Manitowoc 777

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OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL

3-58 Published 10-01-12, Control # 044-05 v2

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Table of Contents5
Crane Data13
Crane/Attachment Identification13
Change of Ownership Registration13
Crane Orientation13
Manitowoc Dealers13
Identification and Location of Components14
Outline Dimensions16
Crane Weights17
English and Metric Conversions20
- Direct Conversion20
- Inverse Conversion20
Continuous Innovation25
Nameplates and Decals25
Safety Messages25
- General25
- Safety Alert Symbol25
- Signal Words25
- Safety Symbols25
Safety and Information Signs29
- Maintaining Signs29
- Ordering Signs29
Crane Access Points31
Getting on or off Crane31
Operator's Manual/Capacity Chart Storage32
- Storing Manuals32
Safe Operating Practices33
- General33
- Read Operator's Manual33
- Operator Qualifications33
- Operator Conduct33
- Handling Load35
- Size of Load35
- Attaching Load35
- Lifting/Moving Load36
- Multiple Load Line Operation37
Signals38
- Holding Load38
Safety Devices39
Operational Aids39
- Category 1 Operational Aids39
- Category 2 Operational Aids40
Assembling, Disassembling, or Operating Crane Near Electric Power and Transmission Lines41
- Electrocution Hazard41
- Set-Up and Operation41
- Electrocution Hazard Devices42
- Electrical Contact42
Refueling43
Fire Extinguishers43
Accidents43
Safe Maintenance Practices43
- Maintenance Instructions43
Environmental Protection45
Boom Disassembly Safety47
- General47
- Location47
- Pin Removal47
- Disassembly Precaution47
Personnel Handling Policy48
Pedestal/Barge Mounted Cranes50
- Pedestal Mounted Crane50
- Definition50
- Examples50
- Barge Mounted Crane51
- Definition51
- Examples51
- Capacity Charts52
- Shock Loading52
- Operation on Barge52
- Definition52
- General52
- Definitions52
- Crane Inspection53
- Transporting Crane on Barge53
Standard Hand Signals for Controlling Crane Operations59
Symbol Identification61
Front Window Operation65
- Closing Window65
- Opening Window for Ventilation65
- Opening Window for Emergency Exit65
Operating Controls65
Controls Identification and Function68
- A - Power Controls68
- B - Engine Controls68
- A1. Engine Ignition Switch68
- B1. Engine Warning/Diagnostic Lights68
- B2. Ether Starting Aid Switch (for 6CTA8.3-C260 or QSL 340 Engine Only)68
- B3. Engine Hand Throttle68
- B4. Engine Foot Throttle68
- B5. Engine Clutch Pedal68
- B6. Emergency Engine Stop Switch68
- C - Accessory Controls69
- B7. Battery Disconnect Switch69
- C1. Dome Light Switch69
- C2. Panel Light Switch69
- C3. Heater/Air Conditioner Fan Switch69
- C4. Horn Switch69
- C5. Air Conditioner Temperature Selector69
- C6. Air Conditioner/Heater Switch69
- C7. Front Windshield Wiper Switch69
- C8. Overhead Windshield Wiper Switch69
- D - Indicators70
- C12. Windshield Washer Switch70
- D1. Digital Display and Selector Switch70
- D2. Operating Limit Alert70
- D3. System Fault Alert70
- D4. Rotation Indicators70
- D5. Level70
- D6. Mirrors70
- D7. Rated Capacity Indicator/Limiter Console70
- D8. Engine Hourmeter70
- E - Gauges71
- E1. Fuel Level Gauge71
- E2. Engine Water Temperature Gauge71
- E3. Engine Oil Pressure Gauge71
- E4. Battery Voltage Gauge71
- E5. Hydraulic Oil Temperature Gauge71
- F - Special Controls/Indicators74
- F1. Limit Bypass Switch74
- F2. Crane Mode Selector74
- G - Boom Hoist Controls75
- F3. Front Drum Free Fall Light75
- F4. Rear Drum Free Fall Light75
- F5. Seat Switch75
- F6. Jib up Limit Bypass Switch75
- G1. Boom Hoist Handle75
- G2. Boom Hoist Park Switch75
- H - Load Drum Controls76
- G3. Boom Cylinder Hold Switch76
- Full-Power Operation (Free Fall Off)76
- Free Fall Operation (if Equipped)76
- H1. Front Drum Handle76
- H2. Rear Drum or Luffing Jib Handle76
- H3. Auxiliary Drum Handle76
- H4. Front Drum Park Switch77
- H5. Rear Drum Park Switch77
- H6. Auxiliary Drum Park Switch77
- H7. Front Drum Pawl Switch77
- H8. Rear Drum Pawl Switch77
- H9. Auxiliary Drum Pawl Switch77
- J - Swing Controls78
- H10. Front Drum Working Brake Pedal78
- H11. Rear Drum Working Brake Pedal78
- J1. Swing Handle78
- J2. Swing Lock Switch78
- J3. Swing Brake Switch78
- J4. Swing Holding Brake Switch78
- K - Travel Controls79
Remote Controls79
- K1. Right Crawler Handle79
- K2. Left Crawler Handle79
- K3. Travel Detent Selector79
- K4. Travel Park Switch79
- K5. Right Crawler Pedal79
- K6. Left Crawler Pedal79
- K7. Travel Speed Selector79
Limit Devices80
- Counterweight Max up Limit80
- Boom Maximum up Limit80
- Boom Maximum down Limit (if Equipped)80
- Block up Limit80
- Luffing Jib Max up Limit80
- Luffing Jib Max up 1 Limit81
- Luffing Jib Max up 2 Limit81
- Luffing Jib Max down Limit81
- Luffing Jib Max down 1 Limit81
- Luffing Jib Max down 2 Limit81
- Maximum Bail Limit82
- Minimum Bail Limit82
- Load Moment Limit82
Seat Controls83
Preparing Crane for Operation84
Operation84
- Engine Start-Up84
- Engine Diagnostics86
- Onboard Diagnostics86
- Engine off Diagnostics86
- Boom Hoist Operation87
- Boom Hoist Speed Adjustment87
- Luffing Hoist Operation88
- Swing Operation89
- Swing Speed/Torque Adjustment89
- Load Drum Operation90
- Liftcrane Operation - Full Power90
- Liftcrane Operation - Free Fall90
- Clamshell Operation91
- Travel Operation92
- Stopping Engine/Leaving Crane Unattended94
Fuses95
- Fuse Location95
- Fuse Identification95
Voltmeter Operation96
Disabling and Enabling Free Fall97
- Disabling Free Fall97
- Enabling Free Fall97
Remote Controls100
- Controls Identification and Operation101
- Carbody Jack Controls101
- Crawler Pin Controls101
- Counterweight Remote Control101
Programmable Controller Calibration Procedures102
- General102
- Controls Calibration102
- Pressure Sender Calibration102
Digital Display Readings102
- Operating Conditions103
- System Faults103
- Selecting Display Language103
- Operating Limits103
Diagnostic Display107
- Drum 1, 2, and 8107
- BHST (Boom Hoist)107
- Swing108
- Track108
- A1 (Handles)108
- D1 and D2 (Digital Outputs and Inputs)108
Swing Limiter Operation114
- Programming Swing Limits114
- Adjusting Swing Limit Switch117
Hydraulic System Controls119
- Components Function119
- Hydraulic Tank119
- Hydraulic Pump119
- Directional Control Valve119
- Hydraulic Filter119
- Spotter System Dump Valve119
- Cylinder Operating Controls119
Wind Conditions121
Cold Weather Heater Package122
- General122
- Heaters122
- Thermostats122
- Turning Heaters on122
- Turning Heaters off122
- 120 Volt AC Option122
Preparation for Cold Weather125
- Crane Limitations125
- Wire Rope125
- Cold Weather Starting Aid125
- Cooling System125
- Battery125
- Engine Oil125
- Fuel Oil125
- Gear Oil125
- Hydraulic Oil126
Rigging Drawings131
Optional Attachments131
General Safety131
Crane Orientation131
Self-Erecting Equipment131
Assembly and Disassembly Notes132
Assembly and Disassembly Area132
Accessing Parts132
Crane Weights132
Retaining Connecting Pins132
Cold Weather Mast Operation132
Lowerworks Lubrication at Assembly132
Operating Limitations134
Operating Controls135
Shipping Crane Components135
Crane Assembly137
- Pre-Start Checks137
- Remove Crane from Trailer137
- Engine137
- Gear Boxes137
- Hydraulic System137
- Install Crawlers141
- Install Counterweights142
- Assemble Boom147
- Connect Boom Butt to Boom147
Pre-Raising Checks150
Crane Disassembly153
- Disconnect Butt from Boom153
- Install Assembly Block155
- Disassemble Boom157
- Remove Counterweights157
- Remove Crawlers161
- Install Crane on Trailer163
Auxiliary Load Drum Installation163
- Crane Requirements163
- Drum Installation163
- Modifications163
- Equipment Required163
- Hydraulic and Electric Connections165
- Wire Rope Installation165
- Butt Removal165
Boom Ladder Assembly167
- Removal from Boom Butt167
- Installation on Boom Inserts167
- Storage in Boom Butt167
Boom Rigging Guide168
- Assist Crane Requirements168
- Blocked Crawlers171
- Handling Components171
- Boom Rigging Assembly Drawing171
- Identifying Boom Sections and Pendants171
- Removable Lacings173
- Boom Installation175
- Boom Removal178
Pile Driver Adapter182
- Operating Specifications182
Jib Rigging Guide183
- Assist Crane Requirements183
- Blocked Crawler/Extended Outriggers185
- Jib Assembly Drawing185
- Identifying Jib Sections and Pendants185
Installing Jib187
- Removing Jib191
Wire Rope Installation193
- Wire Rope Storage193
- Removing Wire Rope from Shipping Reel193
- Seizing and Cutting Wire Rope194
- Pad Eye Usage for Wire Rope Reeving198
  - General198
  - Safety198
- Load Line Reeving200
- Clamshell Reeving206
- Load Block Tieback209
- Universal Anchor Joint210
Section 5211
- Lubrication211
- Inspection and Maintenance Checklist217
- Fiberglass Maintenance217

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