Bucyrus 495BI Shovel Parts Catalog – BI005191 PDF

Description

Bucyrus 495BI Shovel Parts Catalog – BI005191

This complete Bucyrus 495BI Shovel Parts Catalog, published under document number BI005191, is the illustrated parts reference for the 495BI mining shovel. Every major assembly on the machine is broken down into exploded diagrams with catalog reference numbers, part descriptions, factory part numbers, remarks, and quantities, giving you the exact information needed to identify a component, confirm its part number, and order a replacement with confidence.

Whether you are maintaining a working 495BI, rebuilding a component, or sourcing hard-to-find parts for a machine in the field, this Bucyrus 495BI parts catalog puts the full factory parts breakdown at your fingertips. The catalog spans mechanical, hydraulic, pneumatic, lubrication, and electrical systems, with dedicated sections for the truck frame, revolving frame, crawler machinery, swing, crowd, and hoist machinery, boom, dipper, and the complete electrical parts list.

File Details

• Manual Type: Illustrated Parts Catalog
• Brand: Bucyrus / Bucyrus-Erie
• Model: 495BI (495B) Shovel
• Document Number: BI005191
• Language: English
• Page Count: 408
• File Format: PDF

Chapters Covered

• Truck Frame – Frame assembly, center pintle bushing, lockpin mechanism (spring, pin, handle), lower rail, inner and outer rail clamps, swing rack assembly, rail shims, bottom cover, access cover, open gear lube dam
• Propel Blower Duct
• Cable Reel – Hose, cable reel, bottom and top support pins, yoke ends (front and rear), top connection support, bottom support brackets, turnbuckle yoke end, check valve
• Roller Circle – Complete frame, rail assembly roller, roller pin, bolt and pin, lock nut, outer and inner frame, capscrews, washers, splices, bushings, thrust washers
• Lower Works Air Piping – Air gauge, quick-release valves, air hose, hose couplings
• Propel Machinery – Planetary gearcase (RH and LH), coupling cover, motor coupling, coupling key, gearcase capscrews, motor rod, shims, chocks, wedges, O-rings, retainers
• Planetary Gearcase Propel Brake – Brake assembly, brake hub, socket head screws, brake adapter, guard, tach drive shaft, tach support, tach cover, tach mounting screws
• Lower Works Lubrication – Grease piping and injectors, open gear piping and injectors, lube hose, injectors, caps, crossovers
• Crawler Machinery – Frame and links, drive tumbler shaft, take-up tumbler and axle, rollers: upper idler, lower roller, bushings, shafts, collars, caps, seals, guards, retainer bolts, dowels
• A-Frame – Front leg, back leg, backleg upper pin, tee head bolts, cotter pins, equalizer pins, rear leg rollers, rod bolts, lock washers
• Auxiliary Winch
• Revolving Frame – Front and rear A-frame pins, boom foot pins, bushings, collar clamps, pin retainer bolts, cotter pins, center pintle (sleeve, top and bottom nuts, lock bars, capscrews, dowels, lifting lug), rails (RH and LH front, rear, center), rail end chocks, rail clamps
• Swing Machinery – Gear case (complete with cover), gear case seals, breather filter, dipstick, oil gauge, pinion guards, shaft bearing housing, shim packs, drain cock; intermediate shaft and motor pinion (key, bearings, retainers, covers, spacers, O-rings, gear, pinion, shims); vertical swing shaft (shaft and pinion, sleeve, bearings, retainers, spacers, seals, O-rings, shims, deflectors, swing gear); brake (adapter, brake assembly, motor-to-brake hub, capscrews, shims, cover, guard)
• Crowd Machinery – Frame, covers and guards (crowd frame, gearcase cover, upper and lower gear guards, pinion guard, drum shaft bearing caps, bearing cap bolts and studs, case cover capscrews, bearing bolts and nuts, frame anchor pin, motor shaft coupling bolt, top inspection cover, gearcase cover pins); 2nd intermediate shaft (shaft and pinion, retainers, bearings, seals, covers, gaskets, spacers, carriers, shims); 1st intermediate shaft (shaft, retainers, bearings, seals, gear, spacers, carriers, dowels, shim packs); motor shaft (shaft and pinion, drive pinion, bearings, retainers, spacers, O-rings, shim packs, coupling, capscrews, lock washers, key); rotary limit switch (shaft, cover, gearcase, bearings, gears, pin, capscrews, retainer); drum mounting (drum assembly, spur gear, gear-to-drum bolts, RH and LH bearings, spacers, seals, end caps, retainers, shim packs, sleeves)
• Crowd Machinery Brake – Brake adapter, crowd brake, motor-to-brake hub, motor shaft nut, lock washer, support capscrews, brake mounting capscrews, mesh cover, guard
• Hoist Machinery – Gear enclosures and side frames (rear and front gear case covers, coupling guard, side frames LH and RH, rod bolts, rod nuts, bearing housing, bearing housing bushing, frame side bolts, bearing caps, side inspection covers, clean-out covers, gear case covers, troughs and gaskets, hoist machinery safety gate); intermediate shaft (shaft and pinion, retainers, bearings, carriers, seals, O-rings, spacers, keys, shim packs, V-ring seals, gear); drum mounting (drum spider bolts, drum bearings, spacers, seals, retainers, O-rings, drum-spider bolts, drum gear, spider LH and RH, gear-spider bolts, hoist drum, rope retaining bolts)
• Hoist Machinery Brake – Hoist brake, brake adapter, motor-to-brake hub, support capscrews, brake mounting capscrews, motor shaft nut, lock washer, mesh cover, guard
• Boom – Complete boom, bare boom (includes shipper shaft bushing and boom foot pin bushing), boom bumper, rubber bumper, retainer pin rod, bumper support, boom bumper bolts, T-bolts, cotter pins; boom point sheaves (shaft, clamp collar assemblies, keys, sheaves, bearings, seal retainers, oil seals, sleeves, spacers, O-rings, shims); boom lubrication (grease injectors, mounting bars, lube hoses, drip mounting bars, crossover injectors)
• Dipper – Complete dipper, door snubber (RH and LH), snubber support, inner and outer friction plates, spring housing, friction lining, friction springs, spring retainers, friction plate bolts, inner friction plate bushings, snubber links, link pins, friction plate retainers, support bushings, O-rings, spring housing bolts; dipper handle (complete handle, bare handle, handle tube, handle end, end bushings, spreader and stop retract, spreader retainers, handle end cushions, rod bolts, bumper capscrews, bumper mounting plates); crowd cushion (complete crowd cushion assembly with sheave, equalizer sheave, rope sheave assembly, sheave bushings, sheave pins, sheave pin bolts, cotter pins, guard assemblies, cushion cylinder, housing bolts, flat head socket screws, cushion blocks, split retainers, retainer capscrews, cushion pad stacks, guide spacers, rope guard guides, retainer pins, equalizer bushings and spacers); retract take-up (take-up nut, cylinder guards RH and LH, hinge bolts, take-up pins, rope guide pins, take-up cylinder, take-up guides, piston pads, piston capscrews, hydraulic hose, take-up shims, relief valve, globe valve, shim retainer, cylinder support, thrust nut, retainer capscrews, thrust nut pins, cylinder rod extenders, take-up support); dipper shrouds (RH and LH lower corner shrouds, shroud wedges, locking spools, RH and LH upper corner shrouds)
• Door Snubber (Dipper) – Snubber assembly components including friction plates, springs, retainers, links, pins, bushings, anchors, pressure plates, caps, and pins
• Air System – Revolving frame air system (auxiliary tools shut-off valve, hose assemblies for solenoids, regulator, hoist brake, crowd, horn, steering, pressure switch); brake piping (quick release brake valve, brake pilot valve hose, hoist solenoid to brake hose, operator’s cab gauge hose, regulator to solenoids hose, solenoid to crowd brake hose, solenoid to steering hose, swing pinion spray hose); compressor piping (air compressor, air tank, oil gauge, lube-air-ator kit with filter, lubricator, regulator, auxiliary tools shut-off valve, hose assemblies)
• Lube System – Reservoirs and remote fill piping (grease reservoir, open gear reservoir, covers, gaskets, lubrication hoses, dipsticks, fill disconnects, breathers, reservoir fill caps); panel supply piping (hose assemblies for open gear lube B1, C1, C2, A1 and grease lube A2, B2); crowd machinery and boom foot pin piping (lube injectors 2-spray, 4-spray, 5-spray, 1-spray, lube hoses for bull gear drip, LH and RH intermediate shaft bearings, drum bearings, boom foot pins, injector supply); swing machinery piping (lube injectors, spray control valve, lube hoses for swing intermediate shaft, swing injector supply, roller circle, swing pinion, center pintle thrust washer, lower swing bearing); hoist machinery piping (lube injectors, lube hoses for bull gear drip, intermediate shaft bearings, drum bearings, hoist rope lube, injector supply); air and lube supply manifold
• Fire Protection – Damper air piping (control dampers, air regulator, hoses), collector ring fire protection piping (dry chemical nozzles, dry chemical tanks, supply and feed hoses), control room fire protection piping (dry chemical nozzles, dry chemical tanks, pressure switch, motor control center feed hoses, propel transfer cabinet feed hose, hoist inverter cabinet feed hoses, swing inverter cabinet feed hoses, crowd inverter cabinet feed hose, master control cabinet feed hoses, chopper control cabinet feed hose, power rectifier cabinet feed hose, A-C control cabinet feed hose, PLC cabinet feed hose)
• Electrical Parts – High voltage collector rings (middle phase collector ring, outer phase collector ring, grounding collector ring, inner phase collector ring, insulators, phase shoe supports, phase shoes, springs, pins, connectors, studs, grounding shoe support, spacer, channel, ring mounting); propel collector rings (outer collector ring, spacers, insulators, inner collector ring, tie bar, inner ring, outer shoe assembly, collector ring shoes, springs, shoe supports, pins, connectors, insulators); electrical schematic (for machine numbers 141016, 141039, 141040, 141045, 141052); parts list (breakers, contactors, motors, switches, relays, fuses, gauges, transformers, resistors, rectifiers, capacitors, inverters, cabinets, heaters, lights, horns, solenoids, valves, encoders, tachometers, thermostats, sensors, meters, pushbuttons, receptacles, plugs, suppressors, shunts, transducers); symbol descriptions; electrical part details (relays, contactors, solenoid valves, motors, motor/generators, rectifier cabinets, timing relays, vacuum contactors, multi-speed contactors, motor driven drain valve, transfer switch cabinet, PWM GTO-inverter cabinets, capacitor cabinets, chopper control cabinet, D.C. tach generators, SIMADYN D master control cabinet, auxiliary master control cabinet)

This Bucyrus 495BI parts catalog is not a repair manual. It is the parts identification and ordering reference. Each section presents exploded-view illustrations with reference numbers that map directly to the parts tables, so you can visually locate the exact component, read its description, confirm the Bucyrus part number, check any remarks (such as stocked part indicators or replacement notes), and order the correct quantity. The catalog covers both the mechanical assemblies and the complete electrical parts breakdown, making it the single most useful reference for anyone maintaining, rebuilding, or repairing a 495BI shovel.

What This Bucyrus 495BI Parts Catalog Gives You

With the full factory parts breakdown for the 495BI shovel in hand, you can identify any component on the machine, from a simple O-ring or cotter pin to a complete planetary gearcase or crowd drum assembly, without relying on guesswork or incomplete aftermarket references. The exploded diagrams show how parts fit together, which is invaluable when disassembling an assembly for repair, confirming that you have every component before reassembly, or explaining a parts requirement to a supplier.

For a machine like the 495BI, where downtime is expensive and parts can be difficult to source, having the correct Bucyrus part numbers and descriptions is essential. This catalog eliminates the back-and-forth of trying to describe a part over the phone or match a worn component by sight. You can look up the exact part number, verify it against the illustration, and order with confidence.

The electrical section is particularly valuable, covering everything from high-voltage collector rings to the detailed parts list of relays, contactors, motors, inverters, and control cabinet components. For machines with the electrical schematic covering machine numbers 141016, 141039, 141040, 141045, and 141052, the parts list provides a direct reference to the electrical components used on those specific machines.

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Instant PDF Delivery

This Bucyrus 495BI Parts Catalog is delivered as an instant PDF download, with no shipping and no waiting for a physical book to arrive. Once your order is complete, you can download the file immediately and access it on any device: computer, tablet, or smartphone. The PDF can be printed for use in the shop or stored digitally for quick reference in the field. Whether you are at the machine, in the office, or ordering parts from a supplier, the complete parts breakdown for the 495BI is always within reach.