Electric Mining Shovel 495HR - Bucyrus

BUCYRUS INTERNATIONAL, Inc.
495HR Electric Mining Shovel
Section
Always refer to the safety information in this section of this manual before starting any maintenance procedure on this machine. Table of Contents
GENERAL INFORMATION ........................................................................................................... 3 SAFETY .................................................................................................................................. 4 SAFETY - SWINGING RESTRAINT & BALLAST BOX SUPPORT........................................ 5 BALLAST BOX SUPPORT................................................................................................ 5 SWINGING RESTRAINT .................................................................................................. 6 SAFETY PRECAUTIONS ....................................................................................................... 8 FIRE PREVENTION .............................................................................................................. 11 WARNING SIGNS AND DECALS ......................................................................................... 12
Stored Energy Decals ............................................................................................................... 13
Introduction
MACHINE OVERVIEW ...............................................................................................................14 LOWER WORKS ........................................................................................................................ 15 CRAWLERS .......................................................................................................................... 16

Truck Frame and Crawlers ....................................................................................................... 15 Right Crawler Assembly (Left Opposite) ................................................................................... 16
TRUCK FRAME ....................................................................................................................17 SWING RACK ....................................................................................................................... 18 ROLLER CIRCLE ..................................................................................................................18

Swing Rack and Roller Circle ................................................................................................... 18 Roller Circle Assembly ............................................................................................................. 19
PROPEL MACHINERY ......................................................................................................... 20 COLLECTOR RINGS ............................................................................................................ 21 ROTATING DECK ....................................................................................................................... 22 REVOLVING FRAME ............................................................................................................ 23 CENTER PINTLE ..................................................................................................................23 DECK EXTENSIONS ............................................................................................................ 24 BALLAST BOX ...................................................................................................................... 24 MACHINERY HOUSE ........................................................................................................... 24 VERTICAL BOARDING LADDER ......................................................................................... 25 BOARDING STAIRS - RIGHT ............................................................................................... 26 A-FRAME .............................................................................................................................. 27 HOIST MACHINERY ............................................................................................................. 28 SWING MACHINERY ........................................................................................................... 29 CROWD MACHINERY .......................................................................................................... 30
Crowd Machinery Components ................................................................................................ 30 1-1
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Deck Plan ................................................................................................................................. 22
Deck Extensions and Ballast Box ............................................................................................. 24
A- Frame and Front End Support Components ........................................................................ 27 Hoist Machinery - Plan View ..................................................................................................... 28
Swing Machinery Components ................................................................................................. 29
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OPERATORS CAB ............................................................................................................... 31 COMPRESSED AIR SYSTEM .............................................................................................. 32 AUTOMATIC LUBRICATION SYSTEM................................................................................. 32
Lubrication Room ..................................................................................................................... 33
FRONT END EQUIPMENT ......................................................................................................... 34 SUSPENSION STRANDS .................................................................................................... 34 BOOM ................................................................................................................................... 35 RUNNING ROPES ................................................................................................................ 36 SADDLE BLOCK ...................................................................................................................37 DIPPER HANDLE ................................................................................................................. 37 DIPPER ................................................................................................................................. 38 PADLOCK ............................................................................................................................. 39 DIPPER TRIP ........................................................................................................................ 39
Dipper Trip - General Arrangement ........................................................................................... 39 Dipper Assembly ...................................................................................................................... 38 Ropes - General Arrangement .................................................................................................. 36 Boom Assembly ........................................................................................................................ 35
TYPICAL MACHINE SPECIFICATIONS ..................................................................................... 40 COMPONENT WEIGHTS ........................................................................................................... 42 495HR COLOR DECK PLAN ........................................................................................ ( foldout )
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Section
Introduction
GENERAL INFORMATION This manual is designed to assist the owner in the operation and preventive maintenance of this machine. By following easy to understand step-by-step procedures the operators and maintenance personnel can perform all tasks in a safe manner. It is important to remember that when a systematic and thorough maintenance/service procedure is used for this machine, a minimum of unplanned downtime and more reliable operation will result. THIS MANUAL IS NOT THE PARTS BOOK and cannot be used as reference material to order parts. A separate, detailed parts book has been supplied. Please carefully read the instructions in it. All parts are listed by group and/or product code numbers with the associated item/part numbers for THIS SPECIFIC MACHINE. Order parts in the exact quantity needed. RIGHT and LEFT refer to machine locations as viewed by the operator sitting in the operators seat in the cab. Please state the correct machine SERIAL NUMBER when corresponding or contacting the factory service or parts departments. Records on each machine are filed by serial number and when given this number, the machines specific design and original equipment is accessed quickly by the Bucyrus International parts representative. Periodic additions or revisions may be made to this manual. These can be ordered and will be mailed direct to you from the factory. Should you require additional information or factory service assistance contact your regional service representative or: Bucyrus International, Inc. 1100 Milwaukee Avenue P.O. Box 500 South Milwaukee, Wisconsin 53172-0500, USA Telephone (414)-768-4000 Fax: (414) 768-4210 It is Bucyrus Internationals policy to improve its products whenever possible and practical to do so. The company reserves the right to make changes or add improvements to its machines at any time. This will be without incurred obligation to install such changes on machines sold previously. Due to this ongoing program of product research and development, some procedures, specifications and parts may be altered in a constant effort to improve our machines.
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SAFETY The safety alert symbols displayed here and throughout this manual, are used to call attention to instructions concerning personal safety. Carefully read and follow these instructions and observe all SAFETY, DANGER and CAUTION graphics mounted on various areas of the machine. Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their definitions. If it is impossible to safely perform any of the enclosed maintenance and operational procedures, contact your regional Bucyrus service representative or the factory. The following defines distinctions between safety instructions. In all these definitions the safety alert signal is used. NOTE: This signal word denotes an item of required information pertaining to the equipment. A loss of time, assets, or minor injury may result if the appropriate action is not taken. CAUTION: This signal word serves as a reminder of safety practices, or directs attention to specific safety practices which could prevent possible injury if precautions are not adhered to. This signal word denotes an imminently dangerous hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken. This signal word denotes an imminently dangerous electrical hazard which will result in death, serious bodily injury, or serious damage to equipment if not acknowledged and appropriate action taken.
DANGER:
DANGER:
Operating, maintaining or servicing this machine is dangerous unless performed properly. Each person must satisfy himself and his employer that he is alert, has the necessary skills, knowledge, proper tools and equipment for the task at hand. It is critical that all the methods used are safe and correct. Factory service representatives and specialists are available to provide additional information or technical assistance. The operator must be alert, physically fit and free from the influence of alcohol, drugs, or any medications that might impair his eyesight, hearing or reactions. CAUTION:
STORED ENERGY! Components on machine are heavy and removal of pins without proper preparation and precaution can cause serious bodily injury and/ordamage to the front-end of the machine.
Safety must always be paramount!

Consult your supervisor when safety is in doubt.
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SAFETY - SWINGING RESTRAINT & BALLAST BOX SUPPORT
BALLAST BOX SUPPORT Before performing any maintenance on the mining shovel, it should be resting on a firm, level surface. Any mining shovel field work that requires the removal or lowering of the boom must incorporate additional support of the ballast box. The supports may be wooden cribbing or steel structures. Two supports positioned side-by-side on level ground are recommended. These supports are intended to accept vertical loads only. To prevent machine rotation use the swing brakes, cable stays, welded ties, etc. Refer to SWING RESTRAINT below. When electric-powered, cable-style mining shovels are properly ballasted and operational, the center of gravity for the machine's upper works lies within the roller circle area. This assumes that the boom is attached to the machine and in its elevated, working position. As such, the machine should not be prone to tipping. Boom removal or lowering will cause the center of gravity to shift toward the ballast box, decreasing machine stability. Stability is further dependent on the orientation of the upper works relative to the undercarriage. The machine may tip more easily over one of the four quadrants of the crawler mounting than it may over others. Normally the machine is more likely to tip over the rear-most lower-roller than over the side of a crawler. Therefore, with the boom removed and the ballast box sitting over the rear of the crawlers, the machine may be unstable. Because ballast quantities differ from machine to machine and model to model, it is recommended that the ballast box be supported before beginning any procedure to lower and/or remove the boom.
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SWINGING RESTRAINT Before performing any maintenance on the mining shovel, it should be resting on a firm, level surface. A small ground slope is enough to cause the machine to freely rotate if the brakes are not set or other restraints are not used. Once moving, it will keep going. The following shows the relation between an out-of-level or slope and the resulting difference in elevation over a 14 ft. swing rack: Slope % 0.25o 1.0o 5.0o 0.4% 1.7% 8.7%
Difference in Elevation 0.75 2.9 14.7
Where possible, all work on the swing brakes, motors, gearcases, or rack pinions should occur with the dipper attached to the machine and the full weight of the dipper on the ground. If the dipper is not resting firmly on the ground, then an external means of preventing machine upper works rotation is required. Tie the upper works to the lower works using the preferred method mentioned below. Mining shovels rotate using multiple swing units. Power is transferred from electric motors through individual gearcases, to pinions and into a fixed swing rack. Electric motor control prevents inadvertent machine rotation during operation. Should machine electric power be lost, spring-set brakes on the swing drive motors lock the geartrain to prevent machine rotation. When working on the brakes, motors, or geartrains, it is an accepted practice to set the dipper on the ground. The weight of the dipper and handle will prevent machine rotation. EVEN IF ALL BRAKES, MOTORS, OR SWING GEARCASES ARE REMOVED the machine should not rotate. In certain circumstances it may not be possible to rest the full weight of the dipper firmly on the ground. For instance, the dipper, handle or the boom may not be attached to the machine. To prevent machine rotation, with any of the major structures removed, two swing motor brakes should be set. A single brake in good operational condition is acceptable. However, a minimum of two brakes is recommended due to the possibility that the proper operation of a single brake may be unknown. Caution: ON MACHINES USING PLANETARY DUAL-OUTPUT SWING DRIVES, BOTH SWING PINIONS PER DRIVE MUST BE ENGAGED WITH THE SWING RACK IN ORDER FOR THE SWING BRAKE TO BE EFFECTIVE. The internal differential drive in the gearcase allows one pinion to rotate, even if the brake is set, when the other pinion has been removed.
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An external means of preventing machine rotation must be used - if the dipper is not resting firmly on the ground and if any of the following are true: Two brakes are not effectively set and coupled to the motors, or The motors and geartrain are not fully coupled to the swing pinions, or The swing pinions are not engaged to the swing rack
The preferred method to prevent machine rotation is to use a pair of one inch diameter steel cables to tie the upper works to the lower works. Other alternatives such as welded plates etc. can also be used.
To use the steel cables, attach one end of each cable to the bottom surface of the revolving frame. Attach the other end of each cable to the top surface of the truck frame. This arrangement will prevent relative motion between the revolving frame and the truck frame. Installation of these cable restraints should become a part of the lockout procedure if conditions so warrant. For typical part numbers and locating dimensions, refer to Bucyrus drawing E021447
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SAFETY PRECAUTIONS
General Precautions: The employment of qualified maintenance personnel, through a scheduled maintenance program, is the best way to minimize machine downtime and maximize productivity of equipment. Keep hands, feet and clothing away from rotating parts. Wear a hard hat, safety shoes and protective lenses at all times. Replace any and all safety and warning placards if they are defaced or removed from the machine. Think before you act. Carelessness is one luxury the service man cannot afford. Excessive or repeated skin contact with sealants or solvents may cause skin irritation. In case of skin contact refer to the Material Safety Data Sheet (MSDS) for that material and the suggested method of cleanup. Inspect safety catches (keepers) on all hoist hooks. Do not take a chance, the load could slip off of the hook if they are not functioning properly. If a heavy item begins to fall, let it fall, dont try to catch it. Keep your work area organized and clean. Wipe up oil or spills of any kind immediately. Keep tools and parts off of the ground. Eliminate the possibility of a fall, slipping or tripping. Floors, walkways and stairways must be clean and dry. After fluid draining operations be sure all spillage is cleaned up. Electrical cords and wet metal floors make a dangerous combination. Regularly inspect for any loose bolts or locking devices and properly secure them. Use extreme caution while working near any electrical lines or equipment whether it be high or low voltage. Never attempt electrical repairs unless you are qualified. Check limit switches for proper operation. After servicing, be sure all tools, parts or servicing equipment are removed from the machine and secured in an appropriate storage area. Mechanical Brakes are designed for use as static holding brakes only. Use as a motion (dynamic) brake in emergency situations only. Use proper interior and exterior lighting. Install and maintain proper grounding and ground fault protection systems. Allow electrical inspection and maintenance to be performed only by a qualified electrician. Use extreme caution when working around drilled holes.
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Maintenance Precautions: Do not wear rings, wristwatches or loose fitting clothing when working on machinery. They could get caught on moving parts causing serious injury. Always wear a safety belt or harness when the danger of falling exists. Always have a second person to monitor the lifeline when working in confined spaces. Do not start an engine indoors unless adequate exhaust ventilators are provided and in operation. Never utilize the machine air or hydraulic systems for support when working on the machine. Deactivate or isolate the entire system prior to performing maintenance. Equipment should be parked on level ground at all times during machine servicing and periods of idleness. Cranes and hoists must be of sufficient capacity to lift the heavier components (gearcases, pipe arms, etc.) Always work within the limitations of the equipment being utilized. Be sure heavy items are properly rigged and supported from cranes or hoists before removing supporting members from the machine. Utilize guide lines or ropes to minimize the swing of suspended heavy components. Have sufficient service personnel available when removing or installing large heavy items to maintain control at all times. Always use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on the jack or hoist to carry the load, they could fail. When disassembling a machine, be sure to use safety stands and adequate cribbing to prevent tipping or rollover of components. When using an oxy/acetylene torch, always wear welding goggles and gloves. Keep a charged fire extinguisher within reach. Be sure the acetylene and oxygen tanks are separated by a metal shield and are chained to the cart. Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when applicable. Use hammers, punches and chisels only when absolutely necessary. Always be sure to wear safety glasses. Use extreme caution when using compressed air to dry parts. Use approved air blowguns, do not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding to protect everyone in the work area. Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or servicing the machine. Protective eye goggles should be worn at all times when working on the air conditioning system. Work on the air conditioning system only in a well ventilated area.
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Wipe away excess lubricants around bearings and gears. Never lubricate parts in motion. Always wear approved rubber gloves and use insulated hooks or tongs when handling trail cable. Operating Precautions: Wear hearing protection when exposed to the following noise levels in excess of the period indicated: 8 hours at 90 dBa 4 hours at 95 dBa 2 hours at 100 dBa 1 hour at 105 dBa 30 minutes at 110 dBa 15 minutes at 115 dBa When in doubt about the noise level, wear approved hearing protection. Do not attempt to get on or off the machine while it is in operation. Notify the operator prior to any attempt to board/exit the machine. Do not move or operate the machine without first knowing the location and purpose of all personnel, test or support equipment, on or near the machine. Do not allow unauthorized personnel on board the machine while in operation. Use audible signals to warn of machine movements. A signal horn button is provided for this purpose. Do not propel until the travel route has been cleared of obstructions. Do not propel the machine on a slope greater than that specified in SLOPE LIMITATIONS in Section 2 ~ OPERATION. Prevent trail cable from being dragged on the ground for long distances or at high speeds. Limit the amount of cable being pulled by the machine. Pulling too much cable will damage both the cable and the machine.
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FIRE PREVENTION Always have a charged fire extinguisher on hand and know how to use it. Inspect and service the extinguisher as indicated on its instruction plate. DO NOT smoke while handling flammables or when near batteries. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque. See Chapter 4 of this manual for the Scheduled Maintenance recommendations and the Daily Inspection procedure. Repair or replace loose or damaged lines, tubes and hoses as soon as possible. Make certain all clamps, guards and shields are replaced correctly so as to prevent vibration and the chafing of parts during operation. DO NOT carry flammable fluids such as gasoline or solvents on board the machine. DO NOT over-bend or strike pressurized lines or hoses. DO NOT install bent or damaged lines, tubes, or hoses. Replace them immediately. DO NOT start the machine or move any of the controls if a warning tag is attached to the controls or the start panel.
Fire Extinguisher Locations
Keep all cleaning rags properly stored. DO NOT discard them into a pile on board. Keep all structural frame compartments, walkways and work areas clean and free of lubricant residue. NEVER weld, burn, or perform service on the machine alone. If a motor or other component is running hot, shutdown the machine until it has cooled and the cause is determined and repaired.
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WARNING SIGNS AND DECALS The placards depicted below are mounted on the machine as delivered from Bucyrus International, Inc. These hazard warning placards convey information to operators, maintenance personnel, or anyone who will be on or near the machine. The information is designed to help prevent situations which may result in injury to personnel or damage to the machine.
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Stored Energy Decals
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MACHINE OVERVIEW This Mining Shovel is designed and constructed to provide efficient service under the most severe conditions. The machine is built to the highest possible standards and will provide trouble free operation if properly maintained. This section of the manual introduces the machine and its functional capabilities and limitations.
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LOWER WORKS The lower works is comprised of the truck frame, right and left crawler frames, crawler belts, propel machinery, swing rack and roller circle.
Truck Frame and Crawlers
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CRAWLERS This machine is provided with a crawler system composed of 2 independently-driven crawler frame assemblies, one on each side of the truck frame. Each crawler has its own belt driven by a sprockettype drive tumbler. Individual crawler links are heavy alloy steel castings connected by heat treated pins. Innovative drive tumblers made from large diameter steel castings have lugs extending beyond the tumbler rims. They are mounted on forged alloy steel shafts which turn on large anti-friction bearings mounted within the crawler frame. The sprocket type lugs provide a large area of contact against the crawler links, extending the life of both links and tumblers. Lower rollers rotate on forged steel shafts mounted within the crawler side frames. Eight smaller rollers and 1 large roller per frame are specially suited to withstand the periodic single point ground reaction caused by uneven pit floors. Slide bars on top of each frame support the upper crawler belt, reducing propel friction and drag. These side frames are stress relieved weldments comprised of steel castings and cold weather steel plates. The crawler assemblies are bolted to the truck frame with large diameter rods and torque nuts. Each crawler belt can be independantly adjusted for tension.
Right Crawler Assembly (Left Opposite)
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TRUCK FRAME The truck frame is a stress relieved welded cellular box structure which utilizes impact resistant steel in the major load carrying members. The low temperature toughness of the steel assures adequate strength and durability across a wide range of temperatures frequently encountered in machine applications. A fabricated support structure welded integrally into the truck frame supports the center pintle hub area. The inner diameter of the hub is machined to accept the center pintle bushing. Truck frame surfaces which mate to crawler side frames and swing rack are shop machined to assure proper alignment and solid foundation.
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SWING RACK The swing rack is a large diameter external tooth gear mounted on the top of the truck frame concentric with the center pintle bore. The rack is a 4-piece gear bolted to the truck frame.
Swing Rack and Roller Circle
ROLLER CIRCLE The roller circle is composed of the upper rails, lower rails, thrust rails, 50 tapered rollers and inner/ outer roller cages. The lower rail segments are secured to the top surface of the swing rack forming a continuous rolling path for the rollers. The upper rails are attached to the bottom of the revolving frame, fore and aft of the center pintle. Upper rail ends are tapered to provide a smooth approach for the rollers. Rollers are tapered to ensure non-skid contact with rails. The rollers are spaced and aligned with pins and low maintenance polyurethane bushings.
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Roller Circle Assembly
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PROPEL MACHINERY The propel machinery is driven by two AC motors, each horizontally mounted to the crawler frames. Each motor is coupled to a right-angled planetary gearcase high up off the pit floor for protection from water and rock damage. One spring-set, air-released, disc brake is mounted to each of the two motors. The dual planetary configuration with separate drive motors permits straight ahead or reverse propel as well as counter rotation steering.
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COLLECTOR RINGS High voltage collector rings between the revolving frame and truck frame transfer electric power from the truck frame to the rotating deck. Electric power enters the truck frame between the propel motors and is transferred by means of collector ring shoes to the collector rings. The shoes are mounted between the cast center pintle hub and the swing rack.
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ROTATING DECK The rotating deck consists of revolving frame, center pintle, right and left deck extensions, operators cab and the machinery house. Also included are the electrical system components, operating controls, air system, A-frame, along with the hoist, swing and crowd machinery units.
Deck Plan
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REVOLVING FRAME
The revolving frame is the main structural member of the rotating deck. It is a welded, stress relieved structure with integral lugs for mounting the Aframe, crowd machinery and boom. Provisions are made for mounting deck extensions, operators cab, ballast box and swing gearcases. Machined pads on the deck locate hoist drive motor and machinery frames. Refer to the following page for an view of the revolving frame assembly with deck extensions and ballast box. The revolving frame is connected to the truck frame by the center pintle.
CENTER PINTLE The center pintle is a large diameter, hollow cylindrical forging and threaded at the bottom. A bronze coated steel core spherical thrust washer between the lower adjusting nut and the bottom surface of the truck frame provides a wear surface for pintle loads. The top of the center pintle is doweled and bolted to the revolving frame using a split clamping collar. The hollow pintle provides passage for air and grease lines and electrical cables from the revolving frame to the lower works using a swivel and collector ring assembly,.
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DECK EXTENSIONS Right and left side deck extensions are bolted to each side of the revolving frame. They provide a mounting area for the electrical transformers and accessory machinery as well as supporting the machinery house walls.
Deck Extensions and Ballast Box
BALLAST BOX The ballast box is an all-welded steel fabrication located at the rear of the main revolving frame. A series of vertical plates in the box form compartments for holding ballast. MACHINERY HOUSE The machinery house encloses the revolving frame, ballast box and deck extensions. It is constructed of self-supporting steel panels with built-in framing. Removable roof sections are provided over the swing machinery and to the side and rear of the A-frame. The house also provides mounting for the air ventilation and pressurization system. A separate electrical room is located over the ballast box. Platforms and stairs facilitate access to the sides and tops of the house for inspection and maintenance purposes. Boarding stairs and/or ladders permit easy access onto the machine.
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VERTICAL BOARDING LADDER
The vertical boarding ladder is one of the means for boarding the machine and is located on the left side of the machine, at the rear of the machinery house. Use the pull chord from ground level to lower the ladder. This ladder must be in their raised and latched position to enable the operators controls.
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BOARDING STAIRS - RIGHT A set of boarding stairs is attached to the right side machinery house platform. When lowered, the stairs allow entrance to the machinery house from ground level. These stairs must be in their raised and latched position to enable the operators controls.
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A-FRAME An A-frame with seamless tubular alloy steel front legs provides ample space for the retracted dipper handle end. The rear legs are cold weather steel fabricated beams. Both front and rear legs are pin connected to lugs integral with revolving frame. The A-frame supports the boom via structural strands.
A- Frame and Front End Support Components
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HOIST MACHINERY The hoist machinery consists of a motor coupled to two gear reductions which drive the hoist drum. A spring-set, air-released disc brake is mounted to the motor. A hoist rotary encoder limits hoist travel. The hoist motor is connected to the motor pinion shaft by a multiple coupling shaft assembly. The first reduction gear set is mounted in an oil lubricated, totally enclosed gearcase. The second reduction gears are drip lubricated with open gear lubricant from the automatic lubrication system. All shafts run on anti-friction bearings. The hoist bull gear is bolted to a spider on the left hand side of the drum. The hoist drum is manufactured with machined, flame hardened rope grooves. Drum spider stub shafts turn on an anti-friction bearings supported by side frames which are bolted to the rotating deck.
Hoist Machinery - Plan View
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SWING MACHINERY
Swing Machinery Components
Two planetary swing gearboxes, each driven by a vertically mounted motor, are mounted on either side of the revolving frame. Dual output shafts from each gearbox are splined to pinions which engage the swing rack. Bolt-on mounting permits easy field exchange or replacement of either the planetary gearboxes or the splined pinions. The four pinions result in lower shared tooth loads for longer pinion and rack life. A spring-set, air-released, disc brake is mounted on each of the two swing motors.
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CROWD MACHINERY The crowd machinery is located at the front, center of the revolving frame. It consists of a motor, spring-set, air-released disc brake, drum and gearing. A crowd rotary encoder prevents overtravel of the dipper handle. With the crowd machinery on the revolving frame instead of the boom, front end weight is substantially reduced - resulting in lower swing inertia and reduced required swing effort. The entire machinery unit can be removed from the machine should maintenance or overhaul become necessary
Crowd Machinery Components
The crowd drum drives the crowd and retract rope system. Rope grooves are machined into the drum and flame hardened. The crowd and retract ropes are attached to the drum by ferrulebecket anchors which greatly simplifies rope changes.
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OPERATORS CAB The isolated and elevated operators cab at the right, front of the machinery house provides a comfortable, safe and efficient working environment for the operator. Sufficient space is provided for the fully adjustable operators seat, a helpers seat and the standard operators display panel.
All operating controls are incorporated into the arms of the seat. The cab is sound and heat insulated with interior walls made of a sound deadening steel-plasticsteel composite. Electric powered windshield wipers are provided for quiet, dependable operation. A one-piece front window is supplied in a rugged, easy-to-change frame. A forward front window slant with over hanging roof helps keep the window clean. Transparent sun shades are provided in front and side windows. Visibility through both side and front windows is excellent. The operator has the best view in the industry of the digging face and for truck spotting. This view is enhanced by the streamlined sides and top surfaces of the boom, unencumbered by crowd machinery or dipper handles on the outside of the boom. An air conditioner and pressurizing unit utilizes environmentally friendly 134a refrigerant in the cooling system. Interior ducting distributes the airflow to best suit the comfort of the operator.
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COMPRESSED AIR SYSTEM The compressed air system consists of a rotary screw type air compressor, air receiver, air brakes, controls and center pintle air swivel. Hydraulic high pressure hose is used throughout. The air system is used to operate all machinery motion brakes and lubrication components and to perform various other functions.
AUTOMATIC LUBRICATION SYSTEM The lube system is located in an insulated, double wall, lube room which can be heated for cold weather operation. A one ton (907 kg) monorail-mounted electric chain hoist is provided to be used to raise supplies from the ground onto the left house platform and into the lube room. Lube points on the electric motors, suspension rope pins and some dipper pins are manually accessed. All other lube points are fed from the automatic system or by oil bath.
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A single-line automatic lubrication system applies open gear lubricant (OGL) and grease via a programmable logic controller (PLC). The system has six lube pumps (four for OGL and two for grease), each feeding individual PLC controlled circuits. Lincoln Powermaster Four 75:1 air powered pumps are mounted on two reservoirs. High pressure hoses with reusable fittings are utilized.
Lubrication Room
The six separately controlled lube circuits provide selective distribution frequency and quantity resulting in reduced lubricant usage and cost.
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FRONT END EQUIPMENT The front end equipment consists of the boom, the boom point sheaves, padlock, saddle block, dipper handle, dipper, dipper trip mechanisms, running ropes and boom suspension strands.
SUSPENSION STRANDS The suspension strands are designed to maintain the proper boom angle. These are fixed-length strands that support the entire weight of the boom and the load.
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BOOM The boom is a welded steel structure consisting of twin box girders integrally connected at the boom point and in the lower section between the shipper shaft and boom feet. Impact resistant steel is utilized, coupled with 100% penetration and UT quality welds on all main splice joints. Design optimization has resulted in heavier outside skin plates, minimizing the need for internal diaphragms. This reduction in weld related stress concentrations further enhances structural life. Open manholes have been incorporated in the boom as a standard feature permitting periodic structural inspection. Integral ladders within the upper boom sections permit internal access without lowering the boom.
Boom Assembly
The boom is supported by four pre-stressed suspension (structural) strands attached to equalizer links on the A-frame. These inherent long life structural strands carry the working loads of the front end equipment. A boom limit switch with soft setdown prevents boom jacking shock loads.
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RUNNING ROPES Hoist, crowd, retract and dipper trip ropes are all plastic impregnated for increased life and for sheave and drum grooving life enhancement. The double twin hoist ropes are attached to the center of the hoist drum using ferrule-becket anchoring for faster rope change out. Each rope passes over a boom point sheave through the padlock and back over the boom point sheave to the hoist drum. The dual twin hoist rope configuration stabilizes the dipper while digging by attachment to the outer edges of the dipper body.
Ropes - General Arrangement
Crowd and retract ropes are attached to the crowd drum and work as an integral system. As the crowd rope is wound on to the drum, the retract rope is reeled off.
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SADDLE BLOCK The saddle block is positioned between the boom side girders in the mid-section of the boom. It pivots on manganese-bronze bushings about the shipper shaft. It acts as a guide for the longitudinal movement of the dipper handle. The free-floating design of the handle in the saddle block eliminates handle torsion.
DIPPER HANDLE The dipper is attached to one end of the large diameter handle. The crowd rope half-sheave is attached to the other end. A hydraulic rope take-up mechanism at the dipper end, and the crowd rope adjusting mechanism are used to remove slack from the crowd/retract rope system. The dipper handle crowds out and retracts within the saddle block. An electrical rate reduction circuit, along with the crowd ropes, absorb digging shock loads encountered when the dipper is crowded into the bank.
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Manual No. 10213

DIPPER A general purpose dipper is usually constructed as a casting and plate weldment. The dipper lip and lower front are alloy heat treated castings. The dipper body, back, upper sides and door are made of steel plate. Removable Whistler type tooth adapters and replaceable tooth points are attached to the lip casting to penetrate the bank material. The door is hinged and latched to the dipper body. A dipper trip mechanism controls the release of the latch bar, allowing the door to swing open. The latch bar holds the door shut during digging. Spring loaded snubbers dampen the doors swinging action.
Dipper Assembly
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August 2003

PADLOCK
Padlocks connect the hoist ropes to the outer edges of the dipper while still permitting fore and aft and sideways movement.
DIPPER TRIP The dipper trip is a wire rope activated dipper door trip mechanism driven by an electric motor through gear reduction mounted on the boom near the boom foot.
Dipper Trip - General Arrangement
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Manual No. 10213

TYPICAL MACHINE SPECIFICATIONS

This specification describes the principal mechanical features of a standard Bucyrus International, Inc. 495B IGBT Acutrol controlled machine. The machine is fully revolving, crawler mounted and equipped to operate from an alternating current power source. NOTE: These are typical machine specifications.
Weights Working Weight (w/Dipper) Dipper (60 yd3, 46 m3) Ballast Net Weight, minus Ballast and Dipper 2,688,000 138,000 700,000 1,850,000
(pounds)
1,219,300 62,600 318,200 839,200
(kilograms)
Front End Equipment Boom Boom Point Sheaves Boom Point Sheave Diameter Shipper Shaft Sheaves Shipper Shaft Sheave Diameter Dipper Handle Diameter Dipper Handle Wall Thickness Welded, Impact Resistant Steel Twin Grooved, Flame Hardened 96" 243.84cm Twin Grooved, Flame Hardened 72" 182.88cm 34" 86.36cm 3" (nominal) 7.62 cm
Rope Data Hoist Crowd Retract Dipper Trip Boom Suspension 2 1 1 1 4

# Ropes
2 3/4" 2 1/2" 2 1/2" 5/8" 3 1/4"
Diameter
69.88mm 63.5mm 63.5mm 15.9mm 82.6mm
Twin Dual Single Dual Single Dual Single Equalized
Type
6X37 6X37 6X37 6X37 Structural Strand
Constr.
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August 2003

Dimensions and Working Ranges

US Metric
Dipper Capacity (nominal) ............................................ 60 yd3 Dipper Capacities (range) ........................................ 40-80 yd3 Length of Boom ..................................................................67' Boom Angle ........................................................................... Effective Length of Dipper Handle ................................ 35-10" Overall Length of Dipper Handle .........................................47' A: Dumping Height ...................................................... 34-10" A1: Dumping Height at Maximum Radius ....................... 28-3" B: Dumping Radius - Maximum .................................... 66-9" C: Cutting Height - Maximum ........................................ 59-3" D: Cutting Radius - Maximum ....................................... 78-2" E: Radius of Level Floor ................................................ 56-1 F: Depth Below Ground Level - Maximum .................... 10-6" G: Clearance Height @ Boom Point Sheaves ............... 68-6" H: Clearance Radius @ Boom Point Sheaves .............. 63-1 I: Clearance Radius @ Revolving Frame ..................... 29-7" J: Clearance - Revolving Frame to Ground ................ 10-10" K: Height of A-Frame .................................................... 44-4" L: Overall Machine Width.............................................. 42-8" M: Ground Clearance (Lowest point of Truck Frame) ........22" N: Operators Cab Eye Level ......................................... 29-0"
46 m3 30.6-61.2 m3 20.4 m 45o 10.9 m 14.3 m 10.6 m 8.61 m 20.34 m 18.1 m 23.83 m 17.1 m 3.20 m 20.9 m 19.02 m 9.02 m 3.3 m 13.51 m 13.01 m 0.57 m 8.84 m
August 2003
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Manual No. 10213

COMPONENT WEIGHTS Quantity
Weight Each
(U.S. Pounds)
Lower Works Truck Frame ............................................... 1 ........... 190,000 Bushing, Center Pintle ............................... 1 .................. 300 Lower Rail .................................................. 9 .................. 570 Thrust Rail .................................................. 9 .................. 170 Propel Brake Adapter ................................. 2 .................. 365 Propel Brake .............................................. 2 .................. 650 Propel Brake Hub ....................................... 2 .................. 130 Propel Motor............................................... 2 ............... 4,500 Propel Motor Blower ................................... 2 .................. 210 Propel Motor Guard Top Cover Plate ......... 2 .................. 670 Crawler Belt (2 per Machine)...................... 2 ........... 123,300 Crawler Link (47 per Belt) ..................... 94 .............. 2,500 Pin, Link (2 per Link) ............................ 188 .................. 70 Crawler Assembly ~Shipping ..................... 2 ........... 128,591 Crawler Assembly ~Shop ........................... 2 ........... 128,600 Structure ..................................................... 2 ............. 77,650 Propel Gearcase ........................................ 2 ............. 16,000 Front Idler ................................................... 2 ............... 5,000 Shaft, Front Idler ........................................ 2 ............... 1,200 Adjusting Block........................................... 4 .................. 400 Load Roller ................................................. 8 ............... 2,000 Shaft, Load Roller ...................................... 8 .................. 550 Rear Idler ................................................... 2 ............... 3,800 Shaft, Rear Idler ......................................... 2 .................. 700 Drive Sprocket ............................................ 2 ............... 7,200 Sprocket Shaft Assembly ........................... 2 ............... 4,597 Sprocket Shaft ........................................ 2 ............... 3,520 Center Pintle Sleeve .................................. 1 ............... 8,750 Center Pintle Split Clamp, Upper ............... 1 .................. 590 Center Pintle Lower Nut ............................. 1 ............... 1,080
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August 2003

Quantity
Weight Each
(U.S. Pounds)
Upper Works
A-Frame Front Leg ............................................ 1 ................ 23,000 A-Frame Rear Leg............................................. 2 .................. 6,220 Auxiliary Winch Assembly ................................. 2 ..................... 500 Boom Foot Pin ................................................... 2 ..................... 460 Upper Rail ........................................................ 10 .................... 500 Swing Planetary Gearcase ................................ 2 ................ 11,000 Swing Pinion Shaft Assembly ............................ 4 .................. 2,000 Swing Pinion Shaft ............................................ 4 .................. 1,500 Swing Bearing Carrier ....................................... 4 ..................... 230 Swing Shaft Bearing .......................................... 4 ..................... 100 Swing Brake Adapter ......................................... 2 ..................... 270 Swing Brake ...................................................... 2 ..................... 550 Swing Motor ...................................................... 2 .................. 4,600 Crowd Drive Pinion ............................................ 1 ..................... 130 Crowd 2nd Intermediate Shaft........................... 1 .................. 2,000 Crowd 2nd Intermediate Gear ........................... 1 .................. 2,650 Crowd Motor Shaft Coupling ............................. 1 ..................... 150 Crowd Frame ..................................................... 1 ................ 11,500 Crowd Pinion Guard .......................................... 1 ..................... 280 Crowd Gearcase Cover ..................................... 1 .................. 2,120 Crowd Upper Gear Guard ................................. 1 ..................... 170 Crowd Gear Guard - Lower ............................... 1 ..................... 340 Crowd Drum ...................................................... 1 ................ 12,800 Crowd Drum Spur Gear ..................................... 1 .................. 4,970 Crowd 1st Intermediate Shaft ............................ 1 ..................... 130 Crowd 1st Intermediate Gear ............................ 1 .................. 1,080 Crowd Brake ...................................................... 1 ..................... 500 Crowd Brake Adapter ........................................ 1 ..................... 270 Crowd Motor ...................................................... 1 .................. 4,000 Air Swivel ........................................................... 1 ..................... 150 Front Swivel Housing ........................................ 1 ..................... 135 Rear Swivel Housing ......................................... 1 ..................... 135 Swivel Collector Ring Assembly ........................ 1 ..................... 330
Hoist Planetary Gearcase .......................... 1 ............. 25,000 Hoist Pinion ................................................ 2 ............... 1,650 Hoist Pinion Bearing Carrier ....................... 2 .................. 500 Hoist Machinery Guard - Bottom ................ 1 ............... 2,000 Hoist Machinery Guard - Rear.................... 1 ............... 1,100
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Manual No. 10213

Quantity
Weight Each
(U.S. Pounds)
Upper Works (Cont.) Hoist Machinery Guard - Front ................... 1 ............... 1,250 Hoist Bearing Housing ............................... 2 ............... 3,200 Hoist Drum ................................................. 1 ............. 30,700 Hoist Spider ................................................ 1 ............. 16,000 Hoist Drum Gear ........................................ 1 ............. 11,980 Hoist Frame - R. H. .................................... 1 ............... 8,600 Hoist Oil Cooler .......................................... 2 ................ 2600 Hoist Motor ................................................. 1 ............. 15,000 Hoist Brake ................................................. 1 ............... 1,350 Hoist Brake Adapter ................................... 1 .................. 500 Hoist Brake Hub ......................................... 1 .................. 205 Hoist Motor Coupling Shaft Assembly ........ 1 ............... 1,350 Hoist Motor Coupling Guard ....................... 1 .................. 300 Boarding Stairs ........................................... 1 ................ 4100 Boarding Ladder ......................................... 1 .................. 450 Machinery House Filter Assembly .............. 2 ............... 1,330 Control Room Filter - Tenkay ..................... 1 ............... 7,500 Revolving Frame ........................................ 1 ........... 163,500 Front End Boom (Bare) ............................................... 1 ........... 138,500 Boom Bumper Assembly ............................ 8 .................... 30 Boom Point Sheave Assembly ................... 1 ............... 6,900 Boom Point Shaft ....................................... 2 ............... 1,040 Boom Point Sheave ................................... 2 ............... 4,230 Saddle Block Assembly (W/O Shaft) .......... 1 ............... 5,100 Shipper Shaft ............................................. 1 ............... 4,880 Crowd / Retract Rope ................................. 2 ............... 2,100 Hoist Rope ............................................. 1 pair ......... 10,400 Suspension Rope ....................................... 4 ............... 2,750 Pendant Equalizer - R.H. ........................... 1 ............... 1,820 Pendant Equalizer - L.H. ............................ 1 ............... 1,820
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August 2003

Quantity
Weight Each
(U.S. Pounds)
Front End (Cont.) Handle Weldment ...................................... 1 ............. 46,910 Crowd Take-Up Mechanism ....................... 1 ............. 10,500 Crowd Take-Up Guide ............................ 1 ............... 2,160 Crowd Take-Up Worm Gear ................... 1 .................. 610 Crowd Take-Up Gear Housing ............... 1 .................. 445 Crowd Take-Up Screw Rod .................... 1 ............... 4,520 Crowd Half-Sheave ................................ 1 ............... 2,280 Retract Take-Up Cylinder ........................... 2 .................. 145 Retract Take-Up Guide ............................... 1 .................. 500 Retract Spreader and Stop ......................... 1 ............... 2,100 Pin, Handle-Dipper ..................................... 2 .................. 430 Pin, Pitch Brace to Handle, Dipper ............. 4 .................. 280 Pin, Door to Dipper..................................... 2 .................. 385 Padlock ...................................................... 2 ............... 9,270 Pin, Padlock to Dipper............................ 2 .................. 370 Pin, Padlock Sheave .............................. 2 .................. 370 Sheave, Padlock .................................... 2 .................. 620 Dipper Assembly: Dipper Body with Liners ............................. 1 ........... 105,200 Dipper Body Bare ....................................... 1 ............. 99,771 Dipper Door ................................................ 1 ............. 23,814 Latch Bar ................................................ 1 .................. 600 Latch Lever ............................................ 1 .................. 410 Snubbers ................................................ 2 ............... 1,750 Pitch Brace, Adjustable .......................... 2 ................ 2930 Center Shroud ........................................ 8 .................. 440 Corner Shroud, Upper ............................ 2 .................. 465 Corner Shroud, Lower ............................ 2 .................. 365 Teeth .......................................................... 9 .................. 205 Adapter, Tooth ........................................ 6 .................. 825 Wear Cap, Tooth .................................... 6 .................... 50
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Manual No. 10213

Manual No. 10213
1 - 46
August 2003

Electric Mining Shovel 495HR - Bucyrus

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BUCYRUS INTERNATIONAL, Inc.

495HR Electric Mining Shovel

Deck Plan ................................................................................................................................. 22

Deck Extensions and Ballast Box ............................................................................................. 24

Swing Machinery Components ................................................................................................. 29

BUCYRUS INTERNATIONAL, Inc.

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Safety must always be paramount!

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

SAFETY - SWINGING RESTRAINT & BALLAST BOX SUPPORT

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Difference in Elevation 0.75 2.9 14.7

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

BUCYRUS INTERNATIONAL, Inc.

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Fire Extinguisher Locations

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Stored Energy Decals

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Truck Frame and Crawlers

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Right Crawler Assembly (Left Opposite)

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Swing Rack and Roller Circle

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Roller Circle Assembly

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.

Deck Extensions and Ballast Box

BUCYRUS INTERNATIONAL, Inc.

VERTICAL BOARDING LADDER

Manual No. 10213

BUCYRUS INTERNATIONAL, Inc.