEPTABLE
AVOID!
TB5.4-1
Illustration 5-6: Scenario 1-Two Rear, One Front Outrigger Extended

Safety Instructions
Scenario 2 – One Rear Outrigger In Rear Position
In this set-up, scenario #1 is modified to have the rear outrigger on the restricted side pinned into the rear-
facing position (vs. the standard side-facing position).
EXAMPLE
Do not slew boom beyond the

rear outrigger foot on the short
rigged side
ACCEPTABLE
Range

the front outrigger foot
DANGER
NOT ACCEPTABLE
AVOID!
TB5.4-2
Illustration 5-7: Scenario 2-One Rear Outrigger in Rear Position with Opposite Rear and Front Out-
rigger Extended
NOTE:
Both scenarios 1 and 2 can be used in a mirror image configuration with the restriction
being to the side of the stored/unpinned leg.

Scenario 3 – Two Rear Outriggers Only
In this set-up, both rear outriggers are fully extended and pinned into the side-facing position. Both front
outriggers are either in the stored position or unpinned. This is the most restricted scenario and is meant only
for working to the rear of the machine.
EXAMPLE
ACCEPTABLE
Range

the rear outrigger feet
DANGER
NOT ACCEPTABLE
AVOID!
TB5.4-3
Illustration 5-8: Scenario 3-Two Rear Outriggers Extended

Safety Instructions
5.5 Lock Out – Tag Out Procedure

Personnel servicing the unit should be protected from unexpected start-ups. Use of the following procedures
is strongly recommended:
1. Lock Out-Tag Out Procedure Where Contact With Moving Parts Is Possible:
• Disengage the PTO (if engaged)
• Switch engine off and remove the key. The key must be kept by the individual performing the work
• Put a notice on the truck near the ignition switch stating ‘Under Repair - DO NOT START’
2. Lock Out Procedure Where Contact With Moving Parts Is Not Possible:
• The individual performing the work must engage the ‘E-stop’ on the remote control unit.
• The individual performing the work must maintain complete control of the remote control unit until
the work is completed.

Glossary
Appendix A: Abbreviations and Technical Terms
A
Acre U. S. unit of area measurement equal to 43,560 square feet.
Adjusting bolt Bolt used to adjust pulley alignment.
Air pressure, hydraulic reservoir Air pressure in hydraulic tank held constant by air pressure
regulator and monitored by the three inlet filter gauges.
Air pressure, pusher axle Air pressure exerted on pusher axle to create load weight on
axle.
Air pressure regulator with water trap A non-adjustable regulator that maintains constant air pressure
in the hydraulic oil tank and has a water trap to capture con-
densate water.
Aligning Adjustment of conveyor belt to run centered on conveyor belt
pulley. See training.
Arm A section of the main conveyor boom. The bracket that
attaches the head scraper assembly to end of main conveyor
head section.
ASME American Society of Mechanical Engineers (www.asme.org)
AW46 Anti-wear hydraulic oil with ISO viscosity grade of 46.
Axle lock A device used to lock the tandem axles together for maximum
traction (see interaxle lockout).
B
Bar Metric unit of pressure measurement equal to 100 kilopascals,
1.02 kilograms of force per square centimeter (kgf/cm2), or
approximately 14.504 PSI (lbf/in2).
Base The main (first) or “Arm 1” section of the Telebelt conveyor
boom.
Belt See conveyor belt.
Belt capacity The amount of material that the feed or conveyor belt can con-
vey/move at a specific speed and angle.
A820143_Appendix A_0702K Putzmeister America, Inc. A-1

Glossary
Belt card Computer card with black face located in the upper left section
of the electric control box. There are two cards and they con-
trol the speed of the main and feeder belts.
Belt speed The distance that a reference point on the belt travels for a spe-
cific amount of time.
Belt speed determination Consideration of a specific conveyor belt speed setting that
will convey the desired amount of material.
Belt tension The amount of tightness of the conveyor belt.
Blocking Method for spreading ground pressure of outrigger pads using
appropriate lengths of timber blocks or other suitable material.
Also called “Cribbing”.
Boom Main conveyor structure.
C
CCW Counterclockwise.
CG Center of gravity.
CW Clockwise.
Cable remote Control box and cable used as a backup for the radio remote.
Celsius Metric unit of temperature. 1° C equals 33.8 degrees Fahren-
heit. Refer to Metric Conversions table on page 1-12.
Centimeter Metric unit of length equal to one-hundreth of a meter.
Checklist The document used to verify various procedures.
Circuit breaker An automatic switch that stops the flow of electric current.
Conveyor belt The continuously moving rubber belt that moves material from
one place to another.
Conveyor rails The frame structure for both the feeder and main belts.
Corner bearing load The force transferred to the ground through each outrigger pad.
Cubic centimeter A metric unit of volume equal to one hundreth of a liter or
0.034 ounces.
Cubic inch U. S. unit of volume equal to 0.554 ounce or 16.4 cubic centi-
meters.
A-2 Putzmeister America, Inc. A820143_Appendix A_0702K

Glossary
Cubic feet U. S. unit of volume equal to 1728 cubic inches or 0.03 cubic
meters.
Cubic meter A metric unit of volume equal to 1000 liters or 1.31 cubic
yards.
Cubic yard U. S. unit of volume equal to approximately 202 gallons or 764
liters.
D
Discharge boot Device used to direct material flow in transfer and discharge
reducer.
Drive to Pump Turning power take off (PTO) switch from “Off” to “On”
(engaged).
E
E-stop Emergency stop.
F
Fahrenheit U. S. unit of temperature. 1° F equals -17.222 degrees Celsius.
Refer to Metric Conversions table on page 1-12.
Feather To control a remote function and cause slow movement by
“bumping” or “quick clicking” the remote switch. Proportional
controls are feathered by varying the movement of the function
control lever.
Feeder Feed conveyor where concrete or material is discharged.
Flow Quantity of fluid movement versus time, usually expressed in
Gallons Per Minute (GPM) or Liters Per Minute (LPM) and
affects the speed of a function.
Foot-pound A unit of work equal to the work done by the force of one
pound at a distance of one foot.
Function(s) Any controlled movement, such as Swing Right, Telescope In,
Main On, etc.

Glossary
G
Gallon U. S. unit of volume (liquid measure) equal to four quarts or
3.78 liters also used in the British Imperial System for volume
measurement (liquid and dry).
GPM Gallons Per Minute, see Flow.
Gear reducer Mechanical transmission that converts high speed rotation
from motor, to low speed high torque output. Used for boom
slewing, feeder slewing, and telescope drive.
Grain U. S. unit of weight equal to 0.002285 ounce or 0.065 gram.
Gram A metric unit of weight (mass) equal to one thousandth of a
kilogram or 0.0352 ounces.
H
Head section Last boom section or discharge end of conveyor. Can also be
referred to as the “fly” or “tip”, or Arm 4.
Hectare A metric unit of area equal to 2.471 acres.
Heel End opposite the head or end of the boom sections closest to
truck. Can also be referred to as the “tail”, or Arm 1.
High slump concrete Concrete that is ‘wet’ and will slide down the feeder belt when
the belt is stopped.
Hopper grate Device covering hopper to keep large pieces of material that
come from ready mix trucks; such as cement balls, and set con-
crete chunks.
I
Icon A graphic image used to convey a message, or to represent an
idea or function.
Inch-pound U. S. unit of work equal to 0.145 PSI.
Inner mid The first telescoping boom section, counting from the base sec-
tion toward the head section, or Arm 2.
Interaxle lockout Locks tandem axles together for added traction under slippery
conditions.

Glossary
J
Job site The predefined area in which concrete or other material is to be
placed.
K
Kilogram Metric unit of weight equal to 1,000 grams or 2.20462 pounds.
Kilogram-meter Metric unit of work equal to 9.0865 newton meters
Kilometer Metric unit of length equal to 1,000 meters (0.62 miles)
Kilopascal A metric unit of pressure equal to 1,000 pascals or 0.145 PSI.
L
LED Light Emitting Diode. A semiconductor diode that converts
applied voltage to light and is used as an indicator.
LPM Liters Per Minute. Metric unit of the flow of one liter per
minute and equals 0.2642 gallon per minute.
Liter Metric unit of volume equal to one hundreth cubic meter or
1.056 quarts.
Lithium grease Long lasting grease that reduces friction and wear of metal
parts, repels water and protects against rust and corrosion.
Low slump concrete Concrete that is ‘dry’ and will stay in place on the feeder belt
when the belt is stopped.
LPM Liters Per Minute. See Flow.
M
Machine rating plate Machine information stamped on a metal plate affixed to the
machine.
Main Refers to the main conveyor, base boom section, or Arm 1.
MBC Modular Boom Control. The series of hydraulic control valves
that control the boom and outriggers.
Meter International standard unit of length equal to approximately
39.37 inches.

Glossary
Metric ton Metric unit of weight equal to 1000 kilograms or 2,205

pounds. Can also be referred to as a “long ton”.
Mile U. S. unit of distance equal to 1,760 yards, 5280 feet or
1.60934 kilometer.
Millimeter Metric unit of length equal to one thousandth of a meter or
0.0394 inch
Mineral oil Hydraulic oil that protects metal surfaces from moisture and
oxidation.
N
Newton Metric unit of force (work) that will accelerate a mass of one
kilogram at a rate of one meter per second or equal to 0.225
pounds of force (lbf).
Newton-meter The International System of Unit of torque or the tendency of a
force to cause rotation and equals 0.737562 pound foot (lbft).
NiCd battery Nickel Cadmium battery. A battery that is capable of exceed-
ing 500 charging cycles.
O
O-ring A rubber circular shaped gasket with a round cross section.
Oil cooler A device used to cool hydraulic oil. Also called “Heat
Exchanger”.
Ounce U. S. unit of weight equal to 437.5 grains or 28.35 grams.
Outer mid The second telescoping boom section counting from the base
section toward the tip section, or Arm 3.
Outrigger A weight supporting device (leg) used to stabilize the machine
machine and allow boom movement.
Outrigger pad The ‘foot’ or base of the outrigger that supports the weight of
the machine.
P
Pascal Standard unit of pressure in the International System of Units
equal to one newton per square meter or 0.000145 PSI.

Glossary
Plasticized concrete Concrete with reagent added to improve workability. Tempo-

rarily increases slump without changing water/cement ratio.
Pound U. S. unit of weight equal to 16 ounces or 453.592 kilograms.
Pouring Material placement.
Pressure (Hydraulic) Force applied to a fluid, usually measured in BAR, or Pounds
Per Square Inch (PSI).
Proportional A proportional control applies more oil flow as displacement
of the control lever increases.
PSI Pounds Per Square Inch equal to 144 pounds per square feet or
0.07 bar.
PTO Power Take-Off
Pump to Drive Turning power take off (PTO) switch from “On” to “Off” (dis-
engaged)
Pusher axle An air pressure activated axle that is used to redistribute axle
loads for highway travel.
Q
Quart U. S. unit of volume (liquid) equal to one quarter of a gallon,
two pints, or 32 ounces.
R
Radio remote control transmitter Wireless device powered by a battery used by the operator to
operate the machine from any convenient location.
Range diagram Pictorial presentation of the horizontal and vertical limits of the
machine.
Remote control A electronic device used by the operator to operate the
machine from any convenient location.
S
Scraper bounce Head scrapers are tensioned with springs. Obstructions that
break scraper contact with the belt can cause the scraper to
“bounce” or “hop”. This condition is not desirable as scrapers
must maintain full contact with the belt.

Glossary
Segment Working sections of a stack valve. One segment controls a sin-

gle function in both directions.
Serial number A unique set of numbers assigned to each Telebelt at the fac-
tory.
Skirts A rubber device used at the transfers and hoppers to channel
material flow onto the next conveyor.
Skive A slant cut made on an angle to the surface of the belt to pro-
duce a tapered edge.
Slewing Term used to describe the ‘swinging’ or ‘rotating’ of the feed
conveyor or main conveyor.
Spool The internal piece of a valve segment that directs oil flow.
Spotter An individual who guides the operator in safely placing the
machine or conveyors into working position by use of mutually
understood hand signals.
Square centimeters Metric unit of area measurement equal to one thousandth of a
square meter or 0.155 square inch.
Square feet/foot U. S. unit of area measurement equal to 0.111 square yard or
0.093 square meter.
Square inch A U. S. unit of area equal to 0.007 square feet or 6.4156 square
centimeters.
Square kilometer Metric unit of area measurement equal to 0.386 square miles.
Square meter A metric unit of area equal to one thousand square centimeters.
Square mile U. S. unit of are measurement equal to 640 acres.
Stack valve An assembly of hydraulic valves consisting of an inlet section,
single or multiple valve segments and an outlet section.
T
Tail Same as Heel or Arm 1, the end of boom closest to the truck.
Telescoping The ‘in’ and ‘out’ movement of the main conveyor to place
material at various distances from the machine.
Tie gum an intermediate layer of rubber used to promote bonding of two
surfaces; usually a soft rubber compound.

Glossary
Tip Same as Fly, the head section, or Arm 4.

Ton U. S. unit of weight equal to 2,000 pounds or 0.907 metric ton
or 907.18 kilograms. Can also be referred to as “short ton”.
Training Term used to describe alignment of the conveyor belt in the
center of the pulleys.
Transfer An area or assembly where concrete/material transfers from
one conveyor to another.
Tremie The metal reducer that hangs from the discharge end of the
conveyor and connects to the end hose. May also refer to the
end hose.
V
Vertical limit The height or “up”/”down” limits of the feed and main convey-
ors when raised or lowered.
Vulcanizing A process where a rubber compound goes through a change in
its chemical structure and becomes more elastic.
Y
Yard U. S. unit of distance equal to three feet, 36 inches, 91.44 centi-
meters or 0.9144 meter.

Glossary
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Index
Appendix B: Index of Key Words

A - Feeder turntable bearing, 4-47
Additional standard features, 1-5 Boom
Adjusting equalizer cables, 4-37 - Lubrication, 4-15
Adjusting U-roller, 4-26 Boom control valve, 2-7
Adjustment values, 4-6 Boom position, job site travel, 3-7
Aligning Boom rating plate, 1-10
- Feed conveyor belt, 4-25 Box, electrical control, 2-9

- Main conveyor belt, 4-41 - Button, emergency stop, 2-1
- Main conveyor belt at drive pulley, 4-42
C
Automatic transmission
Cable remote control, 2-14
- PTO switch, 2-24
Cable remote control icons, 2-14
Axle, pusher (control), 3-3
Cab lift system, 2-18
B
Calculating ground pressure, 2-30
Battery charging, radio remote, 2-17
Changing oil
Belt
- Changing lower reservoir oil, 4-22
- Characteristics, 4-51 - Changing upper reservoir oil, 4-23
- Conveyor (speed settings), 2-47 - Feeder slewing gear reducer, 4-22
- Feed conveyor (raise/lower), 2-36 - Main conveyor slewing gear brake, 4-21
- Length determination, 4-52 - Main conveyor slewing gear reducer, 4-18
- Main conveyor (raise/lower)
- Rolling, 4-52 Charging, battery (radio remote), 2-17
- Speed determination, 2-48 Charts
- Splicing, 4-55
- Splicing procedure, 4-51 - Belt speed/capacity, 2-49
Belt speed Checking and adjusting
- Capacity charts, 2-49 - Hydraulic pump pressure

- Control valve, 2-45 Checking main conveyor turntable bearing
- Determination, 2-48 bolts, 4-49
Belt splicing Checks, pre-operational, 2-3
- Materials required, 4-52 Cleaning, 2-56
- Precautions, 4-54
- Procedure, 4-52 Cold weather start-up, 2-3
- Tools required, 4-53 Component locations, 1-7
- Working area, 4-52
Concrete
Bolt tightening
A820143_Appendix B_0702K Putzmeister America, Inc. B–1

Index
- Dry (pouring), 2-53 E

- High slump (pouring), 2-54
- Low slump (pouring), 2-53 Electric control box, 2-9
- Placing material, 2-53 Emergency
- Plasticized (pouring), 2-54
- Cab-lift system, 2-18
Contingency boom pump, 2-18 - Stop, 2-1
Control box, electric, 2-9 Engaging interaxle lockout, 3-6
Control switch, outrigger, 2-26 Equalizer cables, adjustment, 4-37
Control valve Equipment, optional, 1-5
- Belt speed, 2-45 E-stop, 2-1
- Boom, 2-7
- Outrigger, 2-7 F
Control valves Feed conveyor
- Hydraulic, 2-5 - Job site travel, 3-7

- Raise/lower, 2-36
Control, pusher axle, 3-3 - Set-up, 2-38
Conveyor - Swing (slewing), 2-38
- Set-up, 2-35, 2-42 Feed conveyor belt

- Slewing gear reducer maintenance, 4-17 - Installation, 4-29
Conveyor belt - Removal, 4-27
- Replacement, 4-27
- Feed (tensioning), 4-25 - Splicing, 4-51
- Feeder (raise/lower), 2-36 - Tensioning, 4-24
- Main (raise/lower), 2-40 - Training, 4-25
- Operation, 2-45
- Replacement, main, 4-44 Feed conveyor motor collet
- Speed settings, 2-47 - Installation, 4-32
- Tensioning, 4-39 - Removal, 4-31
- Tensioning with hydraulic jack, 4-40 - Replacement, 4-31
- Training, 4-41
- Training at drive pulley, 4-42 Feeder slewing gear reducer, changing oil, 4-22
- Training at head section, 4-41 Filter
Conveyor boom swing (slewing), 2-41 - High pressure, 2-5
Conveyor sheave, lubrication, 4-16 - Suction, 2-5
Conveyor, telescoping, 2-41 Filter element
Cooler, oil, 2-5 - High pressure (replacing), 4-11

- Replacement, 4-8
Customer support, 1-4 - Suction (replacing), 4-8
D G
Dimensions, overall, 1-11 Gear selection, job site travel, 3-7
Dry materials pouring, 2-54
B–2 Putzmeister America, Inc. A820143_Appendix B_0702K

Guidelines, safety, 5-1 - Boom position, 3-7
- Feed conveyor, 3-7
H - Gear selection, 3-7
Hand signals, 2-4 - New location, 3-8
- Outriggers, 3-7
Heater,
L
- Oil tank, 2-61
Location, components, 1-7
- Water tank, 2-61
Lock out - Tag out procedure, 5-10
High pressure filter, 2-5
Low slump concrete (pouring), 2-53
High slump concrete pouring, 2-54
Lubrication
Highway travel, 3-2
- Boom, 4-15
Horizontal limit, range, 5-5
- Conveyor sheave, 4-16
Hydraulic - Outrigger, 4-13, 4-15
- Wire rope, 4-16
Control valves, 2-5
- Pumps, 2-5 M
Hydraulic jack, 4-40 Machine rating plate, 1-3
Hydraulic jack set, 4-24 Machine set-up, 2-33
Hydraulic pump Main conveyor
- Checking and adjusting pump pressure, 4-62 - Raise/lower, 2-40

- Set-up, 2-42
I
Main conveyor belt
Icons
- Replacement, 4-44
- Cable remote control, 2-14 - Training at drive pulley, 4-42
- Radio remote control, 2-12
Main conveyor slewing gear brake oil change, 4-
Information, travel safety, 3-1 21
Installing feed conveyor belt, 4-29 Main conveyor turntable bearing bolt inspec-
tion, 4-49
Installing feed conveyor motor collet, 4-32
Maintenance
Instructions, safety, 5-1
- Feed conveyor slewing gear reducer, 4-21
Interaxle lock, switch, 3-5
- Conveyor slewing gear reducer, 4-17
Interaxle lockout, engagement, 3-6 - Intervals, 4-4
- Pour, 4-54
Introduction, operating instructions, 1-1
- Preventative, 4-1
J Manual transmission, PTO switch, 2-21
Job site Metric / U. S. conversions, 1-12
- Travel, 3-6 Modular Boom Control (MBC), 2-7
Job site travel

Index
N Position, operating, 2-9
New job site location, 3-8 Pouring, 2-53
Number, serial, 1-3 - Backfill, 2-54

- High slump concrete, 2-54
O - Landscaping materials, 2-54
Oil cooler, 2-5 - Low slump concrete, 2-53
- Maintenance, 2-54
- Fan switch, 2-11 - Plasticized concrete, 2-54
Oil tank - Rock, 2-54
- Sand, 2-54
- Heater, 2-61
Power Take-Off (PTO) switch, 2-21
Operating
Pre-operational checks, 2-3
- Conveyor belt, 2-45
- Machine, 2-1 Preparing pressure washer after winterizing, 2-
- Position, 2-9 60
- Pressure washer, 2-59 Pressure washer, 2-57
- Safety zones, 2-4
- Tips, 2-1 - Operation, 2-59
- Preparing for use after winterizing, 2-60
Operating instructions - Winterizing, 2-60
- Introduction, 1-1 Preventative maintenance, 4-1
- Scope, 1-1
Procedure
Operation, 2-1
- Lock out - Tag out, 5-10
Optional equipment, 1-5
Pro-Vantage warranty, 1-3
- Oil tank heater, 2-61
- Water tank heater, 2-61 PTO switch
Outrigger - Automatic transmission, 2-24

- Manual transmission, 2-21
- Control switch, 2-26
- Lubrication, 4-13, 4-15 Pumps, hydraulic, 2-5
- Set-up, 2-26 Pusher axle control, 3-3
Outrigger control valve, 2-7 Q
Outriggers Quick reference, adjustment values, 4-6
- Job site travel, 3-7
R
- Special configuration scenario #1, 5-7
- Special configuration scenario #2, 5-8 Radio
- Special configuration scenario #3, 5-9
- Battery charging, 2-17
- Special configurations, 5-6
- Remote control, 2-11
Overall dimensions, 1-11 - Remote control transmitter, 2-12
- Remote control transmitter icons, 2-12
P
Plate, boom rating, 1-10

Range diagram - Feed conveyor, 2-38
- Main conveyor boom 2-41
- Horizontal limit, 5-5
- Vertical limit 5-6 Slewing gear reducer
Rating plate - Changing brake oil, 4-20
- Changing oil, 4-18
- Boom, 1-10
- Checking oil level, 4-18
- Machine, 1-3
Special outrigger configuration,
Recommended lubricants, 4-1
- Scenario #1, 5-7
Remote control
- Scenario #2, 5-8
- Cable, 2-14 - Scenario #3, 5-9
- Radio, 2-11
Special outrigger configurations, 5-6
Remote control transmitter, radio, 2-12
Special outrigger set-up, 2-28
Removing feed conveyor belt, 4-27
Speed settings, conveyor belt, 2-47
Removing feed conveyor motor collet, 4-31
Spotter, 2-4
Replacing
Standard outrigger set-up, 2-28
- Feed conveyor belt, 4-27
Start-up, cold weather, 2-3
- Feed conveyor motor collet, 4-31
- Main conveyor belt, 4-44 Switch
S - E-stop reset/horn, 2-11
- Interaxle lock, 5-5
Safe operating zones, 5-4 - Oil cooler fan, 2-11
Safety - Outrigger control, 2-26
- Power Take-Off (PTO), 2-21
- Guidelines, 5-1 - Work light #1, 2-11
- Icons, 1-2 - Work light #2 (if equipped), 2-11
- Instructions, 5-1
- Symbols, 1-2 T
Safety information, travel, 3-1 Tank
Serial number, 1-3 - Heater, 2-61
- Hydraulic oil, 4-7
Setting-up conveyor, 2-43
- Water, 2-57
Set-up
Tear-down, 2-62
- Conveyors, 2-35
Telebelt
- Feed conveyor, 2-38
- Machine, 2-33 - Belt characteristics, 4-51
- Main conveyor, 2-42 - Belt length determination, 2-48
- Outrigger, 2-26 - Belt rolling, 4-52
- Outrigger, special, 2-28 - Belt speed determination, 2-48
- Outrigger, standard, 2-28 - Cleaning, 2-56
- Lubrication, 4-13
Signals, hand, 2-4
- Tear-down, 2-62
Slewing (Swinging) - Transport, 3-1

Index
- Warranty, 1-3 V
Telebelt belt Valve
- Belt rolling, 4-52 - Belt speed control, 2-45
- Characteristics, 4-51 - Boom control, 2-7
- Length determination, 4-52
- Splicing, 4-55 Valves
- Splicing procedure, 4-51 - Hydraulic control
Telebelt belt splicing Vertical limit, range, 5-6
- Material required, 4-54 W
- Precautions, 4-54
- Procedure, 4-52 Warranty
- Tools required, 4-53 - Pro-vantage, 1-3
- Working area, 4-52 - Standard telebelt, 1-3
Telebelt warranty, 1-3 Washer, pressure, 2-57
Telescope traction drive cable Water tank
- Replacement, 4-35 - Heater, 2-61
- Tensioning, 4-33
Winterizing, pressure washer, 2-60
Telescoping conveyor, 2-41
Wire rope, lubrication, 4-16
Tensioning
Z
- Conveyor belt with hydraulic jack, 4-40 Zones, safe operating, 5-5
- Feed conveyor belt, 4-24, 4-25
Tips, operating, 2-1
Torquing feeder turntable bearing bolts, 4-47
Training
- Feed conveyor belt, 4-25
Transmitter, radio remote control, 2-12
Transport, 3-1
Travel
- Highway, 3-2
- Job site, 3-6
- Safety information, 3-1
U
U. S. / Metric conversions, 1-12
U-roller, adjustment, 4-26

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Operating Instructions

1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Safety Alert Icons & Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Serial Number/Machine Rating Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.4 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.5 Customer Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.6 Technical Service Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.7 Additional Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.8 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.9 Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.10 Boom Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

1.11 Overall Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.12 U. S. / Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

2.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Pre-Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

A820143_TOC_0702K Putzmeister America, Inc. I

2.4 Hydraulic Control Valves, Oil Cooler, High Pressure Filter,

2.5 Boom and Outrigger Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.6 Electric Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.7 Radio Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.8 Radio Remote Control Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2.9 Cable Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.10 Radio Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.11 Emergency Cab Lift System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

2.12 Power Take-Off (PTO) Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.13 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

2.14 Machine Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

2.15 Conveyors Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

2.16 Main Conveyor Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

2.17 Conveyor Belt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

2.18 Conveyor Belt Speed Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

II Putzmeister America, Inc. A820143_TOC_0702K

2.18.1 Belt Speed Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48

2.19 Placing Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

2.20 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

2.21 Water Tank and Pressure Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

2.22 Tear-Down (After Cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

3.0 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Highway Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.3 Pusher Axle Control (TB110) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.4 Interaxle Lock Switch (Mack Truck Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.5 Job Site Travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

A820143_TOC_0702K Putzmeister America, Inc. III

4.0 Preventative Maintenance . . . . . . . . . . . . . . . . . . . 4-1

4.2 Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3 Quick Reference of Adjustment Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.5 Filter Element Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.6 Lubricating the Telebelt (TB110) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.7 Maintaining the Conveyor Slewing Gear Reducer . . . . . . . . . . . . . . . . . . . 4-17

4.8 Tensioning the Feed Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4.9 Training (Aligning) the Feed Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . 4-25

4.10 Adjusting U-Roller (Feed Conveyor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4.11 Replacing the Feed Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

IV Putzmeister America, Inc. A820143_TOC_0702K

4.12 Replacing the Feed Conveyor Motor Collet . . . . . . . . . . . . . . . . . . . . . . . . 4-31

4.13 Tensioning the Telescope Traction Drive Cable. . . . . . . . . . . . . . . . . . . . . 4-33

4.14 Replacing the Telescope Traction Drive Cable . . . . . . . . . . . . . . . . . . . . . 4-35

4.15 Adjusting the Equalizer (Helper) Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

4.16 Tensioning the Main Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

4.17 Training (Aligning) the Conveyor Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

4.18 Replacing the Main Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

4.19 Torquing the Feeder Turntable Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . 4-47