Service Manual
B u cy r u s - E r i e
Service Manual
38B, 61B, 71B, 88B,
Excavator and Crane
THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF
BUCYRUS-ERIE OR IT’S SUCCESSORS. BUCYRUS-ERIE AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.
TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.
BU-S-38B+
Evansville (Indiana) Plant
:.... '1.
PART III
,SERVICE TRAINING
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INDEX
PAGE TOPIC
1 - 6 ·......................... . Introduction
7 - 21 ·......................... . 38-B, 61-B, 71-B &88-B Lower Works
22 Replacing Track Links
23 - 26 ·.......................... . Drive Chains
27 - 34 ·......................... . Cone Roller & Swing Ball Circles
35 - 46 ·......................... . 38-B, 61-B, 71-B &88-B Upper Works
47 ·......................... . Flexible Shafts for Output Governors
48 - 81 ·......................... . Torque Convertor Installations
82 - 88 Boom Hoist Arrangements
89 - 100 Reversing Transmissions
101 - 113 Main Drums & Swing Brakes
114 - 128 Brakes
129 - 134 Crowd Machinery
135 - 136 Replacing Crowd and Retract Rope - 88-B
137 Saddle Blocks
138 Fairleads
139 Dragline Buckets
140 Taglines
141 - 158 Air Componentry
159 Single Lever Clamshell Control
160 - 161 Two Lever Dual Governors
162 - 163 38-B Air Schematics
164 .,. 165 61-B Air Schematics
166 - 167 71-B Air Schematics
168 - 176 Governor Adjustments
177 - 187 Engine Data
188 Machine Knockdowns
189 - 191 Machine Weight Reference
192 - 194 Hand Signals - Caution Warnings
195 Hard Facing Shovel Dippers
196 - 197 Nomenclature
198 - 199 Storage Procedure
II. CRAWLER BELT
No definite rule can be given as to how tight or loose the crawler belts should
be as the correct adjustment depends on the type of ground over which the machine
is to be removed. In general t the belts should be kept as loose as possible
without losing proper tracking of the driving tumblers. For normal service, when
the belt is tight on the bottom, it should sag about six inches between the
upper idler rollers.
If the machine is operating on mats or other firm footing 3 or 4 inches sag will
give better tracking. WATCH THE BELTS CLOSELY WHEN THE MACHINE IS WORKING IN
LOOSE DIRT, SAND, OR MUD AND LOOSEN THE ADJUSTMENTS OF THE BELT IF THE DIRT
TAKES UP ALL THE SLACK.
PROPELLING WITH TIGHT BELTS IS EXTREMELY HARD ON THE PROPELLING MACHINERY.
Tension of each crawler belt is adjusted at the take-up tumbler end (opposite
to the propel chain) by adding or removing slotted spacers which position the take-
up tumbler shaft. Adjustment of the crawler belts does not affect the adjustment
of the crawler propelling chains but the propelling chains must be correctly
adjusted BEFORE adjusting the crawler belts, therefore, always check the adjustment
of the propelling chains and adjust if necessary before changing the adjustment
of the crawler belt.
In making adjustment of the crawler belt, be sure that the same thickness of
spacers is used at each end of the shaft so that the shaft is held in correct
alignment. Extra spacers and two special jack screws are included in the tools
and supplies.
A. To adjust the crawler belt tension proceed as follows: SEE FIG. 3
1. Assemble one of the jack screws at each end of the take-up
tumbler shaft, (38-B only).
2. Loosen the take-up tumbler shaft bearing bolts at both ends of the
shaft.
3. Turn the nuts on both jack screws until the desired belt
tension is obtained. (If the belt is being loosened it
will be necessary to remove some of. the spacers from both
sides before backing off on the jack screw nuts.)
4. Insert an equal thickness of spacers on both sides to completely
fill the gaps between the side frame and the take-up tumbler shaft
bearings.
5. Remove the jack screws from both sides.
6. Tighten the bearing bolts securely.
After the adjustment of both crawler belts is completed, clean and oil the jack
screws and store them with extra spacers.
FIG. 3
15
TRANSMISSION AND TORQUE CONVERTER CHAIN
THE TRANSEISSION CHAIN OPERATES IN AN 4. Use adjusting bolts (F) to move engine bed plate.
OIL BATH. OIL SHOULD BE Cl1ECKED EVERY
40 TO 50 HOURS AND CHANGED TvJICE A YEAR. -
5. Check sag at (H) to 2-1/2 inches.
~--.
6. Check and make sure engine is in aUgnment.
Torque converter governor drive chain (B) should be
checked every 90 days. It should have a total move- 7.• If alignment is o.k., tighten studs (E) and bolts (D)
ment at (C) of 1/2 inch. Every time transmissiqn and replace (G).
chain (A) is tightened or loosened converter governor
drive chain should be checked. TO ADJUST TORQUE CONVERTER GOVERNOR
DRIVE CHAIN (B)
TO ADJUST TRANSMISSION CHAIN (A)
1. Loosen bolts (K).
1. Remove inspection plate (G).
2. Move torque converter drive body up or down until
2. LO:lsen bolts (D). total movement at (C) is 1/2 inch.
3. Loosen engine bed plate studs (E). 3. After chain adjustment, tighten bolts (K).
H G
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88-B CHAIN DRIVE
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E
45
7l-B
H. SWING BRAKE: (Also See Page 218) Friction Type Swing Brake is
especially helpful while transporting
The swing brake is located at the upper end of the or on long-boom crane work.
vertical swing shaft. Adjustment of the brake is very Spring-set, air-released V-shoe is
graduated to provide a slight drag
seldom required since it does not slip in normal oper- on long boom work. It wedges
ation. Failure of the brake to hold is more apt to be into the housing for positive
due to grease or oil on the brake or a leaking piston locking of the house.
than to improper adjustment. To adjust the brake for
any lining wear that may take place: (Refer to Fig.
11.) Remove pin "A" connecting the piston rod to the
brake lever and then back off the lock nut and screw
the rod out to lengthen it a small amount.
V-BLOCK SWING BRAKE (Machines 126325 & Up)
The swing brake is located at the upper
end of the vertical swing shaft.
Adjustment of the brake is very seldom
required since it does not slip in
normal operation. Failure of the brake
to hold is more apt to be due to grease
or oil on the brake or a leaking
piston than to improper adjustment.
To adjust for wear~ set brake and tur.n
FIG. 11 nuts to obtain a spring height
The adjustable rod "B" just ahead of the spring car- of 8-5/8".
ries a sleeve spacer between the two brake levers.
When the brake is set there should be a clearance of Always check after an adjustment has
% inch between the one end of the sleeve and one of been made to be sure that the spring ;s
not compressed solid when the brake is
the levers when the sleeve is pushed over so the other released or that the piston does not
end is flush against the other lever. In addition (he bottom when the brake is set.
nuts at extreme ends of the rod should be adj us ted
so that the rod has 3/8 inches end play when the brake F6o6--______~----------~
is set. lJ.'hen lining wear makes it necessary co adjust
F562 --------;~~- h=-.---~
the brake cylinder piston rod as described in the pre-
ceding paragraph then the adjustment of the rod should
also be checked and the clearances corrected if neces- ftb.ooo~---F608
sary.
~----F613
To remove the brake shoes for re.lining or cleaning
proceed as follows: (See Fig. 11.) F609
1. Remove pins "en and "D." F611
2. Rotate shoes around housing uNil clear of brake F607'--------,
arms and remove shoes. F553
F562
109
SE-3149-S.
* Hi-idle - Clutch Disengaged - Throttle Fully Advanced
MODEL 38-B KEY: * * Theo. stall- Clutch Engaged - Throttle Fully Advanced-
ENGINE DATA D - DIESEL Machinery Stalled
Non-current 'G - GASOLINE
DRUM SHAFT SPEED: NO 1..040 OR HIGH SPEED
31.6 +
_ \/2 R.P.M.
AL TITUDE ENGINE SPROCKET CHAIN FUEL RACK ENGINE SPEED TRANSMISSION
ENGINE RANGE PART PITCH ADJ. OR
~~E~~
NO FULL MAKE LOW DIRECT OVER
1000 FEET NUMBER STRANDS INJECTORS LOAD LOAD
D Cat D-342O o to 6.5 1-270266 111-4 0.265 1040 950 ... -... ... ...
D CAt n-q42O
D Cat D-342
6.5 to 9
o to 6.5
i§
19
1-270058
1-270266
1"-4
111-4
O.llO
0.130
llOO 11000
1040 950
-... - -... -...
>
w D Cat D-~42
Q:D Cat D13000
6.5 to 9 18 1..270058 1"-4 0.110 1100 1000 ... - - ...
0
I- Serial #' Series
uw D Cat D13000
4s o to 4 22 1-266987 1"-4 O.joo 900 810 - ... ... -
Q:
Ci
Serial. if Series
D Cat D13000
4s 4 to 6.5 19 1-270266 1"-4 0.360 1040 <nO ... - ...
;
...
Serial. #" Series
D Cat D13000
4s 6.5 to 9 18 1-270058 111-4 0.210 10q0 11000 ... ... - I
1
...
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00
Serial ¥ Series
D cat D13000
4s o to 4 22 :1-266987 ~1I-4 0.465 910 810 ... - ... ...
I--' ~,..1 ..1 :/I; ~,..i ... a 2BB o to 4 19 1-270266 1"-4 0.290 1040 940 ... ... ... ...
DRUM SHAFT SPEED: NO 1..04D OR HIGH SPEED
34.6 :t \/Z R.P.M.
ALTITUDE ENGINE SPROCKET CHAIN FUEL RACK ENGINE SP E ED TORQUE CONVERTOR
ENGINE RANGE PITCH ADJ. OR -HI. lHEO.
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PART MAKE MODEL
w 1000 FEET NUMBER STRANDS INJ ECTORS IDLE STALL
.> o to 4
a;: D Cat D-326F 21 1-27~3e 1"-4 0.195 2050 1755 Clark 16 CK
0 D Cat D-326 o to 4 21 1-279638 1"-4 0.237 2050 1750 Clark 16 CK
w D Bud.a 6DATI9
Q:
Oto4 20 1-2!84~ 1"-4 Test Stand 2050 1745 Clark 16 OK
I-
Q: D Buds 6DAS-779 4 to~. 20 1-2'78496 1"-4 2050 1745 Clark 16 CK
...... w D CUmmins N'H-25O-IP
>
o to 4 17 16131~ 1 4
11 ...
2100 1880 Clark 16 AKCOPG
<.n
<.n :z: D Cumm:Sns NHI 600 Oto4 20 1-2184 1"-4 2100 0.790 Clark 16 CK
c:
,."
8 D Cnmm:S ne NfiS...600 4 to 9 20 1-278496 111-4 2100 1790 Clark 16 OK
o w 6rnQOJn
D me UD-817 o to 4 17 1"-4 2310 1850 Clark. 16 AKCOPG
a
or: D GM 6-71 Oto4 I613190Kl 1"-4
-
..... 17 2000 1830 Clark 16 AKCOPG
N ....0 D GM 6-71 o to 6.5 20 1~ZT8496 1"-4 70 MM 2000 11830 Clark 16 OK
.....
"-..I D Cat 333-A JWAC o to 10 21 623654KI 3/4"-4 2200 1910 Clark 16 AKCOPG
o GM 6-71N o to 6 21 618313KI 3/4"-4 N60 MM 2300 1900 All ison ~CDOA-455
D Cummins NH-250 o to 7.5 22 618314KI 3/4"-4 2200 1900 -----cl ark 16 AKCOPG
MODEl.. ISSUED SUPERSEDE
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