Manitowoc 777 Operator's Manual
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Manitowoc 777 Operator's Manual

Manitowoc 777 Operator's Manual

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Manitowoc 777
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Luffing Jib Attachment

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  • Page 1 Manitowoc 777 Operator Manual Luffing Jib Attachment...
  • Page 3 SECTION 6 MAINTENANCE NOTICE The serial number of the crane and luffing jib is the only method your Manitowoc dealer or Manitowoc Product Support 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 luffing jib.
  • Page 4 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 5: Table Of Contents

    Manitowoc Dealer ........
  • Page 6 TABLE OF CONTENTS 777 LUFFING JIB OPERATOR MANUAL General ..............2-19 Location .
  • Page 7 777 LUFFING JIB OPERATOR MANUAL TABLE OF CONTENTS Identifying Pendants ............. . 4-4 Handling Components .
  • Page 8 TABLE OF CONTENTS 777 LUFFING JIB OPERATOR MANUAL Actuator Rod Replacement ........... . . 6-11 Automatic Boom Stop Adjustment .

  • Page 9: Section 1

    Manitowoc Dealer ........
  • Page 10 777 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 08-10-22, Control # 046-05...

  • Page 11: Crane Data

    MANITOWOC DEALER For the exact location of the identification plates on your For questions about this manual or the 777 crane, contact crane, see the Nameplates and Decals Drawing in Section 2 your Manitowoc dealer. If you do not know the contact of this manual.

  • Page 12: Identification Of Luffing Jib Components

    INTRODUCTION 777 LUFFING JIB OPERATOR MANUAL IDENTIFICATION OF LUFFING JIB COMPONENTS See Figure 1-2 for identification of the luffing jib components. S e e S e c t i o n 1 o f t h e C r a n e O p e r a t o r M a n u a l f o r identification of crane components.

  • Page 13: Crane And Luffing Jib Weights - Crawler

    COUNTERWEIGHT - UPPER: Box - side (4 on 777 SERIES 1, 6 on SERIES 2) (each) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 14 INTRODUCTION 777 LUFFING JIB OPERATOR MANUAL Weight Pounds Kilograms MAST: 26 ft (7 925 mm) mast - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 15 777 LUFFING JIB OPERATOR MANUAL INTRODUCTION Weight Pounds Kilograms LUFFING JIB NO. 139: 27 ft (8.2 m) butt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2,000 23 ft (7.0 m) top (with jib point, wire rope guide, limit control, load sensor and pendant links)
  • Page 16 INTRODUCTION 777 LUFFING JIB OPERATOR MANUAL Weight Pounds Kilograms BOOM AND JIB OPTIONS: Upper boom point (single sheave) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...

  • Page 17: Crane And Luffing Jib Weights - Truck

    777 LUFFING JIB OPERATOR MANUAL INTRODUCTION CRANE AND LUFFING JIB WEIGHTS — TRUCK Weights may fluctuate ±3% due to manufacturing NOTE: tolerances. Weight Pounds Kilograms LIFTCRANE - BOOM NO. 78T: Upperworks and carrier complete, 95,400 Lb. crane counterweight, 25,000 Lb. front bumper counterweight, boom hoist cylinders, mast, fully rigged 42.5 ft (13.0 m) boom No.
  • Page 18 INTRODUCTION 777 LUFFING JIB OPERATOR MANUAL Weight Pounds Kilograms BOOM NO. 78T: 9 ft, 6 in (2.9 m) lower butt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 19 777 LUFFING JIB OPERATOR MANUAL INTRODUCTION Weight Pounds Kilograms LUFFING JIB NO. 139: 27 ft (8.2 m) butt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2,000 23 ft (7.0 m) top (with jib point, wire rope guide, limit control, load sensor and pendant links)

  • Page 20: English And Metric Conversions

    INTRODUCTION 777 LUFFING JIB OPERATOR 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 LUFFING JIB OPERATOR MANUAL INTRODUCTION To Convert Symbol Application Symbol Multiply By 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 22 INTRODUCTION 777 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-12 Published 08-10-22, Control # 046-05...

  • Page 23: Section 2

    Personnel Handling Policy............2-20 Manitowoc...
  • Page 24 777 LUFFING JIB OPERATOR MANUAL Pedestal/Barge Mounted Cranes ........... . 2-21 Pedestal Mounted Crane .

  • Page 25: Continuous Innovation

    If you are in Used with the safety alert symbol, indicates a hazardous doubt about any procedure, contact your Manitowoc dealer situation which, if not avoided, could result in minor or or Manitowoc Product Support.
  • Page 26 SAFETY INFORMATION 777 LUFFING JIB OPERATOR MANUAL Table 2-1 Common Safety Symbols Cut or Crush Hazards Cut Hazard M100090 M100091 M100066 M100065 M100069 M100067 Fire Crush Hazards Extinguisher M100070 M100071 M100072 M100073 M100074 M100082 Explosion Fall Hazards Falling Boom (Crush) Hazards...

  • Page 27: Safety And Information Signs

    777 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION Table 2-1 Common Safety Symbols Emergency Cab Exit Lift Do Not Lift Prohibited M104626 M104627 M104628 Table 2-2 Miscellaneous Symbols Engine Coolant Diesel Fuel Engine Coolant Engine Oil Level Hydraulic Filter Hydraulic Oil...

  • Page 28: Crane Access Points

    Manitowoc has provided a ladder, steps, platforms, and d. if the performance of their duties requires them to do catwalks at the locations shown in...
  • Page 29 777 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION 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...

  • Page 30: Personal Fall-Protection

    Manitowoc dealer for the proper manual or capacity charts. Do not operate the crane if the proper Capacity Chart is not in the cab.

  • Page 31: Safe Operating Practices

    3. Supervisors, inspectors, and maintenance or test operation. Manitowoc cannot foresee all hazards that will personnel when necessary in performance of their arise in the field; therefore, safety remains responsibility duties.

  • Page 32: Operator Conduct

    SAFETY INFORMATION 777 LUFFING JIB OPERATOR MANUAL • E-mail infocentral@asme.org 7. The operator shall test all controls, limits, and communication systems at the start of each shift. Any Operator Conduct defects found must be corrected before operation is begun. 1. The operator shall not engage in any practice which diverts his/her attention while operating the crane.

  • Page 33: Handling Load

    Do not operate the crane with a snow or ice covered other than lifting service and/or special lifting operations, boom. The extra weight may cause overload, tipping, or Manitowoc or a qualified person shall establish the structural damage. ratings, operating limitations, maintenance, testing, and inspection requirements.

  • Page 34: Attaching Load

    SAFETY INFORMATION 777 LUFFING JIB OPERATOR MANUAL Attaching Load g. The hook is brought over the load in a manner that will minimize twisting or swinging. 1. Attach the hook to the load with slings, or other suitable h. The load line and the boom hoist rope are properly rigging.

  • Page 35: Signals

    777 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION Before lifting a load which requires the use of Lash or otherwise restrain unused hooks so they outriggers (or anytime outriggers are used), fully cannot swing freely. extend the outrigger beams and jacks so the truck 4.

  • Page 36: 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 37: Category 2 Operational Aids

    777 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION 1. Boom or Luffing Jib Angle Limiter Exception: If the employer documents that he/she has (automatic boom or jib stop) ordered the necessary parts within 7 calendar days of the occurrence of the deficiency, and the part is not received in...

  • Page 38: Assembling, Disassembling, Or Operating Crane Near Electric Power And Transmission Lines

    WARNING Set-Up and Operation Electrocution Hazard! Manitowoc cranes are not equipped with all features 1. During crane use, assume that every line is energized required to operate within OSHA 29CFR1926.1408, (“hot” or “live”) and take necessary precautions. Table A clearances when the power lines are energized.

  • Page 39: Electrical Contact

    If the dealer is not immediately available, contact with a loud signal whistle or horn and voice Manitowoc Product Support. The crane must not be communication equipment, to warn the operator when returned to service until it is thoroughly inspected for any...

  • Page 40: Safe Maintenance

    Maintenance Instructions off the crane only when it is parked and only with operator’s permission. To ensure safe and proper operation of Manitowoc cranes, Use both hands and handrails, steps and ladders they must be maintained according to the instructions provided to climb onto and off the crane.

  • Page 41: Environmental Protection

    14. Avoid battery acid contact with skin and eyes. If contact 28. Unless authorized in writing by Manitowoc, do not alter occurs, flush the area with water and immediately the crane in any way that affects the crane’s consult a doctor.
  • Page 42 SAFETY INFORMATION 777 LUFFING JIB OPERATOR MANUAL View A WRONG – DANGEROUS! If boom is off ground and supported by boom rigging, and there is no blocking under boom sections, boom will collapse when lower pins are removed. View B WRONG –...

  • Page 43: Boom Disassembly Safety

    777 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION BOOM DISASSEMBLY SAFETY blocking, individual pin connections may still be under load. Pins can be ejected forcefully if the boom has any pressure NOTE The term “boom” used in the following instructions on it or if the boom is not supported properly.

  • Page 44: Special Application/Service

    As identified in ASME B30.5, cranes are sometimes used for Use of a Manitowoc crane to handle personnel is acceptable service other than lifting service and/or special lifting provided: operations. In such cases Manitowoc or a qualified person •...

  • Page 45: Pedestal/Barge Mounted Cranes

    All safety Cranes with outriggers or stabilizers must have them all signs must be in place and legible. We also urge Manitowoc extended and locked. All outriggers or stabilizers must crane owners to upgrade their cranes with rated capacity be extended equally in accordance with the Capacity indicator/limiter systems for all lifting operations.

  • Page 46: Pedestal Mounted Crane

    Manitowoc does not permit use of a lattice boom truck crane on a barge, a ship, or a floating platform. Pedestal Mounted Crane Figure 2-6.

  • Page 47: Capacity Charts For Barge Mounted Crane

    Capacity Charts for Barge Mounted Crane NOTE RINGERS must be equipped with hook rollers on Manitowoc provides two types of Capacity Charts for a crane the boom carrier and the counterweight carrier. mounted on a barge or other supporting structure under static conditions.

  • Page 48: Shock Loading Caused By Barge Dynamics

    1. A Capacity Chart based on tipping when the crane is anchored only to prevent shifting. 1. Machine List, as defined by Manitowoc, is the crane’s 2. A Capacity Chart based on structural competence when out-of-level condition — from side-to-side — as...

  • Page 49: Transporting Crane On Barge

    Manitowoc crawler showing inspections were performed on the crane crane. These notes are in addition to any guidelines during the time it was used for pile driving or extraction.

  • Page 50: Electrocution Hazard Devices

    6. Manitowoc recommends that each load line be equipped instructions, limitations and restrictions related to the with an anti two-block device.

  • Page 51: Multiple Crane Lifts

    777 LUFFING JIB OPERATOR MANUAL SAFETY INFORMATION 9. The crane operator shall be familiar with the operational decision and all other requirements identified in the characteristic of the crane as it relates to multiple drum operator manual. operation (simultaneous operation, same or opposite Ensure the lift director coordinates and instructs all direction, or individual operation).
  • Page 52 SAFETY INFORMATION 777 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-28 Published 08-10-22, Control # 046-05...

  • Page 53: Section 3

    Wind Conditions............3-13 Manitowoc...
  • Page 54 777 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-ii Published 08-10-22, Control # 046-05...
  • Page 55 777 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES THIS SECTION STARTS ON THE NEXT PAGE Manitowoc Published 08-10-22, Control # 046-05...

  • Page 56: Standard Hand Signals For Controlling Crane Operations

    OPERATING CONTROLS AND PROCEDURES 777 LUFFING JIB OPERATOR MANUAL STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30.5-2014. Table 3-1Standard Hand Signals for Controlling Crane Operations M100118 M100119 M100120 M100121 M100122 M100123 M100124...
  • Page 57 777 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Item Description HOIST—With forearm vertical, forefinger pointing up, move hand in small horizontal circles. LOWER—With arm extended downward, forefinger pointing down, move hand in small horizontal circles. USE MAIN HOIST—Tap fist on head. Then use regular signals.
  • Page 58 OPERATING CONTROLS AND PROCEDURES 777 LUFFING JIB OPERATOR MANUAL Left Inboard Leg of CHART: 1205B/70 RAD: 12.5 M Boom Butt PARTS [12] NET LOAD: 100000 KGS FRONT DRUM MAX CAP: 110000 KGS CONFIRM SELECT 178567 Engine Engine Engine Engine FRONT...

  • Page 59: Luffing Jib Operating Controls

    777 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES LUFFING JIB OPERATING CONTROLS • Rotate limit bypass switch (F1) clockwise and release. The limits will remain bypassed for 10 seconds. See Figure 3-1 for Location of Controls. • Move the desired control handle (luffing hoist, boom The instructions in this section supplement the operating hoist, load drum) —...

  • Page 60: 4A - Limit Bypass Switch And

    OPERATING CONTROLS AND PROCEDURES 777 LUFFING JIB OPERATOR MANUAL 4a – Limit Bypass Switch and support and is visible through right side window in operators’s cab. 4b – Jib Up Limit Bypass Switch Switch (4a) bypasses the limits identified in Table 3-2 and Table 3-3.
  • Page 61 777 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Operate all crane functions slowly and smoothly. Avoid Charts. Contact your local weather station for wind sudden starts and stops which could side load or shock velocity. load attachment. 10. Disable free fall for rear drum. See instructions in this Do not operate crane, to include raising boom from section.
  • Page 62 OPERATING CONTROLS AND PROCEDURES 777 LUFFING JIB OPERATOR MANUAL Table 3-2 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)
  • Page 63 777 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-3 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...
  • Page 64 OPERATING CONTROLS AND PROCEDURES 777 LUFFING JIB OPERATOR 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...

  • Page 65: Disabling And Enabling Free Fall

    777 LUFFING JIB OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES DISABLING AND ENABLING FREE FALL Install dust caps to keep unused couplers clean. The quick-disconnect couplers in the hydraulic hoses to the drum clutch solenoid valves allow FREE FALL operation to be disabled at either or both drum clutches.
  • Page 66 OPERATING CONTROLS AND PROCEDURES 777 LUFFING JIB OPERATOR 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 67: Wind Conditions

    777 LUFFING JIB OPERATOR 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 3-6.
  • Page 68 OPERATING CONTROLS AND PROCEDURES 777 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-14 Published 08-10-22, Control # 046-05...

  • Page 69: Section 4

    Install Jib Inserts ..........4-33 Manitowoc...
  • Page 70 777 LUFFING JIB OPERATOR MANUAL Install Jib Top ..........4-33 Install Jib Pendants .

  • Page 71: Luffing Jib Attachment

    Optional boom ladders (stored in boom butt) are available • Maintain communication between operator and from Manitowoc. If your crane has ladders, see Section 3 in assemblers to avoid accidents. Operator Manual provided with crane. •...
  • Page 72 WARNING 17.5 ft (5.3 m) Overload Hazard! Assembly Insert See Crane Assembly/Disassembly Guide in Crane Operator Manual provided with 777 or 777T for lifting capacities when crane is rigged in set-up mode as Boom Hoist shown here. Boom Cylinder Exceeding specified lifting capacities can result in Butt tipping or structural failure of boom.

  • Page 73: Assist Crane Requirements

    Luffing Jib Capacity Chart Manual for instructions. An assist crane is not required for jib installation and removal. The 777 or 777T can be used to self-assemble the boom and jib components when rigged in the set-up mode shown in Figure 4-1. See the Crane Assembly and...

  • Page 74: Identifying Boom/Jib Components

    SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL IDENTIFYING BOOM/JIB COMPONENTS HANDLING COMPONENTS T h e b o o m a n d j i b s e c t i o n s a r e m a r k e d f o r p r o p e r...

  • Page 75: Shipping Luffing Jib Components

    777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION SHIPPING LUFFING JIB COMPONENTS P2498 It is the owner/user’s responsibility to ensure the following: • That all trailer loads comply with local, state, and federal transportation requirements. • That all components are properly blocked and secured so they cannot shift or fall off trailers.
  • Page 76 SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL A1039 Control Cable Control Cable in Jib Butt from Hand Winch Bracket P743 Roller P744 (1 each insert) Jib Top P745 View A Shackle View B Sheaves Jib Stop Control Cable Cage-Type...

  • Page 77: Luffing Jib Rigging Guide (#139 Luffing Jib) - Crawler And Truck

    Remove following components from 180 ft (54.86 m) Tapered end of connecting pins must face in (View E). boom (777 and 777T) or 170 ft (51.8 m) boom (777T only) (operation with only one load line is permitted): Wire rope rollers on inserts (View B) may be shipped upside down.
  • Page 78 SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL Main Strut Support A1039 P749 P750 P751 Main Strut Strut Stop Storage Frame Lugs Main Strut View B View A View C Main Strut Strut Strut Guide Bar Pendant Removed Link (L1)

  • Page 79: Install Jib Stop Control Cable

    777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Install Jib Stop Control Cable It is owner/user’s responsibility to securely attach stowable pendants to jib sections so that pendants See Figure 4-5 for following procedure. cannot fall off jib sections during shipment.

  • Page 80: Connect Crane To Boom

    Route luffing hoist wire rope between rollers and bottom of guide sheave on main strut stop. If 777 or 777T was used to self-assemble the boom and jib, Route luffing hoist wire rope between guide bar and connect the boom butt (777) or boom butt and 17-1/2 ft top of upper sheave on boom butt.
  • Page 81 777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-11 Published 08-10-22, Control # 046-05...
  • Page 82 777 LUFFING JIB OPERATOR MANUAL A1041 P758 Boom Pendant Pinned to Mast Main for Raising Main Strut Strut (777 shown – See Figure 4-8 for 777T) 20 ft (6.0 m) of Boom Pendants Backstay View C Strut Support Pendants P757...

  • Page 83: Raise Main Strut And Connect Backstay Pendants

    13. 777: Pin boom pendants and backstay pendants to strut stop tubes. proper holes in mast or link (L2, View H, I, or J).

  • Page 84: Install Fixed Jib

    SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL Install Fixed Jib Reeve load line through required jib point sheaves and anchor load line at dead-end socket and wedge (see If required, install fixed jib at this time or after boom and Load Line Reeving in this section).

  • Page 85: Pre-Raising Checks

    Make sure rope guard pins, bars, or rollers are installed to  777: Crawlers blocked (required for all boom and jib retain wire rope in sheaves. lengths). See Crawler Blocking Diagram for blocking procedure.
  • Page 86 P764 P763 View F Item Description Jib Stop Pendant (777) – 24 ft, 1 in (7.34 m) Jib Stop Pendant (777T) – 21 ft, 11 in (6.4 m) Jib Stop Pendant – 7 ft, 9-1/2 in (2.37 m) Inner Strut...

  • Page 87: Raising Boom And Luffing Jib

    777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Raising Boom and Luffing Jib Using hand winch on jib top, lower jib stop strut to vertical as shown in View A. Pin jib stop pendants (1) to lugs on boom top (View E).
  • Page 88 SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL A1040 ITEM NUMBERS CORRESPOND TO IN-LINE RAISING PROCEDURE STEPS 777 Crawler Crane Shown 777T Truck Crane Similar FIGURE 4-10 4-18 Published 08-10-22, Control # 046-05...

  • Page 89: In-Line Raising Procedure

    777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION In-Line Raising Procedure Slowly luff up until jib and backstay pendants start to go into tension and stop. It will be necessary to use limit See Figure 4-10 for following procedure. bypass switch if MAX UP 1 limit is on.
  • Page 90 SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL ITEM NUMBERS CORRESPOND TO JACK-KNIFE A1040 RAISING PROCEDURE STEPS 777 Crawler Crane Shown 777T Truck Crane Similar 4, 6 5, 6 FIGURE 4-11 4-20 Published 08-10-22, Control # 046-05...

  • Page 91: Jack-Knife Raising Procedure

    777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Jack-Knife Raising Procedure See Figure 4-11 for following procedure. WARNING NOTE: Item numbers in Figure 4-11 correspond to Tipping Hazard! numbered steps in following procedure. Do not allow jib pendants to become too tight during raising steps.
  • Page 92 SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL A1040 ITEM NUMBERS CORRESPOND TO IN-LINE LOWERING PROCEDURE STEPS 777 Crawler Crane Shown 777T Truck Crane Similar FIGURE 4-12 4-22 Published 08-10-22, Control # 046-05...

  • Page 93: Lowering Boom And Luffing Jib

    Haul in load line as boom and jib are lowered, but do not procedure. lift load block or weight ball off ground. 777: Swing upperworks in-line with lowerworks so boom is over front of crawlers. CAUTION 777T: Swing upperworks in-line with lowerworks so Jib Stop Damage! boom is over rear of truck.
  • Page 94 SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL A1040 ITEM NUMBERS CORRESPOND TO JACK-KNIFE LOWERING PROCEDURE STEPS 777 Crawler Crane Shown 777T Truck Crane Similar 7,10 FIGURE 4-13 4-24 Published 08-10-22, Control # 046-05...

  • Page 95: Jack-Knife Lowering Procedure

    MAX UP 2 limits to come on during the lowering procedure. Slowly lower boom until jib point rollers contact ground. 777: Swing upperworks in-line with lowerworks so boom Depending on boom and jib combination, jib may be is over front of crawlers.

  • Page 96: Lowering Jib Strut And Main Strut

    SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL Lowering Jib Strut and Main Strut CAUTION Jib Stop Damage! WARNING Once jib stop pendants start to go into tension, do not lower boom any farther until step 11 is performed. Moving Part Hazard!

  • Page 97: Removing Jib

    777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Removing Jib 12. Stop when end of main strut is approximately 3-1/2 ft (1.07 m) above jib strut. 13. Unpin strut supports from underside of main strut (Figure 4-7, View C) and lower supports to vertical.
  • Page 98 SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL Item Description Backstay Rigging for 777 Crawler Crane Main Strut Link Mast Link Basic Backstay Pendant – 35 ft, 5-1/2 in (10.81 m) Backstay Pendant – 10 ft (3.05 m) Backstay Pendant – 20 ft (6.10 m) Backstay Pendant –...
  • Page 99 777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Item Description Backstay Rigging for 777T Truck Crane Main Strut Link Mast Link Basic Backstay Pendant – 35 ft, 5-1/2 in (10.81 m) Backstay Pendant – 10 ft (3.05 m) Backstay Pendant – 20 ft (6.10 m) Backstay Pendant –...
  • Page 100 SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL Item Description Jib Top Link 70 ft (21.34 m) Jib Strut Link Basic Jib Pendant – 24 ft (7.32 m) Jib Pendant – 20 ft, 1-1/2 in (6.13 m) Stowable 20 ft (6.10 m) Non-Stowable Jib Pendant –...

  • Page 101: Fixed Jib Rigging Guide (#138 Fixed Jib) - Crawler And Truck

    777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION FIXED JIB RIGGING GUIDE (#138 FIXED JIB) Assist Crane Requirements – CRAWLER AND TRUCK An assist crane is required to assemble and disassemble the jib. See the Crane Weights in Section 1 of this manual for This topic contains installation and removal instructions for weights of jib components.
  • Page 102 SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL Middle Hole 40 ft (12.19 m) Jib Jib Stop P772 Bottom Hole Top Hole 50-60 ft 30 ft (9.14 m) Jib (15.24-18.29 m) Jib Pendant Links (P1) Strut Wheel Pendant (P2) Wheel...

  • Page 103: Preparing Boom And Luffing Jib

    Install Jib Top Following components removed from 180 ft (54.86 m) boom (777 and 777T) or 170 ft (51.8 m) boom (777T Securely attach proper holes in wheel frame links to end only) (operation with only one load line is permitted): of jib top as shown in View C: Auxiliary drum from boom butt.

  • Page 104: Install Jib Load Line

    SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL Install Jib Load Line Reeve load line through required jib point sheaves and anchor load line at dead-end socket and wedge (see If the boom and luffing will be jack-knifed into position before Load Line Reeving in this section).
  • Page 105 777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-35 Published 08-10-22, Control # 046-05...
  • Page 106 SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL A1042 Backstay P775 Pendant (P1) Links (L1) Fixed Jib Strut View A View B Crawler crane shown 777T similar. ITEM NUMBERS CORRESPOND TO STEPS IN LOWERING BOOM AND JIB PROCEDURE. Stop Luffing...

  • Page 107: Raising Boom And Jibs

    10. Pay out load line as boom and jib are raised. 11. Position luffing jib at required operating radius. Using an assist crane, raise fixed jib strut and pin 12. Travel crawler rollers off blocking (777) or retract backstay pendants (P1) to links (L1). outriggers (777T).

  • Page 108: Lowering Boom And Jibs

    SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL A1042 Crawler crane shown 777T similar. ITEM NUMBERS CORRESPOND TO STEPS IN LOWERING BOOM AND JIB PROCEDURE. View A (See Figure 4-19, View D) View B (See Figure 4-19, View B) View C...

  • Page 109: Removing Fixed Jib

    777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Swing boom and jib slightly to either side of center and Disconnect fixed jib backstay pendants (Figure 4-19, lower weight ball or load block onto ground. Then swing View B): boom and jib in-line with crawlers or rear of truck.

  • Page 110: Wire Rope Installation And Maintenance

    SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL WIRE ROPE INSTALLATION AND MAINTENANCE NOTE: Wire rope installation instructions from various Reel OEM’s are provided at the end of this section. If a conflict exists between the following instructions and the OEM instructions, the OEM instructions...

  • Page 111: Anchoring Wire Rope To Drum

    777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Seizings WARNING! Wire Rope Type Required Falling Load Hazard! Preformed Wire rope can be pulled out of drum if following steps are Non-preformed not taken. 7/8 in (22 mm) Diameter or Smaller Non-preformed •...

  • Page 112: Anchoring Wire Rope To Wedge Socket

    SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL Carefully inspect drums and all rope guides, rollers, and sheaves for defects that can cause wire rope to wear or CAUTION! be cut. If defects cannot be fixed, replace faulty parts. Wire Rope Damage! Apply tension to wire rope as it is wound slowly onto drum.
  • Page 113 777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION NOTE: Use Right Method A only if wire rope clip is small enough to be securely tightened to dead end. Right Method C is only for a Terminator wedge socket. WARNING After socket is pinned in place, hoist load slowly so Falling Load Hazard! wedge seats tight.

  • Page 114: Breaking In Wire Rope

    See Figure 4-27 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. 4-44...
  • Page 115 777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Rope Clips Sucker Line Sucker Pull Sucker Line with Line Winch or Fork-Lift Truck Sucker Line Wire Wire Rope Rope from Drum P1519 A1189 Boom Point Sheaves Wire Rope Load Block Sheaves No.

  • Page 116: Load Line Reeving - Crawler And Truck

    20% faster than the front drum. Load Blocks Wire Rope Installation Two different size load blocks are available from Manitowoc: • 15 USt (14 t) hook and weight ball. See the Wire Rope Installation and Maintenance for the following instructions: •...
  • Page 117 777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Universal Anchor Joint A universal anchor joint (Figure 4-29) is available to provide an alternate dead-end location for 2-part reeving. WARNING See Universal Anchor Joint in this section for safety Falling Load Hazard!
  • Page 118 SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL Legend for Figure 4-28 Item Note From Front Drum All sheaves are viewed from boom butt. Gap between clamps must be equal on both sides. Torque bolts From Auxiliary Drum lubricated with SAE 20 oil to 120 ft-lb (1 751 Nm).
  • Page 119 777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION Note 1 Lower Rope Guide Auxiliary Drum Rope Guide on Boom Butt on 10' (3.05 m) Insert F or A A1036 Bolt Note 2 Clamps 7 in (178 mm) Lockwasher Nuts 7 in (178 mm)
  • Page 120 SETUP AND INSTALLATION 777 LUFFING JIB OPERATOR MANUAL Load Indicator Jib Point Load Indicator Sheave (if equipped) Jib Point Jib Point Load Indicator Sheave (if equipped) Sheave (if equipped) Dead-End Universal Wedge Anchor Socket Joint Weight Ball Load Load Block...

  • Page 121: Universal Anchor Joint

    777 LUFFING JIB OPERATOR MANUAL SETUP AND INSTALLATION 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 122: Load Block Tieback

    When sizing slings, take into account the dynamic affects of traveling and swinging the crane. It is For Models 777 and 777T, Manitowoc provides a lug on the the crane user’s responsibility to calculate this load.

  • Page 123: Section 5

    Lubrication ............5-1 Manitowoc...
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  • Page 125: Section 6

    777 LUFFING JIB OPERATOR MANUAL LUBRICATION SECTION 5 LUBRICATION LUBRICATION See F2107 at the end of this section. Manitowoc Published 08-10-22, Control # 046-05...
  • Page 126 LUBRICATION 777 LUFFING JIB OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 08-10-22, Control # 046-05...
  • Page 127 Adjustment ............6-29 Manitowoc...
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  • Page 129: Maintenance And Adjustment

    777 LUFFING JIB OPERATOR MANUAL MAINTENANCE SECTION 6 MAINTENANCE MAINTENANCE AND ADJUSTMENT This section contains maintenance and adjustment instructions for the limit devices used with the #139 luffing jib attachment on both a crawler crane and a truck crane. F o r m a i n t e n a n c e a n d i n s p e c t i o n o f t h e f o l l o w i n g...
  • Page 130 MAINTENANCE 777 LUFFING JIB OPERATOR MANUAL Item Description Power Cord (J1) to MAX Angle Limit Switch Shorting Plug for MAX Angle Limit Power Cord (J2) to MIN Angle Limit Switch Shorting Plug for MIN Angle Limit Junction Box in Boom Top...

  • Page 131: Jib Stop Adjustment - Past Production

    777 LUFFING JIB OPERATOR MANUAL MAINTENANCE JIB STOP ADJUSTMENT — PAST Adjustment PRODUCTION The automatic luffing jib stops must be installed, adjusted, and sealed at initial assembly of the attachment. The luffing jib attachment is equipped with two limit switches...
  • Page 132 MAINTENANCE 777 LUFFING JIB OPERATOR MANUAL A1035 MAX Limit Switch CAUTION Check this distance after adjusting either limit switch. Distance from both ends of actuator (MIN or MAX) to Alignment Pin outside edge of actuator bracket must be equal. Limit...

  • Page 133: Maximum Boom To Luffing Jib Angle

    777 LUFFING JIB OPERATOR MANUAL MAINTENANCE Maximum Boom to Luffing Jib Angle d. If jib stop pendants get tight before luffing jib has stopped, stop raising luffing jib immediately. Failing See Figure 6-2, View A for following procedure, unless to do so will result in damage.
  • Page 134 MAINTENANCE 777 LUFFING JIB OPERATOR MANUAL A20242-1 Item Description Limit Switch - MAX UP Actuator Rod Limit Switch - MAX DOWN Actuator Rod Boom Top Luffing Jib Butt Far Side Boom Centerline Luffing Jib Centerline View A Item Description Luffing Jib Centerline Max Up 1 Angle = 168°...
  • Page 135 777 LUFFING JIB OPERATOR MANUAL MAINTENANCE A20242-2 A20242-3 Deactivated Activated Item Description Edge of Actuator Rod (1a) to Edge of 9-11/16 in (246,1 mm) 9-7/16 in (239,7 mm) Limit Switch Mounting Pad Edge of Actuator Rod (2a) to Center 8-25/32 in (223,0 mm)

  • Page 136: Jib Stop Adjustment - Current Production

    MAINTENANCE 777 LUFFING JIB OPERATOR MANUAL JIB STOP ADJUSTMENT — CURRENT Jib Max Up 2 Limit Check PRODUCTION See Figure 6-3 for following procedure. Perform the following steps with the boom and luffing jib on the ground: Check Dimension (D1, View A) and if necessary, adjust WARNING actuator rod to obtain deactivated dimension.
  • Page 137 777 LUFFING JIB OPERATOR MANUAL MAINTENANCE Turn appropriate limit bypass key switch to bypass 10. Operating limit alarm should come on indicating JIB position. MAX UP 2 limit has been reached. I f m a x i m u m s t o p s d o n o t o p e r a t e p r o p e r l y, troubleshoot system.
  • Page 138 MAINTENANCE 777 LUFFING JIB OPERATOR MANUAL 176813-3 Roller Over-Travel LED OFF (if equipped) LUFFING JIB MAX UP LIMIT SWITCH View A SWITCH OPENED LED ON 176813-1 (if equipped) View B SWITCH CLOSED Item Description Item Description Past Production Adjusting Rod...

  • Page 139: Actuator Rod Replacement

    777 LUFFING JIB OPERATOR MANUAL MAINTENANCE Actuator Rod Replacement Install proper adjusting rod (1) and adjust as needed for correct maximum angle. Max Up Limit Actuator Rod Max Down Actuator Rod See Figure 6-4, View B for following procedure. See Figure 6-4 View D for following procedure.
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  • Page 141: Automatic Boom Stop Adjustment

    777 LUFFING JIB OPERATOR MANUAL MAINTENANCE 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 6-5) automatically stops the...
  • Page 142 MAINTENANCE 777 LUFFING JIB OPERATOR 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 143: Limit Bypass Test

    777 LUFFING JIB OPERATOR MANUAL MAINTENANCE Limit Bypass Test Raise the boom to specified Angle A while monitoring the angle on the mechanical indicator or on the Perform the following test to determine if the boom up limit operating conditions screen of the front-console display.

  • Page 144: Physical Boom Stop

    MAINTENANCE 777 LUFFING JIB OPERATOR MANUAL • Assist in preventing the boom rigging from pulling the boom back when traveling or setting loads with the Boom Digital Level boom at any angle above 81°. Angle Angle • Assist in moving the boom forward when lowering the 83°...
  • Page 145 777 LUFFING JIB OPERATOR MANUAL MAINTENANCE A991 90° 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 in. Boom Stop Boom Stop...

  • Page 146: Jib Angle Indicator Adjustment- Crawler And Truck

    MAINTENANCE 777 LUFFING JIB OPERATOR MANUAL Junction Box A1035 in Boom Top Item Description Power Cord to Luffing Jib Angle Sending Unit Shorting Plug for Luffing Jib Angle Boom Connect and Disconnect Butt Cords Here Angle FIGURE 6-8 Sending Unit JIB ANGLE INDICATOR ADJUSTMENT—...

  • Page 147: Sending Unit Assembly

    777 LUFFING JIB OPERATOR MANUAL MAINTENANCE Sending Unit Assembly Solid State Sensor When replacing an existing pendulum-type potentiometer Replacement sending units (Figure 6-10) can be either the with a current production solid state sensor, take the pendulum-type 178° potentiometer (past production) or the following precautions (see Figure 6-10, View B): solid state sensor (current production).

  • Page 148: Disconnecting Luffing Jib Angle Indicator

    MAINTENANCE 777 LUFFING JIB OPERATOR MANUAL Disconnecting Luffing Jib Angle Indicator Adjusting Angle Indicator Perform the following steps when removing the luffing jib Perform following adjustment steps at initial installation, after (see Figure 6-8): installing a new sending unit or potentiometer, and at least monthly when jib is lowered to ground.
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  • Page 150: Block-Up Limit Adjustment

    MAINTENANCE 777 LUFFING JIB OPERATOR MANUAL BLOCK-UP LIMIT ADJUSTMENT Block-Up Limit Control Deactivated During normal operation, the weight overcomes the spring A block-up limit control (also called anti two-block device) is force and rotates the actuating lever away from the limit a two-blocking prevention device which automatically stops switch lever.
  • Page 151 777 LUFFING JIB OPERATOR MANUAL MAINTENANCE Upper Boom Limit Switch Point Assembly Chain Lower Boom 8 ft Point (2.4 m) Limit Switch Assembly A1007 Weight Lift Block Chain 6 ft (1.8 m) Weight Lift Weight Ball Plate Load Block #78 Boom Shown;...

  • Page 152: Disconnecting Block-Up Limit Control

    MAINTENANCE 777 LUFFING JIB OPERATOR MANUAL Disconnecting Block-Up Limit Control the limit switch must be connected to the proper shorting plug when the corresponding attachment is removed. Shorting plug (SP1, Figure 6-14, 6-15, and 6-16) is provided Failing to perform this step will prevent the load drum from on the left front corner of the rotating bed so the block-up limit hoisting and the boom from lowering.

  • Page 153: Past Production (Crawler 7771001 Through 7771006)

    777 LUFFING JIB OPERATOR MANUAL MAINTENANCE PAST PRODUCTION (CRAWLER 7771001 THROUGH 7771006) A1007 Wiring For Boom Top With Upper Boom Point Wiring For Boom Top With Jib M3 SP2 C5/C7 Note 1 FIGURE 6-15 Item Description Item Description Cable Reels...
  • Page 154 MAINTENANCE 777 LUFFING JIB OPERATOR MANUAL C5, C7, C12 Used FIGURE 6-16 A1107 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...
  • Page 155 777 LUFFING JIB OPERATOR MANUAL MAINTENANCE 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 156: Maintenance

    MAINTENANCE 777 LUFFING JIB OPERATOR MANUAL Maintenance Check that the electric cords are clear of all moving parts on the boom and jib and that the cords are Inspect and test the block-up limit control weekly or every 40 securely fastened to the boom and jib with metal hours of operation, as follows: straps.

  • Page 157: Adjustment

    777 LUFFING JIB OPERATOR MANUAL MAINTENANCE Adjustment Manually lift the weight to allow the actuating lever to rotate upward. See Figure 6-18 for following procedure. Hold lever at Dimension A. Lower the boom onto blocking at ground level and adjust...
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  • Page 159 Manitowoc Dealer ........
  • Page 160 777 LUFFING JIB OPERATOR MANUAL Retaining Connecting Pins ............4-4 Rigging Drawings .

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