Manitowoc 777 Manuals

Manuals and User Guides for Manitowoc 777. We have 3 Manitowoc 777 manuals available for free PDF download: Service And Maintenance Manual, Operator's Manual

Manitowoc 777 Service And Maintenance Manual (306 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 31.07 MB

Table of Contents
5
Safe Maintenance Practices
13
Maintenance Instructions
13
Identification and Location of Components
15
Crane Orientation
15
General Operation
19
Operating System
19
Hydraulic Components
19
Hydraulic Pumps
20
Hydraulic Motors
22
Charge Pressure
23
Main System Pressure
23
Accessory System Pressure
23
Hydraulic Supply
23
Hydraulic Tank
24
Filtration
24
Suction Manifold
27
EPIC Programmable Controller (PC)
28
Supercharge Manifold
28
Oil Return Manifolds and Cooling System
28
Standard Crane Mode
30
Other Crane Modes
30
Digital Display
31
Voltage Availability
32
Brake Release System
38
Hydraulically Released
38
Load Drum Clutch Release System (with Free Fall)
39
Boom System
41
Boom Hoist Rotation Indicator
41
Counterweight Handling
41
Boom off
41
Boom Raise
43
Boom Lower
45
Swing System
48
Swing Lock
48
Off
49
Swing
49
Travel System
51
Off
51
Left Crawler Forward
51
Travel Detent Button
52
Load Drum Pawl
53
Drum Pawl Engage
54
Drum Pawl Disengage
54
Load Drum (Full Power Mode)
55
Liftcrane Operation
56
Off
56
Hoist
56
Lower
58
Clamshell Operation: Clamshell Mode
59
Programming
59
Off
59
Close Bucket
59
Hoist Bucket
61
Open Bucket
62
Lower Bucket
63
Load Drum (Free Fall Mode)
64
Front Drum in Free Fall
66
Crane Setup Systems
69
Carbody Jacking System
69
Jacking Cylinder Extend
69
Jacking Cylinder Neutral
69
Jacking Cylinder Retract
71
Crawler Attachment System
73
Crawler Lock Pin Extend
73
Crawler Lock Pin Retract
74
Optional Systems
75
Luffing Jib Hoist System
75
Auxiliary Hoist System
76
Auxiliary Hoist Rotation Indicator
77
Auxiliary Drum Pawl System
77
Auxiliary Hoist off
77
Auxiliary Hoist Raise
77
Auxiliary Hoist Lower
78
Abbreviations
80
Hydraulic Schematics
83
Hydraulic System - General
83
Checking and Replacing Hydraulic Hoses
83
Hydraulic System Maintenance
84
Safety
84
Storing and Handling Oil
84
Storing and Handling Parts
84
Inspecting System
84
Servicing Pumps
85
Cleaning Fill Cap Assembly
85
Replacing Filter Elements
86
Filter 1
86
Filter 2
87
Filters 3 and 4
87
Changing Oil
89
Tightening Hydraulic Connections
90
Pipe Thread Connection
90
SAE Straight Thread Connection
91
ORS Connection
92
Split Flange Connection
92
SAE Flare Connection
93
Programmable Controller Calibration Procedures
94
Controls Calibration
94
Pressure Sender Calibration
94
Pressure Sender Replacement
94
Load Drums, Swing, Track, and Boom Hoist Pump
95
Boom Hoist Cylinder
95
Disc Brake Operational Test
97
Operational Test
97
Shop Procedure
99
Initial Oil Fill
102
Pressure Sender Calibration
105
Initial Start-Up
106
Controls Calibration
108
Pressure Adjustments
108
Charge Pressure Checks
108
Accessory System Pressure Checks
109
Band Brake Relief Valve Pressure Check
110
Drum Clutch Pressure Adjustment
110
Operating Pressure Checks
111
Boom Hoist Leakage Test
111
Operating Speed Checks
112
Electrical Drawings and Schematics
115
Checking and Replacing Electrical Components
115
Abbreviations and Symbols
116
Test Voltages
117
Controller Board Layout
117
Pin Identification
118
Wire Identification
123
Description Identification
128
Display Readings
133
Operating Conditions
133
Operating Limits
133
System Faults
133
Selecting Display Language
135
Crane Diagnostics
138
Drum 1, 2, and 8
138
BHST (Boom Hoist)
138
Swing
138
Track
138
A1 (Handles)
139
D1 and D2 (Digital Outputs and Inputs)
139
Crane Software Installation
144
CPU and Eprom Compatibility
144
EPROM (Chip) Identification
144
Eprom Replacement
145
Counterweight Limit Switch Adjustment
146
Adjustment
146
Bench Setup
146
Engine Control Module Ground Modification
147
Installation
147
Test before Installing Counterweights
147
Dielectric Grease
148
Connector Pin Identification
149
Mini-Change Type Connectors
149
2-Pole Plugs
149
3-Pole Plugs
150
5-Pole Plugs
151
10-Pole Plugs
152
Micro-Change Type Connectors
153
Quick-Change Type Connectors
153
4-Pole Plugs
153
3-Pole Plugs
154
Section 4
157
Automatic Boom Stop Adjustment
157
Maximum Boom Angle
157
Operation
157
Maintenance
157
Bypass Limit Test
159
Adjustment
159
Physical Boom Stop
160
Operation
160
Removal
160
Boom Angle Indicator
162
Adjusting Angle Indicator
162
Sensor Replacement
162
Pendulum-Type 120° Potentiometer
162
Solid State Sensor
162
Servicing Boom Hoist Cylinder
164
Boom Hoist Cylinders - Welding
164
Before Welding on Crane
164
Boom and Jib Inspection and Lacing Replacement
165
Inspection Intervals
165
Inspection Guidelines
165
Replacement Criteria
165
Dents
166
Gradual and Sweeping Bends
166
Corrosion and Abrasion
166
Kinks
168
Cracks and Breaks
168
Chord Straightness
168
Ordering Lacings
170
Assistance
170
Boom or Jib Identification
170
Ordering Lacings from Lacing Drawings
171
Ordering Lacings Without Lacing Drawings
172
Repair Procedure
173
Extent of Repair
173
Preparing for Welding
173
Repair Facility
173
Outdoor Repairs
173
General Equipment Requirements
173
Repair Procedures and Processes
174
Lacing Replacement
174
End Lacing Replacement
175
End Lacing Replacement on an Insert (Angle and Tubular Chords)
176
End Lacing Replacement on Tapered Sections (Tubular Chords)
176
Lacing Removal - Boom Section with a Bent or Bowed Chord Member
177
Determining Amount of Stick Electrode Needed
177
Inspection Checklist
183
Record Keeping
183
Section 5
187
Hoist Drawings
189
Minimum Bail Limit Adjustment
189
Weekly Maintenance
189
Wire Rope Removal
189
Electric Wiring
189
Adjustment
191
Block-Up Limit Installation and Adjustment
192
Operation
192
Installation
192
Adjustment
192
Block-Up Limit Control Deactivated
192
Block-Up Limit Control Activated
192
Storing Electric Cable
194
Disconnecting Block-Up Limit Control
197
Removing Jib or Boom Point
197
Maintenance
197
Adjustment
198
Drum Brake Adjustment
200
Full-Power Operation (Free Fall Off)
200
Free Fall Operation (Optional)
200
Brake Inspection
200
Brake Adjustment
201
Foot Pedal Adjustment
202
Drum Pawl Adjustment
204
Actuator Removal
204
Actuator Installation and Adjustment
204
Drum Pressure Roller Adjustment
206
General
206
Adjustment
206
Wire Rope Lubrication
207
Wire Rope Inspection and Replacement
207
Keeping Records
207
Inspecting Wire Rope
207
Frequent Inspection
207
Periodic Inspection
207
Rope Not in Regular Use
207
Replacing Wire Rope
207
Distributing Wire Rope Wear
209
Sheave, Roller, and Drum Inspection
210
Load Block and Hook-And-Weight Ball
213
Maintenance and Inspection
213
Section 6
217
Manual Release of Swing Brake and Lock
219
Manual Release Procedure
219
Section 7
219
Battery Maintenance
223
Safety Information
223
Causes of Battery Failure
223
Overcharging
223
Undercharging
223
Lack of Water
223
Hold-Downs
223
Overloads
223
Multiple Battery System
224
Maintenance
224
Weekly - Check Electrolyte Level
224
Every 2 Months - Test Batteries
224
Charging
225
Storage
225
Battery Electrical Disconnect Switch
225
Quarterly
225
Engine Air Cleaner Maintenance
226
Mounting
226
Inspection
226
Service
226
Engine Clutch Adjustment
227
Operation
227
Adjustment
227
Engine Throttle Adjustment - Cummins C330
228
Foot Throttle Linkage Adjustment
228
Electronic Fuel Control Adjustment
228
Engine Throttle Adjustment - Cummins 6CTA8.3-C260 Engine
230
Foot Throttle Linkage Adjustment
230
Electronic Speed Control Adjustment
230
Setting High Speed
230
Setting Gain and Stability
230
Test Voltages
231
Engine Throttle Adjustment - Caterpillar 3176B and 3176C Engines
232
Foot Throttle Linkage Adjustment
232
Engine Speed Calibration
232
Engine Throttle Adjustment - Cummins QSL 340, QSC8.3, QSM11, or QSX15 Engine
233
Foot Throttle Linkage Adjustment
233
Engine Speed Calibration
233
Wiring Diagram
233
Onboard Diagnostics
234
Engine Stop Light
234
Engine off Diagnostics
234
Engine Warning Light
234
Engine Maintain Light
234
Turntable Bearing Bolt Torque
237
Bearing Installation
237
Torque Requirements
237
Bolt Replacement
237
Lubrication
237
Torque Values
237
Torque Sequence
237
Torque Intervals
237
Crawler Adjustment
238
Maintenance
238
Tread Slack Adjustment
239
Adjustment Guideline
239
Adjustment Procedure
239
Hydraulic Hand Pump
240
Assembly
240
Maintenance
240
Air Removal
241
Operation
241
Section 9
243
Lubrication
243
Section 10
247
Safety Summary
249
General Guidelines
249
Introduction
249
Test Equipment
250
Troubleshooting Charts
251
Testing
276
Test 1 - Battery Test (12 and 24 VDC)
276
Test 2 - Electric Fuel Control (EFC) Box Test Points
277
Test 3 - Checking Resistance at Engine Temperature Switch
279
Test 4 - Checking Resistance at Engine Oil Pressure Sender
280
Test 5 - Cleaning and Adjusting the Engine RPM Transducer (Past Production)
281
Test 6 - Testing for Voltage at the Fuse Box
282
Test 7 - Checking Voltage at the Control Handle
283
Test 8 - Adjusting the Control Handle Potentiometer
284
Test 9 - Location of Pump Test Ports
285
Test 10 - Location of Motor Test Ports
287
Test 11 - Manually Stroking the Pump
289
Test 12 - Setting the Pump Pressure
290
Test 13 - Setting Pump Neutral
291
Test 14 - Adjusting Pump Charge Pressure Relief
292
Test 15 - Checking Pump Charge Pressure
293
Test 16 - Checking Charge Pressure at Motor Port X1
294

Manitowoc 777 Operator's Manual (222 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 24.61 MB

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

Manitowoc 777 Operator's Manual (162 pages)

Luffing jib attachment

Brand: Manitowoc | Category: Construction Equipment | Size: 19.84 MB

Table of Contents
5
Section 1
9
Crane Data
11
Crane/Attachment Identification
11
Change of Ownership Registration
11
Crane Orientation
11
Manitowoc Dealer
11
Identification of Luffing Jib Components
12
Crane and Luffing Jib Weights - Crawler
13
Crane and Luffing Jib Weights - Truck
17
English and Metric Conversions
20
Direct Conversion
20
Inverse Conversion
20
Section 2
23
Continuous Innovation
25
Nameplates and Decals
25
Safety Messages
25
General
25
Safety Alert Symbol
25
Signal Words
25
Symbol Identification
25
Safety and Information Signs
27
Maintaining Signs
27
Ordering Signs
27
Crane Access Points
28
General
28
Getting on or off Crane
28
Personal Fall-Protection
30
Operator Manual/Capacity Chart Storage
30
General
30
Storing Manuals
30
Safe Operating Practices
31
General
31
Work Area Control
31
Read Operator Manual
31
Operator Qualifications
31
Operator Conduct
32
Handling Load
33
Size of Load
33
Attaching Load
34
Lifting/Moving Load
34
Signals
35
Holding Load
35
Safety Devices
36
Operational Aids
36
Category 1 Operational Aids
36
Category 2 Operational Aids
37
Assembling, Disassembling, or Operating Crane Near Electric Power and Transmission Lines
38
Electrocution Hazard
38
Set-Up and Operation
38
Electrical Contact
39
Refueling
39
Fire Extinguishers
39
Accidents
39
Safe Maintenance
40
Maintenance Instructions
40
Safe Maintenance Practices
40
Environmental Protection
41
Boom Disassembly Safety
43
General
43
Location
43
Pin Removal
43
Disassembly Precaution
43
Special Application/Service
44
Personnel Handling Policy
44
Pedestal/Barge Mounted Cranes
45
Pedestal Mounted Crane
46
Barge Mounted Crane
46
Definition
46
Examples
46
Capacity Charts for Barge Mounted Crane
47
Shock Loading Caused by Barge Dynamics
48
Operation on Barge
48
Barge Mount Definitions
48
Inspection of Barge-Mounted Crane
48
Transporting Crane on Barge
49
Pile Driving and Extracting
49
Introduction
49
Operation of Pile Driving and Extracting Equipment
49
Crane Equipment
49
Crane Inspection
49
Electrocution Hazard Devices
50
Multiple Load Line Operation
50
Multiple Crane Lifts
51
Section 3
53
Standard Hand Signals for Controlling Crane Operations
56
Luffing Jib Operating Controls
59
Rated Capacity Indicator/Limiter (RCL)
59
Crane Mode Selector
59
Digital Display
59
4A - Limit Bypass Switch and
60
4B - Jib up Limit Bypass Switch
60
Rear Drum Park Switch
60
Rear Drum Pawl Switch
60
Boom Hoist Control
60
Luffing Hoist Control
60
Boom Angle Indicator
60
Level
60
Operating Precautions
60
Disabling and Enabling Free Fall
65
Disabling Free Fall
65
Enabling Free Fall
65
Wind Conditions
67
Section 4
69
Luffing Jib Attachment
71
Accessing Parts
71
Assist Crane Requirements
73
Crane Weights
73
Operating Controls
73
Counterweight Requirement
73
Blocked Crawlers
73
Extended Outriggers
73
Rigging Drawings
73
Luffing Jib Raising Procedure
73
Identifying Boom/Jib Components
74
Identifying Pendants
74
Handling Components
74
Retaining Connecting Pins
74
Mast Links
74
Shipping Luffing Jib Components
75
Luffing Jib Rigging Guide (#139 Luffing Jib) - Crawler and Truck
77
Installing Jib
77
Lower Boom
77
Prepare Crane for Jib
77
Install Jib Butt
77
Install Jib Inserts and Top
77
Install Jib Stop Control Cable
79
Install Main Strut
79
Install Jib Pendants
79
Install Backstay Pendants
79
Connect Crane to Boom
80
Install Luffing Hoist Wire Rope
80
Raise Main Strut and Connect Backstay Pendants
83
Install Fixed Jib
84
Install Jib Load Line
84
Connect Electric Cords and Adjust Electronic Devices
84
Pre-Raising Checks
85
Raising Boom and Luffing Jib
87
Preliminary Raising Procedure
87
In-Line Raising Procedure
89
Jack-Knife Raising Procedure
91
Lowering Boom and Luffing Jib
93
In-Line Lowering Procedure
93
Jack-Knife Lowering Procedure
95
Lowering Jib Strut and Main Strut
96
Final Lowering Procedure
96
Removing Jib
97
Fixed Jib Rigging Guide (#138 Fixed Jib) - Crawler and Truck
101
Assist Crane Requirements
101
Jib Assembly Drawing
101
Preparing Boom and Luffing Jib
103
Luffing Jib Configuration
103
Installing Fixed Jib
103
Install Jib Butt
103
Install Jib Inserts
103
Install Jib Top
103
Install Jib Pendants
103
Install Backstay Pendants
103
Install Jib Load Line
104
Install Electronic Devices
104
Raising Boom and Jibs
107
Lowering Boom and Jibs
108
Removing Fixed Jib
109
Wire Rope Installation and Maintenance
110
Wire Rope Storage
110
Removing Wire Rope from Shipping Reel
110
Seizing and Cutting Wire Rope
110
Anchoring Wire Rope to Drum
111
Winding Wire Rope Onto Drum
111
Anchoring Wire Rope to Wedge Socket
112
Breaking in Wire Rope
114
Pad Eye Usage for Wire Rope Reeving
114
General
114
Safety
114
Load Line Reeving - Crawler and Truck
116
Wire Rope Specifications
116
Wire Rope Installation
116
Guide Sheave Identification
116
Reeving Diagrams
116
Load Blocks
116
Universal Anchor Joint
121
Load Block Tieback
122
Specifications
122
Shackle
122
Section 5
123
Lubrication
123
Section 6
125
Maintenance and Adjustment
129
Jib Stop Adjustment - Past Production
131
Maintenance
131
Adjustment
131
Maximum Boom to Luffing Jib Angle
133
Minimum Boom to Luffing Jib Angle
133
Jib Stop Adjustment - Current Production
136
General
136
Maintenance
136
Pre-Erection Checks
136
Operational Checks
136
Jib Max up 2 Limit Check
136
Jib Max down Limit Check
136
Actuator Rod Replacement
139
Max up Limit Actuator Rod
139
Max down Actuator Rod
139
Automatic Boom Stop Adjustment
141
Maximum Boom Angle
141
Operation
141
Maintenance
141
Limit Bypass Test
143
Adjustment
143
Physical Boom Stop
144
Operation
144
Removal
144
Jib Angle Indicator Adjustment- Crawler and Truck
146
Sending Unit Assembly
147
Pendulum-Type 178° Potentiometer
147
Solid State Sensor
147
Disconnecting Luffing Jib Angle Indicator
148
Adjusting Angle Indicator
148
Block-Up Limit Adjustment
150
Operation
150
Installation
150
Storing Electric Cord
150
Block-Up Limit Control Deactivated
150
Block-Up Limit Control Activated
150
Disconnecting Block-Up Limit Control
152

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