MANUAL

ORIGINAL INSTRUCTIONS

MODEL 817-20213 MANUAL NO. 1-3545

SPREADER MODEL 6087.405+451+454+456+457+463

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All information, illustrations and speci cations in this manual are based on the latest information at the time of publi-
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6 7,21 86 5 ,16758 7,21

A100-097 General safety instructions
A100-008 User instruction
A100-089 User instruction lifting eyes
A100-147 Important information
A100-174 Handling during installation of spreader

6 7,21 6 59, 0 18 /
B110-517 Lubrication chart
B110-017 Maintenance instruction
B110-068 Servicing pendular twistlock
B110-081 Extension cylinder service inst.
B110-251 Twistlock indication and end beam adjustment
B110-302 Tightening torques
B110-509 Tighten of wear pads
B110-564 Assembly instruction (Nordlock)
B110-613 Change wear pads in rear end of extension beams
B110-324 Storage
B9-111 Description damping block
B9-134 Description rotation block

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The plugs connecting the spreader electrical system to the control box(es)
P /: 6 be disconnected before any welding is performed on the
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have multiple control boxes.

The plugs are removed from the controllers by pressing the locking
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the controller. All plugs need to be disconnected.

After nishing the welding operation, the plugs should be reconnected in the
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C120-001 Hydraulic symbols

829 834 Hydraulic schematic
C120-003 Pins, LEDs, electric schematic (Neuron Canbus)
833 380 Wiring diagram
833 379 Electric schematic
833 381 Electrical device list

6 7,21 0 1, / 3 576

D10-1353 Welded spare parts

D10-1369 Flex track chain guide
D10-1612 Wear pads (main frame)
D10-1613 Wear pads (extension beam)
D10-1510 Rotator assy.
D10-1511 End beam
D10-1343 Hydraulic stop assy.
D50-471 Pendular twistlock assy.

6 7,21 5 8/, 3 576

E60-187 Damping cylinder assy.

E60-751 Sideshift cylinder assy.
E60-757 Extension cylinder assy.
E60-759 Fork end extension cylinder assy.
E70-758 Valve assy. (swivel)
E70-1138 Valve assy. (damping)
E70-1361 Valve assy. (rotation/brake)
E70-1484 Valve assy. (sideshift/twistlock/ext./stop)
E70-1731 Swivel assy.
E70-1845 Hydraulic system
E70-610 Parker ttings

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F80-1044 Electric system

F80-1046 Sensor arr. (rotator)
F80-1047 Sensor arr. (end beam)

6 7,21 * ,7,21 / 3 576

G90-121 Additional parts (hose clamp)

G90-673 Additional parts (bracket for Deutsch connector)
G90-784 Additional parts (bracket assy. in ext. beam)
G90-919 Additional parts (bracket for working light)
G90-953 Additional parts (hydraulic bracket assy.)
G90-959 Additional parts (sensor bracket assy.)
G90-961 Additional parts (light panel assy.)
G90-970 Additional parts (20’-40’ indication lights)
G90-978 Additional parts (lifting hook, endbeam)
G90-980 Additional parts (wear pad/retainer assy. on rotator)
G90-1010 Additional parts (pin for sideshift cylinder)

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(regardless model) where there are pinching and crushing risks.

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When working on the spreader, there are various dangerous situations that must be
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There is a PINCHING and CRUSHING risk at the following points on the spreader:

* Between the moving parts of the ipper (see gure 2a).

* Between a ipper and the end beam of the spreader (see gure 2b).

* Between the carriage/rotator and the main frame of the spreader

(see gure 3a and 3b).

* Between ”T”-beams and main frame of the spreader (see gure 4).

* Between legs/feet and load (see gure 5).

Some spreaders are equipped with 3 emergency stop buttons (see gure 1). The
emergency stop buttons are a yellow box with a red stop button in the middle. By
pressing the red button, all spreader functions will be stopped. When the spreader is
restarted, it will be necessary to restart any function that was activated at the time of
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Figure 2a - Danger zone - ipper D

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H 0 0RGHO Container spreader is a technically advanced piece of equipment

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Each work shift should be started by making a visual check of the unit (this must be part
of the daily routine). Possible damage will in this way be discovered at an early stage,
thus enabling repairs to be carried out at a much lower cost.

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First of all, the length of the spreader must be adjusted to the size of container that is
required to be lifted. This is done by retracting the stops (if tted) and then activating the
extention lever or button, in order to extend or retract the spreader beams to the desired
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NOTE! It is important to remember that loads should only be lifted at the speci ed
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45ft. Where stops are tted, these should be used to position the beams accurately
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the speci ed positions may result in serious damage to the spreader.

When the required length has been reached, lift the spreader high enough to give good
visibility under it. This serves two purposes; 1) it gives good visibility for travelling and
2) it positions the spreader ready for picking up the rst container. The spreader should
now be side shifted to the center position and the reach function operated to the fully
retracted position. This will be termed 7 6, 326,7,21 L H H RI H
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If necessary, raise the spreader in order to have plenty of space between it and the
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The nal adjustments for lining up the twistlocks with the corner castings of the
container can now be made.

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corner castings and then lower the spreader into them. If any of the twistlocks do not t
into the corner castings properly, CAREFULLY lift the spreader just free of the contai-
ner, readjust its position and the try again. 1 9 5 386 25 6, 6 ,)7 LOH D RI
the twistlocks are still engaged in the corner castings of the container. When all twist-
locks are correctly engaged in the corner castings, the spreader should be lowered until
it rests unsupported on the container. This is termed as the spreader being correctly
6 7 and this will be indicated by the SEATED LIGHT being switched on. As soon
as this happens, the twistlocks can be activated to the locked position and the LOCKED
LIGHT will be switched on.
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container to the required height for loading and/or travelling. Before moving the
container, return the spreader to the ”BASIC POSITION”. The container is now ready to
be transported to a new location. When travelling, always keep the load at the lowest
possible height and drive carefully.

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When approaching the new location for the container (this could be a chassis or a stack
etc.) lower the container to the required height and adjust the position of the corner cas-
tings, so that they are accurately situated above the corner locks of the chassis. Lower
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The twistlocks may now be activated to the ”UNLOCKED” position, the spreader lifted
free of the container and the truck backed away.

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- Always adjust the spreader back to the 6, 326,7,21 DI H HYH D GOL F FOH

- When parking the truck and spreader or when they are not in use for longer periods of
time, always make a habit of lowering the spreader to its lowest position.

- Read all instruction books carefully and be sure that you understand them.

- Should there be anything you do not understand, please contact your local dealer who
will ensure that all your questions are answered.

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Elme attachment model 817, 857

Indication light Indication light Indication light
Container Position
Green Orange Red
Twistlocks unlocked both sides. No container attached.
Top lift OFF OFF ON
Seated - 1, 2, or 3 corners seated.
-"- -- BLINK --
Seated - All 4 corners seated.
-"- Twistlock can be activated to lock or unlock. -- ON --

Twistlocks locked both sides and container lifted.

-"- ON OFF OFF
Twistlock in locked position with a faulty unlock signal.
-"- OFF -- BLINK

Twistlock in unlocked position with a faulty lock signal.

-"- BLINK -- OFF

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RF HG HD HG Unlocked

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used for the design, take into account a certain amount of uneven distribution of the
loads inside the container. The criteria that is used is, that the center of gravity (the load)
can be offset from both the axial and transvers center-lines by a maximum of 10%. This
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beams. (Lifting eyes mounted underneath the main frame are for lifting mixed cargo.
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Lifting eyes mounted on the endbeams are for lifting damaged containers).

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the loads may only be lifted at the speci ed lengths for which the spreader is de
signed i.e. 20ft, 30ft, B7, 40ft and in some cases 45ft. Where stops are tted (op
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ci ed positions can result in serious damage to the spreader.

Standard lifting eyes welded to the inside surface of the spreader end beam close to
each twistlock. Various designs of lifting eyes can be tted, see below.

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The main frame can be equipped with 2 lifting eyes centre mounted or 4 lifting eyes
which can be spaced equally on each side of the spreader centre line at various
distances. Various designs of lifting eyes can be tted, see below.

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Common for all lifting eye combinations tted during the production of the spreader, is
that their collective capacity is the same as the capacity of the spreader. For example,
a spreader with a total lift capacity of 40 metric tons with 4 lifting eyes tted to the main
frame, can lift 40 metric tons LWK WKH ORDG HYHQO GLVWULEXWHG EHW HHQ DOO IRXU OLIWLQ
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Note! The max. capacity for one open hook (Fig 5) is only 12.5 metric tons.
Therefore in the case of only 2 hooks (of this model) tted in the center position
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Ideally, the load should be lifted with the lifting slings vertical between the lifting eyes and
the load (90° to the underside of the spreader). However, the slings can be attached to the
load with a negative angle (less than 90°), but the smaller the angle the lower the load that
can be lifted. The lifting eyes should never be used to lift a load with the lifting slings at a
positive angle (greater than 90° angle to the underside of the spreader). However, if a
damaged container needs to be lifted with slings then this is acceptable.

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ELME GENUINE PARTS

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If you are using non-genuine parts, you put weak links into a strong, perfectly
designed chain of interactive components. Please note that non-genuine parts are made by
factories that have not been approved by ELME and they are often
manufactured to be as cheap as possible, using inferior materials, workmanship and by
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Non-genuine parts are high risk. Real cost and real risk is measured not in the price, but
in the cost of the component in the event of failure. Use of non-genuine parts may lead to
higher downtime and lower productivity due to more frequent failures.

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approved by ELME should be used. If non-genuine parts are used, the warranty is not valid.
By using ELME genuine parts and accessories approved by ELME, you will maintain origi-
nal standard. ELME will disclaim all responsibility if parts from third party are used.

INSPECTION/MAINTENANCE

Always inspect your spreader before using it. If any kind of damage is detected – which may
affect the function of the spreader - this must be corrected before use.

If the spreader needs to be repaired, please contact a specialist and see to that only ELME
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reliable. Repairs made by a non-quali ed person or use of non-genuine parts may lead to
increased risk of personal injuries or damages.

Service and maintenance are necessary to keep capacity and ef ciency of the
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MODIFICATION OF THE SPREADER/PRODUCT LIABILITY/WARRANTY

For the avoidance of doubt, ELME is not liable in case of damage due to factors
beyond ELME’s control or due to a lack of maintenance or the use of non-genuine parts.
The spreader should not be modi ed without consultation with ELME.
If so, this means that the spreader is not CE approved and thus ELME has no product liabi-
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marked with corresponding capacity - SWL ...... T.

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according to below

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marked with corresponding capacity - SWL ...... T.

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according to below

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LUBRICANT:
MULTI PURPOSE GREASE (EP2)

POSITION 1

: 53 6 )25 0 ,1 06 1 7 1 ,1* 06

NO. OF GREASE POINTS 24.

4 TRACKS ON THE INSIDE OF EACH MAIN BEAM.

(SEE ARROWS "A")
INTERVAL - EVERY 2000 HOURS OR 12 MONTHS.

4 TRACKS ON EACH EXTENSION BEAM.

(SEE ARROWS "B")
INTERVAL - EVERY 2000 HOURS OR 12 MONTHS.

2 TRACKS ON THE INSIDE OF EACH MAIN BEAM.

(SEE ARROWS "C")
INTERVAL - EVERY 500 HOURS OR 3 MONTHS.

OPTIONAL

POSITION 2

6723 /,1 56

NO. OF GREASE POINTS 2.

PP
INTERVAL - EVERY 500 HOURS OR 3 MONTHS.
LOCKING PLATE
POINTS. 1 GREASE NIPPLE ON EACH STOP CYLINDER.

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LOCKING PLATE

INTERVAL - ON A REGULAR BASIS OR EVERY 6 MONTHS.

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POSITION 3

6/ :,1* 5,1* 5,1* 1 * 5

NO. OF GREASE POINTS 6.

INTERVAL - EVERY 100 HOURS OR MONTHLY

4 GREASE NIPPLES POSITION "A" MOUNTED AT

ONE CENTRAL POINT ON THE UPPER ROTATOR
FRAME PLATE FOR GREASING THE BEARING.
2 HOLES AT POSITION "B" IN THE STOP BLOCKS
FOR SPRAYING LUBRICATION ONTO THE GEAR
RING WITH A SPRAY CAN OF SPECIAL GREASE.

POSITION 4

6, 6 ,)7 /,1 5 5,1*6

NO. OF GREASE POINTS 2.

INTERVAL - EVERY 500 HOURS OR 3 MONTHS

2 GREASE NIPPELS ON EACH CYLINDER TUBE BEARING.

POSITION 5

SLEWING GEARBOX (2 off).

NO. OF GREASE POINTS 2.

INTERVAL - CHECK OIL LEVEL EVERY 100 HOURS OR MONTHLY.

CHANGE OIL AFTER THE FIRST 50 HOURS OF
OPERATION AND THEN EVERY 2000 HOURS OR YEARLY.

POINTS. - PLUG "A" IN ELBOW AT TOP OF GEARBOX = FILLER

AND LEVEL PLUG.
PLUG "B" IN THE BOTTOM OF THE BOX = DRAIN PLUG.

LUBRICANT. - ISO VG 150 OIL

POSITION 6

03,1* /,1 5 5,1*6

NO. OF GREASE POINTS 2.

INTERVAL - EVERY 500 HOURS OR 3 MONTHS

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 0 17(1 1 ( 1 7 8 7 21 PAGE NO.
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1. - The nylon wear pads should be inspected for wear at the same time
as their tracks are lubricated. Replacing the wear pads can be done with
ordinary hand tools and without removing the beams.

2. - Twistlocks are wearing parts and need inspection for wear and damage on a
regular basis.

The drawing below shows where the heads of the twistlocks wear.
When the worn part exceeds the area indicated by cross-hatching,
the twistlocks should be replaced.

The twistlocks must be replaced after a max. use of 5 000 working hours
or 80 000 twistlock cycles (1 cycle = unlocked/locked/lift).

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less than 60 mm
Wear max.
4 mm

7 LVWORFN LWHP QR Wear max. 6mm.

Should be replaced
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less than 25mm

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3. - Lifting eyes are wearing parts and need inspection for wear and damage on a
regular basis.

Lifting eye maximum wear measurement. Minimum 25 mm thickness from

wear area (see picture below).

Min. 25 mm

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To be replaced when
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Part no. 825 907 (589TB)
Part no. 825 906 (589TB)
Part no. 824 343 (817)
Part no. 824 344 (817)

On spreaders equipped with soft landing/low noise, these parts should be replaced
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4. The extension cylinder support has wear pads under it (for model 517 and
800 series). These should also be inspected on a regular basis and replaced
when their thickness is reduced to minimum 18 mm. See item 1.

5. Maintenance of the stop cylinders if tted (option), consists of checking all

mounting bolts for tightness and inspection for leakage from the cylinder.

6. The side shift wear pads should be inspected for wear at the same time as
lubrication is carried out. The wear pads should be replaced when their
thickness is reduced to minimum 18 mm. See item 1.

7. If the spreader is equipped with hangers, an ocular inspection must be carried

out in connection with lubrication or after every 250 hours. In addition, a
non-destructive test must be carried out after 5000 hours (either MT or UT).
If cracks and/or other damages are detected, the hangers must be replaced.

8. Other recommended spreader maintenance is:

a- Inspect the main spreader components for damage, cracks and distortion.
b- Check the signal and safety systems for correct operation.
c- Check the hydraulic pressures periodically.
d- Check all hydraulic cylinders for leakage and reseal if necessary.
e- Inspect all hydraulic hoses for damage and leakage. Replace if faulty.

9. Warnings to operators:

- It is strictly forbidden to lift loads over person.

- Do not stand under suspended load.
- Never lift two containers (20'), when the intention is to lift one container (40') in single
lift operation, as there is a big risk that the containers will fall off the spreader.
- The spreader should be handled by trained and approved personnel only.
- Never exceed SWL of unit (see name plate for detail).
- Stay clear of spreader when in operation.
- Stay away from all moving parts, such as moving frames etc.
- Do not connect or disconnect electrical connectors while power is on.
- Do not tamper with hydraulic pressure settings, once adjusted by quali ed personnel
(see service manual for proper pressure adjustment)
- Use spreader only for the purpose for which it is designed.
- Unlocking spreader while suspended in the air could create personnel injury and
property damage. Never unlock spreader while suspended in the air.
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10. Warnings for service technicians:

a- Personnel working with the spreader shall be informed of where to nd

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b - Do not stand under suspended load!
c - Stay clear of spreader when in operation.
d - Do not connect or disconnect electrical connectors while power is on.
e - Unlocking spreader while suspended in air could create personnel injury
and property damage. Never unlock spreader while suspended in air.
f - Maintenance inside spreader frame must be carried out under extreme
precaution and by personnel that is familiar with risks related to spreader
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g - Spreader shall be isolated from all energy sources prior to repairs or
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To avoid damage to the spreader, it is important to follow the below directions.

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* Use spreader only for purpose for which it is designed.
* Limit dynamic loading (acceleration, retardation, collision).
* Maintain all electrical and hydraulic components for proper adjustments.
* Never exceed SWL of unit (see name plate for details).

12. Short-time storage of the spreader (up to 3 months)

* All chromed piston rods must be activated to the closed position so that the rods are
stored inside the cylinder where this is possible. If it is not possible to retract the rod
into the cylinder (for example the twistlock cylinders) then the exposed part of the
chromed rod should be sprayed with a rust inhibitor similar to, for example ”Tectyl”.
* All grease points must be pumped full of molybdenum saturated grease.
* Where possible it would be advisable to equip the electric box with a heater (this
could be a small electric bulb for ex. 40 watt which is allowed to burn constantly).
* The spreader should be in 20ft position, and if the spreader is equipped with legs,
these should be in folded position.

13. Instructions for repair and after repair:

Lubrication, adjustments, recti cation of malfunctions and replacement of parts

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hazard or impair operation of the spreader, or that may constitute a hazard before the
next routine inspection. Our recommendations for minor repairs (e.g., replacement of
cables, hoses, ttings, etc) are that they may be undertaken by ordinary service per-
sonnel provided that a competent person (which may be the service person, if ade-
quately quali ed and experienced) rst documents how the incident happened or the
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nature of the damage or defects, documents the proposed action based on these

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recommendations, which shall require replacement of parts like for like using identical
or equivalent parts, and documents the repair.
All repairs shall be carried out by competent persons under competent direction and
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international Standards. The repairs shall be appropriately tested.

Upon completion, the competent person’s report and the documentation produced by
the repairer shall be lodged in a records management system.

Major repairs that consist of more than replacement of a minor part must be performed
and veri ed by specialist or quali ed personnel. If suitably competent personnel are
not available on site, please contact ELME After Sales department for instructions and
help. If suitably competent personnel are available for major repairs, they should detail
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then refer the matter to ELME in order to obtain the manufacturer’s recommendations.
Once those recommendations are received, all major repairs shall be carried out by
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relevant national or international Standards. The repairs shall be appropriately tested.
Upon completion, the competent person’s report and the documentation produced by
the repairer shall be lodged in a records management system.

14. After repair

The repairs shall be appropriately tested. Upon completion, the competent person’s
report and the documentation produced by the repairer shall be lodged in a records
PD D HPH HP

15. Check of spreader functions

All spreader functions are tested and approved at ELME factory before delivery to
customer. When the spreader is mounted on to the lift truck, it is very important to
check and verify that the spreader is working properly. (check signals for e.g. leg
indication, lift interrupt etc.)

There are no instructions relevant to the maintainer on special adjustments and

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16. Disposal of spreader

,I D FRPSH H SH R GH H PL H D H S HDGH D HDF HG H H G RI L

operational life, it shall be rendered inoperable.
H H G RI RSH D LR DO OLIH RI H S HDGH L L LPSR D R IROOR D LR DO GL HF LR
D G H OD LR RI R R GL SR H L H S HDGH FR L RI G D OLF RLO HOHF LFDO
parts and mechanical parts (such as steel and plastic parts). These different materials
have to be sorted and disposed in accordance with national laws and regulations.

(OP SU D U
 3 ( 12
( 9 1 (1 7 7 2

The tie rod is a xed unit and not adjustable. 14

(does not apply for WTP) 13

4 6
5 3

7
To remove the tie-rod proceed as follows:

1 Remove the indicator assy. (item 14) or the Locked / Not locked sensor bracket
(item 1), if it is a spreader with WTP or with overheight legs.

2 Loosen one of the adjuster bolts at the twistlock cylinder, enough to give some play.

3 Loosen and remove the M8 x 80 bolts (item 2) in the top of both twistlocks in the
same end beam.*

4 Use two of the M8 x 80 bolts (item 2) as pullers by inserting them in the two threaded
holes (item 3) in each of the cranks (item 4) and tighten them alternatly until they lift
the cranks (item 4) off the top of the twistlock shaft (item 5).

5 The tie-rod (item 6) including both cranks (item 4) can now be removed from the
end beam.*

R HPRYH H L ORF D G OHHYH S RFHHG D IROOR

6 The key (item 7) that locates the crank (item 4) to the twistlock (item 5) is held in
place on the twistlock by a roll pin so that it will remain in place on the twistlock after
H F D L HPRYHG

(OP SU DG U
 3 ( 12
( 9 1 (1 7 7 2

7 Support the twistlock (item 5) from below so that it does not drop out.
Using a screwdriver prise the collet (item 8) out of the recess in the twistlock (item
5). It is now possible to lower the twistlock out of the end beam. The sleeve (item 9)
and lower bearing set (item 10) will in most cases accompany the twist lock as it is
removed, this is quite normal.

INSPECTION PRIOR TO REASSEMBLY

8 After removal of all twistlock parts remove all grease and dirt from the parts and also
from the corner of the end beam. Steam clean or clean with some form of solvent.

9 Check the twistlock (item 5) for wear at the head and also for wear at the bushing
surfaces. Inspect the lower (item 10) and upper (item 11) bearing sets for wear and
damage, if badly worn or damaged they should be replaced. The collet (item 8) and
and the crank (item 4) should be inspected for possible wear or damage and replaced
LI HFH D

It should be noted that the state of the collet (item 8) and the recess in the
twist lock (item 5) is very important as these parts are carrying the load when a
FRQWDLQHU LV OLIWHG

REPLACING / FITTING TWISTLOCKS

10 Prepare the sleeve (item 9), place and grease the bushing and t the four centering
SL L H LGH RI H OHHYH

11 Grease the upper bearing set (item 11) and place in position on the greased top sur
face of the corner plate (in the endbeam) with the convex half uppermost
(threaded holes up). Grease the lower bearing set (item 10) and place in position on
the greased bottom surface of the corner plate (in the endbeam, the grease will hold
it in place).

12 Lift the sleeve assembly as assembled in point 10 and position up through the corner
plate in the endbeam. Note the direction of the grease nipple! Then place the
twistlock in the sleeve, ensuring that both bearings (item 10 and 11) are positioned
correctly around the twistlock. Support the assembly with a jack or other means.

13 Fit the collet (item 8) with the pointed part upwards.

14 Fit the key (item 7) incl. roll pin to the keyway of the twistlock (item 5)

15 In order to t the tie-rod (item 6) it is necessary to mount both cranks (item 4) to the
tie-rod before placing it in the end beam.* Fit the ball joints, O-rings, and plastic
washers to the tie-rod ends and then t the fork of the crank (item 4) over the tie-rod
H G H D H FR H H G RI H HF L ROH L H F D D H SSH
most. Secure the crank to the tie-rod end by tting the pin (item 12) and then the ring
pin and allen screw (item 13).

16 In order to simplify assembly of the crank to the twistlock it is advisable to t two

alignment pins to the assy. The pins can be made from two M8 x 75 bolts or allen
FH L H HDG HPRYHG D G OL O F DPIH HG
These pins should be screwed into the top plate of the upper bearing (item 11)
diagonally so that each pin guides one half of the collet (item 8).

(OP SU DG U
 3 ( 12
( 9 1 (1 7 7 2

17 Insert the tie-rod (item 6) into the end beam and the t the cranks (item 4) onto the
DOL PH SL D G H H D H H D G H D OL H S L R RI H DOOH
securing (item 2) in the remaining two holes and screw in and tighten lightly. Remove
the alignment pins and t the other two securing screws. The securing screws can
now be tightened to approx. 25 Nm.

18 Activate the twistlocks to the NOT LOCKED position and then adjust the twistlock
cylinder adjuster bolts so that the twistlocks are positioned accurately in the NOT
LOCKED position. Then adjust properly, see ”Twistlock angle adjustment”.

19 Grease the complete assembly with a high-pressure grease gun.

, R GH R H H RSH D LR L L HFH D R OD G H S HDGH R D FR DL H R D H

HD HG SL D H DF LYD HG

* for spreaders with WTP (section 3, 5 and 15 above), the removal/ tting of bolts, tie
rods and cranks can be done one by one.

(OP SU DG U
 3 ( 12
2 5 5 5 2

Removal and tting instructions

for the spreader extension cylinders.

A Extension beams
B Extension cylinder
, SHF LR ROH
D Hose / Cable chain

H DF H S HDGH R H I SR L LR

2 Before removing the securing pin pos.1 of the extension cylinder it must be
supported by a small hydraulic jack or likewise so that the cylinder pos. B does
R IDOO GR
Remove the pin from the rear of the cylinder g.1 pos. 1 (opposite end to the
piston rod) and at the same time also remove the hose and electrical connec-
tions at the rear of the extension cylinder pos. B. The securing bracket that
secures the cable chain to the track in the bottom of the extension beam should
also be disconnected.

3 By using a crane or fork lift truck pull the end beam pos. A out approx. 50cm so
that it is just possible to get into the inspection hole pos.C in the top of the beam.

4 Remove the pin from the piston rod end of the extension cylinder.

5 The extension cylinder pos. B can now be lifted out of the spreader by sliding it
horizontally with the help of suitable lifting equipment, (by "suitable lifting
equipment" is meant that the crane or truck must be capable of lifting 150kg.)
until the slider pads slide out of the rail by which the foot of the cylinder is guided.

6 Replacing the cylinder is the revers procedure of the removal.

S
 3 ( 12

Proximity switch / Sensor

Proximity switch / Sensor

bracket

0R L IDFH
7 to 8mm

8-10 mm
L D FH I RP OD GL IDFH
R GH LGH RI HD HG SL

HD HG SL
Landing surface of end beam

SEATED / LANDED signal adjustment

1. Check that the SEATED PIN can move up and down freely. The force needed to lift the pin
is approx. 10 kg (20 lbs).

2. The SEATED signal should switch on with the pin protruding approx. 9mm below the landing
surface of the end beam.

3. If adjustment of the proximity switch / sensor is necessary, remove the seated sensor
mounting bracket incl. sensor from the top of the seated tower, and adjust the proximity
switch / sensor so that the end surface is 7-8 mm above the lower mounting surface of the
bracket. This adjustment will result in the seated pin indication being switched on when the
underside of the seated pin is approx. 8 to 10 mm lower than the end beams landing
surface. This adjustment also ensures that the mechanical and electrical lockout is released
so that the twistlocks can be turned.

S
 3 ( 12

D
2b
3

5a 4 4 5b

TWISTLOCK ANGLE ADJUSTMENT

1. Turn the twistlocks (pos1) to the fully UNLOCKED position (as shown).

2. If the twistlock heads do not line up with the twistlock sleeve, they can be adjusted by
loosening the lock nuts (pos 5) for the adjuster bolts (pos 2)

3. Turn the twistlocks at each end of the end beam so that they line up with the sleeves, if it
is found dif cult to line up the twistlocks and sleeves accurately distribute the
misalignment equally on both sides of the sleeve. Make sure that the twistlock heads
DO NOT protrude outside the theoretical line between thetwistlocks. If the twistlocks do
protrude outside the previously mentioned line between the twistlocks it can cause
jamming in corner castings as the spreader is lifted off the container.

4. Run both adjuster bolts (pos 2) up to the piston rod (pos 4) ends of the twistlock cylinder
(pos 3) by hand making sure that neither the twistlocks nor the cylinder are moved.
Tighten the lock nut (pos 5a) of the inside adjuster (pos 2a) rst.

5. Unscrew / back off the outer adjuster bolt (pos 2b) no more than 2 ats of the hexagan
head (60°) so that there is only just enough play to allow the tie rod (pos 6) to slide back
and forth across the adjuster bolts when the twistlock cylinder (pos 3) is activated.
CAUTION if the gap between the twistlock cylinder rod ends is too large the rod ends will
hammer against the adjusters and subsequent damage will occur to the piston rod ends.

6. Tighten the lock nut (pos 5b) securely while at the same time ensuring that the adjuster
bolt (pos 2b) does not move.

7. Activate the twistlocks to the LOCKED position and check that the twistlock heads are
90 +/- 10 R H L ORF OHHYH

S
 PAGE NO.
7 7(1 1 72 8(

The two tables below are showing recommended standard torque values in Nm for
different coatings on hexagon headed screws (strength class SS-ISO 898/1* and
SS-ISO 3506/1**). In order to obtain the correct torque values, a reliable torque wrench
should always be used. For stainless steel screws, use a stall tool.
0HWULF WKUHDGV
(coarse) ROW 4XDOLW
Size (mm) RDWLQ
1P 1P 1P 1P
M5 ainless steel (lubr) 3,5
fzb (lubr) 4,9 6,7 8,3
fzb (dry) 5,5 7,8 9,3
fzv (lubr) 6,1 8,7 10,4
fzv (dry) 6,7 9,5 11,4

M6 ainless steel (lubr) 6

fzb (lubr) 8,4 14,6
fzb (dry) 9,4 13,4 16
fzv (lubr) 10,5 15 18,2
fzv (dry) 11,5 16,4

M8 ainless steel (lubr) 14

fzb (lubr) 28 34
fzb (dry) 23 32 38
fzv (lubr) 26 35 43
fzv (dry) 28 39 47

M tainless steel (lubr) 28

fzb (lubr) 40 56 68
fzb (dry) 45 62 76
fzv (lubr) 50 70 85
fzv (dry) 55 76 92

M tainless steel (lubr) 48

fzb (lubr) 70 98 117
fzb (dry) 78 109 131
fzv (lubr) 87 146
fzv (dry) 95 133 159

M14 tainless steel (lubr)

fzb (lubr) 156 187
fzb (dry) 123 174 208
fzv (lubr) 137 194 232
fzv (dry) 150 254

M16 tainless steel (lubr)

fzb (lubr) 169 238 286
fzb (dry) 189 266 320
fzv (lubr) 296 356
fzv (dry) 230 324 390

fzb = electrogalvanisation
fzv = hot-dip galvanisation

(O H SUH GHU
 PAGE NO.
7 7(1 1 72 8(

Metric threads
(coarse) Bolt Quality
Size (mm) Coating 8.8* 10.9* 12.9*
Nm Nm Nm
M18 Stainless steel (lubr)
fzb (lubr) 236 332 398
fzb (dry) 264 370 444
fzv (lubr) 294 413 495
fzv (dry) 322 452 542

M20 Stainless steel (lubr)

fzb (lubr) 331 465 558
fzb (dry) 370 519 623
fzv (lubr) 412 579 694
fzv (dry) 450 633 759

M22 Stainless steel (lubr)

fzb (lubr) 445 626 752
fzb (dry) 497 699 839
fzv (lubr) 554 779 935
fzv (dry) 606 852 1023

M24 Stainless steel (lubr)

fzb (lubr) 572 804 963
fzb (dry) 638 898 1075
fzv (lubr) 712 1000 1198
fzv (dry) 778 1094 1310

M30 Stainless steel (lubr) 1100 1546 1856

fzb (lubr) 1127 1582 1900
fzb (dry) 1257 1766 2121
fzv (lubr) 1402 1969 2365
fzv (dry) 1533 2153 2586

M36 Stainless steel (lubr) 1915 2696 3234

fzb (lubr) 1961 2761 3311
fzb (dry) 2189 3081 3696
fzv (lubr) 2440 3435 4120
fzv (dry) 2668 3756 4504
1RWH When spreader is equipped with rotator, bolts and nuts for the slewing
ring are M24 (10,9) Dacrolite and recommended torque value is 898 Nm.

fzb = electrogalvanisation
fzv = hot-dip galvanisation

(O H SUH GHU
 PAGE NO.

L H H F H IR H HD SDG DI H
the rst 500 working hours.

L DIIHF DOO OPH S HDGH

See page B110-302 Tightening torques for HFRPPH GHG

standard torque values in Nm.

In order to obtain the correct torque values, a reliable

torque wrench should always be used and the
threads should be dry.

OPH S HDGH
 PAGE NO.
66(0 16 21 12 2

The Nordlock bolt securing system

L FR SR D H D SDL RI D H D DYH
FDP IDFH R R H LGH D G DGLDO HH R
HR H

The preassembled washers must be

L DOOHG L SDL FDP IDFH R FDP IDFH
GL HF O R H FR DF IDFH

When reusing Nordlock washers, make sure

D H D H D H L DOOHG FDP IDFH R
cam face and to lubricate the joint.

HDGHG ROH 1. Lubricate the threads and the underside

of the bolt head. Place a pair of Nordlock
washers under the bolt head.

2. Tighten the bolt at a torque

FR H SR GL R H GH L HG FODPS ORDG

1. Lubricate the threads and the underside

of the fastener to be tightened. Place a pair
R ROH of Nordlock washers under both the nut
and bolt in order to prevent rotation of both
ID H H

2. Tighten both fasteners lightly by hand to

close the cams of both washers. Retain one
side of the joint while tighten the opposite
side at a torque corresponding to the
GH L HG FODPS ORDG

(O 6SU D U
 PAGE NO.
1 1 1 1 2 1 21 0 B110-613-1

1. Extend the left extension beam ~1000 mm to make room for service on the right
beam. If the spreader has the option hydraulic stops, disassemble the stop cylinder.

A A

2. Use a M6S 20x90 bolt (1) to lift the rear end of the extension beam ~2 mm to make
sure the extension beam does not rest on the lower wear pad. There should be a
gap left between the upper wear pads and the main frame.
Loosen the 4 bolts (2). In order to replace the side wear pads, remove the inner
bolts (3), on each side.

3. Extend the right extension beam ~400 mm. The beam will slide on (1).

B B

OPH S HDGH
 3 ( 12
1 1 1 1 2 1 21 0 B110-613-2

4. Now it is possible to remove the upper wear pads by loosening bolts (4) and pull
R H HD SDG H DL H
Remove the side wear pad bolts (5) and pull out the wear pad retainer. *

Guide bolt for upper retainer

5. Remove the lower wear pads (6) by pulling the retainer (7) to the position shown in
the below gure. *
Finish the service by retracting the extension beam and remove the M6S 20x90
bolt (1). Tighten all bolts to recommended tightening torque, according to manual.
Reassemble the stop cylinder, if you have the option hydraulic stop.

6. Repeat the procedure for the opposite extension beam.

* Change wear pads and reassemble in reverse order.

OPH S HDGH
 PAGE NO.
672 (

( )( ( ( ( ( ( ( ( ( (
( ( (

When storing an ELME spreader, the following precautions should be taken:

1 All chromed piston rods must be activated to the closed position so that the
rods are stored inside the cylinder where this is possible.
If it is not possible to retract the rod into the cylinder (for example the twistlock
cylinders) then the exposed part of the chromed rod should be sprayed with a
rust inhibitor similar to, for example "Tectyl".

87,21 Ef cient rust inhibitors often dry with time and should therefore be
removed by a solvent before using the spreader again. Failure to do this can
cause damage to the seals of the cylinders with subsequent leakage to follow.

2 All grease points must be pumped full of molybdenum saturated grease.

3 The hydraulic tank should be lled to 80% of its total volume with clean
G D OLF RLO L R GH R HG FH FRYH HG D HD L LGH H D R LF
FR GH D LR FD IR P

4 Grease all sliding surfaces by brushing on a suitable layer of grease.

5 Where possible it would be advisable to equip the electric box with a heater
(this could be a small electric bulb for ex. 40 watt which is allowed to burn
constantly) and if the hydraulic tank is equipped with a heater, it would be
advisable to have it connected during the spring and autumn months.

6 Spray all electric connections both inside and outside of the box with a self-
drying lubricant. This will ef ciently protect electric connections against
FR R LR

7. Spray the whole spreader with corrosion protective wax.

(O 6S G
 3 ( 12
( 5 72 2) 0 2

4 7

5 6

6
5

3 7

Adjusting the damping force:

Tighten the adjuster on cartridge No.1 to increase the
GDPSL IR FH H H SL R L S H HG L D G D G
loosen the adjuster to reduce the force.
Tighten the adjuster on cartridge No. 5 to increase the
damping force when the piston is extended, and loosen
the adjusting to reduce the damping force.

, HP OL
OR FR RO YDOYH
2 Relief valve Setting: 80 Bar
3 Cylinder port
4 Tank port connected to tank line
5 Flow control valve
6 Relief valve Setting: 80 Bar
7 Cylinder port

S
 ( 5 7 21 2) (( 3 ( 12
527 7 21 2

Adjustment of the initial low speed rotation

To alter the initial speed of rotation, turn the adjuster on cartridge no 3,
clockwise to decrease speed and anti-clockwise to increase speed.

Adjustment of high speed rotation

To alter the high speed of rotation, turn the adjuster on cartridge no 2,
clockwise to decrease speed and anti-clockwise to increase speed.

Adjustment of rotation motor pressure

To alter the rotation motor pressure, turn the adjusters on cartridge nos 9 and 10 clockwise to
increase the pressure and anti-clockwise to decrease the pressure.

, 0 ,
ROH RLG YDOYH R D LR GL HF LR
L SHHG OR FR RO YDOYH
3 Low speed Flow control valve
4 Solenoid valve Rotation speed
5 Solenoid valve Brake release
6 Drain port
7 Brake port 1
8 Brake port 2 7 3
9 Relief valve Setting (80 bar)
10 Relief valve Setting (80 bar)
0R R SR
0R R SR
13 Pressure line
14 Relief valve Setting (40 bar)
15 Tank port
16 Gauge adapter

S
6 7,21

, *5 06
 PAGE NO.
C 120-001

PS 13. L HF LR DO YDOYH
(variable displacement) (single solenoid, 2 positions)

0R R L HF LR DO YDOYH
14.
( xed displacement) (single solenoid, 2 positions)

H H HOLHI YDOYH 15. L HF LR DO YDOYH

3.
(normally closed) (single solenoid, 2 positions)
RPEC-FAN
L HF LR DO YDOYH
Sequence valve 16.
4. (double solenoid, 2 positions,
(normally closed) without spring)
RSDC-LAN
L HF LR DO YDOYH
H H HG FL YDOYH 17. (double solenoid, 3 positions,
5.
(normally open) spring centred)
PBDB-LAN
PRH 102 S 50 L HF LR DO YDOYH
18. (double solenoid, 3 positions,
spring centred)

6. RDG FR RO YDOYH L HF LR DO YDOYH

(counterbalance) 19. (double solenoid, 3 positions,
spring centred)
CBCA-LHN
7. HF YDOYH L HF LR DO YDOYH
CXDA-XCN (double solenoid, 3 positions,
9C600S spring centred)
CVH 103 P
HF YDOYH 0DL OL H
8. (pilot operated)
CKCB-XCN

9. HF YDOYH LOR OL H
(pilot operated)
20

OR FR RO YDOYH 23. OR HG FR HF LR
(fully adjustable)
NFCC-LCN
NV 101 S 24. R HF LR SRL

OR FR RO YDOYH
(fully adjustable with 25. R L SRL L R FR HF LR
reverse free ow check)
NCCB-LCN
9F600S
FM2DDKN 26. LO H

OR FR RO YDOYH 27. Double acting cylinder

(fully adjustable,
FDCB-LAN pressure-compensated
with reverse free ow check) 28. H H

29. D

30. RPSR H D H

S
 3 ( 12
(

*HQHUDO GHVFULSWLRQ
Neuron is a system of purpose made ECUs, used at ELME Spreader to control
spreader motions. The system communicates to TRUCK/RS via CAN J1939. Spreader
sensors and actuators are hardwired to ECUs. The system consists of 1 to 5 ECUs
with centralised control and optional PC service interface on CAN bus via CAN-USB
GR OH

6 VWHP GLD UDP

As a minimum neuron system will consist of one MASTER ECU controlled (and powe-
red) from TRUCK or RS via CAN J1939. Each one of the SLAVE ECUs (also the ser-
vice tool) can be added or removed independently of all other optional units on the bus.
Each ECU has 2 CAN/Power ports in order to easily allow extension of the bus (see
also CAN termination below).

6WDWXV /
Each ECU has a status LED to indicate that software is running, everything OK and
connection is established.

S
 3 ( 12
(

Example of status LED signal. This indicates all OK, ECU is SLAVE1.

7KH / VL QDO FDUULHV W SHV RI LQIRUPDWLRQ

• Colour indicates the state of the ECU.
• Green = all OK, no errors.
• Orange = timeout for CAN messages.
For MASTER it means TRUCK timeout.
For SLAVEx it means MASTER timeout.
When LED is showing orange all output on that ECU is off [1].
• Red = error state. Internal error detected / starting up system.
For example micro controller has experienced a non-reversible error with one of
the other ICs on the ECU PCB. Or ECU stuck in start-up.

• Sequence indicate the ECU type (ECU role).

• 1 ash = MASTER
• 2 ashes = SLAVE1 (shown in example above)
• 3 ashes = SLAVE2
• 4 ashes = SLAVE3
• 5 ashes = SLAVE4
• Rapid ashes = In bootloader mode (no difference depending on ECU type)
• Continuous lit = software stuck or not executing properly [2].
• Continuous dark = same as continuous lit or ECU is not properly powered.
A special case is continuous lit in red colour. This occurs when ECU is powered
up, but not connected to CAN. Connection to CAN will make program start.

[1] 24V supply to sensors will still be on. 24V supply to greasing pump will still be on.
Working lights will be left in whatever state they were when timeout occurred
(motivation for this is that in case of emergency lights better be on).
OO R H R S DH HG RII
[2] The software task that is ashing the LED is in lowest priority, so if LED ashes all
other tasks are executed. This also means that LED can be either lit or dark if
software is not executing properly.