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Manitowoc 777 User Manual
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SET-UP AND INST
ALLATION
777 OPERATOR
’
S MANUAL
4-16
Published 10-01-12, Cont
rol # 044-05
FIGURE
4-10
A982d
A983
A982
Count
erwei
ght
Handli
ng Pend
ant
View
C
Front
Hook
Rol
ler
P467
Lug
View
D
Counter
weight
Handling
Pendant
P468
Rear Pin
Connec
tion
Lug
P469
View
F
Front Hook
Fixed P
in
on En
gine B
ase
P470
View
G
Rear Pin
Installe
d
View
A
View
B
View
E
Counter
weight
Hand
ling
Pendan
ts
Lug
Front Hoo
k
View
H
Counter
weight
Lifting Link
Counter
weight
Lifting Penda
nt
Pin
P520
145
147
Table of Contents
Table of Contents
5
Crane Data
13
Crane/Attachment Identification
13
Change of Ownership Registration
13
Crane Orientation
13
Manitowoc Dealers
13
Identification and Location of Components
14
Outline Dimensions
16
Crane Weights
17
English and Metric Conversions
20
Direct Conversion
20
Inverse Conversion
20
Continuous Innovation
25
Nameplates and Decals
25
Safety Messages
25
General
25
Safety Alert Symbol
25
Signal Words
25
Safety Symbols
25
Safety and Information Signs
29
Maintaining Signs
29
Ordering Signs
29
Crane Access Points
31
Getting on or off Crane
31
Operator's Manual/Capacity Chart Storage
32
Storing Manuals
32
Safe Operating Practices
33
General
33
Read Operator's Manual
33
Operator Qualifications
33
Operator Conduct
33
Handling Load
35
Size of Load
35
Attaching Load
35
Lifting/Moving Load
36
Multiple Load Line Operation
37
Signals
38
Holding Load
38
Safety Devices
39
Operational Aids
39
Category 1 Operational Aids
39
Category 2 Operational Aids
40
Assembling, Disassembling, or Operating Crane Near Electric Power and Transmission Lines
41
Electrocution Hazard
41
Set-Up and Operation
41
Electrocution Hazard Devices
42
Electrical Contact
42
Refueling
43
Fire Extinguishers
43
Accidents
43
Safe Maintenance Practices
43
Maintenance Instructions
43
Environmental Protection
45
Boom Disassembly Safety
47
General
47
Location
47
Pin Removal
47
Disassembly Precaution
47
Personnel Handling Policy
48
Pedestal/Barge Mounted Cranes
50
Pedestal Mounted Crane
50
Definition
50
Examples
50
Barge Mounted Crane
51
Definition
51
Examples
51
Capacity Charts
52
Shock Loading
52
Operation on Barge
52
Definition
52
General
52
Definitions
52
Crane Inspection
53
Transporting Crane on Barge
53
Standard Hand Signals for Controlling Crane Operations
59
Symbol Identification
61
Front Window Operation
65
Closing Window
65
Opening Window for Ventilation
65
Opening Window for Emergency Exit
65
Operating Controls
65
Controls Identification and Function
68
A - Power Controls
68
B - Engine Controls
68
A1. Engine Ignition Switch
68
B1. Engine Warning/Diagnostic Lights
68
B2. Ether Starting Aid Switch (for 6CTA8.3-C260 or QSL 340 Engine Only)
68
B3. Engine Hand Throttle
68
B4. Engine Foot Throttle
68
B5. Engine Clutch Pedal
68
B6. Emergency Engine Stop Switch
68
C - Accessory Controls
69
B7. Battery Disconnect Switch
69
C1. Dome Light Switch
69
C2. Panel Light Switch
69
C3. Heater/Air Conditioner Fan Switch
69
C4. Horn Switch
69
C5. Air Conditioner Temperature Selector
69
C6. Air Conditioner/Heater Switch
69
C7. Front Windshield Wiper Switch
69
C8. Overhead Windshield Wiper Switch
69
D - Indicators
70
C12. Windshield Washer Switch
70
D1. Digital Display and Selector Switch
70
D2. Operating Limit Alert
70
D3. System Fault Alert
70
D4. Rotation Indicators
70
D5. Level
70
D6. Mirrors
70
D7. Rated Capacity Indicator/Limiter Console
70
D8. Engine Hourmeter
70
E - Gauges
71
E1. Fuel Level Gauge
71
E2. Engine Water Temperature Gauge
71
E3. Engine Oil Pressure Gauge
71
E4. Battery Voltage Gauge
71
E5. Hydraulic Oil Temperature Gauge
71
F - Special Controls/Indicators
74
F1. Limit Bypass Switch
74
F2. Crane Mode Selector
74
G - Boom Hoist Controls
75
F3. Front Drum Free Fall Light
75
F4. Rear Drum Free Fall Light
75
F5. Seat Switch
75
F6. Jib up Limit Bypass Switch
75
G1. Boom Hoist Handle
75
G2. Boom Hoist Park Switch
75
H - Load Drum Controls
76
G3. Boom Cylinder Hold Switch
76
Full-Power Operation (Free Fall Off)
76
Free Fall Operation (if Equipped)
76
H1. Front Drum Handle
76
H2. Rear Drum or Luffing Jib Handle
76
H3. Auxiliary Drum Handle
76
H4. Front Drum Park Switch
77
H5. Rear Drum Park Switch
77
H6. Auxiliary Drum Park Switch
77
H7. Front Drum Pawl Switch
77
H8. Rear Drum Pawl Switch
77
H9. Auxiliary Drum Pawl Switch
77
J - Swing Controls
78
H10. Front Drum Working Brake Pedal
78
H11. Rear Drum Working Brake Pedal
78
J1. Swing Handle
78
J2. Swing Lock Switch
78
J3. Swing Brake Switch
78
J4. Swing Holding Brake Switch
78
K - Travel Controls
79
Remote Controls
79
K1. Right Crawler Handle
79
K2. Left Crawler Handle
79
K3. Travel Detent Selector
79
K4. Travel Park Switch
79
K5. Right Crawler Pedal
79
K6. Left Crawler Pedal
79
K7. Travel Speed Selector
79
Limit Devices
80
Counterweight Max up Limit
80
Boom Maximum up Limit
80
Boom Maximum down Limit (if Equipped)
80
Block up Limit
80
Luffing Jib Max up Limit
80
Luffing Jib Max up 1 Limit
81
Luffing Jib Max up 2 Limit
81
Luffing Jib Max down Limit
81
Luffing Jib Max down 1 Limit
81
Luffing Jib Max down 2 Limit
81
Maximum Bail Limit
82
Minimum Bail Limit
82
Load Moment Limit
82
Seat Controls
83
Preparing Crane for Operation
84
Operation
84
Engine Start-Up
84
Engine Diagnostics
86
Onboard Diagnostics
86
Engine off Diagnostics
86
Boom Hoist Operation
87
Boom Hoist Speed Adjustment
87
Luffing Hoist Operation
88
Swing Operation
89
Swing Speed/Torque Adjustment
89
Load Drum Operation
90
Liftcrane Operation - Full Power
90
Liftcrane Operation - Free Fall
90
Clamshell Operation
91
Travel Operation
92
Stopping Engine/Leaving Crane Unattended
94
Fuses
95
Fuse Location
95
Fuse Identification
95
Voltmeter Operation
96
Disabling and Enabling Free Fall
97
Disabling Free Fall
97
Enabling Free Fall
97
Remote Controls
100
Controls Identification and Operation
101
Carbody Jack Controls
101
Crawler Pin Controls
101
Counterweight Remote Control
101
Programmable Controller Calibration Procedures
102
General
102
Controls Calibration
102
Pressure Sender Calibration
102
Digital Display Readings
102
Operating Conditions
103
System Faults
103
Selecting Display Language
103
Operating Limits
103
Diagnostic Display
107
Drum 1, 2, and 8
107
BHST (Boom Hoist)
107
Swing
108
Track
108
A1 (Handles)
108
D1 and D2 (Digital Outputs and Inputs)
108
Swing Limiter Operation
114
Programming Swing Limits
114
Adjusting Swing Limit Switch
117
Hydraulic System Controls
119
Components Function
119
Hydraulic Tank
119
Hydraulic Pump
119
Directional Control Valve
119
Hydraulic Filter
119
Spotter System Dump Valve
119
Cylinder Operating Controls
119
Wind Conditions
121
Cold Weather Heater Package
122
General
122
Heaters
122
Thermostats
122
Turning Heaters on
122
Turning Heaters off
122
120 Volt AC Option
122
Preparation for Cold Weather
125
Crane Limitations
125
Wire Rope
125
Cold Weather Starting Aid
125
Cooling System
125
Battery
125
Engine Oil
125
Fuel Oil
125
Gear Oil
125
Hydraulic Oil
126
Rigging Drawings
131
Optional Attachments
131
General Safety
131
Crane Orientation
131
Self-Erecting Equipment
131
Assembly and Disassembly Notes
132
Assembly and Disassembly Area
132
Accessing Parts
132
Crane Weights
132
Retaining Connecting Pins
132
Cold Weather Mast Operation
132
Lowerworks Lubrication at Assembly
132
Operating Limitations
134
Operating Controls
135
Shipping Crane Components
135
Crane Assembly
137
Pre-Start Checks
137
Remove Crane from Trailer
137
Engine
137
Gear Boxes
137
Hydraulic System
137
Install Crawlers
141
Install Counterweights
142
Assemble Boom
147
Connect Boom Butt to Boom
147
Pre-Raising Checks
150
Crane Disassembly
153
Disconnect Butt from Boom
153
Install Assembly Block
155
Disassemble Boom
157
Remove Counterweights
157
Remove Crawlers
161
Install Crane on Trailer
163
Auxiliary Load Drum Installation
163
Crane Requirements
163
Drum Installation
163
Modifications
163
Equipment Required
163
Hydraulic and Electric Connections
165
Wire Rope Installation
165
Butt Removal
165
Boom Ladder Assembly
167
Removal from Boom Butt
167
Installation on Boom Inserts
167
Storage in Boom Butt
167
Boom Rigging Guide
168
Assist Crane Requirements
168
Blocked Crawlers
171
Handling Components
171
Boom Rigging Assembly Drawing
171
Identifying Boom Sections and Pendants
171
Removable Lacings
173
Boom Installation
175
Boom Removal
178
Pile Driver Adapter
182
Operating Specifications
182
Jib Rigging Guide
183
Assist Crane Requirements
183
Blocked Crawler/Extended Outriggers
185
Jib Assembly Drawing
185
Identifying Jib Sections and Pendants
185
Installing Jib
187
Removing Jib
191
Wire Rope Installation
193
Wire Rope Storage
193
Removing Wire Rope from Shipping Reel
193
Seizing and Cutting Wire Rope
194
Anchoring Wire Rope to Drum
194
Winding Wire Rope Onto Drum
195
Anchoring Wire Rope to Wedge Socket
196
Breaking in Wire Rope
198
Pad Eye Usage for Wire Rope Reeving
198
General
198
Safety
198
Load Line Reeving
200
Reeving Diagrams
200
Wire Rope Specifications
200
Wire Rope Installation
200
Guide Sheave Identification
200
Load Pin Sheaves
200
Universal Anchor Joint
200
Load Blocks
200
Clamshell Reeving
206
General
206
Wire Rope Specifications
206
Wire Rope Installation
206
Load Block Tieback
209
Specifications
209
Shackle
209
Sling Length
209
Sling Capacity
209
Universal Anchor Joint
210
Section 5
211
Lubrication
211
Inspection and Maintenance Checklist
217
Fiberglass Maintenance
217
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Manitowoc 777 Specifications
General
Brand
Manitowoc
Model
777
Category
Construction Equipment
Language
English
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