Manitowoc 777

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HYDRAULIC SYSTEM 777 SERVICE MANUAL

2-6 Published 10-01-2012, Control # 045-08

P494

View C

Install

Padlock

Here

Open

Latch

Access

Cover

Filter 5 (under

cover)

Temperature

Gauge

Sight

Gauge

Level

Decal

Hydraulic

Ta n k

Fill Cap

Hydraulic Tank

Shut-off Valve

Fuel Tank

Hydraulic Tank

Drain Valve

Hydraulic

Tank

Hydraulic Filters

(see Figure 2-2)

FIGURE 2-4

View B

View A

P454

P432

A961

Main Page

Table of Contents5
Safe Maintenance Practices13
Maintenance Instructions13
Identification and Location of Components15
Crane Orientation15
General Operation19
Operating System19
Hydraulic Components19
Hydraulic Pumps20
Hydraulic Motors22
Charge Pressure23
Main System Pressure23
Accessory System Pressure23
Hydraulic Supply23
Hydraulic Tank24
Filtration24
Suction Manifold27
EPIC Programmable Controller (PC)28
Supercharge Manifold28
Oil Return Manifolds and Cooling System28
Standard Crane Mode30
Other Crane Modes30
Digital Display31
Voltage Availability32
Brake Release System38
Hydraulically Released38
Load Drum Clutch Release System (with Free Fall)39
Boom System41
Boom Hoist Rotation Indicator41
Counterweight Handling41
Boom off41
Boom Raise43
Boom Lower45
Swing System48
Swing Lock48
Off49
Swing49
Travel System51
Off51
Left Crawler Forward51
Travel Detent Button52
Load Drum Pawl53
Drum Pawl Engage54
Drum Pawl Disengage54
Load Drum (Full Power Mode)55
Liftcrane Operation56
Off56
Hoist56
Lower58
Clamshell Operation: Clamshell Mode59
Programming59
Off59
Close Bucket59
Hoist Bucket61
Open Bucket62
Lower Bucket63
Load Drum (Free Fall Mode)64
Front Drum in Free Fall66
Crane Setup Systems69
Carbody Jacking System69
Jacking Cylinder Extend69
Jacking Cylinder Neutral69
Jacking Cylinder Retract71
Crawler Attachment System73
Crawler Lock Pin Extend73
Crawler Lock Pin Retract74
Optional Systems75
Luffing Jib Hoist System75
Auxiliary Hoist System76
Auxiliary Hoist Rotation Indicator77
Auxiliary Drum Pawl System77
Auxiliary Hoist off77
Auxiliary Hoist Raise77
Auxiliary Hoist Lower78
Abbreviations80
Hydraulic Schematics83
Hydraulic System - General83
Checking and Replacing Hydraulic Hoses83
Hydraulic System Maintenance84
Safety84
Storing and Handling Oil84
Storing and Handling Parts84
Inspecting System84
Servicing Pumps85
Cleaning Fill Cap Assembly85
Replacing Filter Elements86
Filter 186
Filter 287
Filters 3 and 487
Changing Oil89
Tightening Hydraulic Connections90
Pipe Thread Connection90
SAE Straight Thread Connection91
ORS Connection92
Split Flange Connection92
SAE Flare Connection93
Programmable Controller Calibration Procedures94
Controls Calibration94
Pressure Sender Calibration94
Pressure Sender Replacement94
Load Drums, Swing, Track, and Boom Hoist Pump95
Boom Hoist Cylinder95
Disc Brake Operational Test97
Operational Test97
Shop Procedure99
Initial Oil Fill102
Pressure Sender Calibration105
Initial Start-Up106
Controls Calibration108
Pressure Adjustments108
Charge Pressure Checks108
Accessory System Pressure Checks109
Band Brake Relief Valve Pressure Check110
Drum Clutch Pressure Adjustment110
Operating Pressure Checks111
Boom Hoist Leakage Test111
Operating Speed Checks112
Electrical Drawings and Schematics115
Checking and Replacing Electrical Components115
Abbreviations and Symbols116
Test Voltages117
Controller Board Layout117
Pin Identification118
Wire Identification123
Description Identification128
Display Readings133
Operating Conditions133
Operating Limits133
System Faults133
Selecting Display Language135
Crane Diagnostics138
Drum 1, 2, and 8138
BHST (Boom Hoist)138
Swing138
Track138
A1 (Handles)139
D1 and D2 (Digital Outputs and Inputs)139
Crane Software Installation144
CPU and Eprom Compatibility144
EPROM (Chip) Identification144
Eprom Replacement145
Counterweight Limit Switch Adjustment146
Adjustment146
Bench Setup146
Engine Control Module Ground Modification147
Installation147
Test before Installing Counterweights147
Dielectric Grease148
Connector Pin Identification149
Mini-Change Type Connectors149
2-Pole Plugs149
3-Pole Plugs150
5-Pole Plugs151
10-Pole Plugs152
Micro-Change Type Connectors153
Quick-Change Type Connectors153
4-Pole Plugs153
3-Pole Plugs154
Section 4157
Automatic Boom Stop Adjustment157
Maximum Boom Angle157
Operation157
Maintenance157
Bypass Limit Test159
Adjustment159
Physical Boom Stop160
Operation160
Removal160
Boom Angle Indicator162
Adjusting Angle Indicator162
Sensor Replacement162
Pendulum-Type 120° Potentiometer162
Solid State Sensor162
Servicing Boom Hoist Cylinder164
Boom Hoist Cylinders - Welding164
Before Welding on Crane164
Boom and Jib Inspection and Lacing Replacement165
Inspection Intervals165
Inspection Guidelines165
Replacement Criteria165
Dents166
Gradual and Sweeping Bends166
Corrosion and Abrasion166
Kinks168
Cracks and Breaks168
Chord Straightness168
Ordering Lacings170
Assistance170
Boom or Jib Identification170
Ordering Lacings from Lacing Drawings171
Ordering Lacings Without Lacing Drawings172
Repair Procedure173
Extent of Repair173
Preparing for Welding173
Repair Facility173
Outdoor Repairs173
General Equipment Requirements173
Repair Procedures and Processes174
Lacing Replacement174
End Lacing Replacement175
End Lacing Replacement on an Insert (Angle and Tubular Chords)176
End Lacing Replacement on Tapered Sections (Tubular Chords)176
Lacing Removal - Boom Section with a Bent or Bowed Chord Member177
Determining Amount of Stick Electrode Needed177
Inspection Checklist183
Record Keeping183
Section 5187
Hoist Drawings189
Minimum Bail Limit Adjustment189
Weekly Maintenance189
Wire Rope Removal189
Electric Wiring189
Adjustment191
Block-Up Limit Installation and Adjustment192
Operation192
Installation192
Adjustment192
Block-Up Limit Control Deactivated192
Block-Up Limit Control Activated192
Storing Electric Cable194
Disconnecting Block-Up Limit Control197
Removing Jib or Boom Point197
Maintenance197
Adjustment198
Drum Brake Adjustment200
Full-Power Operation (Free Fall Off)200
Free Fall Operation (Optional)200
Brake Inspection200
Brake Adjustment201
Foot Pedal Adjustment202
Drum Pawl Adjustment204
Actuator Removal204
Actuator Installation and Adjustment204
Drum Pressure Roller Adjustment206
General206
Adjustment206
Wire Rope Lubrication207
Wire Rope Inspection and Replacement207
Keeping Records207
Inspecting Wire Rope207
Frequent Inspection207
Periodic Inspection207
Rope Not in Regular Use207
Replacing Wire Rope207
Distributing Wire Rope Wear209
Sheave, Roller, and Drum Inspection210
Load Block and Hook-And-Weight Ball213
Maintenance and Inspection213
Section 6217
Manual Release of Swing Brake and Lock219
Manual Release Procedure219
Section 7219
Battery Maintenance223
Safety Information223
Causes of Battery Failure223
Overcharging223
Undercharging223
Lack of Water223
Hold-Downs223
Overloads223
Multiple Battery System224
Maintenance224
Weekly - Check Electrolyte Level224
Every 2 Months - Test Batteries224
Charging225
Storage225
Battery Electrical Disconnect Switch225
Quarterly225
Engine Air Cleaner Maintenance226
Mounting226
Inspection226
Service226
Engine Clutch Adjustment227
Operation227
Adjustment227
Engine Throttle Adjustment - Cummins C330228
Foot Throttle Linkage Adjustment228
Electronic Fuel Control Adjustment228
Engine Throttle Adjustment - Cummins 6CTA8.3-C260 Engine230
Foot Throttle Linkage Adjustment230
Electronic Speed Control Adjustment230
Setting High Speed230
Setting Gain and Stability230
Test Voltages231
Engine Throttle Adjustment - Caterpillar 3176B and 3176C Engines232
Foot Throttle Linkage Adjustment232
Engine Speed Calibration232
Engine Throttle Adjustment - Cummins QSL 340, QSC8.3, QSM11, or QSX15 Engine233
Foot Throttle Linkage Adjustment233
Engine Speed Calibration233
Wiring Diagram233
Onboard Diagnostics234
Engine Stop Light234
Engine off Diagnostics234
Engine Warning Light234
Engine Maintain Light234
Turntable Bearing Bolt Torque237
Bearing Installation237
Torque Requirements237
Bolt Replacement237
Lubrication237
Torque Values237
Torque Sequence237
Torque Intervals237
Crawler Adjustment238
Maintenance238
Tread Slack Adjustment239
Adjustment Guideline239
Adjustment Procedure239
Hydraulic Hand Pump240
Assembly240
Maintenance240
Air Removal241
Operation241
Section 9243
Lubrication243
Section 10247
Safety Summary249
General Guidelines249
Introduction249
Test Equipment250
Troubleshooting Charts251
Testing276
Test 1 - Battery Test (12 and 24 VDC)276
Test 2 - Electric Fuel Control (EFC) Box Test Points277
Test 3 - Checking Resistance at Engine Temperature Switch279
Test 4 - Checking Resistance at Engine Oil Pressure Sender280
Test 5 - Cleaning and Adjusting the Engine RPM Transducer (Past Production)281
Test 6 - Testing for Voltage at the Fuse Box282
Test 7 - Checking Voltage at the Control Handle283
Test 8 - Adjusting the Control Handle Potentiometer284
Test 9 - Location of Pump Test Ports285
Test 10 - Location of Motor Test Ports287
Test 11 - Manually Stroking the Pump289
Test 12 - Setting the Pump Pressure290
Test 13 - Setting Pump Neutral291
Test 14 - Adjusting Pump Charge Pressure Relief292
Test 15 - Checking Pump Charge Pressure293
Test 16 - Checking Charge Pressure at Motor Port X1294
Test 17 - Testing the Motor PCP and Pump EDC295
Test 18 - Testing for Pump and Motor Leakage296
Test 19 - Testing Hydraulic Solenoid Brake Valves297
Test 20 - Checking Hydraulic Brake Pressure298
Test 21 - Adjusting the Lower Accessory Relief Valve299
Test 22 - Adjusting Jacking Counterbalance Valves300

Table of Contents

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