Manitowoc 777 Service And Maintenance Manual
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Manitowoc 777 Service And Maintenance Manual

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Manitowoc 777
Service/Maintenance Manual

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  • Page 1 Manitowoc 777 Service/Maintenance Manual...
  • Page 3 The serial number of the crane and applicable attachments (i.e. luffing jib, MAX-ER ) is the only method your Manitowoc dealer or Manitowoc 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 and each attachment.
  • Page 4 THIS PAGE BLANK...

  • Page 5: Table Of Contents

    777 SERVICE MANUAL TABLE OF CONTENTS See end of this manual for Alphabetical Index SECTION 1 ..........Introduction Safe Maintenance Practices .
  • Page 6 TABLE OF CONTENTS 777 SERVICE MANUAL Cleaning Fill Cap Assembly............2-3 Replacing Filter Elements .
  • Page 7 (internal leakage). If damage is found, contact the Service Depart- ment at Manitowoc Cranes for repair/replacement instructions......4-9 Boom and Jib Inspection and Lacing Replacement.
  • Page 8 TABLE OF CONTENTS 777 SERVICE MANUAL Storing Electric Cable ............5-6 Disconnecting Block-Up Limit Control .
  • Page 9 777 SERVICE MANUAL TABLE OF CONTENTS Engine Speed Calibration ............7-10 Engine Throttle Adjustment - Cummins QSL 340, QSC8.3, QSM11, or QSX15 Engine.
  • Page 10 TABLE OF CONTENTS 777 SERVICE MANUAL Test 23 – Transducer Test........... . . 10-53 Test 24 –...
  • Page 11 Programming ..........1-47 Manitowoc...
  • Page 12 777 SERVICE MANUAL Off ............1-47 Close Bucket .

  • Page 13: Safe Maintenance Practices

    Maintenance Instructions operator’s permission. Use both hands and handrails, steps and ladders To ensure safe and proper operation of Manitowoc cranes, provided to climb onto and off crane. they must be maintained according to the instructions contained in this manual and the Operator ’s Manual Lift tools and other equipment which cannot be carried in provided with the crane.
  • Page 14 28. Unless authorized in writing by Manitowoc, do not alter crane in any way that affects crane’s performance (to 19. Never handle wire rope with bare hands. Always wear include welding, cutting, or burning of structural heavy-duty gloves to prevent being cut by broken wires.

  • Page 15: Identification And Location Of Components

    777 SERVICE MANUAL INTRODUCTION IDENTIFICATION AND LOCATION OF COMPONENTS Crane Orientation Terms RIGHT, LEFT, FRONT, REAR used in this section refer to operator’s right, left, f r o nt , a nd r ea r s ide s w he n se a te d in operator’s cab looking forward.
  • Page 16 INTRODUCTION 777 SERVICE MANUAL A969 P558 P490 Item Description Item Description Lower Boom Point Hydraulic Tank Wire Rope Guide (boom top) Fuel Tank #78 Boom Pump Drive Wire Rope Guide (boom butt) Front Drum Pump Mast Right Crawler Pump Boom Hoist Cylinder...
  • Page 17 777 SERVICE MANUAL INTRODUCTION P428 P502 Typical 20 Places Typical 2 Places P558 Item Description Crawler Input Planetary Crawler Drive Shaft Crawler Intermediate Roller Crawler Front Roller Crawler Motor Crawler Brake Crawler Output Planetary Jack Pad (stored) Carbody Carbody and Crawler Control Valves...
  • Page 18 INTRODUCTION 777 SERVICE MANUAL P558 P572 Typical 2-4 Places P585 P434 P580 Item Description Item Description Swing Motor Junction Box Fuse Swing Lock System Ground Swing Brake 50 Amp Circuit Breaker Swing Planetary 12 Volt DC Power Supply Drum Motor Speed Sensor...

  • Page 19: General Operation

    777 SERVICE MANUAL INTRODUCTION GENERAL OPERATION CONTROL RF-01 HANDLE HANDLE COMMAND SIGNAL PROGRAMMABLE CONTROLLER (PC) CONTROL SIGNAL (MOTOR STROKE) PRESSURE CONTROL SIGNAL FEEDBACK (PUMP STROKE) SPEED SENSOR PRESSURE FEEDBACK ELECTRONIC CONTROL DISPLACEMENT PILOT CONTROL HIGH-PRESSURE SIDE HYDRAULIC HYDRAULIC CHARGE DRUM...

  • Page 20: Hydraulic Pumps

    INTRODUCTION 777 SERVICE MANUAL An accessory tandem gear pump supplies supercharged throttle sets engine speed; temporary increases are filtered oil to the suction ports of some of these pumps, accomplished with an electrical foot throttle. provides oil to establish cylinder valve actuation, and The pump’s external EDC sets the amount and direction that...
  • Page 21 777 SERVICE MANUAL INTRODUCTION RF-02 CONTROL VOLTAGE FROM CONTROLLER ARMATURE PILOT PRESSURE PILOT PRESSURE ORIFICE ORIFICE PORT PORT PILOT PRESSURE SPOOL SPRING MODULATION SPRING SPOOL SWASHPLATE SERVO PISTONS FIGURE 1-6 The PC transmits a command signal to one of the two coils in causing more oil to be pumped to the system motor or the EDC via two of the four EDC connector pins.

  • Page 22: Hydraulic Motors

    INTRODUCTION 777 SERVICE MANUAL pressure. When rapid loading produces pressure spikes, the cylinder block on its axis while its tilt to the flange face system relief valve (16) shifts, allowing the high pressure oil reciprocates the pistons as they rotate. The oil displaced by to be returned to tank through charge pump relief valve (3) or the pistons returns to the system pump.

  • Page 23: Charge Pressure

    INTRODUCTION closed-loop circuit. In addition to oil slippage for the cylinder of the front hoist drum motor from maximum to prevention of excessive heat buildup, the 777 swing and minimum displacement. track motors incorporate an integral loop flushing (purge Main System Pressure valve) system consisting of control valve (29) and relief valve (30).

  • Page 24: Hydraulic Tank

    INTRODUCTION 777 SERVICE MANUAL Hydraulic Tank switch closes to complete a circuit to the PC. The PC responds by sending a diagnostic message HYDRAULIC Hydraulic tank (7) is mounted on the right side of the rotating FILTER 5 to the operator display, indicating the strainer bed.
  • Page 25 777 SERVICE MANUAL INTRODUCTION FIGURE 1-7 Manitowoc 1-13 Published 10-01-2012, Control # 045-08...
  • Page 26 INTRODUCTION 777 SERVICE MANUAL FIGURE 1-8 1-14 Published 10-01-2012, Control # 045-08...

  • Page 27: Suction Manifold

    777 SERVICE MANUAL INTRODUCTION FIGURE 1-9 The front, rear, and auxiliary (optional) hoist pumps have hydraulic sensing switch on the filter head to close and charge pressure filtration to meet the needs of each hoist’s complete the circuit to the PC. The PC responds by sending closed-loop circuit.

  • Page 28: Epic Programmable Controller (Pc)

    INTRODUCTION 777 SERVICE MANUAL Supercharge Manifold EPIC Programmable Controller (PC) The front section of tandem accessory pump (1) delivers up See Figures 1-10 and 1-11 for following procedures. to 58 gpm of supercharge oil to supercharge manifold (16). Most of the crane’s solenoid valves, pumps, and motors are The oil is filtered as it enters manifold through filter 1 (12).
  • Page 29 777 SERVICE MANUAL INTRODUCTION FIGURE 1-10 FIGURE 1-11 The programmable controller uses the binary mathematical They are used to represent the electrical inputs to the controller. The controller processes this information by system for its basic alphabet. comparing it to its programming requirements, and its stored...

  • Page 30: Standard Crane Mode

    INTRODUCTION 777 SERVICE MANUAL in the form of binary counts at crucial points during lift crane than the last half. During lowering, the voltage is decreased operation. at a slower rate as the handle gets closer to the off position...

  • Page 31: Digital Display

    777 SERVICE MANUAL INTRODUCTION • In clamshell operation, the PC allows two drums to be Digital Display operated at the same time with one control handle and A digital display in the operator’s cab shows the operating turns on the power down and closing features of this conditions, operating limits, and system faults being mode.

  • Page 32: Voltage Availability

    INTRODUCTION 777 SERVICE MANUAL Voltage Availability See Figures 1-12, 1-13, 1-14 and 1-15 for following procedures. Accessory Circuits Voltage is available at key-operated cab power on/off switch, dome light switch, and horn switch. After cab power switch is activated, voltage is available to the run/stop, which when activated, provides power to cab power relay Kl, DC power output relay K2, and Air Conditioner Relay ACR.
  • Page 33 777 SERVICE MANUAL INTRODUCTION FIGURE 1-13 Engine Start Circuit The primary components of the crane throttle system include electronic fuel control (EFC) module, EFC actuator, See Figure 1-13 for following procedures. magnetic engine rpm transducer, foot throttle, and hand throttle.
  • Page 34 INTRODUCTION 777 SERVICE MANUAL FIGURE 1-13 continued When detecting a difference in the two signals, module engine rpms and will resume the lower travel speed when changes the current input to EFC actuator, causing the engine speed falls below 1500 rpm.
  • Page 35 777 SERVICE MANUAL INTRODUCTION FIGURE 1-14 Limit Switch • BOOM UP LIMIT automatically stops the boom when it is raised to a preset maximum angle (82° inline top, 83° See Figure 1-14 for following procedures. Offset top, 88° Luffing Jib).
  • Page 36 INTRODUCTION 777 SERVICE MANUAL NOTE: If a control handle is moved when the operator is drum or removed from the load drums after an operating limit out of seat, the FUNCTION IS PARKED fault has been activated with use of the limit bypass switch.
  • Page 37 777 SERVICE MANUAL INTRODUCTION e q u a l v a l u e ; l i k e w i s e , t h e t w o l i n e s e n t e r i n g t h e...

  • Page 38: Brake Release System

    INTRODUCTION 777 SERVICE MANUAL FIGURE 1-16 Brake Release System When in free fall, the operator can control the lowering of a load by applying a linear force to the working brake pedal (4) The load drum, travel, swing, and auxiliary hoist disc brakes to control pressure to the working brake (band brake are hydraulically released.

  • Page 39: Load Drum Clutch Release System (With Free Fall)

    777 SERVICE MANUAL INTRODUCTION modulating valve. The flow passes through system solenoid Load Drum Clutch Release System (with free control valves which are held open when in free fall mode fall) and open and close by the drum control handle when in standard operating mode.
  • Page 40 INTRODUCTION 777 SERVICE MANUAL FIGURE 1-17 1-28 Published 10-01-2012, Control # 045-08...

  • Page 41: Boom System

    777 SERVICE MANUAL INTRODUCTION BOOM SYSTEM cylinder than is pumped to the cylinder when retracting the cylinders (raising the boom). See Figures 1-18 and 1-19 for following procedures. The boom hydraulic circuit provides supplemental oil when If boom pump charge pressure is lost for any reason, boom...
  • Page 42 INTRODUCTION 777 SERVICE MANUAL PC are blocked by the neutral switch on the control handle. does not stroke and the boom load holding valves maintain Unless the Boom Cylinder Hold switch is on, the boom pump the position of the boom cylinders.

  • Page 43: Boom Raise

    777 SERVICE MANUAL INTRODUCTION Boom Raise Boom pump pressure sender supplies the PC with pressure information that the PC compares to the load holding See Figures 1-18 and 1-19 for following procedures. pressure, monitored by the boom cylinder pressure sender.
  • Page 44 INTRODUCTION 777 SERVICE MANUAL FIGURE 1-19 1-32 Published 10-01-2012, Control # 045-08...

  • Page 45: Boom Lower

    777 SERVICE MANUAL INTRODUCTION Boom Lower HS18. The valve shifts to block the tank ports and supply pilot pressure from the boom charge pump to the load See Figures 1-20 and 1-21 for following procedures. holding valve at the rod end of each boom cylinder. The pilot...
  • Page 46 INTRODUCTION 777 SERVICE MANUAL M1045 FIGURE 1-20 1-34 Published 10-01-2012, Control # 045-08...
  • Page 47 777 SERVICE MANUAL INTRODUCTION FIGURE 1-21 Manitowoc 1-35 Published 10-01-2012, Control # 045-08...

  • Page 48: Swing System

    INTRODUCTION 777 SERVICE MANUAL SWING SYSTEM the brake by closing the circuit to swing park brake hydraulic solenoid HS7. See Figures 1-22 and 1-23 for following procedures. To prevent damage to the swing system components, swing In order for normal swing operation to occur, the rear load holding brake switch should only be applied when the drum charge pressure must be about 232 psi (16 bar).

  • Page 49: Off

    777 SERVICE MANUAL INTRODUCTION FIGURE 1-23 The piston extends to detent location for the extend position, swing right operation. The flows are opposite for disengages locking pins from slots concentrically located on swing left operation. the shaft locking flange, permitting the crane to swing in When swing control handle is moved in either direction from either direction after the parking brake is released.
  • Page 50 INTRODUCTION 777 SERVICE MANUAL FIGURE 1-24 1-38 Published 10-01-2012, Control # 045-08...

  • Page 51: Travel System

    777 SERVICE MANUAL INTRODUCTION TRAVEL SYSTEM The EDC tilts the swashplate of left travel pump in the forward direction, and the pump strokes on. Oil flows from See Figures 1-25 and 1-26 for following procedures. port A of pump through the swivel to port B of left travel motor.

  • Page 52: Travel Detent Button

    INTRODUCTION 777 SERVICE MANUAL To ensure crane travel in a straight forward or reverse dome of the handle, the PC memorizes and locks in the direction, both crawler hydraulic drive circuits in the travel travel command received from one or both crawler control system have pressure senders and shuttle valves.

  • Page 53: Load Drum Pawl

    777 SERVICE MANUAL INTRODUCTION LOAD DRUM PAWL The pawl should be used to maintain loadline positions, especially when the crane is in the park position or left See Figure 1-27 and 1-28 for following procedures. unattended. Likewise, the front and rear drum pawls should...

  • Page 54: Drum Pawl Engage

    INTRODUCTION 777 SERVICE MANUAL Drum Pawl Engage drum actuator rod to retract (rear hoist drum actuator rod extend), moving the pawl in (out). The drum is secure and The following description is for the front drum only. The rear will not move in the lowering direction until its pawl switch is drum actuator orientation is the opposite, as well as its disengaged and its park brake is released.

  • Page 55: Load Drum (Full Power Mode)

    777 SERVICE MANUAL INTRODUCTION LOAD DRUM (FULL POWER MODE) brakes remain applied and front hoist pump does not stroke in response to movement of front hoist control handle. See Figures 1-29, 1-30, and 1-31 for following procedures. When performing liftcrane, clamshell, or luffing operations in...

  • Page 56: Liftcrane Operation

    INTRODUCTION 777 SERVICE MANUAL FIGURE 1-30 Liftcrane Operation handle potentiometer to the PC is not completed. The PC receives no voltage from the handle, and it opens the circuits When FULL-POWER mode is selected and confirmed at to the front hoist pump EDCs, front hoist motor PCP valve,...
  • Page 57 777 SERVICE MANUAL INTRODUCTION FIGURE 1-31 PC programming requires front hoist pump to stroke before Front hoist pressure sender supplies the PC with pressure the front drum band brake HS16 is released. This ensures information which the PC compares to the memorized holding pressure of the front hoist.

  • Page 58: Lower

    INTRODUCTION 777 SERVICE MANUAL increased as the control handle is moved farther backward, Lower pumping more oil to the motor and raising the load faster. See Figures 1-33, 1-34, and 1-35 for following procedures. As control handle approaches the full handle command...

  • Page 59: Clamshell Operation: Clamshell Mode

    777 SERVICE MANUAL INTRODUCTION The weight of the load on the front drum will attempt to drive When an open or closed bucket is lowered, the PC monitors the motor faster than return oil is available to the pump. Front...
  • Page 60 INTRODUCTION 777 SERVICE MANUAL FIGURE 1-33 1-48 Published 10-01-2012, Control # 045-08...

  • Page 61: Hoist Bucket

    777 SERVICE MANUAL INTRODUCTION FIGURE 1-34 Hoist Bucket At the same time, the PC closes regulated voltage circuits to the front and rear hoist pump EDCs. The EDCs tilt the pump See Figure 1-34 for following procedures. swashplates in the hoisting direction, causing the front and rear hoist motors to rotate the drums and raise the bucket.

  • Page 62: Open Bucket

    INTRODUCTION 777 SERVICE MANUAL used to increase or decrease the displacement of each EDC. The EDC tilts the pump swashplate in the lowering pump to control both system working pressures. direction, causing the bucket to open with the closing line.

  • Page 63: Lower Bucket

    777 SERVICE MANUAL INTRODUCTION The PC also energizes front drum park brake solenoid HS12 is supplied to release the front and rear drum hydraulic park and front drum band brake solenoid HS16. As the solenoid brakes. shift, hydraulic system pressure is supplied to release the At the same time, the PC closes reverse regulated polarity front drum hydraulic park brakes.

  • Page 64: Load Drum (Free Fall Mode)

    INTRODUCTION 777 SERVICE MANUAL LOAD DRUM (FREE FALL MODE) Always park load drums not in use and fully apply and latch the working brake for the load drum being used. See Figures 1-36 and 1-37 for following procedures. When the working brake pedal is fully depressed and...
  • Page 65 777 SERVICE MANUAL INTRODUCTION When the front drum is placed in free fall mode, the PC closes a circuit to front drum clutch solenoid HS20. A path for oil supply is opened from the front drum hoist charge pump to clutch cylinder and the clutch is released disconnecting WARNING the load drum from its drive motor.

  • Page 66: Front Drum In Free Fall

    INTRODUCTION 777 SERVICE MANUAL FIGURE 1-38 Front Drum in Free Fall NOTE: When the drum working brakes are released, the load on the drum will free fall. Lowering speed must See Figures 1-37 and 1-38 for following procedures. be controlled with the drum working brake.
  • Page 67 777 SERVICE MANUAL INTRODUCTION hoisted load will drop unless controlled by application of the drum clutch. The clutch spring-applies, connecting the working brake. drum to the motor drive assembly. • CLOSES a regulated voltage circuit to the front hoist pump EDC.
  • Page 68 INTRODUCTION 777 SERVICE MANUAL FIGURE 1-39 1-56 Published 10-01-2012, Control # 045-08...

  • Page 69: Crane Setup Systems

    777 SERVICE MANUAL INTRODUCTION CRANE SETUP SYSTEMS The accessory valve used in this circuit contains a motor spool (both cylinder ports and tank port of the valve spool See Figure 1-40 for following procedures. section are connected in the center or neutral position). This...
  • Page 70 INTRODUCTION 777 SERVICE MANUAL FIGURE 1-40 1-58 Published 10-01-2012, Control # 045-08...

  • Page 71: Jacking Cylinder Retract

    777 SERVICE MANUAL INTRODUCTION FIGURE 1-41 Jacking Cylinder Retract NOTE: Hydraulic pressure entrapped by the cylinder counterbalance valve at the head end of the See Figure 1-43 for following procedures. carbody jacking cylinder supports the weight and gravitational force of the carbody.
  • Page 72 INTRODUCTION 777 SERVICE MANUAL FIGURE 1-42 1-60 Published 10-01-2012, Control # 045-08...

  • Page 73: Crawler Attachment System

    777 SERVICE MANUAL INTRODUCTION Crawler Attachment System accessory valve. Note the system pump flow pressure is limited by relief valve in system disable valve which is preset The following description is for one set of crawler lock pin to approximately 2,700 psi (186 bar).

  • Page 74: Crawler Lock Pin Retract

    INTRODUCTION 777 SERVICE MANUAL Crawler Lock Pin Retract The oil leaves the pin cylinder valve section of lower accessory valve and enters the rod end of crawler lock pin See Figure 1-44 for following procedures. cylinder, causing the cylinder rod to retract the pins,...

  • Page 75: Optional Systems

    777 SERVICE MANUAL INTRODUCTION OPTIONAL SYSTEMS With optional clutch assembly, free fall switch must be closed for brakes to release and pump to go on stroke. Luffing Jib Hoist System In the luffing mode, the rear drum operates the luffing jib while the front drum is the whip line.

  • Page 76: Auxiliary Hoist System

    INTRODUCTION 777 SERVICE MANUAL When luffing jib has been selected and confirmed at crane mode selector, and rear drum park brake switch, located on the front console in the operator’s cab, is placed in the off position, the PC is prepared for any luffing commands received from rear hoist control handle.

  • Page 77: Auxiliary Hoist Rotation Indicator

    777 SERVICE MANUAL INTRODUCTION FIGURE 1-47 Auxiliary Hoist Rotation Indicator When auxiliary hoist control handle, located on the right console in the operator’s cab, is in the off position, the handle Whenever the auxiliary drum rotates, auxiliary drum speed neutral switch is open, the PC receives no voltage from the...

  • Page 78: Auxiliary Hoist Lower

    INTRODUCTION 777 SERVICE MANUAL stroke the pump in the up direction. Oil then flows from pump port A to port A of auxiliary hoist motor. Auxiliary hoist pressure sender supplies the PC with pressure information, which the PC compares to the memorized holding pressure of the auxiliary hoist.
  • Page 79 777 SERVICE MANUAL INTRODUCTION Auxiliary hoist pressure sender supplies the PC with pumped to the motor, and the auxiliary drum lowers the load pressure development data that the PC compares to the faster. memorized holding pressure of the auxiliary hoist. When...

  • Page 80: Abbreviations

    INTRODUCTION 777 SERVICE MANUAL ABBREVIATIONS Hydraulic Solenoid Valves Abbreviations Item Description Item Description Travel Park Brake Alternator B1, B2 Motor Swing Park Brake Ether Disable Rear/Luffing Drum Park Brake Electric Displacement Control (Pump) Auxiliary Drum Park Brake Electronic Fuel Control...
  • Page 81 Operating Speed Checks ..........2-30 Manitowoc...

  • Page 83: Hydraulic Schematics

    Section 3 of this Leaking ports. manual. b. Leaking valve sections or manifolds and valves Contact Manitowoc Crane Care for an explanation of any installed into cylinders or onto motors. procedure not fully understood. Damaged or missing hose clamps, guard or shields.

  • Page 84: Hydraulic System Maintenance

    HYDRAULIC SYSTEM 777 SERVICE MANUAL mechanical properties and long term exposure to these • Do not unpack parts or remove port plugs until parts are cold temperatures will negatively impact service life. It is needed. recommended for these hoses to be inspected to step 1 •...

  • Page 85: Servicing Pumps

    777 SERVICE MANUAL HYDRAULIC SYSTEM Listen to pumps and motors for unusual noises; a high b. Remove fill cap from flange (see Figure 2-1). pitched whine or scream can indicate that air is being Thoroughly clean fill cap with clean, nonflammable drawn in.

  • Page 86: Replacing Filter Elements

    HYDRAULIC SYSTEM 777 SERVICE MANUAL Replacing Filter Elements NOTE: Filter 5 (not shown) in suction line to pumps is located in hydraulic tank. Tank must be drained to This topic contains procedures for replacing the following clean filter. See procedures under Changing Oil.

  • Page 87: Filter 2

    777 SERVICE MANUAL HYDRAULIC SYSTEM Lubricate seal on new filter element with clean hydraulic oil. Head Install new filter element hand tight on filter housing. Do not fill new element with oil. Using a filter wrench, tighten element an additional 1/4 O-Ring turn.
  • Page 88 HYDRAULIC SYSTEM 777 SERVICE MANUAL Fuel Tank P494 Hydraulic Tank Hydraulic Tank Drain Valve Hydraulic Filters (see Figure 2-2) View A Fill Cap Hydraulic Tank Level View B Decal Sight Gauge A961 View C Hydraulic Tank Latch Shut-off Valve Close...

  • Page 89: Changing Oil

    777 SERVICE MANUAL HYDRAULIC SYSTEM Changing Oil 17. Fill hydraulic tank to proper level as indicated on decal next to tank sight gauge (Figure 2-4, View B). Use Drain and refill hydraulic system every 1,000 hours or proper hydraulic oil (see Lubrication Guide in Section 9 semiannually, whichever comes first, unless an alternate of this manual).

  • Page 90: Tightening Hydraulic Connections

    HYDRAULIC SYSTEM 777 SERVICE MANUAL Tightening Hydraulic Connections Pipe Thread Connection Apply sealant (Loctite 92 or equivalent) to male threads, • Make sure fittings and O-rings being used are proper never to female threads. Do not apply sealant to first two size and style.

  • Page 91: Sae Straight Thread Connection

    777 SERVICE MANUAL HYDRAULIC SYSTEM S107 Jam Nut Washer O-Ring View A View B When jam nut and washer are not Washer cannot seat properly on spot face. backed up, there is not enough room Compressed rubber between washer and spot for O-ring when squeeze takes place.

  • Page 92: Ors Connection

    HYDRAULIC SYSTEM 777 SERVICE MANUAL ORS Connection Align shoulder with port and assemble flanges over shoulder. NOTE: ORS is the registered trade mark for a face-type Bolts used must be grade-5 or better. Grade-5 bolt has seal manufactured by Aeroquip Corporation.

  • Page 93: Sae Flare Connection

    777 SERVICE MANUAL HYDRAULIC SYSTEM Table 2-7 Table 2-8 Split Flange Leakage SAE 37° Flare Tightening Causes Cures Connector Nut Size Fitting Adapter Flats inch across flats Size to Rotate Tighten bolts evenly to Flanges not tight. proper torque. 9/16 2-1/2 Replace O-rings.

  • Page 94: Programmable Controller Calibration Procedures

    HYDRAULIC SYSTEM 777 SERVICE MANUAL PROGRAMMABLE CONTROLLER • When a new programmable controller is installed. CALIBRATION PROCEDURES • When a new CPU board is installed. To ensure proper operation of the crane functions, the • When a new controller chip is installed.

  • Page 95: Load Drums, Swing, Track, And Boom Hoist Pump

    777 SERVICE MANUAL HYDRAULIC SYSTEM Load Drums, Swing, Track, and Boom Hoist Boom Hoist Cylinder Pump WARNING WARNING Falling Boom Hazard! High Pressure Oil Hazard! Do not remove boom hoist cylinder pressure sender until f o l l o w i n g s t e ps a r e p e rf o rm e d . B o o m w i l l l o w e r Do not attempt to remove load drum, swing, track, or uncontrolled.
  • Page 96 HYDRAULIC SYSTEM 777 SERVICE MANUAL 10. Bleed air from boom hoist cylinder pressure sender as d. Observe oil flowing from bleed line at boom hoist follows: cylinder pressure sender. Connect a bleed line with a shut-off valve to coupler Close shut-off valve for boom hoist cylinder...

  • Page 97: Disc Brake Operational Test

    777 SERVICE MANUAL HYDRAULIC SYSTEM Solenoid Valves Right Side Enclosure Electrical Plug P515a Solenoid Function Description Travel Brake (crawler crane only) Controls two brakes. Rear Drum Brake Controls one or two brakes. Front Drum Brake Controls one or two brakes.
  • Page 98 HYDRAULIC SYSTEM 777 SERVICE MANUAL THIS PAGE BLANK 2-16 Published 10-01-2012, Control # 045-08...

  • Page 99: Shop Procedure

    HYDRAULIC SYSTEM SHOP PROCEDURE This topic covers hydraulic adjustments for the hydraulic system and related components on the 777 crane. Experienced technicians, trained in the operation of this crane and its hydraulic system, shall perform the procedures in this topic. These technicians shall read, understand, and comply with the instructions in this topic.
  • Page 100 HYDRAULIC SYSTEM 777 SERVICE MANUAL A1032 Pump Port Identification Oil Flow Diagram Pump Flow From Flow From Number Port A Port B 0, 1, 2, 10 Raise Lower Right Left Reverse Forward Forward Reverse Down Down From B To A...
  • Page 101 777 SERVICE MANUAL HYDRAULIC SYSTEM Item Description EDC (Electronic Displacement Control) Manual Override Control Displacement Adjusting Screw (Note 1) Case Drain Port (Note 2) Charge Pressure Relief Valve Filter Adapter (Note 3) Multi-Function Valve (Note 4) Charge Pressure Gauge Port...

  • Page 102: Initial Oil Fill

    HYDRAULIC SYSTEM 777 SERVICE MANUAL A1033 (from pump) Filter (arrows on head indicate proper oil flow) (to filter) (to pump) Filter Adapter IN (from filter) FIGURE 2-17 Closest Port to Pump Typical All Load Drum Pumps Initial Oil Fill At engine, check that engine clutch is engaged (Figure 2-21).
  • Page 103 777 SERVICE MANUAL HYDRAULIC SYSTEM Case Drain Case Drain Port Port P572 P494 Pump Load Drum Motor (Typical) (Typical) Case Drain Case Drain Port Port P495 P516 Travel Motor Swing Motor (Typical 2 Places) FIGURE 2-18 A1033 Fuel Tank To Hydraulic...
  • Page 104 HYDRAULIC SYSTEM 777 SERVICE MANUAL Must Pull Latch Padlock Up to Turn Handle Hole P432 P433 Latch Open Supercharge Close Filter Shut-off Valve Close Open Filter 1 Padlock Hole Left Side of Pumps Front of Hydraulic Tank FIGURE 2-20 Left Side of...

  • Page 105: Pressure Sender Calibration

    777 SERVICE MANUAL HYDRAULIC SYSTEM Fill hydraulic tank to FULL HOT level mark on sight procedure contained in Pressure Sender Calibration in gauge (Figure 2-23). this section. Stop engine. P454 Perform following steps for boom hoist cylinder pressure Fill Cap...

  • Page 106: Initial Start-Up

    HYDRAULIC SYSTEM 777 SERVICE MANUAL Initial Start-Up Gauge Coupler Calibrate pressure transducers, if not already done. (typical) Before starting engine first time with free fall, Pressure remove adjusting screw from drum clutch pressure Sender reducing valve (Figure 2-31). Then reinstall screw 1/4 in.
  • Page 107 777 SERVICE MANUAL HYDRAULIC SYSTEM Rear Drum Front Drum Disc Brake Disc Brake Solenoid Solenoid Travel Disc Swing Disc Brake Solenoid Brake Solenoid Electrical Plug Right Side Enclosure P515 Past Production Rear Drum Front Drum Travel Disc Disc Brake Disc Brake...

  • Page 108: Controls Calibration

    • Make sure pressure reading for each pump is 200 – 500 NOTE: Manitowoc Shop Personnel — pressures and psi (13.8 – 34.5 bar). speeds noted in remaining procedures and any If pump pressures are not within acceptable range, stop adjustments you make to correct them must be engine immediately.

  • Page 109: Accessory System Pressure Checks

    777 SERVICE MANUAL HYDRAULIC SYSTEM ±100 psi (6.9 bar) from that shown on the pressure Note and record gauge reading. Gauge should read gauges. 325 – 375 psi (22.4 – 25.9 bar) and not exceed 450 psi (31.0 bar) at high idle.

  • Page 110: Band Brake Relief Valve Pressure Check

    HYDRAULIC SYSTEM 777 SERVICE MANUAL Gauge Coupler Supercharge and Accessory Pump (behind) P571 Band Brake Gauge Relief Valve Coupler P578 Right Side of Crane Left Side of Pumps When Band Brake Behind Rear Drum Crane has Free Fall Relief Valve When Crane does not have Free Fall.

  • Page 111: Operating Pressure Checks

    777 SERVICE MANUAL HYDRAULIC SYSTEM Operating Pressure Checks Boom Hoist Leakage Test NOTE: It will be necessary to monitor pressure and pump command on the diagnostic screens of the digital display during the following steps. See Diagnostic WARNING Display Readings in Section 10 of this manual. Do...

  • Page 112: Operating Speed Checks

    HYDRAULIC SYSTEM 777 SERVICE MANUAL Operating Speed Checks Check operating speeds for below listed functions in SETUP mode with engine running at high idle and control handles moved fully forward and back. Load drum speeds are shown on diagnostic screens for each pump.
  • Page 113 4-Pole Plugs ..........3-40 Manitowoc...

  • Page 115: Electrical Drawings And Schematics

    777 SERVICE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM ELECTRICAL DRAWINGS AND b. Damaged or missing electrical clamps or tie straps. SCHEMATICS Excessive corrosion or dirt on the junction boxes. Applicable electrical system drawings and schematics are d. Loose junction box mounting hardware.

  • Page 116: Abbreviations And Symbols

    ELECTRIC SYSTEM 777 SERVICE MANUAL ABBREVIATIONS AND SYMBOLS See Table 3-2 for abbreviation and symbols used in this section. Table 3-2 Abbreviations and Symbols ITEM DEFINITION ITEM DEFINITION ITEM DEFINITION Plus/Minus Value Digital - On/Off Inputs Normally Closed (Switch) Plus/Positive Volts...

  • Page 117: Test Voltages

    777 SERVICE MANUAL ELECTRIC SYSTEM TEST VOLTAGES Controller Board Layout This section contains test voltages sorted into three The board locations in the programmable controller are categories: shown below. Pin Identification..........3-4 Wire Identification..........3-9 Description Identification ........3-14 Rear Cab Wall...

  • Page 118: Pin Identification

    ELECTRIC SYSTEM 777 SERVICE MANUAL Pin Identification Test Voltage Pin # Wire # I/O # Description Connection (DC unless otherwise specified) A-01 — 10 VDC Regulated 10 VDC A-02 68KA AI-35 Foot Throttle 0.101 to 10.09 Volts CPU J3-64 0 VDC Neutral; 5 to 1.4 VDC Lower;...
  • Page 119 777 SERVICE MANUAL ELECTRIC SYSTEM Test Voltage Pin # Wire # I/O # Description Connection (DC unless otherwise specified) B-04 89ZA DI-4 Left Side Counterweight Limit 12 VDC Nominal I/O 1 J6-10 B-05 89ZB DI-5 Right Side Counterweight Limit 12 VDC Nominal...
  • Page 120 ELECTRIC SYSTEM 777 SERVICE MANUAL Test Voltage Pin # Wire # I/O # Description Connection (DC unless otherwise specified) 0 to 2.8 ± 10% (110 Ma ± 10%) VDC Down; Boom Cylinder Pump Control (Servo C-14 AO-S3 I/O 2 J8-41 0 to -2.8 ±...
  • Page 121 777 SERVICE MANUAL ELECTRIC SYSTEM Test Voltage Pin # Wire # I/O # Description Connection (DC unless otherwise specified) D-19 — Display - White (Input) Approximately 2.5 VDC CPU J4-05 D-20 TX2-0 — Display - Black (Common) CPU J4-07-08 D-21 —...
  • Page 122 ELECTRIC SYSTEM 777 SERVICE MANUAL Test Voltage Pin # Wire # I/O # Description Connection (DC unless otherwise specified) E-25 80MALS ECA7 Left Front Drum Encoder Channel A 7.5 VDC Plus or 0 VDC Not Moving; 3.5 VDC Moving I/O 4 J12-01...

  • Page 123: Wire Identification

    777 SERVICE MANUAL ELECTRIC SYSTEM Wire Identification Test Voltage Wire # Pin # I/O # Description Connection (DC unless otherwise specified) A-10 AI-8 Spare I/O 1 J5-64 A-11 — Shield A-29 AI-26 Spare CPU J3-52 A-30 AI-27 Spare CPU J3-54...
  • Page 124 ELECTRIC SYSTEM 777 SERVICE MANUAL Test Voltage Wire # Pin # I/O # Description Connection (DC unless otherwise specified) SIG 3 A-36 AI-33 Load Cell 3 0 to10 VDC Nominal CPU J3-60 SIG 4 A-37 AI-34 Load Cell 4 0 to10 VDC Nominal...
  • Page 125 777 SERVICE MANUAL ELECTRIC SYSTEM Test Voltage Wire # Pin # I/O # Description Connection (DC unless otherwise specified) Rear Drum Flange Direction Encoder 81MB D-04 ECB2 7.5 VDC Plus or 0 VDC Not Moving; 3.5 VDC Moving I/O 1 J6-04...
  • Page 126 ELECTRIC SYSTEM 777 SERVICE MANUAL Test Voltage Wire # Pin # I/O # Description Connection (DC unless otherwise specified) E-37 DO-37 Auxiliary Drum Pump Control Down 0 to 2.8 VDC Engine On; 0 to 2.4 VDC Engine Off I/O 4 J12-33-34...
  • Page 127 777 SERVICE MANUAL ELECTRIC SYSTEM Test Voltage Wire # Pin # I/O # Description Connection (DC unless otherwise specified) 89Z3 D-09 DI-38 Rear Drum Disc Brake Park Switch 12 VDC Nominal (when brake is applied) I/O 3 J10-16 89Z4 E-24...

  • Page 128: Description Identification

    ELECTRIC SYSTEM 777 SERVICE MANUAL Description Identification Test Voltage Connection Description Wire # Pin # I/O # (DC unless otherwise specified) (Signal Type) 10 VDC Regulated A-01 — 10 VDC 10 VDC Regulated Monitor 87FM A-16 AI-13 5 VDC I/O 2 J7-58...
  • Page 129 777 SERVICE MANUAL ELECTRIC SYSTEM Test Voltage Connection Description Wire # Pin # I/O # (DC unless otherwise specified) (Signal Type) Computer 12 VDC E-31 — Computer Ground E-32 — Crane Mode Confirm 89T2 B-10 DI-10 12 VDC Nominal I/O 1 J6-16...
  • Page 130 ELECTRIC SYSTEM 777 SERVICE MANUAL Test Voltage Connection Description Wire # Pin # I/O # (DC unless otherwise specified) (Signal Type) Left Rear Drum Encoder Channel B 81MBLS E-28 ECB8 7.5 VDC Plus or 0 VDC Not Moving; 3.5 VDC Moving...
  • Page 131 777 SERVICE MANUAL ELECTRIC SYSTEM Test Voltage Connection Description Wire # Pin # I/O # (DC unless otherwise specified) (Signal Type) Right Rear Drum Clutch Switch 89ZJ B-36 DI-36 12 VDC Nominal I/O 3 J10-14 Right Rear Drum Shaft Direction Encoder...
  • Page 132 ELECTRIC SYSTEM 777 SERVICE MANUAL Test Voltage Connection Description Wire # Pin # I/O # (DC unless otherwise specified) (Signal Type) 0 to 2.8 ± 10% (110 Ma ± 10%) VDC Right; Swing Pump Control (Servo Driver 6) C-24 AO-S6 I/O 3 J10-42 0 to -2.8 ±...

  • Page 133: Display Readings

    777 SERVICE MANUAL ELECTRIC SYSTEM DISPLAY READINGS Name of limit appears on display at least once. Cause of limit is corrected. Display allows operator to monitor three groups of crane information: operating conditions (normal and diagnostic), For this reason, it is normal for names of limits to appear operating limits, and system faults.
  • Page 134 ELECTRIC SYSTEM 777 SERVICE MANUAL THIS PAGE BLANK 3-20 Published 10-01-2012, Control # 045-08...

  • Page 135: Selecting Display Language

    Selecting Display Language To select a different display language, perform both of the following steps at the same time: Current software for Model 777 contains English and several Depress limit bypass switch. foreign-language display readings. When a new computer chip is installed, any one of the languages could appear on Turn digital display confirm/select key switch to confirm the screen when the system is powered up the first time.
  • Page 136 ELECTRIC SYSTEM 777 SERVICE MANUAL 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 137 777 SERVICE MANUAL ELECTRIC SYSTEM 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 seconds at startup if there is a DATALOGGER FAULT Does not affect operation.

  • Page 138: Crane Diagnostics

    ELECTRIC SYSTEM 777 SERVICE MANUAL CRANE DIAGNOSTICS BHST (Boom Hoist) To activate the diagnostic display screens, depress the limit bypass switch and scroll up. Once this step is performed, you can scroll up and down through the diagnostic screens in BHST addition to the normal operating screens.

  • Page 139: A1 (Handles)

    777 SERVICE MANUAL ELECTRIC SYSTEM Parking brake command (1 release, 0 engage). *For certain operating conditions handle command can be set to neutral by the controller even if handle is not in neutral. A1 (Handles) 1 – 8. Bank number.
  • Page 140 ELECTRIC SYSTEM 777 SERVICE MANUAL Table 3-6 D1 (Digital Outputs) Table 3-7 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 Boom Up Enable Minimum Bail Limit –...
  • Page 141 777 SERVICE MANUAL ELECTRIC SYSTEM Drum Identification Drum Drum Number Front Load Drum Rear Load Drum Auxiliary Load Drum (in boom butt) A969 FIGURE 3-7 Handle/Pedal Identification Handle Handle Number Front Load Drum Rear Load Drum or Luffing Hoist* Boom Hoist...
  • Page 142 ELECTRIC SYSTEM 777 SERVICE MANUAL Table 3-8 8-Bit Binary System Dark shaded boxes indicate ON; white boxes OFF. 3-28 Published 10-01-2012, Control # 045-08...
  • Page 143 777 SERVICE MANUAL ELECTRIC SYSTEM Table 3-8 8-Bit Binary System (continued) Dark shaded boxes indicate ON; white boxes OFF. Manitowoc 3-29 Published 10-01-2012, Control # 045-08...

  • Page 144: Crane Software Installation

    The chip will be blank above the window. Below the window, the Texas Instruments symbol and a 5- The Model 777 must be replaced with CPU 366113 and digit code will appear in the first line and a 6-digit code 150 nano second chips.

  • Page 145: Eprom Replacement

    Carefully remove both EPROMs from upper right corner 13. Follow instructions in operator’s manual to calibrate of CPU board. An EPROM remover should be used. pressure senders (transducers) and pump control Each EPROM has a label containing A Manitowoc thresholds (feed forward). program number,...

  • Page 146: Counterweight Limit Switch Adjustment

    ELECTRIC SYSTEM 777 SERVICE MANUAL View A (2 places) Electrical Cord Light: ON During Normal Operation (past production only) Limit Switch Shaft Lever Bottom edge of Rotating Bed Head A1004 1-1/2 in. (38 mm) Roller 1-1/4 in. (32 mm) Bench Setup...

  • Page 147: Engine Control Module Ground Modification

    777 SERVICE MANUAL ELECTRIC SYSTEM Installation ENGINE CONTROL MODULE GROUND MODIFICATION Mount limit switches and adjust position to installation dimension in Figure 3-12, View A. The Cummins QSC 8.3 engine ECM (Engine Control Module) on the models listed below may not be grounded Securely tighten screws.

  • Page 148: Dielectric Grease

    ELECTRIC SYSTEM 777 SERVICE MANUAL DIELECTRIC GREASE The following Figures show the proper application of dielectric grease on J - tech type connectors. Dielectric grease is need when assembling J - tech type connectors. A bead of grease needs to be applied on O-ring and face of the socket connector and only on the O-ring for a pin connector.

  • Page 149: Connector Pin Identification

    This section is provided to assist service and maintenance personnel in identifying connector pins for all Brad Harrison 65 ft (19.8 m) 911031 type connectors used on Manitowoc cranes: 70 ft (21.3 m) 477494 • Extension cords with plug on both ends — M (male) one 130 ft (40.0 m)

  • Page 150: 3-Pole Plugs

    ELECTRIC SYSTEM 777 SERVICE MANUAL 3-Pole Plugs Receptacle: Plug Part # 1-Green 1-Green 589635 F 90° 589636 2-Black 3-White 3-White 2-Black 589871 Female Male M 90° 589938 FIGURE 3-17 4-Pole Plugs Extension: 1-Black 4-Green 1-Black 4-Green Length Plug Part # 3 ft (0.9 m)

  • Page 151: 5-Pole Plugs

    777 SERVICE MANUAL ELECTRIC SYSTEM 5-Pole Plugs Length Plug Part # 6 ft (1.8 m) 572442 5-Black 1-White 6 ft (1.8 m) 572517 12 ft (3.7 m) 572415 4-Orange 2-Red 12 ft (3.7 m) 572568 3-Green 20 ft (6.1 m)

  • Page 152: 10-Pole Plugs

    ELECTRIC SYSTEM 777 SERVICE MANUAL 10-Pole Plugs 12-Pole Plugs 9-Green 8-Green 1-Orange 9-Black 10-White 8-Black/White 12-Black 7-Red 10-Red 1-Orange 7-Blue/Black 6-Orange/Black 2-Blue 2-Blue 6-Orange/Black 3-White/Black 5-Green/Black 5-Green/Black 3-White/Black 4-Red/Black 4-Red/Black 11-White Female Female 8-Green 9-Green 9-Black 8-Black/White 10-White 1-Orange 1-Orange...

  • Page 153: Micro-Change Type Connectors

    777 SERVICE MANUAL ELECTRIC SYSTEM Micro-Change Type Connectors Length Plug Part # 13.1 ft (4.0 m) 572476 4-Pole Plugs 16 ft (4.9 m) 572472 16 ft (4.9 m) F 90° 572501 2-White 3-Blue 1-Brown 2-White 16.4 ft (5.0 m) 572475 23 ft (7.0 m)

  • Page 154: 3-Pole Plugs

    ELECTRIC SYSTEM 777 SERVICE MANUAL 3-Pole Plugs 4-Pole Plugs 1-Black 2-White 1-Black 1-Black 3-Green 2-White 2-Green 3-Red Female Female 3-Green 2-White FIGURE 3-27 Male Plug With Cord: FIGURE 3-26 Length Plug Part # 20 ft (6.1 m) 572566 Extension: Length...
  • Page 155 (internal leakage). If damage is found, contact the Service Depart- ment at Manitowoc Cranes for repair/replacement instructions....4-9 Boom and Jib Inspection and Lacing Replacement.

  • Page 157: Section 4

    777 SERVICE MANUAL BOOM SECTION 4 BOOM AUTOMATIC BOOM STOP ADJUSTMENT Maintenance At least once weekly, check that the automatic boom stop Maximum Boom Angle stops the boom at the specified maximum angle. If not, Boom stop limit switch (2, Figure 4-1) automatically stops the...
  • Page 158 BOOM 777 SERVICE MANUAL Centerline of Angle A Boom 83° #78 Boom. #78 Boom with #139 Luffing Jib when the 88° boom up limit can be bypassed.* #78 Boom with #139 Luffing Jib when the 89° boom up limit cannot be bypassed.*...

  • Page 159: Bypass Limit Test

    777 SERVICE MANUAL BOOM Bypass Limit Test Limit switch will not trip open if it is too far from actuator bracket. Limit switch could be damaged Perform the following test to determine if the boom up limit from over-travel if it is too close to actuator bracket.

  • Page 160: Physical Boom Stop

    BOOM 777 SERVICE MANUAL 90° A991 81° Boom Butt 81° Start of Spring Cushion. Solid at 90° Use care when handling boom stop tubes. Lower tube is not retained in upper tube. 32 inch Boom Stop Boom Stop Overlap Spring...
  • Page 161 777 SERVICE MANUAL BOOM THIS PAGE BLANK Manitowoc Published 10-01-2012, Control # 045-08...

  • Page 162: Boom Angle Indicator

    BOOM 777 SERVICE MANUAL BOOM ANGLE INDICATOR Hold a protractor-level along scribed line. Record angle indicated on protractor-level. A n a n g l e s e n d i n g u n i t m o u n t e d o n t h e b o o m b u t t (Figure 4-4) monitors the boom angle.
  • Page 163 777 SERVICE MANUAL BOOM A990 O-Black 52.5° REF. 3- Pole Receptacle with Protective Cap 82BA-Green Boom Angle Sending Unit 87FA-White Pendulum-Type VIEW A Potentiometer A1294 Solid State Sensor (+/- 60×) Position Sensor M.C.C. #A09716 Like This Vendor #CS17 52.5° O-Black...

  • Page 164: Servicing Boom Hoist Cylinder

    BOOM 777 SERVICE MANUAL SERVICING BOOM HOIST CYLINDER Install holding valves and connect hoses as required: Thoroughly clean all fittings. b. Make sure all O-rings are properly installed. WARNING Apply thread sealant to vent plug threads and securely install vent plugs.

  • Page 165: Boom And Jib Inspection And Lacing Replacement

    • If the attachment has been struck by lightning. Contact Manitowoc Crane Care for any damage to chords or platework exceeding the allowable criteria contained in Inspection Guidelines this publication. Special instructions are required for repair or replacement of these components.

  • Page 166: Dents

    BOOM 777 SERVICE MANUAL Dents For angular lacing, gradual and sweeping bends must not deviate from straight more than 5 percent of the angle leg Refer to Figure 4-9. length. For tubular lacings or chords, dents must not be deeper than B231 the wall thickness or 1/8 in (3.2 mm), whichever is less.
  • Page 167 777 SERVICE MANUAL BOOM CORRODED CHORD P325 Not Acceptable Not Acceptable Acceptable Abrasion from handling with Surface is badly pitted; Surface is relatively smooth: chain exceeds allowable limit exceeds allowable limit within allowable limit P326 FIGURE 4-11 Manitowoc 4-11 Published 10-01-2012, Control # 045-08...

  • Page 168: Kinks

    If visual inspection indicates that a chord may not be straight, back into alignment. proceed as follows: If any chord or platework is kinked, contact Manitowoc Crane Remove the suspect lattice section from the attachment. Care for approved repair instructions. Do not bend kinked Place wood blocks or steel plates having the same chords or platework back into alignment.
  • Page 169 777 SERVICE MANUAL BOOM B231 Wood Block Steel Plate Measurement (chord to line) Line A = Measurement to Determine Straightness B = Measurement to Determine Toe Waviness Angular Chord Tubular Chord and Lacing and Lacing Angular Chord and Lacing Line (black dot)

  • Page 170: Ordering Lacings

    Manufacturing PAST PRODUCTION If you are in doubt as to which lacings to order, DO NOT Code GUESS. Contact your Manitowoc distributor for assistance. Boom or Jib Identification All parts orders for lacings must contain the boom or jib Component...

  • Page 171: Ordering Lacings From Lacing Drawings

    EXAMPLE: Assume you have a number 22 boom and the The parts order must contain the following information to lacings with circled letters in Figure 4-16 are damaged. ensure that Manitowoc provides you with the correct lacings: Your parts order should be similar to the following example: Crane serial number (can be found on builders plate in operator's cab.)

  • Page 172: Ordering Lacings Without Lacing Drawings

    Figure 4-17 are damaged. The parts order must contain the following information to Your parts order should be similar to the following ensure that Manitowoc provides you with the correct lacings: example: Crane serial number (can be found on builders plate in Crane Serial Number: 00000 (from Crane Identification operator's cab.)

  • Page 173: Repair Procedure

    Field repair is limited to replacing damaged lacings — Repair Facility unless otherwise approved by Manitowoc — but only if To ensure proper welding, the repair area must: the following conditions are complied with: Be heated to 70° F (21° C) minimum.

  • Page 174: Repair Procedures And Processes

    Always replace diagonal lacings first. Diagonal Gouge marks on the chord are unacceptable. Stop all lacings run from one corner to another (for work if chord is damaged and contact Manitowoc example, from upper left chord to lower right Crane Care via your Manitowoc Distributor.

  • Page 175: End Lacing Replacement

    16. Prime and paint the welded area. weld pass shall start at the 6:00 O’clock position and end at the 12:00 O’clock position (Figure 4-21). 17. Send all completed inspection reports to Manitowoc Crane Care. If possible, digital photographs should be NOTE See Figure 4-24 for pass placement.

  • Page 176: End Lacing Replacement On An Insert (Angle And Tubular Chords)

    BOOM 777 SERVICE MANUAL Send all completed inspection reports to Manitowoc Crane Care. Digital photographs should be taken and sent with the inspection reports. Brace Tack Welded to Connectors Parallel to Damaged End Lacing End Lacings Damaged End Lacings FIGURE 4-22...

  • Page 177: Lacing Removal - Boom Section With A Bent Or Bowed Chord Member

    Actual use could be higher or lower depending on a lacings. Perform a thorough inspection of the lacings number of factors outside of Manitowoc’s control, such as and identify the lacings that will need to be replaced. over or under welding, damaged electrodes, length of Remove all of the damaged lacings by performing discarded electrode stubs, etc.
  • Page 178 BOOM 777 SERVICE MANUAL Weld Pass Detail Lacing 1/4 in (6 mm) Horizontal 2F Chord Use 3/32 in (2,5 mm) E9018M-H4 Stick Electrode 1/4 in (6 mm) Vertical 5F Use 3/32 in (2,5 mm) E9018M-H4 Stick Electrode 1/4 in (6 mm) Overhead 4F...
  • Page 179 777 SERVICE MANUAL BOOM Weld Pass Detail Lacing 5/16 in (8 mm) Horizontal 2F and Vertical 5F Chord Use 3/32 in (2,5 mm) E9018M-H4 Stick Electrode 5/16 in (8 mm) Overhead 4F Use 3/32 in (2,5 mm) E9018M-H4 Stick Electrode...
  • Page 180 BOOM 777 SERVICE MANUAL Weld Pass Detail Lacing 3/8 in (10 mm) Horizontal 2F and Vertical 5F 3/8 in (10 mm) Horizontal 2F and Vertical 5F Chord Use 3/32 in (2,5 mm) E9018M-H4 Stick Electrode Use 3/32 in (2,5 mm) E9018M-H4 Stick Electrode...
  • Page 181 777 SERVICE MANUAL BOOM Weld Pass Detail Lacing 1/2 in (12 mm) Horizontal 2F and Vertical 5F Chord Use 3/32 in (2,5 mm) E9018M-H4 Stick Electrode 1/8 in (3,2 mm) E9018M-H4 Stick Electrode 1/2 in (12 mm) Overhead 4F Use 3/32 in (2,5 mm) E9018M-H4 Stick Electrode...
  • Page 182 BOOM 777 SERVICE MANUAL THIS PAGE BLANK 4-26 Published 10-01-2012, Control # 045-08...

  • Page 183: Inspection Checklist

    777 SERVICE MANUAL BOOM INSPECTION CHECKLIST Use the following checklist to record any damage found while inspecting lattice sections. WARNING If no damage is found or the damage is within the allowable If damage found that is not within allowable criteria, do not...
  • Page 184 BOOM 777 SERVICE MANUAL Insert: Length Manufacturing Code Part Number Dents Bends Kinks Cracks Breaks Corrosion Abrasion Straightness Welds Other Insert: Length Manufacturing Code Part Number Dents Bends Kinks Cracks Breaks Corrosion Abrasion Straightness Welds Other Insert: Length Manufacturing Code...
  • Page 185 777 SERVICE MANUAL BOOM NOTES DRAW SKETCHES OR ATTACH PHOTOGRAPHS HERE AND NEXT PAGE Manitowoc 4-29 Published 10-01-2012, Control # 045-08...
  • Page 186 BOOM 777 SERVICE MANUAL 4-30 Published 10-01-2012, Control # 045-08...

  • Page 187: Section 5

    Maintenance and Inspection ........5-25 Manitowoc...

  • Page 189: Hoist Drawings

    777 SERVICE MANUAL HOISTS SECTION 5 HOISTS HOIST DRAWINGS b. Pay out wire rope from auxiliary drum. Load drum must stop when there are three to four Applicable hoist and load block drawings are attached at the wraps of wire rope remaining on drum.
  • Page 190 HOISTS 777 SERVICE MANUAL 3 to 4 Wraps of Wire Rope Remaining on Load Drum Turn Adjusting Screw Down to Open Switch (light off, if equipped) Bare 1-21/32 in Drum (42,1 mm) Lagged 1-15/32 in Drum (37,3 mm) Item Description...

  • Page 191: Adjustment

    777 SERVICE MANUAL HOISTS Adjustment Turn adjusting screw against limit switch roller only enough to “click” limit switch open (light off, if equipped). See Figure 5-2 for following procedure. Securely tighten jam nut on adjusting screw to lock Land load for drum being adjusted.

  • Page 192: Block-Up Limit Installation And Adjustment

    HOISTS 777 SERVICE MANUAL BLOCK-UP LIMIT INSTALLATION AND Lift block clamped to single-part load line or lift plates fastened to multiple-part load block. ADJUSTMENT Operation A block-up limit control (also called anti two-block device) is a two-blocking prevention device which automatically stops See Figure 5-3 and Figure 5-8 for component identification.
  • Page 193 777 SERVICE MANUAL HOISTS A1007 Item Description Weight Ball Lift Block Weight Chain - 8 ft (2.4 m) Limit Switch Assembly Upper Boom Point Lower Boom Point Chain - 8 ft (2.4 m) Lift Plate Load Block #78 Boom Shown;...

  • Page 194: Storing Electric Cable

    HOISTS 777 SERVICE MANUAL Storing Electric Cable Store the excess cords for the boom and luffing jib on the reel mounted on either butt. The reel has a locking pin. See Figure 5-5 for component identification. Disengage the locking pin to allow the reel to be wound.
  • Page 195 777 SERVICE MANUAL HOISTS Item Description Item Description Cable Reels Limit Switches Cable Reel on Boom Butt Upper Boom Point Limit Switch Cable Reel on Luffing Jib Butt Lower Boom Point Limit Switch Electric Cords Lower Jib Point Limit Switch Cord from Main Junction Box Behind Operator’s Cab...
  • Page 196 HOISTS 777 SERVICE MANUAL Heavy Lift Boom Top with Upper Boom Point (for Luffing Jib only) Heavy Lift or Long Reach Boom Top with Fixed Jib or Luffing Jib or Fixed Jib on Luffing Jib Heavy Lift Boom Top with Upper Boom Point...

  • Page 197: Disconnecting Block-Up Limit Control

    777 SERVICE MANUAL HOISTS Disconnecting Block-Up Limit Control Maintenance See Figures 5-6 and 5-7 for identification of the electric cords See Figure 5-8 for following procedure and shorting plugs. Inspect and test the block-up limit controls weekly or every Shorting plug SP1 is provided on the left front corner of...

  • Page 198: Adjustment

    HOISTS 777 SERVICE MANUAL Adjustment Manually lift the weight to allow the actuating lever to rotate upward. See Figure 5-8 for following procedure. Hold lever at Dimension A. Lower the boom onto blocking at ground level and adjust Hold the roller on the limit switch lever against the...
  • Page 199 777 SERVICE MANUAL HOISTS THIS PAGE BLANK Manitowoc 5-11 Published 10-01-2012, Control # 045-08...

  • Page 200: Drum Brake Adjustment

    HOISTS 777 SERVICE MANUAL DRUM BRAKE ADJUSTMENT Two types of brakes are provided on right end of both load drums: WARNING • An external, contracting, band-type brake (wrapped Personnel Injury Hazard! around drum flange) and an actuator. See Figure 5-12.

  • Page 201: Brake Adjustment

    If there is evidence of cracks or 10% reduction in area due to corrosion, destroy and discard the band and replace with it a new band or a band that has passed non-destructive test/inspection. Contact your Manitowoc Right Side of Crane Hole dealer for brake band thickness.

  • Page 202: Foot Pedal Adjustment

    (Figure 5-11, View C). Faulty Operation Hazard! Lower actuator so actuator connector is clear of band. Use only Manitowoc original equipment lining. Other lining may not provide proper braking torque. Turn actuator connector in desired amount (this will shorten distance between band end and actuator).
  • Page 203 777 SERVICE MANUAL HOISTS Item Description P533 Eyebolt READJUST Brake When Leading Edge of Spring Sleeve Reaches This Line Spring Guide SAFE WORKING RANGE Drum Flange Brake Lining Adjusting nut DRUM BRAKE ADJUSTMENT INDICATOR Lock Nut See Operator’s Manual for Procedure...

  • Page 204: Drum Pawl Adjustment

    HOISTS 777 SERVICE MANUAL DRUM PAWL ADJUSTMENT Actuator Installation and Adjustment The drum pawls are positive locking devices which, when See Figure 5-13 for following procedure. engaged, prevent the load drums from turning in the lowering Move cab power switch to ON position and engine run- direction.
  • Page 205 777 SERVICE MANUAL HOISTS A973 3/8 in. 7/8 in. (9 mm) (22 mm) Item Description Mounting Bracket Nuts Actuator Mounting Lug Leaf Spring Pawl Ratchet Jam Nut Adjusting Screw View B View A FRONT DRUM PAWL 3/8 in. 7/8 in.

  • Page 206: Drum Pressure Roller Adjustment

    HOISTS 777 SERVICE MANUAL DRUM PRESSURE ROLLER ADJUSTMENT Adjustment The operator must monitor drum spooling during operation. General If the wire rope jumps layers or does not wind smoothly onto Optional pressure roller assemblies are available for the the drum, perform following steps: front and rear load drums.

  • Page 207: Wire Rope Lubrication

    777 SERVICE MANUAL HOISTS WIRE ROPE LUBRICATION Broken or cut strands. Broken wires (see Periodic Inspection for additional Refer to the Lubrication Guide supplied with your crane for information). recommendations. Core failure in rotation resistant rope (indicated by lay WIRE ROPE INSPECTION AND lengthening and reduction in diameter).
  • Page 208 HOISTS 777 SERVICE MANUAL Measure the rope’s diameter across crowns of the strands so • Any Rope — one outer wire broken at the point of the true diameter is measured as shown in Figure 5-14. contact with the core. The broken wire protrudes or loops out of the rope structure.

  • Page 209: Distributing Wire Rope Wear

    777 SERVICE MANUAL HOISTS WARNING Falling Load Hazard! Wire rope can break if following precaution is not Dog-Leg observed. Replacement wire rope must meet specifications given in Kink Wire Rope Specifications Chart (load lines) or Boom S144 Rigging Drawing (boom hoist) supplied with your crane.

  • Page 210: Sheave, Roller, And Drum Inspection

    HOISTS 777 SERVICE MANUAL Sheave, Roller, And Drum Inspection For steel sheaves, check depth, width, and contour of Perform the following inspections WEEKLY. each sheave using a groove gauge as shown in Figure 5-18. Replace sheaves that have over or under Check drum clutches and brakes for proper adjustment.
  • Page 211 777 SERVICE MANUAL HOISTS Inspect nylon sheaves to verify they have not separated Make sure sheaves, drums, and rollers are properly and “walked off” steel inserts or bearings as shown in lubricated according to lubrication instructions in Figure 5-20. Maximum sideways displacement is 1/8 in.
  • Page 212 HOISTS 777 SERVICE MANUAL SHEAVE DATA Outside Sheave Width Rope Diameter Tread Diameter Diameter Part No. inch inch inch inch 912738 631054 13.19 335.0 11.42 290.1 1.77 45.0 631056 631065 16.00 406.4 13.37 339.6 2.17 55.1 9/16 631071 16.00 406.4 13.88...

  • Page 213: Load Block And Hook-And-Weight Ball

    777 SERVICE MANUAL HOISTS Load Block and Hook-And-Weight Ball Check sheaves for uneven wear in the grooves and on flanges. Check for loose or wobbly sheaves. These Maintenance and Inspection conditions indicate faulty bearings or bushings. A923 WARNING Falling Load Hazard!
  • Page 214 11. Check that each hook has a hook latch and hook latch (contact your Manitowoc dealer for material and welding operates properly. Latch must not be wired open or specifications). removed.
  • Page 215 777 SERVICE MANUAL HOISTS Check for Wear and Deformation Check for Wear and Straightness Check that Pin is Shackle Always Seated Check for Opening Up Check for Wear Check for and Deformation Opening Up Check that Hook is Not Twisted...

  • Page 217: Section 6

    Manual Release Procedure ......... . . 6-1 Manitowoc...

  • Page 219: Manual Release Of Swing Brake And Lock

    777 SERVICE MANUAL SWING SECTION 6 SWING MANUAL RELEASE OF SWING BRAKE AND Manual Release Procedure LOCK Hydraulic hand pumps with pressure gauges are needed to manually release the swing brake and swing lock. The hydraulic swing brake and hydraulic swing lock must be...
  • Page 221 Engine Off Diagnostics ............7-12 Manitowoc...

  • Page 223: Battery Maintenance

    777 SERVICE MANUAL POWER TRAIN SECTION 7 POWER TRAIN BATTERY MAINTENANCE the plates, reducing the battery’s capacity or causing an internal short. Safety Information Undercharging Undercharging can cause a type of sulfate to develop on the plates. The sulfate causes strains in the positive plates which results in plate buckling.

  • Page 224: Multiple Battery System

    POWER TRAIN 777 SERVICE MANUAL Multiple Battery System When reading a hydrometer, hold the barrel vertical with the float freely suspended. Multiple battery systems are connected either in series or in Draw the electrolyte in and out several times to bring the parallel.

  • Page 225: Charging

    777 SERVICE MANUAL POWER TRAIN Table 7-3 of-thumb value for a slow rate is a current equal to about Open Circuit Cell Voltage one-half the number of plates per cell in the battery. A battery with 13 plates per cell, should be charged at 7 amps.

  • Page 226: Engine Air Cleaner Maintenance

    POWER TRAIN 777 SERVICE MANUAL ENGINE AIR CLEANER MAINTENANCE Loosen the clamp securing the air inlet cap or pre- cleaner and pull it off. Servicing the engine air cleaner is an important maintenance Inspect the air inlet cap or pre-cleaner for dirt and function: obstructions.

  • Page 227: Engine Clutch Adjustment

    777 SERVICE MANUAL POWER TRAIN ENGINE CLUTCH ADJUSTMENT practice will clean the disc surfaces and prevent the discs from seizing. A disc-type manually operated clutch (see Figure 7-3) is When disengaging the clutch, check free travel. Free mounted between the engine and the pump drive on this travel should be 1 to 1-1/8 in.

  • Page 228: Engine Throttle Adjustment - Cummins C330

    POWER TRAIN 777 SERVICE MANUAL ENGINE THROTTLE ADJUSTMENT - Press foot pedal down fully to HIGH IDLE position against shim or floor mat. CUMMINS C330 Adjust reach rod (4) and rod end (5) so controller lever is The throttle assembly for the Cummins C330 engine consists rotated fully to HIGH IDLE position.
  • Page 229 777 SERVICE MANUAL POWER TRAIN If the specified engine speeds cannot be obtained during Set flexible coupling damping switch to ON position. the adjustment steps, the engine speed sensor (on Set RMT SPD switch to 4-8V position. engine flywheel housing) may not be adjusted properly: Set A/B switches to RUN 1 position —...

  • Page 230: Engine Throttle Adjustment - Cummins 6Cta8.3-C260 Engine

    POWER TRAIN 777 SERVICE MANUAL 18. Set A/B switches to RUN MODE position — A switch ON Electronic Speed Control Adjustment and B switch ON. See Figure 7-6 for following procedure. 19. Test hand and foot throttles for proper full throttle...

  • Page 231: Test Voltages

    777 SERVICE MANUAL POWER TRAIN Gain Speed Stability Adjustment Adjustment Adjustment Terminal Strip 40 AMP Relay 15 AMP Circuit Breaker P855 Junction Box on Right Side of Engine FIGURE 7-6 Test Voltages The following test voltages are provided for troubleshooting purposes and are measured at the terminal strip in the junction box on the engine (Figure 7-6).

  • Page 232: Engine Throttle Adjustment - Caterpillar 3176B And 3176C Engines

    POWER TRAIN 777 SERVICE MANUAL ENGINE THROTTLE ADJUSTMENT - Engine Speed Calibration CATERPILLAR 3176B AND 3176C ENGINES See Figure 7-7 while calibrating engine speed. The throttle assembly for the Caterpillar 3176B and 3176C Engine speeds are calibrated on the converter board engines consists of a hand throttle controller in the left mounted in the left console near the hand throttle controller.

  • Page 233: Engine Throttle Adjustment - Cummins Qsl 340, Qsc8.3, Qsm11, Or Qsx15 Engine

    777 SERVICE MANUAL POWER TRAIN Low Idle Left Console Hand Throttle Controller Cover A974 Threshold Potentiometer Converter Span Board Potentiometer FIGURE 7-7 ENGINE THROTTLE ADJUSTMENT - Adjust reach rod (4) and rod end (5) so controller lever is rotated fully to HIGH IDLE position. Securely tighten jam CUMMINS QSL 340, QSC8.3, QSM11, OR...

  • Page 234: Onboard Diagnostics

    POWER TRAIN 777 SERVICE MANUAL ENGINE DIAGNOSTICS – CUMMINS QSL 340 Engine Warning Light AND QSC8.3 ENGINE When on, the yellow Warning light indicates the need to repair fault at first available opportunity. The Cummins QSC8.3 and QSL 340 engine has two...
  • Page 235 Operation ............8-5 Manitowoc...

  • Page 237: Turntable Bearing Bolt Torque

    777 SERVICE MANUAL UNDER CARRIAGE SECTION 8 UNDER CARRIAGE TURNTABLE BEARING BOLT TORQUE Lubrication Before installing the turntable bearing bolts, lubricate the Bearing Installation threads of each bolt with Never-Seez (MCC No. 361010) or an equivalent antiseizing lubricant. A dowel pin is installed in the inner ring as show in Figure 8-1, View B-B.

  • Page 238: Crawler Adjustment

    UNDER CARRIAGE 777 SERVICE MANUAL Bold Numbers Indicate Tightening Sequence FRONT of Rotating Bed Access to inner ring bolts is and Carbody through hole in center of the carbody and 4 access holes. Rotating Rotating Inner Inner Ring Ring Outer...

  • Page 239: Tread Slack Adjustment

    777 SERVICE MANUAL UNDER CARRIAGE Look for oil leaks, excessive wear, cracks, and other Adjustment Procedure damage. Broken or cracked parts can indicate that the Adjust tread slack at primary roller end of each crawler treads are adjusted too tight.

  • Page 240: Hydraulic Hand Pump

    Maintenance Personnel Do not overtighten connections. Connections only need Manitowoc has provided hand pump and cylinder for to be snug and leak free. Overtightening can cause crawler adjustment only. Any other use is neither intended premature thread failure and may cause fittings or nor approved.

  • Page 241: Air Removal

    777 SERVICE MANUAL UNDER CARRIAGE Place pump in vertical position with hose end Repeat steps until cylinder operates smoothly. Erratic down. operation indicates air in system. Using a screw driver, remove vent/fill cap. Operation Add hydraulic oil until it is at mark on dipstick.

  • Page 243: Section 9

    Lubrication ............9-1 Manitowoc...
  • Page 245 777 SERVICE MANUAL LUBRICATION SECTION 9 LUBRICATION LUBRICATION See F2107 at the end of this section. Manitowoc Published 10-01-2012, Control # 045-08...

  • Page 247: Section 10

    Test 20 – Checking Hydraulic Brake Pressure ......10-50 Test 21 – Adjusting the Lower Accessory Relief Valve..... 10-51 Manitowoc 10-i...
  • Page 248 777 SERVICE MANUAL Test 22 – Adjusting Jacking Counterbalance Valves ..... . 10-52 Test 23 – Transducer Test ......... . 10-53 Test 24 –...

  • Page 249: Safety Summary

    The first part of this section provides a series of flow charts that identify problems that could be encountered during WARNING normal operation of the Model 777. These charts contain instructions to assist in identifying and correcting problems. Eye, Skin, And Respiratory Hazards! Follow the procedural steps in the order indicated.

  • Page 250: Test Equipment

    • Use the standard test plug adapters (available from • Check the encoder electric supply at the test plug MANITOWOC CRANES INC.) for electrical testing. adapter of the encoder under test. • Check ground potentials when testing electric circuits for •...

  • Page 251: Troubleshooting Charts

    777 SERVICE MANUAL TROUBLESHOOTING TROUBLESHOOTING CHARTS Problem 1 Engine will not turn over to start. POSSIBLE CAUSES Dead battery; Loose connection on battery; Bad starter; Bad solenoid (MS1) relay, or starter solenoid (SS). CHECKS Check for voltage at battery terminals while attempting to start engine. (See Test...
  • Page 252 TROUBLESHOOTING 777 SERVICE MANUAL Problem 2 Engine turns over, but will not start. POSSIBLE No fuel to or from injector pump; Water or algae in fuel; Air intake restricted or blocked; Engine load is too high; Low battery amperage to gain starting RPM; Fuel shut-off is not working correctly.
  • Page 253 777 SERVICE MANUAL TROUBLESHOOTING Problem 3 Engine runs, but no hydraulic operation. POSSIBLE CAUSES Clutch not engaged; No hydraulic fluid in tank; Blocked charge inlet to pumps; Clogged tank vent; Drive train damaged from flywheel to pump mount. CHECKS Check hydraulic filter service shut-off valve.
  • Page 254 TROUBLESHOOTING 777 SERVICE MANUAL Problem 4 Engine runs, but battery is not charging. POSSIBLE CAUSES Belt loose or broken; No input to alternator terminals; Damaged alternator; Corroded or loose battery connection; Battery charge is low. CHECKS Check drive belt for correct tension.
  • Page 255 777 SERVICE MANUAL TROUBLESHOOTING Problem 5 Engine fault alerts enable during engine operation. POSSIBLE CAUSES High engine coolant temperature or low engine oil pressure. High Engine Temperature Low Oil Pressure Check engine oil level at dipstick. Check coolant level and quality.
  • Page 256 TROUBLESHOOTING 777 SERVICE MANUAL Problem 6 Engine will not go to high idle. POSSIBLE CAUSES No signal from hand or foot throttle; No power to control module; Engine speed sender is damaged; Lack of supply fuel. CHECKS Do hand and foot throttle operate correctly?
  • Page 257 777 SERVICE MANUAL TROUBLESHOOTING Problem 7 Crawler travels at slow speed. POSSIBLE CAUSES Partial control voltage from handle to PC; Partial control voltage from PC to pump EDC; Pump or motor is damaged. CHECKS Check travel speed switch for high-speed selection.
  • Page 258 TROUBLESHOOTING 777 SERVICE MANUAL Problem 8 Crawlers will not travel in either direction (one or both tracks) POSSIBLE CAUSES Brake valve is damaged; Control handle is worn; No voltage from handle to PC controller; No voltage out of PC controller to pump EDC; Low brake pressure; Wiring or switch is damaged; Pump, motor or gearbox is damaged.
  • Page 259 777 SERVICE MANUAL TROUBLESHOOTING Problem 9 No front or rear load drum operation. POSSIBLE CAUSES Load drum disc brake not releasing; Load drum pawl not released or hung up; No voltage through control handle to PC controller; No voltage out of PC controller to pump EDC; Wiring or switch is damaged.
  • Page 260 TROUBLESHOOTING 777 SERVICE MANUAL Problem 10 Front or rear load drum will not raise load, but will lower load. POSSIBLE CAUSES Block up limit is opened; Pump is damaged; Rated Capacity Indicator/Limiter (RCL) circuit is open; Control handle is worn; Maximum bail limit is opened; Speed sender is damaged.
  • Page 261 777 SERVICE MANUAL TROUBLESHOOTING Problem 11 Front or rear load drum will not lower load, but will raise load. POSSIBLE CAUSES Pawl in; Control handle is damaged; Minimum bail limit opened; Pump is damaged; Speed sender is damaged. CHECKS Check Diagnostic Screen D2. (See Diagnostic Display topic in Section 3.) When applicable switch was enabled…...
  • Page 262 TROUBLESHOOTING 777 SERVICE MANUAL Problem 12 Front or rear load drum will not reach load drum maximum speed. POSSIBLE CAUSES Partial control from handle to PC; Partial control voltage from PC to pump EDC; Pump or motor is damaged. CHECKS...
  • Page 263 777 SERVICE MANUAL TROUBLESHOOTING Problem 13 No boom cylinder operation. POSSIBLE CAUSES Boom hoist park switch (boom pump enable) not releasing; Boom cylinder hold switch or valve(s) damaged; No voltage through control handle to PC controller; No voltage out of PC controller to pump EDC; Wiring or switch is damaged.
  • Page 264 TROUBLESHOOTING 777 SERVICE MANUAL Problem 14 Boom will not reach maximum speed. POSSIBLE CAUSES Partial control voltage from handle to PC; Partial control voltage from PC to pump EDC; Pump or motor damaged. CHECKS When moving boom hoist control handle fully in both directions, diagnostic...
  • Page 265 777 SERVICE MANUAL TROUBLESHOOTING Problem 15 Boom will not boom up or boom down. POSSIBLE CAUSES Pump is damaged; Block-up limit opened; Equalizer/boom stop limit opened; Control handle is damaged. CHECKS Check Diagnostic Screen D2. (See Diagnostic Display topic in Section 3.) When applicable switch was enabled…...
  • Page 266 TROUBLESHOOTING 777 SERVICE MANUAL Problem 16 No swing operation, but engine loads. POSSIBLE CAUSES Mechanical hang-up; Solenoid failure; Wiring fault. CHECKS Check swing operation in both directions with brake and swing lock released. Slight swing movement No swing movement Check swing lock for damage.
  • Page 267 777 SERVICE MANUAL TROUBLESHOOTING Problem 17 No swing operation, engine does not load. POSSIBLE CAUSES No voltage through control handle to controller; No voltage out of controller to pump EDC; Wiring or switch is damaged; Pump or motor is damaged; Swing holding brake switch actuated.
  • Page 268 TROUBLESHOOTING 777 SERVICE MANUAL Problem 18 Travel system response is sluggish. POSSIBLE CAUSES Pump or motor is damaged; Travel speed out of adjustment. CHECKS Use a gauge to check charge pressure at travel pressure senders. 300 psi or less 300 psi or more Adjust charge pressure relief for 350 psi.
  • Page 269 777 SERVICE MANUAL TROUBLESHOOTING Problem 19 Closed-loop hydraulic system response is sluggish. POSSIBLE CAUSES Low hydraulic oil level in reservoir; Low hydraulic oil temperature; Reservoir shut-off is partially closed; Dirty charge filter; System multifunction valves are not set correctly; Pump or motor problem.
  • Page 270 TROUBLESHOOTING 777 SERVICE MANUAL Problem 20 Hydraulic system is operating hot. POSSIBLE CAUSES Low hydraulic oil level in reservoir; Heat exchanger problem; Dirty filter; System multifunction valves are not set correctly; Pump or motor problem. CHECKS Is hydraulic oil level in reservoir OK and shut-off valve fully open? Fill tank to full level or open shut-off valve.
  • Page 271 777 SERVICE MANUAL TROUBLESHOOTING Problem 21 Jacking cylinder(s) will not extend or retract. POSSIBLE CAUSES Not in setup mode; Faulty control valve section; Low pump pressure; Bad pump; Faulty counterbalance valve. CHECKS Check for 2,700 psi at lower accessory valve test port while manually enabling jacking cylinder on lower accessory valve.
  • Page 272 TROUBLESHOOTING 777 SERVICE MANUAL Problem 22 Crawler pin cylinder(s) will not extend or retract (left or right set). POSSIBLE CAUSES Not in setup mode; Faulty control valve section; Low pump pressure; Bad pump; Mechanical problem. CHECKS Check for 2,700 psi at lower accessory valve port while manually enabling crawler pin cylinder handle on lower accessory valve.
  • Page 273 777 SERVICE MANUAL TROUBLESHOOTING Problem 23 System pump will not return to neutral. POSSIBLE CAUSES System control handle is damaged; System pump EDC is damaged or out of adjustment; System pump is not centered or damaged. CHECKS Diagnostic display screen A1 displays voltage for problem system handle in neutral position?
  • Page 274 TROUBLESHOOTING 777 SERVICE MANUAL Problem 24 A load drum pawl is not operating correctly. POSSIBLE CAUSES Mechanical hang-up; No hydraulic pressure; No voltage to front or rear drum motor; No voltage to auxiliary drum pawl solenoid; Cylinder failure; Motor failure.
  • Page 275 777 SERVICE MANUAL TROUBLESHOOTING THIS PAGE IS BLANK Manitowoc 10-27 Published 10-01-2012, Control # 045-08...

  • Page 276: Testing

    TROUBLESHOOTING 777 SERVICE MANUAL TESTING Test 1 – Battery Test (12 and 24 VDC) 12 VDC AA301 FIGURE 10-1 Item Description Item Description Positive probe Negative probe To test the 12 VDC accessory system voltage using a digital multimeter, record the voltage before and during cranking. A voltage reading of 12 volts or less before cranking may indicate a charging system fault.

  • Page 277: Test 2 - Electric Fuel Control (Efc) Box Test Points

    777 SERVICE MANUAL TROUBLESHOOTING Test 2 – Electric Fuel Control (EFC) Box Test Points FIGURE 10-3 AA305 Item Description Item Description Terminal block TB1 EFC relay TB1 Test Points – EFC for Cummins C330 Engine TB1-1 Battery (+) TB1-6 Magnetic pick up (0)
  • Page 278 TROUBLESHOOTING 777 SERVICE MANUAL Test 2 (Continued) P855 FIGURE 10-4 Item Description Terminal block TB1 EFC relay TB1 Test Points – for Cummins C260 Engine TB1-F Battery (+) TB1-B Actuator (4EFC) TB1-J Remote speed pot (68J) TB1-E Battery (-) TB1-C Magnetic pick up (24)

  • Page 279: Test 3 - Checking Resistance At Engine Temperature Switch

    777 SERVICE MANUAL TROUBLESHOOTING Test 3 – Checking Resistance at Engine Temperature Switch FIGURE 10-5 AA303 Item Description Negative probe Temperature switch Positive probe Using a digital multimeter, measure the resistance at the engine temperature switch wire terminal with the engine cold.

  • Page 280: Test 4 - Checking Resistance At Engine Oil Pressure Sender

    TROUBLESHOOTING 777 SERVICE MANUAL Test 4 – Checking Resistance at Engine Oil Pressure Sender AA304 FIGURE 10-6 Item Description Oil pressure sender Negative probe Positive probe To test the 12 VDC starting batteries connected in series for 24 volts using a digital multimeter, record the voltage before and during cranking.

  • Page 281: Test 5 - Cleaning And Adjusting The Engine Rpm Transducer (Past Production)

    777 SERVICE MANUAL TROUBLESHOOTING Test 5 – Cleaning and Adjusting the Engine RPM Transducer (Past Production) P564 FIGURE 10-7 Item Description Engine RPM transducer Loosen the locking nut and remove the threaded transducer from the flywheel housing. Clean any metallic debris from the magnetic pickup on the transducer with a cleaning solvent.

  • Page 282: Test 6 - Testing For Voltage At The Fuse Box

    TROUBLESHOOTING 777 SERVICE MANUAL Test 6 – Testing for Voltage at the Fuse Box P580 FIGURE 10-8 Item Description Item Description Fuse block Fuse box chassis Metal fuse contact K2 power output K1 cab power relay Table 10-1 Fuse No.

  • Page 283: Test 7 - Checking Voltage At The Control Handle

    777 SERVICE MANUAL TROUBLESHOOTING Test 7 – Checking Voltage at the Control Handle FIGURE 10-9 AA318 Item Description Item Description Load drum handle Test terminals Boom/swing handle Ground terminal R Crawler handle Use the following test points to determine if the correct...

  • Page 284: Test 8 - Adjusting The Control Handle Potentiometer

    TROUBLESHOOTING 777 SERVICE MANUAL Test 8 – Adjusting the Control Handle Potentiometer Single Axis Controller AA318 Double Axis Controller AA318 FIGURE 10-10 Item Description Item Description Neutral (snap) switch Terminal C center Jumper connection (N/O) Potentiometer Ground terminal R Socket set screw (1 of 2)

  • Page 285: Test 9 - Location Of Pump Test Ports

    777 SERVICE MANUAL TROUBLESHOOTING Test 9 – Location of Pump Test Ports Swing System Pump Port L2 Note: M3 is located between the malfunction valves Port L1 Ports A and B AA 314 FIGURE 10-11 Port Port Gauge O-Ring Fitting...
  • Page 286 TROUBLESHOOTING 777 SERVICE MANUAL Test 9 (Continued) System Pump (Except Swing) A1032 Pump Port B Pump Port A L1, L2 (Both Sides) Multifunction Valve Multifunction Valve FIGURE 10-12 10-38 Published 10-01-2012, Control # 045-08...

  • Page 287: Test 10 - Location Of Motor Test Ports

    777 SERVICE MANUAL TROUBLESHOOTING Test 10 – Location of Motor Test Ports SYSTEM MOTORS (Except Swing) Port B Port A Port L2 Port B Port L1 AA309 FIGURE 10-13 AA 309 Manitowoc 10-39 Published 10-01-2012, Control # 045-08...
  • Page 288 TROUBLESHOOTING 777 SERVICE MANUAL Test 10 (Continued) SWING MOTOR Charge Pressure Gauge Port FIGURE 10-14 AA 310 System Pressure Gauge Port 2 System Pressure Gauge Port 3 AA 311 FIGURE 10-15 Case Outlet 1 Port Designation Port Description Gauge (psi)

  • Page 289: Test 11 - Manually Stroking The Pump

    777 SERVICE MANUAL TROUBLESHOOTING Test 11 – Manually Stroking the Pump FIGURE 10-16 P966 Item Description Manual override Pump EDC With the engine running and all brakes and locks engaged, rotation of the manual override in the clockwise direction will cause engine load down and pressure rise in port A of the pump under test.

  • Page 290: Test 12 - Setting The Pump Pressure

    TROUBLESHOOTING 777 SERVICE MANUAL Test 12 – Setting the Pump Pressure P1537 FIGURE 10-17 Item Description Multifunction valve A Multifunction valve B Jam nut Remove the protective cap from multifunction valve and Pump Port Control Function loosen the lock nut. Insert a hex wrench into the multifunction valve adjusting screw.

  • Page 291: Test 13 - Setting Pump Neutral

    777 SERVICE MANUAL TROUBLESHOOTING Test 13 – Setting Pump Neutral P966 FIGURE 10-18 Item Description Neutral adjustment screw Servo gauge ports To set pump neutral, set the pawls and brakes, and disable counterclockwise until pressure increases in the other the pump from the PC by disconnecting the PC cable at the gauge.

  • Page 292: Test 14 - Adjusting Pump Charge Pressure Relief

    TROUBLESHOOTING 777 SERVICE MANUAL Test 14 – Adjusting Pump Charge Pressure Relief P966 FIGURE 10-19 Item Description System pressure port Adjustment screw Adjustment lock nut The pump charge pressure must be measured to adjust the Install the gauge at the selected test port. Start the engine charge pressure relief.

  • Page 293: Test 15 - Checking Pump Charge Pressure

    777 SERVICE MANUAL TROUBLESHOOTING Test 15 – Checking Pump Charge Pressure Diagnostic Gauge Couplers Electrical DIN Connector P697 FIGURE 10-20 Item Description Item Description Left Track Forward/Reverse Boom Hoist Pump (Boom Up) Right Track Forward/Reverse Front Load Drum Hoist Swing Left...

  • Page 294: Test 16 - Checking Charge Pressure At Motor Port X1

    TROUBLESHOOTING 777 SERVICE MANUAL Test 16 – Checking Charge Pressure at Motor Port X1 P574 FIGURE 10-21 Item Description Connector Port X1 connection Hydraulic hose Install a 0-500 psi gauge between the hydraulic hose and the connector at port X1. See Test 10 for location of port X1.

  • Page 295: Test 17 - Testing The Motor Pcp And Pump Edc

    (which can be ordered from the high speed to low speed range and vice versa is Manitowoc Cranes, Inc.) and a digital multimeter. equivalent to the voltage at the given point in the speed range. Load current (amps) can be measured directly by...

  • Page 296: Test 18 - Testing For Pump And Motor Leakage

    (207 bar) in line flow meter with minimum flow rated capacity running at 1,000 rpm, measure motor flow rate. Swing and of 10 gpm. Flow meters can be ordered from Manitowoc travel motors should not exceed 1 gpm case flow at neutral.

  • Page 297: Test 19 - Testing Hydraulic Solenoid Brake Valves

    (which can be ordered test. Load current (amps) can be measured directly by from Manitowoc Cranes, Inc.) and a digital multimeter. making the appropriate adapter connections (red and white) to the digital multimeter.

  • Page 298: Test 20 - Checking Hydraulic Brake Pressure

    TROUBLESHOOTING 777 SERVICE MANUAL Test 20 – Checking Hydraulic Brake Pressure P515a P572 FIGURE 10-25 Item Description Item Description Travel 2-speed solenoid valve Swing lock out solenoid valve Travel disc brake solenoid valve Electrical DIN connector Rear drum disc brake solenoid valve...

  • Page 299: Test 21 - Adjusting The Lower Accessory Relief Valve

    777 SERVICE MANUAL TROUBLESHOOTING Test 21 – Adjusting the Lower Accessory Relief Valve Under Left Side of Pumps P577 FIGURE 10-26 Item Description Accessory System Relief Valve Accessory System Pilot Check Valve Accessory System Gauge Coupler Connect 0 to 1,000 psi (0 to 69 bar) pressure gauge to If correct pressure is not obtained, adjust accessory system coupler at accessory system relief valve.

  • Page 300: Test 22 - Adjusting Jacking Counterbalance Valves

    TROUBLESHOOTING 777 SERVICE MANUAL Test 22 – Adjusting Jacking Counterbalance Valves P562 FIGURE 10-27 Item Description Counterbalance valve (Retract) Counterbalance valve (Extend) Jacking cylinder To adjust jacking cylinder retract or extend counterbalance valve, loosen the adjustment lock nut and rotate screw clockwise to decrease pressure setting or counterclockwise to increase pressure setting.
  • Page 301 (which can be ordered from transducer to the programmable controller, test with engine Manitowoc Cranes, Inc.) and a digital multimeter. Connect off/power on. Make the appropriate connections at the digital the test plug adapter between the desired transducer and its multimeter (green + and black -) and verify 1.00 to 1.04 volts...
  • Page 302 (which can be ordered from PC, make the appropriate connections at the digital Manitowoc Cranes, Inc.) and a digital multimeter. Connect multimeter (white + and black -, channel 1) or (green + and the test plug adapter at the encoder electrical connector and black -, channel 2).
  • Page 303 (internal leakage). If damage is found, contact the Service Depart- ment at Manitowoc Cranes for repair/replacement instructions......4-9 Inspection Checklist.
  • Page 304 777 SERVICE MANUAL Optional Systems ..............1-63 Ordering Lacings .

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