JEKKO SPD265C+ Operating instructions

OPERATING AND MAINTENANCE MANUAL
SPD265C+ SPD360C+ SPD360CD SPD500CD
SERIAL NUMBER:_____

IMAI S.r.l. - Pag e 2 of 73
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IMAI S.r.l.
Via Campardone, 7
Z.I. Colle Umberto ( TV)
Tel. [phone] Fax [phone]
www.imai.it
www.jekko.it e-mail inf [e-mail]
Copyright © 2007 IMAI S.r.l.
MANUAL REVIEW
VERSION DATE REVIEW
1.0 02/2007 First Release
1.1 11/2007 Firs Review

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TABLE OF CONTENTS
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TABLE OF CONTENTS
TABLE OF CONT ENT S ......................................................................................................................3
1PREFACE ................................................................................................................................5
1.1 General Information 5
1.2 Technical Specifications 7
1.3 Original Seals 13
1.4 Operator Training 13
1.5 Intended use 13
1.6 Warranty 14
2SAFETY INFORMATION ......................................................................................................16
2.1 Rules 16
2.2 Noise 17
2.3 Conveyance of instructions 17
2.4 Dangerous zones 19
2.5 Emergency stop 19
2.6 Daily check 20
2.7 Features of the working area 20
3MACHINE SIGNALS AND CONTROLS...............................................................................21
3.1 Main sw itchboard 21
3.2 Radio rem ote control 28
3.3 Main electrical cabinet 28
4USE OF THE MACHINE IN REGULAR WORKING CONDITIONS.....................................30
4.1 Machine starting 30
4.2 Handling and stabilization of the machine 30
4.3 Use of the crane 31
4.4 From crane configuration to truck configuration 31
4.5 Stop and laying-up of the m achine 31
4.6 Settings of the tools installed 32
4.7 Diesel engine 15LD440 emergency start 32
4.8 Emergency procedure to change configuration 32
5MAIN PART S OF MODEL SPD265C+ ................................................................................33
6MAIN PARTS OF MODEL SPD360C+/CD...........................................................................36
7MAIN PARTS OF MODEL SPD500CD.................................................................................38

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TABLE OF CONTENTS
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8HANDLING AND T RANSPORT............................................................................................40
9TROUBLESHOOTING ..........................................................................................................41
9.1 Alarms of battery charger model BC1 41
9.2 Alarms of battery charger model NG1 41
9.3 Alarms of battery charger model NG3 42
9.4 Machine alarms 43
10 STANDAR OPERATOR MAINT ENANCE............................................................................44
10.1 Ordinary Maintenance 44
10.2 Battery recharging 45
10.3 How to increase the battery lifetime 46
10.4 General w arnings for maintenance activity 48
10.5 Extraordinary maintenance 48
11 SERVICING FORMS .............................................................................................................50
11.1 Introduction 50
11.2 Events that relieve the m anufacturer from its liability 51
11.3 Maintenance and servicing register 51
12 ENCL OSURE.........................................................................................................................52
12.1 Summarizing list of maintenance and servicing interventions 52
12.2 Detailed Forms On Servicing And Maintenance 53
12.3 Form For The Conveyance Of Information 54
13 TOOLS ...................................................................................................................................57
13.1 380V FEEDING KIT FOR SPD265C+/360C+ 57
13.2 380V FEEDING KIT FOR SPD360CD 61
13.3 380V FEEDING KIT FOR SPD500CD 64
13.4 MECHANICAL JIB ( JM ) SPD360 65
13.5 HYDRAULIC JIB ( JH ) SPD500 69
13.6 LEV EL BASKET CONNECTION ( ONLY SPD360 EXTRA U.E.) 73

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1-PREFACE
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1 PREFACE
1.1 General Information
Each machine is equipped w ith a copy of this manual.
This instruction manual is intended to facilitate users and maintenance technicians to carry out all
of the operations necessary to operate the machine under safety conditions.
Only fundamental operations have been described. After practicing w ith the machine, the user will
be able to develop further technical skills.
Note: This manual is an integral part of the machine and must therefore accompany
the machine should this be sold, passed on or moved to another place.
A proper training at the moment of delivering must complete the instructions described in this
manual.
As regards the accessories, please read their ow n instruction and m aintenance m anual.
Keeping the Manual
The Manual shall alw ays be kept w ith the machine, even in case of sale.
In case of resell of the machine, the manual must follow it in its present conditions, even in case of
integrations and modifications sent by the manufacturer.
The Manual w ill alw ays be kept w ith the machine until its last demolition: for this reason, it must be
kept w ith care in a safe place.
In case this manual w as lost or subject to w ear, please order another copy from the manufacturer
Ow nership information
This manual contains proprietary information. All r ights are reserved.
No part of this manual may be reproduced or photocopied w ithout prior written consent of IMAI
S.r.l. Only customers to w hom the manual has been supplied together w ith the machine are
allow ed to use it to carry out use and maintenance operations on the machine it refers to.
This manual deals w ith all normal operations to be performed by the machine and w ith the main
regular maintenance operations required. The instruction herew ith provided must be carefully
observed in order to properly use the machine. Machine operator training is required to operate the
machine. Take care not to perform operations and maintenance not recommended in this manual.
Make sure that only suitably qualified and authorized personnel carries out servicing w hen
dismantlement of some parts of the machine is required.
The manufacturer does not undertake any responsibility w hatsoever for any direct or indirect
damage to objects or pets arising from the use of this manual or the machine in other conditions
than those stated herein. IMA I S.r.l. reserves the right to modify or improve this manual and the
machines w ithout notice, even those sold under the same model this manual refers to, but having
different serial numbers.
IMA I reserves the right to change data equipment w ithout prior notice as w ell as instructions for
maintenance and other measures. The measurements, w eights and performance etc. given in this
manual are approximate and can vary depending on the equipment.
The CE marking approves the conformity by the machinery guideline 98/37/EC.

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1-PREFACE
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Conventions:
Qualified technicians: people w ho have the necessary expertise, skill and know ledge
concerning the standards, safety regulations and service conditions, to recognise and avoid any
possible danger for people and damage to the processed materials and to the machine itself.
Right side: Right side of the system, as identified by the operator positioned in the back part of
the crane, in front of the switchboard and of the valve bank.
Left side: Left side of the system, as identified by the operator positioned in the back part of
the crane, in front of the switchboard and of the valve bank.
Marking
On the right side of the crane frame there is an
identification plate bearing the machine's model,
manufacturing number, year of manufacturing and
weight. Model and number are also punched
closed to the plate. The machine is supplied CE-
marked w here required by the market. The CE
marking means that the machine meets the EU's
requirements.

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1-PREFACE
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1.2 Technical Specifications
Model
ModelModel
Model SPD 265+
SPD 265+SPD 265+
SPD 265+ Model
ModelModel
Model SPD 360C+
SPD 360C+SPD 360C+
SPD 360C+
Loading momentum
2600 Kgm
Loading momentum
4300 Kgm
Maxim um working
height
7 m
Maxim um working
height
9.7 m
Maxim um SWL
1200 kg
Maxim um SWL
1800 kg
Rotation
220°
Rotation
360°
Dim ensions
2500x800x1750 mm
Dim ensions
3100x800x1750 mm
Weight
1.700 Kg
Weight
2200 Kg
Max outriggers load
1400 Kg
Max outriggers load
1900 Kg
Track area
Max track loadings
1080x230x2 mm
0.34 Kg/cm
2
Track area
Max track loadings
1080x230x2 mm
0.44 Kg/cm
2
E NGINE
Electric 24V-DC 3kW
(4 batteries 12V-120Ah)
E NGINE
Electric 24V-DC 3kW
(4 batteries 12V-390Ah)
Model
ModelModel
Model SP
SPSP
SPD 360CD
D 360CDD 360CD
D 360CD Model
ModelModel
Model SPD 500CD
SPD 500CDSPD 500CD
SPD 500CD
Loading momentum
4300 Kgm
Loading momentum
5100 Kgm
Maxim um working
height
9.7 m
Maxim um working
height
10.7 m
Maxim um SWL
1800 kg
Maxim um SWL
1750 kg
Rotation
360°
Rotation
360°
Dim ensions
3100x800x1750 mm
Dim ensions
2500x800x1750 mm
Weight
2200 Kg
Weight
2800 Kg
Max outriggers load
1900 Kg
Max outriggers load
2100 Kg
Track area
Max track loadings
1080x230x2 mm
0.44 Kg/cm
2
Track area
Max track loadings
1400x250x2 mm
0.40 Kg/cm
2
E NGINE
Diesel 7.4/10.1kW/hp 12V
(tank 5 Liter)
E NGINE
CD- Diesel 14/19kW/CV
12V (tank 4 Liter)

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1-PREFACE
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DIMENSIONS A ND LOADING DIAGRAM OF THE CRANE WITH HOOK
SPD265

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SPD360

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SPD500

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1-PREFACE
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Apply t e ook directly to t e crane boom.
C h e c k a l w a y s t h e h o o k S W L c a p a c i t y .
WINCH LOADING DIAGRAM (EX:spd265)
The w inch capacity of model SPD265 is of 600 kg (see the machine CE plate).
The load limiting device avoid the machine tilting w hile using the w inch. In any case, the operator
has to make sure not to lift loads exceeding the boom capacity.
W it h i n t h e 6 0 0 - k g l o a d i n g c a pa c i t y , t h e b o o m c a n li f t l o a d s e x c e e d i n g t he
w i n c h c a p a c it y t h u s a c t iv a t i n g t h e l o a d l i m i t i n g d e v i c e . I n o r d e r t o l if t
h e a v i e r l o a ds it is ne c e s s a ry t o m o d i f y t he p u l le y c o nf i g u ra t i o n b y us i n g a
s i n g l e , d o u b l e o r t r i p le li n e p u ll .
Kg 600

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1-PREFACE
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T he r o p e r e pl a c e m e n t o r s h o r t e n i n g ha s t o b e c a r r ie d o ut b y s pe c ia l i ze d
t e c h n i c i a n s , o n ly .
In order to increase the rope lifting capacity
it is necessary to assemble the hook device
as indicated in the picture and to set the
machine by means of the sw itchboard.
Every machine is equipped w ith a chart, as
the one indicated in the picture, w hich
indicates the w inch lifting capacity
depending on the configuration chosen.
Double line pull Triple line pull

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1-PREFACE
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1.3 Original Seals
The manufacturer has placed lead sealings on machine
components to assure w orking under safe conditions.
O R I G I N A L S E A L R E M O V A L W I L L C A U S E
M A C H I N E U N S A F E W O R K I N G . T H E
M A N U F A C T U R E R D E C L I N E S A N Y
R E S P O N S I B I L I T Y A R I S I N G F R O M U N S A F E
U S E O F M A C H I N E S .
1.4 Operator Training
Technical training is required to the operator in order to correctly operate this machine. IMA I S.r.l.
qualified personnel is available to train your personnel in many European countries. Contact your
dealer for more information. If you can not find a dealer in your country please call IMA I S.r.l.
1.5 Intended use
The machine has been designed to handle loads by means of a lifting hook, a w inch or an
accessory jib: loads must not exceed the load diagram printed or labelled on the crane.
 All uses not expressly declared in this manual are to be considered not intended, especially
any use different from those described in this manual.
C A U T I O N !
D o n ' t us e t he m a c h i ne t o l if t pe o p l e
ATTENTION
THE MACHINE DON’T HAVE BEEN PROJECTED TO LIFT PEOPLE, IT
DON’T RESPECT THE SAFETY REQUIREMET OF THE U.E. NORMATIVE
FOR THIS KIND OF LIFTING

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1-PREFACE
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1.6 Warranty
ART.1 This w arranty cancels and replaces any other kind of explicit or implicit w arranty; any
variations shall have no effect unless stated in a document issued by IMAI S.r.l. Any disputes as to
the interpretation or fulfilment of the w arranty conditions shall be submitted to the jurisdiction of the
court of Conegliano (TV).
ART.2 IMA I S.r.l.' s w arranty w ill expire after 12 months from the day of delivery of the machine to
the final user. Within this period, IMA I S.r.l. shall replace free of charge any parts that have
manufacturing defects in IMA I S.r.l. 's opinion.
ART.3 The w arranty shall not cover any labour involved in assembling and dismantling the
machine to replace the faulty parts, nor any transport costs for the delivery of the replacement
parts. The w arranty doesn't include goods damaged or perished after the forwarding from the
factory.
ART.4 Under no circumstance is expected a refund for the machine's stop w orking because of the
fault and the repairing. Delays on repairing don't give right to refund or extension of the w arranty.
ART.5 The w arranty does not include deficiencies and defects due to the normal w ear of
component parts that are usually subject to rapid and continuous w ear (oil, grease, brass, ecc.). As
for hydraulic devices dilate cylinders and bended piston rods are excluded because those events
are caused by not right loads or not right movements of the machine.
ART.6 All requested spare parts should be invoiced at the price-list in force at the time of the
enquiry. IMAI S.r.l. shall acknow ledge any right to replacements under w arranty by means of a
credit note.
ART.7 Equipment not manufactured by IMAI S.r.l. and applied to IMA I S.r.l. products - such as
engines, electrical components and others - are not covered by this guarantee but by their ow n
manufacturer's guarantee. IMAI S.r.l. w ill w arrant to its customers only and all the terms of the
manufacturer's guarantee.
ART.8 The buyer shall not be entitled to interrupt payments or other obligations related to the
purchase, even in case of a valid complaint. This w arranty cancels and replaces any other kind of
explicit or implicit w arranty; any variations shall have no effect unless stated in a document issued
by IMAI S.r.l.
ART.9 The w arranty claim w ill be effective only if it is returned w ith the delivery verbal to IMA I S.r.l.
within 30 days from the date of delivery of the machine. All w arranty claims w ill have to be
submitted to IMA I S.r.l. w ithin 8 days from the moment the damage occurred.
The w arranty w ill expire in case of:
- Improper use of the machine (not complying w ith the instructions given)
- Non authorized modifications, repairs and dis mantling (carried out by technicians non
authorized by IMA I S.r.l.)
- Use of non authorized accessories or accessories not fit for IMAI’s machines
- Wrong installation of the accessories and equipment the machine is supplied w ith
- Damages due to accidents, negligence, non-performance of periodical maintenance, use of
non genuine spare parts
- Damages due to exceptional events.

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1-PREFACE
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Tampering w ith the safety seals placed on the valves or on the accessories w ill cause the w arranty
expiration and w ill release IMAI S.r.l. of w hatever liability.
Further information on responsibility
THE MANUFACTURER DECLARES HE WILL BE RELIEVED FROM ANY RESPONSIBILITY
OR LIABILITY UNDER WARRANTY IN CASE OF:
1. Improper use of the machine
2. Tampering with the machine or with its component parts
3. Machine used by not authorized personnel
4. Serious maintenance shortage
5. Partial or complete non-observance of instructions
6. Non-topping up of lubrication system in the periodical checks and non-filling in of relevant
reports
7. Non-performance of periodical checks
8. Use of non genuine spare parts (spare parts not recommended by the manufacturer)
9. Non authorized modifications and repairs
10. Exceptional events

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2 – SAFETY INFORMATION
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2 SAFETY INFORMATION
The designing and manufacturing of this machine is based on specific safety criteria in compliance
with the rules indicated on the CE certificate:
A careful risk assessment, carried out by the manufacturer, has allow ed to remove the major risks
connected both to scheduled and to rationally foreseeable operative conditions. Complete records
about safety measures adopted can be found in the technical manual of the machine, w hich is kept
by the manufacturer.
The manufacturer strongly recommends to follow all operative instructions and procedures herein
described and to observe all safety rules at w ork, above all as regards both personal protection
equipment and machine safety equipment. L’accurata analisi dei rischi svolta dal fabbricante ha
consentito di eliminare la maggior parte dei pericoli connessi alle condizioni d’uso della macchina,
sia previste che ragionevolmente prevedibili.
2.1 Rules
Some operative rules should be applied in order to best preserve environment and the operator's
safety.
The operator
o He must be a healthy person
o He must be responsible
o He must have sense of direction
o He must act w ith circumspection w hen operating w ith the machine and be able to estimate
dangers and w orking conditions.
o He must have quick reflexes.
o He must have very good pow ers of concentration.
o He mustn't be used to drink alcohols and to take drugs!
The operator m ust not wear:
o rings;
o watches;
o jew ellery.
o torn clothes;
o scarves;
o unbuttoned shirts or smocks;
o jackets not zipped up;
o other clothes w hich could cause dangers with parts in motion
General directions
1st regulation
• Preserve your ow n safety!
• Preserve environment and animals !
• Take care nobody is exposed to dangers!
• Don't get on the machine, slipping danger !

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2 – SAFETY INFORMATION
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2nd regulation
• Use personal protection equipment! (DPI)
• Be careful about sharp corners!
3rd regulation
• Prohibit unauthorized and untrained staff from using the machine!
• In case of alternation, the manual must pass from one to the
follow ing operator.
• Alw ays operate w ith calm, precision and concentration!
Keep the machine clean in all of its component parts: handling members, sw itchboard and
signalling apparatus.
• D on 't s mok e.
• D on 't use o pe n fi re s.
2.2 Noise
If w orke rs are e x pose d to a ti me -wei g hte d av era ge ( TWA ) s o un d
le vel of 85 dB or m ore , he a rin g p ro tec t ors are re co mme n de d.
H e aring pr ote c to rs m us t be w or n by all o pera t ors e x pos e d to a
TW A o f 9 0dB or more .
2.3 Conveyance of instructions
This chapter of the manual is intended to facilitate possible operations in case of change of
operator and in case of inheritance of the machine due to sale.
THE OPERATIV E RESPONSIBLE OF THE MA CHINE IS
THE ONE WHO,
having picked up the m achine at the manufacturer's,
ACCEPTS THE ROL E OF OPERATOR.
BUT
The machine can be picked up for the purchaser by someone else, w ho w on't be the final operator
or ow ner.
In this case, the one w ho picks up the machine w ill not be responsible for the machines, but
WILL TAKE UP THE ROLE OF "TEMPORARY OPERATOR" ONLY UNTIL THE MACHINE IS
DELIV ERED TO THE PURCHASER.
Each "temporary operator" must receive the machine operative instructions from the
manufacturer and convey them to the person w ho, later, w ill be the effective machine OPERATOR.

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2 – SAFETY INFORMATION
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B E C A R E F U L!
W h e n i n t he f i r m t he s a m e m a c h i ne is t o b e u s e d b y m o r e t h a n o n e
o p e r a t o r , w o r k i n g i n s t r uc t i o n s a s w e l l a s t h e u s e a n d m a i ne t a nc e
m a n u a l m u s t b e c o n v e y e d t o a l l t he o p e r a t o r s i n c h a r ge o f t he
m a c h i n e .
How to convey the machine instructions
Train the new operator (or the new owner) properly.
→ Make sure the operator understands instruction on safe operating and safety devices.
→ Make sure the operator understands the information pertaining the machine's dangerous
zone and component parts.
→ Give the operating manual to the new operator (or to the new owner) and explain its
contents to him.
→ Tell him about the existence of the Declaration of Conformity and of the CE mar king
→ In case of resell, give the Declaration of Conformity to the new ow ner, and tell him about the
hallmar ks.
→ Be sure the new operator has correctly understood the instruction and has no doubts about
the machine's functioning.
How to prove the conveyance of instructions
Considering that a proper know ledge of the machine is absolutely necessary and that the operator,
when ends its operative role, is no more responsible for it, w e have prepared some forms intended
to prove the machine has been correctly picked up at the manufacturer’s site (Declaration of
responsibility) and it has been properly conveyed in case of resell.
L a c k i n g o r i nc o r re c t c o n v e y a nc e o f i n s t r uc t i o ns a n d o f t h e m a n u a l
c o ul d c a u s e i nv o l v e m e n t i n ( a ls o p e n a lt y ) p u ni s h m e n t i n c a s e of
e nv i r o n m e nt a l d a m a g e or h a r m s uf f e re d b y p e rs o n s ,t h i n gs o r a n i m a l s .
IN SHORT
 Inform and train the new operator
 Give him the manual and highlight safety instructions
 Fill in the form in all details and sign it
 It is in the conveyor's interest to take and keep a copy of the page proving
the correct conveyance.

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2 – SAFETY INFORMATION
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2.4 Dangerous zones
There are some very dangerous zones near the machine.
The dangerous zone is determined by the field of action of the crane.
It is a b s o l ut e l y f o r b i d de n t o s t a y u n d e r ha n g i n g l o a d s
There could be further dangers in the w orking area: please, observe the follow ing rules
D o n ' t w o r k n e a r e l e c t ri c w i re s , d a n g e r of d e a t h i n c a s e of c o n t a c t
w i t h e le c t r ic w i r e s . W h i le w o r k i n g , k e e p t h e f ol l o w i n g m i n i m u m
d is t a n c e f r o m t h e p o w e r l i ne :
Volt (V) Min dist. Insulated electric
w ire
Min. dist. uninsulated electric wire Place of w ires
< 500 0.5 m 2 m Buildings
500- 45.000 1.5 4 m Tram, trains
>45.000 Not in use 6 m High tension
Power-lines
2.5 Emergency stop
Note: This procedure can be performed in any moment.
In compliance w ith the safety rules in force, the machine has been provided w ith emergency devices.
They must be operated to reduce the stopping time w hen the usual stop procedure would not enable
actual or impending danger to the operator or to the machine itself to be averted.
C A U T I O N ! ! !
Bef ore putting t he mac hine back int o se rv ice , re mov e t he c ause of da nge r.
Location of emergency devices
The machine has been provided w ith several types of emergency devices.
• Emergency push-button - located on main sw itchboard
• Emergency push-button - located on radio remote control
About emergency devices
The main features of the installed emergency devices are:
Mushroom-shaped emergency push-button;
PUSH the mushroom-shaped button to stop the machine.
Machine back into service after emergency
In order to avoid unintended start-up, the emergency state remains active until the machine is put
into service.
To put the machine back into service:

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2 – SAFETY INFORMATION
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Note: Before putting the machine back into service, remove the cause of danger.
→ Find out the push button used to activate the emergency state;
→ Rotate the mushroom-shaped button in the direction indicated by the arrow s printed on it;
→ The push-button is now back in service and the machine is ready to w ork.
→ Push the turn on engine button to start-up the machine
2.6 Daily check
Daily checks to be performed before starting the machine::
o Check hydraulic oil level
o Verify there is no visible oil leakage
o Check safety micro-sw itch. Remove possible mud, grease, etc. residues without using
metal tools.
o Test safety systems
o Carpentry condition visual check
o Check outriggers efficiency
o Verify safety labels are present and readable
o Make sure the w orking area is ventilated as batteries produce explosive gases (C)
o Check greasing of the machine
o Check oil level and gasoline level of diesel engine (CD)
2.7 Features of the working area
To avoid unpleasant troubles or even accidents working areas have to meet specific requirements
such as:
o Enough space to allow outriggers setting according to the different handling necessities
o Ground slope s maller than 5 %;
o The foots of the outriggers must lay on solid ground, w ithout manhole, cover, etc.
o Check pow er supply availability at the voltage required by the machine and in
o conformity w ith the rules in force.
I n c a s e t he m a c h i n e h a s t o w o r k o n u p p e r f l o o rs , v e ri f y t h e i r m a x i m u m
l oa d i n g c a p a c it y a c c o r d i n g t o w h a t i n di c a t e d i n pa ra g r a p h ‘ T e c h ni c a l
S pe c i f i c a t i o n s ’ .
C A U T I O N ! ! !
D o n ' t w o r k o n f l o o r s w it h o u t ha v i n g v e r if ie d t h e i r l o a d i n g c a p a c it y . T h e
m a n u f a c t u re r d e c l i ne s a ny r e s p o n s i b i l it y a ri s i n g f r o m d a m a g e o r
c ol l a ps e .