Page 1 Manitowoc 777 Operator Manual...
Page 3 MAINTENANCE CHECKLIST NOTICE The serial number of the crane is the only method your Manitowoc dealer or Crane Care has of providing you with correct parts and service information. The serial number is located on a crane identification plate attached to the operator’s cab.
Page 4 THIS PAGE BLANK...
Page 5: Table Of Contents
Manitowoc Dealers ........
Page 6 TABLE OF CONTENTS 777 OPERATOR’S MANUAL Disassembly Precaution ............2-23 Personnel Handling Policy .
Page 7 777 OPERATOR’S MANUAL TABLE OF CONTENTS Travel Operation ............. 3-34 Stopping Engine/Leaving Crane Unattended .
Page 8 TABLE OF CONTENTS 777 OPERATOR’S MANUAL Assembly and Disassembly Notes ........... . 4-2 Assembly and Disassembly Area .
Page 9 777 OPERATOR’S MANUAL TABLE OF CONTENTS Anchoring Wire Rope to Drum ..........4-64 Winding Wire Rope onto Drum .
Page 11 Manitowoc Dealers ........
Page 13: Crane Data
CHANGE OF OWNERSHIP REGISTRATION Follow the on-screen instructions to locate your dealer. If you are a new owner of a Manitowoc crane, please register When calling a dealer with parts or service questions, please it with Manitowoc Crane Care so we can contact you if the provide the model and serial number of your crane or need arises.
Page 14: Identification And Location Of Components
INTRODUCTION 777 OPERATOR’S MANUAL IDENTIFICATION AND LOCATION OF COMPONENTS P555 P557 Published 10-01-12, Control # 044-05...
Page 15 777 OPERATOR’S MANUAL INTRODUCTION P558 Item Description Item Description Boom Point, Lower Carriage Guide, Wire Rope (boom top) Bed, Rotating Boom, #78 Drum, Front Pendant, Boom Drum, Rear Guide, Wire Rope (boom butt) Load Block Mast Hook and Weight Ball...
Page 16: Outline Dimensions
INTRODUCTION 777 OPERATOR’S MANUAL OUTLINE DIMENSIONS 179050 C L Rotation 35'-7-1/2" 10.86 m 31'-2-1/2" 9.51 m Center Line Boom Hinge 12'-5" 3.79 m 7'-7" 2.31 m 3'-6" 1.07 m 21'-6 1/2" 6.57 m 29'-11" 9.12 m 18'-7 1/4" 5.67m Tails wing 17'-2"...
Page 17: Crane Weights
COUNTERWEIGHT - UPPER: 18,500 8 391 Box - side (4 on 777 SERIES 1, 6 on SERIES 2) (each) - - - - - - - - - - - - - - - - - - - - - - 31,035...
Page 18 INTRODUCTION 777 OPERATOR’S MANUAL MAST: 5,000 2 267 26 ft 0 in. (7 925 mm) mast - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20 ft 0 in.
Page 19 777 OPERATOR’S MANUAL INTRODUCTION MACHINE OPTIONS: Cummins M11-C330 power plant (increase over standard) - - - - - - - - - - - - - - - - - - - - Free fall for front drum (increase over standard)
Page 20: English And Metric Conversions
INTRODUCTION 777 OPERATOR’S MANUAL ENGLISH AND METRIC CONVERSIONS Inverse Conversion DIVIDE ( ÷ ) known value by conversion factor to obtain Direct Conversion equivalent value in desired units. For example, 3.6576 m is MULTIPLY ( x ) known value by conversion factor to obtain converted to feet, as follows: equivalent value in desired units.
Page 21 777 OPERATOR’S MANUAL INTRODUCTION To Convert Symbol Application Symbol Multiply By VOLUME (LIQUID) Ounce Milliliter 29.5735 Pint Liter 0.4732 Fluid Capacities Quart Liter 0.9464 Gallon Liter 3.7854 Gallon Per Minute Pump Flow Liters Per Minute L/min 3.7854 WEIGHT Pound Unit/Component Kilogram 0.4536...
Page 23 Definition ............. . . 2-26 Manitowoc...
Page 24 777 OPERATOR’S MANUAL Examples ............. . . 2-26 Barge Mounted Crane .
Page 25: Continuous Innovation
Due to continuing product innovation, the information in this could result in death or serious injury. manual is subject to change without notice. If you are in doubt about any procedure, contact your Manitowoc distributor or Crane Care in Manitowoc. CAUTION...
Page 26 SAFETY INFORMATION 777 OPERATOR’S MANUAL Crush Hazards Cut or Crush Hazards Electrocution Hazard Cut Hazard Explosion Hazard Fall Hazard FIGURE 2-1 Published 10-01-12, Control # 044-05...
Page 27 777 OPERATOR’S MANUAL SAFETY INFORMATION Engine Diesel Coolant Fuel Engine Coolant Hydraulic Vent Filter Fall Hazards Engine Oil Level Hydraulic Pump Drive Oil Level Fluid Symbols Flying Object Hazards Falling Boom Hazards (Crush Hazard) Overhead Obstruction Hazard Falling Load Hazards...
Page 28 SAFETY INFORMATION 777 OPERATOR’S MANUAL Sound Power Level Personal Fall Protection Read Manual Pressure Cleaning Tire Pressure (if applicable) Pressure Release Hazard FIGURE 2-1 continued Published 10-01-12, Control # 044-05...
Page 29: Safety And Information Signs
Ordering Signs The crane owner/user shall make sure that all signs are Order replacement signs from your Manitowoc distributor. legible and installed at the proper locations on the crane. If a sign has been defaced or removed, it must be replaced When ordering a sign, give the crane model number, the serial number, and the name and part number of the sign.
Page 30 SAFETY INFORMATION 777 OPERATOR’S MANUAL Pin Hole Brace Catwalk (working position) (typical) Pin (two places) Pin Hole P429 (stored position) Catwalk P427 View B P426 Pin (stored (stored position) position) View A Stairs (working position) View E Pin (working Brace...
Page 31: Crane Access Points
Two ladders, stored in the boom butt, are available for boom assembly and disassembly. See Boom Manitowoc has provided, ladders and catwalks at the Ladder Assembly in Section 4 of this manual for locations shown in Figure 2-2.
Page 32: Operator's Manual/Capacity Chart Storage
If the serial numbers of your manuals and Capacity Charts do not match the serial numbers of the crane or attachment, STORAGE contact your Manitowoc dealer for the proper manuals or Manitowoc provides the following manuals and other Capacity Charts.
Page 33: Safe Operating Practices
(United States Federal Law), in ASME B30.5 American planners, rigging personnel, and job site personnel in safe National Standard, or in any other applicable federal, state, operation. Manitowoc cannot foresee all hazards that will or local laws. arise in the field; therefore, safety remains responsibility Operator training and qualification is crane owner’s...
Page 34 SAFETY INFORMATION 777 OPERATOR’S MANUAL necessary or if there are known defects that impair safe 11. The operator shall verify that: operation, the crane shall not be operated until unsafe All attachments are properly assembled and conditions have been corrected.
Page 35: Handling Load
NOTE: Capacity charts for Manitowoc cranes show the and the like. total weight of freely suspended loads for various boom and jib lengths and operating radii.
Page 36: Lifting/Moving Load
SAFETY INFORMATION 777 OPERATOR’S MANUAL Secure unused legs of a multi-leg sling before handling Accelerate and decelerate the load smoothly to a load with one leg of sling. avoid excessive stress on the crane boom and machinery. Lifting/Moving Load b. Avoid sudden starts and stops while swinging. Keep...
Page 37: Multiple Load Line Operation
Engage the luffing hoist pawl when operating with the luffing jib at a fixed radius. Manitowoc authorizes multiple load line operation for those applications requiring it, provided the following steps are While traveling, the operator shall take the following...
Page 38: Signals
Manitowoc recommends that each load line be equipped crane movements. If communication is disrupted, with an anti two-block device. operator shall stop all crane movements. Manitowoc’s Capacity Charts are based on freely Signals to the operator shall be in accordance with the suspended loads.
Page 39: Safety Devices
• Always tag-out any faulty safety device and place a Manitowoc provides the following operational aids on its warning tag in the cab stating that the crane is out of cranes, either as standard equipment or optional equipment.
Page 40: Category 2 Operational Aids
SAFETY INFORMATION 777 OPERATOR’S MANUAL at a point that gives the signal person sufficient time Refer to the pendulum boom angle indictor on the to signal the operator and have the operator stop boom butt (viewable from operator’s cab). the boom or jib within the minimum allowable radius.
Page 41: Assembling, Disassembling, Or Operating Crane Near Electric Power And Transmission Lines
WARNING dangerous. Electrocution Hazard! Set-Up and Operation Manitowoc cranes are not equipped with all features required to operate within OSHA 29CFR1926.1408, Table During crane use, assume that every line is energized A clearances when the power lines are energized. (“hot” or “live”) and take necessary precautions.
Page 42: Electrocution Hazard Devices
SAFETY INFORMATION 777 OPERATOR’S MANUAL source. This person should have no other duties while The insulating characteristics of these devices can be the crane is working. compromised if not kept clean, free of contamination, and undamaged. Taglines should always be made of non-conductive materials.
Page 43: Refueling
If the dealer is not immediately available, contact maintenance personnel can result in their death or injury Manitowoc Crane Care at the factory. The crane must and costly damage to the crane or property. not be returned to service until it is thoroughly inspected...
Page 44 SAFETY INFORMATION 777 OPERATOR’S MANUAL Place a warning sign at the start controls alerting Do not remove cylinders until the working unit has been other personnel that crane is being serviced and the securely restrained against movement. engine must not be started. Do not remove sign Pinch points are impossible to eliminate;...
Page 45: Environmental Protection
Handle and dispose of waste according to local, state, and connecting bolts or pins are being removed. federal environmental regulations. 28. Unless authorized in writing by Manitowoc, do not alter When filling and draining crane components: do not pour the crane in any way that affects the crane’s...
Page 46 SAFETY INFORMATION 777 OPERATOR’S MANUAL A10415 View A WRONG – DANGEROUS! Typical Crane Shown and there is No Blocking If Boom is Off Ground Under Boom Sections... and Supported by Straps... Boom will COLLAPSE when Lower Pins are Removed! View B WRONG –...
Page 47: Boom Disassembly Safety
777 OPERATOR’S MANUAL SAFETY INFORMATION BOOM DISASSEMBLY SAFETY Pins can be ejected forcefully if the boom has any pressure on it or if the boom is not supported properly. NOTE: The term boom used in the following instructions applies to all lattice attachments (fixed jib, luffing jib, mast, etc.).
Page 48: Personnel Handling Policy
50 percent of the rated capacity conditions. for the radius and configuration of the crane. Use of a Manitowoc crane to handle personnel is acceptable • The crane is uniformly level within one percent of level provided: grade and located on a firm footing.
Page 49 Manitowoc recommends that cranes be properly maintained, regularly inspected, and repaired as necessary. All safety adverse weather conditions which could affect the signs must be in place and legible. We also urge Manitowoc safety of personnel . crane owners to upgrade their cranes with rated capacity •...
Page 50: Pedestal/Barge Mounted Cranes
Manitowoc does not permit use of a truck crane on a barge, ship or floating platform. Pedestal Mounted Crane Carbody Also see ASME publication B30.8-2004, Floating Cranes...
Page 51: Barge Mounted Crane
Front and Required Crawler-mounted crane with carbody anchored with tie- Rear When Parked Carbody downs to the foundation (Figure 2-8). Curbing Foundation NOTE: Manitowoc does not permit traveling with load. FIGURE 2-9 ® RINGER (crawler mounted, carbody mounted) Tie-Downs Carbody...
Page 52: Capacity Charts
Trim Pitch FIGURE 2-11 Capacity Charts Operation On Barge Manitowoc provides two types of Capacity Charts for a crane General mounted on a barge or other supporting structure under Machine list and/or dynamics will be experienced when a static conditions.
Page 53: Crane Inspection
777 OPERATOR’S MANUAL SAFETY INFORMATION angle between horizontal and a line drawn through required. Correct each defect found before placing the crane centerline of the crane’s boom hinge pins. into service. Unless otherwise specified in the Capacity Chart, barge •...
Page 55 F3. Front Drum Free Fall Light ........3-17 Manitowoc...
Page 56 777 OPERATOR’S MANUAL F4. Rear Drum Free Fall Light ........3-17 F5.
Page 57 777 OPERATOR’S MANUAL Boom Hoist Speed Adjustment ........3-29 Luffing Hoist Operation .
Page 58 777 OPERATOR’S MANUAL Turning Heaters Off ..........3-64 Preparation for Cold Weather.
Page 59: Standard Hand Signals For Controlling Crane Operations
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30.5a-2007. USE WHIPLINE (Auxiliary LOWER. With arm extended HOIST. With forearm vertical, USE MAIN HOIST.
Page 60 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL STOP. Arm extended, palm EMERGENCY STOP. Both arms TRAVEL. Arm extended forward, DOG EVERYTHING. Clasp down, move arm back and forth extended, palms down, move hand open and slightly raised, hand in front of body.
Page 61: Symbol Identification
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES SYMBOL IDENTIFICATION The following symbols are used to identify controls on this crane. Data, Confirm Safety Alert: Warning/Caution Operating Limit System Fault Engine Diagnostics Data, Select Battery Voltage Boom Hold (Boom Cylinders) Decrease/Increase...
Page 62 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL Emergency Stop Engine Diagnostics STOP Engine Fan Blower) Engine, Ether Starting Aid Fuel Engine Pressure Heater Engine Run Horn Engine Start Limit Bypass (Current and Past Production) STOP Engine Stop Locked/Unlocked STOP Maintenance...
Page 63 777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Monitor/Display Scroll (up, down, and sideways) Off/Stop Setup Mode Speed — Fast On/Start Speed — Slow Panel Lights (Current and Past Production) Park (Park On) Swing Swing Left Park Off (Current and Past Production)
Page 64 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL Travel Windshield Washer Travel Direction Windshield Wiper Arrow indicates which crawler is operating and direction of travel with drive motors to the rear. Travel Direction Arrow indicates which crawler is operating and direction of travel with drive motors to the rear.
Page 65: Front Window Operation
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES FRONT WINDOW OPERATION Opening Window for Ventilation Rotate window latch handles to position shown in Figure 3-3, Closing Window View B. Window can be swung open 8 in. (203 mm) for Rotate window latch handles to position shown in Figure 3-3, ventilation.
Page 66 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL CHART: 1205B/70 RAD: 12.5 M PARTS [12] NET LOAD: 100000 KGS FRONT DRUM MAX CAP: 110000 KGS H9 H7 H9 H7 H8 G3 K7 Programmable Controller Operator’s Manual Holder Fuses A960 FIGURE 3-4...
Page 67 777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Left Side Left Side Compartment of Engine Between Load Drums Right Inboard Leg of Boom Butt A976 A1206 P450 Right Side and Rear Left Side of Left Side Front of Rotating Bed of Hydraulic Tank...
Page 68: Controls Identification And Function
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL CONTROLS IDENTIFICATION AND RELEASE rocker to DISCHARGE shot of ether into engine air inlet manifold. FUNCTION See Figure 3-4 for following instructions. CAUTION A – Power Controls Engine Damage! A1. Engine Ignition Switch Using too much ether can damage engine.
Page 69: C - Accessory Controls
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES NOTE: Use engine ignition switch (A1) to stop engine for C5. Air Conditioner Temperature Selector normal operating conditions. Rotate knob clockwise for cooler temperatures and counterclockwise for warmer temperatures. B7. Battery Disconnect Switch Turn disconnect handle CLOCKWISE to CONNECT battery C6.
Page 70: D - Indicators
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL To set each thermostat, remove cover and turn knob r o t a t i o n i n d i c a t o r t o m o v e u p a n d d o w n clockwise to 100°F (38°C).
Page 71: E - Gauges
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES E – Gauges E1. Fuel Level Gauge WARNING Shows how much fuel is left in fuel tank. Overload Hazard! E2. Engine Water Temperature Gauge Use boom angle indicator only as a guide to position boom near angle corresponding to radius for given load.
Page 72 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL Table 3-1 Bypassable Limit Identification — PRIOR TO CRANE S/N 7771165 USA and EUROPEAN non-EUROPEAN Limit Limit Jib Up Limit Bypass Switch (F1) Bypass Switch (F1) Bypass Switch (F6) (momentary) (momentary) Limit (maintained)
Page 73 777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-2 Bypassable Limit Identification — CRANE S/N 7771165 AND NEWER non-CE External Luffing Jib Setup Luffing Jib Setup Operating Limit non-CE Override Switch Mode On Mode On Boom Maximum Up Block Up (Drum 1, 2, and 8)
Page 74: F - Special Controls/Indicators
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL F – Special Controls/Indicators Turn key COUNTERCLOCKWISE to CONFIRM desired crane mode when it appears on digital display. F1. Limit Bypass Switch R e l e a s e k e y t o C E N T E R . R e m o v e k e y t o p r e v e n t unauthorized operation.
Page 75: G - Boom Hoist Controls
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES On crane S/N 7771165 and newer, this mode allows the F3. Front Drum Free Fall Light limits listed in Table 3-2 to be bypassed with Limit F4. Rear Drum Free Fall Light Bypass Switch (F1).
Page 76: H - Load Drum Controls
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL G3. Boom Cylinder Hold Switch Automatic operation of band brake is turned off and drum clutch releases when either drum handle is moved to off. Press TOP of rocker to TURN ON boom cylinder hold. When •...
Page 77: H4. Front Drum Park Switch
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Move handle to REAR to RAISE load (or luffing jib on rear H4. Front Drum Park Switch drum). H5. Rear Drum Park Switch H6. Auxiliary Drum Park Switch LIFTCRANE A794 Drum park switches enable and disable drum operation. With...
Page 78: J - Swing Controls
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL H10. Front Drum Working Brake Pedal J – Swing Controls H11. Rear Drum Working Brake Pedal J1. Swing Handle See Figure 3-9 for following procedure. Dual-axis handle allows swing and boom hoist to be Each free fall equipped drum has a brake pedal that can be operated at the same time with one handle.
Page 79: K - Travel Controls
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES K4. Travel Park Switch The travel park switch enables and disables travel operation. CAUTION With travel park on, the travel handles (or pedals) are Swing Drive/Boom Damage! inoperable and the travel brakes are applied.
Page 80: Limit Devices
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL The boom can be raised after the limit is contacted. The appropriate limit bypass switch must be moved to the bypass position to lower the boom below the limit. WARNING Avoid Death or Serious Injury!
Page 81: Luffing Jib Max Up 1 Limit
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Luffing Jib Max Down Limit Prior to Crane S/N 7771156 WARNING Automatically stops the luffing jib when the boom to luffing jib angle is 60°. Falling Boom/Jib Hazard! Do not raise luffing jib above up limit during normal The luffing jib can be raised after the limit is contacted.
Page 82: Maximum Bail Limit
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL Maximum Bail Limit Automatically stops the corresponding load drum from hoisting when there is a preset maximum number of wire WARNING rope layers on the drum. Falling Load Hazard! The load can be lowered after the limit is contacted.
Page 83: Seat Controls
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES SEAT CONTROLS A794 Avoid Damage! Disconnect electric cord from rear of right console before removing ARMREST (unzip cover to expose screw at rear of each armrest) - seat from operator’s cab. Turn screws to raise and lower armrests to desired position.
Page 84: Preparing Crane For Operation
Make sure crawlers are blocked, if required per capacity crane is equipped with. chart, prior to raising and lowering attachment. Read and NOTE: Manitowoc recommends the use of heaters comply with instructions in Crawler Blocking Diagram in (engine, hydraulic tank, etc.) to aid start-up when Capacity Chart Manual.
Page 85 777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES CAUTION CAUTION Pump Damage! Engine Clutch Damage! Do not start engine until hydraulic shut-off valves are To maintain proper engine clutch operation: open; otherwise, pumps could cavitate and be damaged. • Decrease engine speed to 1,300 rpm before engaging or disengaging clutch.
Page 86: Engine Diagnostics
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL possible without stalling engine to give system A1226 fault alert and engine warning/diagnostic lights time to turn off. Run engine at low idle until hydraulic oil temperature is at least 60°F (16°C) and all faults are gone.
Page 87: Boom Hoist Operation
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Yellow WARNING light flashes indicating that a fault NOTE: Besides being equipped with a boom up limit, a code is about to be flashed. physical boom stop is provided. The physical boom s t o p...
Page 88: Luffing Hoist Operation
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL Luffing Hoist Operation CAUTION Machinery Damage! WARNING Do not engage rear drum pawl while lowering luffing jib. Damage to pawl or drum will occur. Avoid Death or Serious Injury! Stop luffing hoist by moving rear drum handle to off and Re a d an d u nd er stan d in st r uct io ns in L uffin g Jib then engage rear drum pawl.
Page 89: Swing Operation
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Swing Operation Once rotating bed is stopped, apply swing holding brake to hold rotating bed in position for short periods during operating cycle. To hold rotating bed in position for long periods, turn on WARNING swing brake and engage swing lock.
Page 90: Load Drum Operation
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL If desired, turn off diagnostic screens: Release drum brake with brake pedal (if equipped) for drum to be operated. Depress limit bypass button or turn limit bypass key clockwise. NOTE: The brake pedal can be pressed down at any time to slow down or to stop the load.
Page 91: Clamshell Operation
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES drum brake with brake pedal to stop load and release Press digital display selector to set closing line drum handle to off. pressure. The CLAM CLOSING PRESS screen will automatically appear on the digital display.
Page 92: Travel Operation
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL Push holding line handle forward to lower bucket at Increase engine speed to desired rpm with hand throttle. desired speed. Press foot throttle to momentarily increase engine speed when more power is required.
Page 93 777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES are to the front, the crane will travel in the direction right crawler handle/pedal farther to front than left opposite of handle movement. crawler handle/pedal; right crawler will turn faster than left crawler.
Page 94: Stopping Engine/Leaving Crane Unattended
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL Stopping Engine/Leaving Crane Unattended Pendants will hold boom between 67° and 73° depending on boom length. d. Turn on boom hoist park. Reverse procedure to return to normal operation. WARNING Moving Load/Tipping Crane Hazard! Operator shall not leave operator’s cab until crane, loads,...
Page 95: Fuses
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES FUSES Fuse Location Fuses are located in the front of the left enclosure (Figure 3-4). Transient Suppressor Diode (k2) (k1) 70 amp DC Power 70 amp Cab Output Relay Power Relay 12–15 268350...
Page 96: Voltmeter Operation
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL VOLTMETER OPERATION Engine not running or Engine running fast enough to running at low idle. make alternator produce. A915 Disconnected meter. Engine could not run with Dead or disconnected battery. Disconnected or dead or disconnected battery unless circuit was badly connected meter.
Page 97: Disabling And Enabling Free Fall
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES DISABLING AND ENABLING FREE FALL Install dust caps to keep unused couplers clean. Quick-disconnect couplers in hydraulic hoses to drum clutch solenoid valves allow FREE FALL operation to be disabled at either or both drum clutches.
Page 98 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL A1058 REAR OF CRANE A1058 To Tank View A Solenoid Valve Assembly Front Drum with Free Fall VIEWED FROM INBOARD SIDE PAST PRODUCTION P568 To Tank To Tank View B View C Rear Drum with Free Fall...
Page 99 777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE BLANK Manitowoc 3-41 Published 10-01-12, Control # 044-05 v2...
Page 100: Remote Controls
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL View A A961 Emergency Stop A10633 RAISE Counterweight (Boom Lowers) LOWER Counterweight (Boom Rises) Power Button Front View C Non-USA Cranes View B Front of Carbody View D P455 USA Cranes LOWER Counterweight...
Page 101: Controls Identification And Operation
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Controls Identification and Operation Crawler Pin Controls 3 – Crawler Pins Control (right crawler) Carbody Jack Controls 4 – Crawler Pins Control (left crawler) 1 – Carbody Jack Control (right front) See Figure 3-24, Views A and B for location of crawler pins 2 –...
Page 102: Programmable Controller Calibration Procedures
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL PROGRAMMABLE CONTROLLER To calibrate the pressure senders, proceed as follows: CALIBRATION PROCEDURES Stop engine. Turn ON cab power switch. General Turn crane mode selector key counterclockwise to To ensure proper operation of the crane functions, the CONFIRM position and hold.
Page 103: Operating Conditions
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES See Table 3-6 for a list of abbreviations used and Table 3-7 System Faults for drum identification. Table 3-5 lists system faults which can be displayed. Operating Conditions When one or more system faults occur, the system fault alert (red light and beeper in cab) turns on to warn the operator.
Page 104 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL Table 3-3 Operating Conditions Listed below are the operating conditions which can be viewed on the digital display. Unit of Display Reading Operating Range Measure Normal Operating Conditions The operating conditions listed below are displayed by scrolling up or down with the digital display selector.
Page 105 777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-4 Operating Limits Listed below are limits which turn on the operating limit alert (yellow light and continuous buzzer). When the alert comes on, OPERATING LIMIT group of digital display will indicate which limit has been reached; take corrective action.
Page 106 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL Display Reading Function Response Corrective Action Do not attempt to operate controls in cab REMOTE ACTIVE FAULT Control in cab inoperable. when operating counterweight remote control. Fault will appear on screen for 60...
Page 107: Diagnostic Display
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-6 DIAGNOSTIC DISPLAY Display Abbreviations To activate the diagnostic display screens, depress the limit Abbreviation Definition bypass switch and scroll up. Once this step is performed, you can scroll up and down through the diagnostic screens in +.........
Page 108: Swing
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL A1 (Handles) Handle command in percent from neutral (+ up, – down). Pump command in percent from neutral (+ up, – down). The variable control handle output voltage is represented in the controller by a number between 0 (0 Volts) and 255 (10 Measured pump pressure (up) in psi.
Page 109 777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES For identification of the digital outputs and inputs (and the Example 2: You want to know if the controller output for the crane components connected to them) see Tables 3-8 and 3- rear drum band brake is ON. In Table 1 you will find Rear 9 in this section.
Page 110 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL Table 3-8 Table 3-9 D1 (Digital Outputs) D2 (Digital Inputs) Identifier* Component Identifier* Component Bank 1 Bank 1 Front Drum Band Brake Travel Detent Set/Cancel Rear Drum Band Brake Maximum Bail Limit – Front Drum Minimum Bail Limit –...
Page 111 777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Handle/Pedal Identification Handle Number Handle Front Load Drum Rear Load Drum or Luffing Hoist* Boom Hoist Swing Right Crawler Left Crawler Auxiliary Load Drum (in butt) Pedal Number Pedal Right Crawler Left Crawler * Activated only in LUFFING JIB Mode.
Page 112 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL Table 3-10 8-Bit Binary System Dark shaded boxes indicate ON; white boxes OFF. 3-54 Published 10-01-12, Control # 044-05 v2...
Page 113 777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-10 8-Bit Binary System (continued) Dark shaded boxes indicate ON; white boxes OFF. Manitowoc 3-55 Published 10-01-12, Control # 044-05 v2...
Page 114: Swing Limiter Operation
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL SWING LIMITER OPERATION To TURN OFF swing limits: Turn crane mode keyswitch to SELECT position. An Swing limiter system is a safety device that allows operator asterisk * will appear to left of SWING LIMITER line.
Page 115 777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Carbody A1073 Actuator Rotating Bracket Limit FRONT View B Switch Lever Limit Roller Switch Actuator Rail Actuator Actuator Roller in Full View A Actuator Contact with Rail Screw Actuator Ramp Carbody View C...
Page 116 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL THIS PAGE BLANK 3-58 Published 10-01-12, Control # 044-05 v2...
Page 117: Adjusting Swing Limit Switch
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Adjusting Swing Limit Switch Securely tighten setscrews to secure actuator. Swing rotating bed to programmed swing limit in The physical limits defined by position of limit switch opposite direction and repeat steps 6 – 7.
Page 118 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL A1062 Left Wall in Cab Green Spotter Light (past) Green Spotter Light (current) CONFIRM SELECT Spotter Cylinder 538647 6-28-00 CRANE SPOTTER MODE POWER Switch Operating Controls Handle Handle Reverse Relief Valve Actuators 3,000 psi (207 bar)
Page 119: Hydraulic System Controls
The Spotter switch controls operation of 2-position dump valve. The lock on rocker must The pump is mounted on and driven by the 777 front drum be moved up before rocker can be placed in ON position.
Page 120 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL Forward stability is affected by wind on the rear of the boom. Wind applies a force to the boom and load that adds to the crane’s overturning moment. This action has the same effect as adding load to the hook.
Page 121: Wind Conditions
777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES WIND CONDITIONS For wind conditions specific to this crane, see Wind Conditions Chart at end of this section or, if applicable, see Wind adversely affects lifting capacity and stability as shown wind conditions in Capacity Charts provided with crane and in Figure 3-36.
Page 122: Cold Weather Heater Package
Hydraulic Oil Tank (two, 500 watts each) components. • Control Console (125 watts) A 777 working in an arctic climate — outside temperature continuously below 0°F (-18°C) to -30°F (-34°C) — should Thermostats be equipped with the heaters identified in this topic and...
Page 123 777 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES 120 Volt AC Option Right Side of Engine A1089 (C-330 Engine) Item Description Power Supply Cord Hydraulic Reservoir Heaters (two, 1000 watts total) Hydraulic Reservoir Junction Box (front of rotating bed beam under engine)
Page 124 OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL P2092 240 Volt AC Option Item Description Power Supply Cord Hydraulic Tank Hydraulic Tank Heaters Front Control Console Control Console Thermostat Control Console Heater Engine Block (left side) Engine Coolant Heater Engine Oil Pan (right side)
Page 125: Preparation For Cold Weather
Man ito wo c crane s is not a ffect ed by cold we at her. owner furnished electric power supply. The coolant heater Manitowoc’s capacity charts are acceptable for use in cold must be capable of maintaining the engine’s coolant and oil weather.
Page 126: Hydraulic Oil
OPERATING CONTROLS AND PROCEDURES 777 OPERATOR’S MANUAL • 80W-90 above: -10 to 100°F (-23 to 38°C) has an extension cord for connecting to an owner furnished electric power supply. • 85W-140 above: 100°F (38°C) Hydraulic tank heaters must be unplugged when engine...
Page 127 Identifying Boom Sections And Pendants....... . 4-41 Manitowoc Published 10-01-12, Control # 044-05...
Page 128 777 OPERATOR’S MANUAL Removable Lacings ..........4-43 Storing Jib Sections .
Page 129 777 OPERATOR’S MANUAL Seizing and Cutting Wire Rope........4-64 Anchoring Wire Rope to Drum .
Page 131: Rigging Drawings
• Keep crane level when operating carbody jacks. SELF-ERECTING EQUIPMENT The Model 777 is a self-erecting crane equipped with the following components for assembly and disassembly: WARNING • Carbody jacks with pads for lifting the crane onto and off Avoid Falling Off Crane and Boom! the trailer.
Page 132: Assembly And Disassembly Notes
(in setup Optional boom ladders (stored in boom butt) are available mode) or by the boom hoist control located in the cab. from Manitowoc. If your crane has ladders, see instructions later in this section. •...
Page 133 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Carbody Crawler P1931 P1932 FIGURE 4-1 Rigging Pendant Wire Rope Guides Mast Counterweight Lifting Pendant Boom Boom Hoist Cylinder Butt Counterweight Boom Handling Link Stop 30 USt (27 t) Counterweight Assembly Block Pivot Frame Operator’s...
Page 134: Operating Limitations
SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL OPERATING LIMITATIONS Table 4-1 Swing and Capacity Limitations During Erection Crane Configuration Swing Limitations Capacity Limitations* Crane on Jacks (No Crawlers) 360° Swing Permitted Load Handling NOT Boom Butt in Transport Position ALLOWED When Crane Is In Handling Second Crawler at 15 ft (4.6 m)
Page 135: Operating Controls
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION OPERATING CONTROLS P2498 See Section 3 for identification and operation of all controls. • The carbody controls (crawler pins and carbody jacks) are operable any time the engine is running. • To operate the mast as a boom using the boom hoist...
Page 136 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL THIS PAGE BLANK Published 10-01-12, Control # 044-05...
Page 137: Crane Assembly
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION CRANE ASSEMBLY Untie crane from trailer. Raise and pin all catwalks in operating position (View A). Pre-Start Checks Check that boom angle indicator electrical cord (View B) Make the following checks before starting the engine upon is plugged into junction box on boom butt.
Page 138 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL P444 Mast Mast Rigging Pendant Stored For Shipping Boom Butt Connecting P471 View F View E Rigging Pendant A977 Side-to-Side Levelness A882 Front-to-Rear Levelness Upper One half of bubble off center indicates approximately one...
Page 139 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION See Figure 4-5 for the rest of this procedure. 13. Remove blocking from between crane and trailer and slowly pull trailer out from under crane. Perform pre-start checks and start engine. NOTE: It is normal for system fault alert and operating limit Operating Note alert to come on when engine is started.
Page 140 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL 15 ft (4.6 m) WARNING Maximum Radius Tipping Hazard! Do not exceed 15 feet (4.6 m) radius while lifting either crawler. Crane will tip. P456 Hook Chain Sling Lifting Connecting Holes Lifting Links Fixed...
Page 141: Install Crawlers
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Install Crawlers WARNING Rotating Drive Shaft Hazard DANGER Crawler drive shaft rotates at high speed. To prevent Tipping Hazard! death or serious injury: Prevent crane from tipping over: • Make sure drive shaft is securely attached at both •...
Page 142: Install Counterweights
SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Check that both counterweight limit switches are properly installed at rear of crane and operational. Test both limit switches as instructed in Counterweight Limit Switch Adjustment in Crane Service Manual. Assemble upper counterweights as shown in Figure 4-8, Views A and B: 45°...
Page 143 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION da0103 Connecting Storage Hole Side Lower Boxes Tray View A-A P227 P462 Lifting Lugs Side Boxes (4 each) • 2 each side for Series-1 • 3 each side for Series-2 Lower Tray View A...
Page 144 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL 2 - Swing 180° Carbody P461 3 - Install 2nd Carbody Counterweight at Front of Carbody 1 - Install 1st Carbody Counterweight at Rear of Carbody View B Slot da0104 Carbody View A 4 - Install Upper...
Page 145 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION If crane will be equipped with Series-2 counterweight, Raise boom until mast is vertical. install carbody counterweights as follows, before Disconnect counterweight lifting pendants from storage installing upper counterweight. If not, go to step 4.
Page 146 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Counterweight Handling Pendants P467 Front Hook A982d View A Roller Counterweight Handling Pendant View C P468 Counterweight Handling Pendant Rear Pin Connection A982 View B View D Front Hook P520 Counterweight Lifting Pendant P469...
Page 147: Assemble Boom
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION 11. Raise boom butt until handing pendants are hanging 19. Lower boom butt until mast is vertical. approximately (152 above ground 20. Pin counterweight lifting pendants to mast for storage (Figure 4-10, View A).
Page 148 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Raise mast (boom up) until upper wire rope guide is fully 12. Pin rigging pendants to lugs on mast for storage raised. Pin upper wire rope guide to lower wire rope (Figure 4-12, View F).
Page 149 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Connector Fixed Vertical Pin Connector View B Fixed Vertical Pin A986 View A Blocking 8 – 10 in BLOCK HERE (203 – 254 mm) if Required per High Capacity Chart Connector Removable Horizontal Pin...
Page 150: Pre-Raising Checks
SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL PRE-RAISING CHECKS Electronic boom angle indicator is properly installed and adjusted (see Boom Angle Indicator Adjustment in Make following checks and correct any defects before Section 4 of the Crane Service Manual). raising attachment: Automatic boom stop is properly installed and adjusted Crane is on firm, level surface.
Page 151 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION THIS PAGE BLANK Manitowoc 4-21 Published 10-01-12, Control # 044-05...
Page 152 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Pendant Link Rigging Pendants Stored Boom Pendant (2 each side) P444 View B View C (both sides of boom) A987 View A BLOCK HERE Removable if Required per Horizontal Pin Capacity Chart Connector View E Blocking 8 –...
Page 153: Crane Disassembly
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION CRANE DISASSEMBLY b. Remove pins to disengage inside latches from intermediate suspension beam (Figure 4-29, Disconnect Butt From Boom View F). Slowly boom down until strut is resting in supports Prepare crane and boom as follows: (Figure 4-29, View C).
Page 154 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Rigging Pendants P440 P521 Upper Boom Wire Rope Junction Box Guide on Rotating Bed Electrical Cord To Boom Angle Indicator Lower Wire Rope Guide View B View A Boom Electrical Cord P445 Rigging Pendants...
Page 155: Install Assembly Block
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION 16. Lower butt onto blocking approximately 15 in. (381 mm) Install Assembly Block high (Figure 4-14). Boom down until upper wire rope guide sheave is 2 – 3 ft 17. Unpin upper wire rope guide from lower wire rope guide (0.6 –...
Page 156 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL P520 Counterweight Lifting Pendant Counterweight Lifting Link View B P463 Mast Counterweight Lifting Pendant (stored position) A984 View A View C P469 Front Hook Fixed Pin on Engine Base View E P470 Rear Pin...
Page 157: Disassemble Boom
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Disassemble Boom The remote controller has sufficient cable to allow operator to stand alongside rear of crane and Disassemble the boom and jib combination as instructed in closely observe operation. the Rigging Guides in this section.
Page 158 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL P518 Pivot Frame Storage Bracket View B P522 Pivot Frame Counterweight Handling Pendants A982c View A View C P517 Mast Counterweight Counterweight Lifting Pendant Lifting Pendant (stored position) Counterweight Lifting Link Pivot Frame Fully Lowered...
Page 159 — lift at four lifting lugs (View F). b. Remove pins (View G) connecting carbody 18. Disassemble upper counterweights (777 boom butt can counterweight to carbody. be used for this purpose). Boom, swing, and hoist as required to disengage Unpin and lift side boxes off lower tray — lift at slots in counterweight from lugs on carbody connecting pins (Figure 4-8, View A-A).
Page 160 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Carbody P460 Fixed Keeper Snap Pin Collar Crawler Drive Shaft Connecting Guard View C P459 Chain Flange Screws Sling (4 places) Lifting Drive Shaft Guard Lifting Links Snap Pin A980 View A View D...
Page 161: Remove Crawlers
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Remove Crawlers Using controls on front of carbody (Figure 4-5, View A), extend carbody jacks until crawler treads are just clear See Figure 4-18 for this procedure unless otherwise noted. of ground. DANGER WARNING...
Page 162 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Catwalk P426 Mast P444 Rigging Pendant Stored For Shipping View C Mast View I Side-to-Side Levelness A882 Boom Butt Front-to-Rear Connecting Levelness One half of bubble off center P471 View E indicates approximately one percent of grade out of level Centered bubble indicates level.
Page 163: Install Crane On Trailer
It is assumed that the hydraulic hoses and electric cable are trailer. connected to the auxiliary load drum (Figure 4-21). If these parts are not installed, see the applicable assembly drawings in your Model 777 Parts Manual for details. CAUTION Boom Stop Interference! Booming above 10° with mast-to-butt connecting pins installed will cause damage to mast cross member.
Page 164 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Stud with Nut and Hydraulic Lockwasher Hoses (4 Places) Lifting Lug Port A (2 Places) P298 Electric Cable P301 W2 Aux Electric Cable W2 A1022 Turnbuckle View A View B View C Hydraulic Motor Operator’s Cab...
Page 165: Hydraulic And Electric Connections
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Remove lacing pinned to top chords of butt (View D), as 11. Pin turnbuckle rod ends to lugs on left side of boom butt follows: and auxiliary load drum (View B). Support lacing so it cannot fall.
Page 166 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL A1023 Ladder Boom Butt Hook (2 Places) View A To Boom Past Production Rubber Latch Ladder Boom Butt Keeper Rubber Latch View A (2 Places) View B Current Production View B FIGURE 4-22 4-36...
Page 167: Boom Ladder Assembly
Avoid improper use. Use this ladder only on Lift ladder to desired outside location on insert so that upper Manitowoc #78 boom inserts. Do not use on any other pads are securely hooked over backside of upper chord and boom.
Page 168: Boom Rigging Guide
Falling Load Hazard! An assist crane is not required to assemble and disassemble the boom components. The 777 can be used to assemble Prevent crane from tipping or structural damage to and disassemble its own boom. See Crane Weights in the components: Crane Operator’s Manual for weights of boom components.
Page 169 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION THIS PAGE BLANK Manitowoc 4-39 Published 10-01-12, Control # 044-05...
Page 170 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL MAST PINNED TO BOOM BUTT FOR LOW CLEARANCE TRAVEL 10 ft 20 ft 40 ft 37.5 ft Length (3.1 m) (6.1 m) (12.2 m) (11.4 m) Insert Insert Insert 37.5 ft (11.4 m) No Block 90 ft (27.4 m)
Page 171: Blocked Crawlers
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Blocked Crawlers and the Boom Rigging Assembly drawing at the end of the manual. See Figure 4-31 to determine the quantity and To prevent the crane from tipping, some boom and jib length of inserts and pendants for various boom lengths.
Page 172 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL P531 Rope Guard Rope Chord Mounting Bracket Guard (Operating Position) Bolt Removable Diagonal Lacing View B View A Rope Guard Mounting Bracket Bolt (Shipping Position) Bottom Chord P529 View C FIGURE 4-27 4-42 Published 10-01-12, Control # 044-05...
Page 173: Removable Lacings
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Removable Lacings when tightening tie-downs. Use protective covering such as tire sections between tie-downs and chords or rope Removable diagonal lacings are provided with the #78 guards. boom. This design feature allows the lacings to be removed...
Page 174 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Optional Cage-Type Rope Guard Fixed Vertical Dead-End View C-C Link Extension P524 P523 Pendants P531 A (Upper Connecting Pin) B (Lower Connecting Pin) Connector Upper Boom Point Insert Insert View A View B Lower Boom...
Page 175: Boom Installation
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Boom Installation for number of rope guards required on each insert. Additionally, two rope guards are required on boom top. Assemble boom inserts proper sequence (Figure 4-31), as follows, starting at butt end of boom: WARNING Place first insert on blocking approximately 6 in.
Page 176 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL FACT Connector Beam Beam Beam (both sides) P536 P537 Strut Strut Strut 16-1/2 in Support (both sides) Strut View A View B Outside View C Latch Strut Support Lacing at End of Inserts A1014...
Page 177 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Install Intermediate Suspension Install Pendants See Figure 4-29 for following procedure. Intermediate suspension is required for booms 190 – 270 ft WARNING (57.9 – 82.3 m) in length. See Table 4-3 for intermediate Falling Boom Hazard! suspension strut and pendant positions.
Page 178: Boom Removal
Block-Up Limit Control Assembly Drawing See procedure earlier in this section. at the end of this section. The 777 can be used to disassemble the boom and jib. See Section 5 of the Crane Service Manual for adjustment of the limit switches.
Page 179 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION arrangement allows the boom to be reassembled Disassemble Boom faster. It is owner/user’s responsibility to securely attach WARNING pendants to inserts so that pendants cannot fall off Collapsing Boom Hazard! inserts during shipment. To prevent death or serious injury, do not stand on, inside, Remove Intermediate Suspension or under boom sections during assembly.
Page 180 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL M = Mast Links 60 ft BOOM IDENTIFICATION Item (18.3 m) S = Intermediate Suspension (see Table 4-3 and Item Description Figure 4-29) 22 ft 6 in (6.9 m) Butt 37 ft 6 in (11.4 m) Top 70 ft (21.3 m)
Page 181 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION M = Mast Links (see Figure 4-12, View G) S = Intermediate Suspension (see Table 4-3 and Figure 4-29) 200 ft (61.0 m) 130 ft (39.6 m) 200 ft (61.0 m) 140 ft (42.7 m) 210 ft (64.0 m)
Page 182: Pile Driver Adapter
Made from Mild Steel Made from T-1 Steel In such cases, contact your Manitowoc dealer for specifications which meet your particular application. 48,000 lb (21 772 kg) 48,000 lb (21 772 kg) Values given in this publication apply to pile driver adapter at 55°...
Page 183: Jib Rigging Guide
Prevent crane from tipping or structural damage to An assist crane is not required to assemble and disassemble components: the jib on a 777 crawler crane. The 777 can be used to • Do not exceed 26 ft (7.9) radius.
Page 184 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL A875 30 ft J1 J2 (19.1 m) 40 ft (12.2 m) 50 ft (15.2 m) 50 ft (15.2 m) 60 ft 18.3 m) 60 ft 18.3 m) 70 ft (21.3 m) 70 ft (21.3 m) 80 ft (24.4 m)
Page 185: Blocked Crawler/Extended Outriggers
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Blocked Crawler/Extended Outriggers View A Past Production To prevent 777 crawler crane from tipping, some boom and Manitowoc jib lengths must be raised and lowered over blocked B238 Part Number Jib Number cr a w l e r s . S e e c a pa ci t y ch a rts f o r b l o c ke d c r a w le r requirements and to Crawler Blocking Diagram in the Crane Operator’s Manual for instructions.
Page 186 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL P544 P543 Wire Rope Roller Guide Wire Rope Timber Guide Bracket Connecting Pin Head Toward Outside View A Insert Jib Insert View B or Butt Strut Jib Backstay Jib Stop Boom Top Jib Top...
Page 187: Installing Jib
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Installing Jib Install Jib Inserts See Figure 4-36 for following procedure unless otherwise noted. WARNING! Prepare Boom Collapsing Jib Hazard! Lower boom onto blocking. To prevent death or serious injury, do not stand on, inside, Remove load line from upper boom point, if equipped.
Page 188 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Item Description Backstay Links Basic Backstay Pendants 44 ft 7 in (13.6 m) Offset Links 28 in (711 mm) and pins for 15° Offset Offset Pendants 4 ft 8 in (1.4 m) and pins for 25° Offset 5°...
Page 189 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Install Jib Pendants Pin jib pendants and proper backstay links to jib strut (View B). See Figure 4-37 for following procedure unless otherwise noted. Install Backstay Pendants NOTE: With the exception of the basic pendants, the jib...
Page 190 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Storage Pin Safety Pin (Stored) Rated Capacity (Stored) Hand Winch Indicator/Limiter Connecting Inner P551 Sheave Frames Tube P550 View B Pawl Strut Haul In Link Cable 5° Offset (Hole) Pay Out P549 Strut 25° Offset Offset 15°...
Page 191: Removing Jib
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Raise Jib Strut Remove safety pins from jib stop pins (View E) and store pins in lugs on jib stop frame (View B). See Figure 4-38 for following procedure. Pay out control cable until cable is loose. Cable should Using appropriate slings, attach hook from assist crane be resting on bottom lacings in jib sections.
Page 192 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Disconnect block-up limit electric cord at cable in boom If required, raise jib point with an outside assist (another point and at junction boxes in jib point. Store cable on jib crane or fork-lift truck) to gain enough slack to allow butt.
Page 193: Wire Rope Installation
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION WIRE ROPE INSTALLATION Provide a brake at shipping reel (see Figure 4-40) so wire rope can be wound tightly onto drum. NOTE: Wire rope manufacturer’s recommendations take precedence over information in this section. Wire Rope Storage...
Page 194: Seizing And Cutting Wire Rope
SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Seizing and Cutting Wire Rope Use the correct wedge part number for the size of wire rope being used; see the parts drawing for the boom hoist drums Apply tight seizings of annealed wire to the ends of all wire or for the load drum shaft to obtain the correct part number.
Page 195: Winding Wire Rope Onto Drum
777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Winding Wire Rope onto Drum Wraps of First Layer Tight Against See Drum and Lagging Chart in Capacity Chart Manual for Wedge Drum and Against Each Other. correct size of drum laggings, if used.
Page 196: Anchoring Wire Rope To Wedge Socket
SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Anchoring Wire Rope to Wedge Socket Assemble wire rope and wedge to socket so live end of wire rope is in a straight line with socket pin hole. Do not assemble WRONG as shown.
Page 197 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION T (Rope Clip Nut Torque) Wire Rope/Clip Size TL (Tail Length) inch 1-1/8 1-1/4 Standard 6 to 8 Strand Wire Rope (mm) (22,23) (25,4) (28,58) (31,75) Minimum of 6 rope diameters, Torque but not less than 6 in (152 mm).
Page 198: Breaking In Wire Rope
See Figure 4-45 for following procedure. it is overloaded, not used properly, or not maintained properly. General Some rotation-resistant wire rope supplied by Manitowoc is equipped with a No. 1.5 pad eye welded to the leading end of the wire rope. 4-68...
Page 199 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Rope Clips Sucker Line Sucker Pull Sucker Line Line with Winch or Sucker Fork-Lift Truck Line Wire Wire Rope Rope from Drum A1189 Boom Point Sheaves Wire Rope Load Block Sheaves P1519 No. 1.5 Pad Eye...
Page 200: Load Line Reeving
See Wire Rope Installation and Maintenance in this section for following instructions: Load Blocks • Anchoring wire rope to drums. Two different size load blocks are available from Manitowoc: • Installing wire rope on drums. • 15 USt (13.6 t) hook and weight ball.
Page 201 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Upper Boom Point Load Pin Sheaves 2-Part Lower Boom Load Pin Dead-End Point Sheave Upper Boom Point Point Hook and Socket Weight Ball and Wedge Boom Top Guide Sheaves Rope 1 or 1-1/8 in...
Page 202 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Boom Top Guide Sheaves (S1 and S2) Load Line Must Be Positioned at Dimensions Given in This Table Identification Front Drum to Sheave S1 Front Lead Line To: Dimension A Note Rear S3 (View C)
Page 203 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Strut See Note 5 Fixed Jib See Clamp Detail and/or Lower Boom Point Boom Top Guide Sheaves View D Two or Three Load Lines with Fixed Jib Lower Strut Boom Point Lower Boom Point...
Page 204 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL A1010 = Dead End Link = Block-Up Limit Weight 12 PART (SKIP) 11 PART (SKIP) 10 PART 9 PART 8 PART 7 PART 6 PART 5 PART 4 PART 3 PART 2 PART FIGURE 4-48...
Page 205 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION THIS PAGE BLANK Manitowoc 4-75 Published 10-01-12, Control # 044-05...
Page 206: Clamshell Reeving
SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL CLAMSHELL REEVING • Position boom top wire rope guide sheaves as shown in Figure 4-50. Sheaves must be positioned at indicated dimensions to ensure proper fleet angles. CAUTION • Route wire rope from load drums as shown in Figure 4-50.
Page 207 777 OPERATOR’S MANUAL SET-UP AND INSTALLATION Gap between clamps must be equal on both sides. Torque bolts lubricated with SAE 20 oil to 120 ft-lb (163 Nm). Item Description Boom Top Wire Rope Guide Right Side Sheave Left Side Sheave...
Page 208 SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL Item Description Tieback Lug (2-1/2 in Diameter) Shackle (2 in) Tieback Sling Load Block VIEW A A830 FIGURE 4-51 4-78 Published 10-01-12, Control # 044-05...
Page 209: Load Block Tieback
Sling Capacity The slings must be capable of supporting the weight of the Manitowoc provides a lug on the front of the rotating bed load block and 1/2 the weight of the wire rope suspended (Figure 4-51, View A) for tieing back the load block when not from the boom point.
Page 210: Universal Anchor Joint
SET-UP AND INSTALLATION 777 OPERATOR’S MANUAL UNIVERSAL ANCHOR JOINT If the anchor link or lug in the boom or jib point has been used for any duty-cycle work with a 2-part load line, check for The dead-end socket and wedge can be anchored to any of cracks due to side bending loads.
Page 211: Section 5
Lubrication ............5-1 Manitowoc...
Page 213 777 OPERATOR’S MANUAL LUBRICATION SECTION 5 LUBRICATION LUBRICATION See F2107 at the end of this section. Manitowoc Published 10-01-12, Control # 044-05...
Page 215 Fiberglass MaintenaNce ..........6-1 Manitowoc...
Page 217: Inspection And Maintenance Checklist
777 OPERATOR’S MANUAL MAINTENANCE CHECKLIST SECTION 6 MAINTENANCE CHECKLIST INSPECTION AND MAINTENANCE CHECKLIST See F2097 at the end of this section. FIBERGLASS MAINTENANCE See Bulletin W04-009 at the end of this section. Manitowoc Published 10-01-12, Control # 044-05...
Page 219 Manitowoc Dealers ........
Page 220 777 OPERATOR’S MANUAL Operation ..............3-26 Operational Aids .

Manitowoc 777 Operator's Manual

Quick Links

Related Manuals for Manitowoc 777

Summary of Contents for Manitowoc 777

Table of Contents