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Summary of Contents for Thwaites SPRITE NIMBUS
- Page 1 SPRITE NIMBUS...
- Page 2 NIMBUS & SPRITE DUMPER IN THE INTEREST OF SAFETY THE DUMPER SHOULD NOT BE DRIVEN IN A MANNER WHICH EXCEEDS THE LIMITS SHOWN BELOW. FOR UNLADEN DUMPER: • MAXIMUM PAYLOAD - 15 CWT. OR 762 Kg. • LOAD WITH CARE - BULKY, HIGH LOADS ARE DANGEROUS. THEY MAY MAKE THE DUMPER UNSTABLE AND MAKE IT DIFFICULT FOR THE DRIVER TO SEE THE ROAD AHEAD.
- Page 3 SERVICING INSTRUCTIONS NIMBUS & SPRITE MODELS CONTENTS: OPERATION & ROUTINE MAINTENANCE SERVICING POINTS CLUTCH GEARBOX AXLES DRIVE SHAFT STEERING GEAR OIL BATH AIR CLEANER MAINTENANCE CHECK OFF LIST...
- Page 4 THWAITES SPRITE/NIMBUS - OPERATION AND MAINTENANCE INSTRUCTIONS Whilst every endeavour has been made to ensure that your dumper is delivered to you ready to commence work, it is advisable before putting machine on site to have the following check carried out:- Check oil level in engine.
- Page 5 CLUTCH ADJUSTMENT (See Illustration) Depress clutch pedal to its full amount of travel, then turn the square headed screw on the clutch back plate in a clockwise rotation until tight, then turn back until clutch unit revolves freely. DO NOT adjust clutch by the wired nut, as this is pre-set at works to give correct spring tension.
- Page 7 Turn square headed screw in clutch back plate for adjustment...
- Page 8 CLUTCH AND HOUSING...
- Page 9 SERVICING THE CLUTCH - SPRITE/NIMBUS MODELS DISMANTLING: Remove the floorboard. Disconnect the clutch operating arm, unbolt and remove the chainguard (item 32). Remove the locking wire from the conical nut (item 18), compress the clutch slide (item 29) and unscrew the conical nut (item 18), care should be taken when releasing the clutch slide as spring tension is considerable.
- Page 10 CLUTCH CLUTCH ROD STOP PIVOT CLUTCH ROD CLUTCH PIVOT 2 ton model only All other models 1/64" ALL CLUTCH SLIDE (Item 102) MODELS 7" DIA CLUTCH 2 TON - 9/16" LOCKING TUSKER - 1/2" WIRE ORION - 1/2" (11) 6" DIA CLUTCH CLUTCH SLIDE SPRITE - 3/8"...
- Page 11 PRECAUTIONS AFTER RE-ASSEMBLY IMPORTANT: Wire the conical nut to the clutch slide, refit the chain guard and clutch operating arm. The gap between the clutch operating arm and the clutch thrust bearing should be 9/16" when the clutch is fully adjusted (2 ton model). Dimensions for Sprite, Nimbus, Orion and Tusker machines - see system drawing - refer to dimension ‘B’.
- Page 12 SPRITE & NIMBUS GEARBOX ASSEMBLY T5260...
- Page 13 SERVICING 40M-3 GEARBOX - SPRITE/NIMBUS MODELS GENERAL: Cleanliness is important. Remove all loose dirt and see that all bolt heads are clear of cement, etc. outside the gearbox before any inner part is exposed. Drain the oil from the gearbox. Use a mandrel press, if available, for pressing out bearings, shafts, etc., otherwise use hardwood or non-ferrous metal drifts.
- Page 14 SERVICING 40M-3 GEARBOX - SPRITE/NIMBUS MODELS REMOVAL OF GEARSET: (CONTD.) Undo the nut (item 63) on the reverse pinion shaft and remove the reverse pinion assembly. The main dis-assembly of the gearbox is now complete. Removal of the circlip from the front part of the lay shaft will enable the forward part of the layshaft assembly to be slid off.
- Page 15 SERVICING 40M-3 GEARBOX - SPRITE/NIMBUS MODELS RE-ASSEMBLY OF MAIN GEARBOX: CONTD. Before pressing the ballrace into place, the layshaft must be supported by placing a steel packing about 3/8" thick between the gear (item 78) and the casing, otherwise the bush (item 76) will be driven out, and it will not be possible to press the ballrace (item 70) into place.
- Page 16 SERVICING 40M-3 GEARBOX - SPRITE/NIMBUS MODELS DISMANTLING THE FRONT EXTENSION HOUSING: Support the extension housing on the underside of the flange with a suitable ring which will permit the input shaft (item 26) and bearing (item 23) to pass through. Press the input shaft through from the driven end.
- Page 17 CONTENTS OF AXLE SERVICING - SECTION 3. SPRITE AND NIMBUS MODELS INTRODUCTION & PRECAUTIONS, AXLE OIL CAPACITIES, AXLE CODE and WHEEL NUT TIGHTNESS. DIAL GAUGE and AXLE END-FLOAT MEASUREMENT. HUB EXTRACTION TOOLS. 3-1-0 AXLE ASSEMBLY DRAWING 3-1-1 REMOVAL OF AXLE SHAFT 3-2-0 REMOVAL OF THE DIFFERENTIAL ASSEMBLY 3-2-1...
- Page 18 Extreme Pressure HYPOID lubricant of approved type in the SAE 90 classification and conforming to the requirements of S.S. Specification MIL-L-2105B. Thwaites Engineering Co., Ltd., do not approve the addition of any proprietory compounds to the oils recommended, as all these oils have been individually compounded from specified base oils and additives in definite proportions, and any addition to these lubricants could result in dangerous dilution, or gear failure.
- Page 19 Axle Shaft End Float Measurement dial gauge shims 3(b)
- Page 21 3-1-10...
- Page 22 CHAPTER 1 - DRUM BRAKE AXLE - SPRITE/NIMBUS MODELS. TO REMOVE AXLE COMPLETE FROM DUMPER: First remove the axle from the machine using the procedure described in the manufacturers service manual. Next, thoroughly clean the exterior of the unit, thus rendering the working conditions more suitable, in addition to ensuring that the inside of the axle shall be kept clean.
- Page 23 CHAPTER 2 - SPRITE/NIMBUS MODELS DISMANTLING & REASSEMBLY OF AXLE CENTRE ASSYS. USING SHIM SPACERS TO REMOVE DIFFERENTIAL UNIT WITH SERVICE TOOLS: First drain the lubricant from the gear carrier housing and then remove the gear carrier rear cover. Flush out the unit thoroughly, so that the parts can be carefully inspected.
- Page 24 Remove any inclusions from stretcher holes and rectify any damage on edges of holes in order that the carrier stretcher tool will fit correctly. Check turn buckle on carrier stretcher tool is free and fit tool to carrier ensuring that pegs locate fully in stretcher hole.
- Page 25 Remove companion flange from pinion using withdrawal tool or by supporting pinion inside carrier and tapping pinion thread end with hide hammer. Remove pinion complete with inner bearing cone. Remove inner bearing from pinion using service tool, see Fig. 6. PRESS SL REMOVER REMOVAL OF OIL SEAL, BEARINGS ETC...
- Page 26 3-2-3...
- Page 27 Differential Assemblies are FOUR PINION TYPE. Below are detailed instructions for stripping and re-assembly. STRIPPING DIFFERENTIAL ASSEMBLY - FOUR PINION TYPE: Remove the bolts holding the two halves of the differential case together and lift off the non-flanged half - having the assembly sitting on the flange-half trunnion. Remove the top side gear and then ease out the crosspin and pinion mates, together with the two halves of the shaft spacer if fitted, from the lower half of the differential case, taking care not to lose the thrust washers fitted behind all the gears.
- Page 28 DIAGRAMS TO SHOW THE PROCEDURE IN REMOVING THE INNER AND OUTER BEARINGS Fig 8 3-2-4...
- Page 29 RE-ASSEMBLY OF PINION: Check that pinion and gear are matched in that the serial number on the end face of the pinion and on the outer diameter of the gears are identical. (It should be noted that marks on the pinion end adjacent to serial number have no significance in service.) Assemble inner bearing cone onto pinion using service tool or suitable press.
- Page 30 RE-ASSEMBLY OF PINION (CONTD.) Fig. 10. INNER BEARING REPLACER Press outer bearing cup into housing, using press and suitable adaptor. NOTES: (i) Ensure both cups are firmly seated into carrier. (ii) Take care not to damage face or taper of bearings whilst assembling. (iii) Both bearing cups may be assembled together if the appropriate service tool is available.
- Page 31 Fig. 12. Fit new oil seal gasket and oil seal. The seal is to be fitted with the lip facing inwards. As an aid to assembly and to prevent lip damage, apply a small amount of grease to lip prior to assembly. The oil seal should be pressed into housing using a suitable adaptor locating near the outer diameter of the seal.
- Page 32 Check the correct positional setting of the pinion as follows:- Check the nominal pinion cone setting distance from chart 1. (ii) Check the variation figure marked on the head of the pinion. This figure is given in thousandths of an inch. Fig.
- Page 33 CHART 1. CROWN WHEEL & PINION SETTINGS: DISTANCE REQUIRED Nimbus/Sprite Axle Codes AS INDICATED PINION DROP 1.375 1.500 ZERO CONE SETTING B 2.250 2.625 PINION Fig 15 DIFF. BEARING 3.2660 SEAT DIAMETER 3.2674 Example: 1. Zero Cone setting ‘B’ The number at the bottom gives the cone setting distance of the pinion and may be Zero (0), Plus (+) or Minus (-).
- Page 34 3-2-11...
- Page 35 TORQUE TIGHTNESS FIGURES FOR 3HA AXLE ASSEMBLIES CHART 2 THWAITES DUMPER MODELS - NIMBUS & SPRITE (FRONT AXLE) Part Item Size Torque Drive Pinion Nut 3/4" U.N.F.T 180/190 Ib.f.ft. Drive Gear Bolt 7/16" U.N.F.X 77/88 Ib.f.ft. Diff. Bearing Cap Bolt 1/2"...
- Page 36 Fig. 17. Ensure the pinion end is free from burrs. Mount the magnetic base of the clock onto the pinion end so that the stylus registers in the bottom of the differential bearing bore. The clock can be moved slightly to and fro by turning the pinion in order to ensure maximum reading is obtained.
- Page 37 The amount of variation away from zero gives the amount of shim adjustment required. (ii) If a change in shim pack is required it is essential that a corresponding opposite change takes place under the outer pinion bearing cup, i.e. if .003" is removed from the inner bearing cup shim pack to give correct pinion height, the .003"...
- Page 38 With bearing cups fitted onto cones lower differential case assembly into the carrier. Take care when meshing gear and pinion not to damage the teeth. Position a dial gauge as shown in Fig. 20. Fit suitable shim packs between the differential bearing caps and carrier on each side in order to give a reading of .007"...
- Page 39 Fig. 21. Assemble differential assembly together with bearing cups into carrier. It may be necessary to tap lightly in order to assemble. Do not force assembly into position as this could cause damage to bearings. Fit bearing caps noting that markings match with markings on carrier. Fig.
- Page 40 Re-fit carrier cover using new gasket. Tighten cover bolts to torque figure given in chart 2. Fig. 23. 3-2-17...
- Page 41 LOW TOOTH CONTACT - In figure C it will be observed that the tooth contact is heavy on the drive gear flank or dedendum, i.e. Low Tooth Contact. This is the opposite condition from that shown in B and is therefore corrected by moving the pinion out of mesh, i.e. increase the pinion cone setting distance by removing shims from between the pinion inner bearing cup and housing, and removing the same thickness of preload shims from between the pinion bearing spacer or the shoulder of the pinion shank and the outer bearing cone.
- Page 42 BACKLASH - CORRECTION PROCEDURE FOR ADJUSTMENT: Remount the dial indicator on the gear carrier housing with the button against one of the drive gear teeth, as nearly in line with the direction of tooth travel as possible, see figure. Move the drive gear to check the backlash which should be as etched on the gear.
- Page 43 Drive Shaft Assembly Servicing...
- Page 44 TO DISMANTLE SNAP RING TYPE To remove sliding joint from splined shaft, unscrew the dust cap and pull back the cork washer. Clean enamel from snap rings and top of bearing races. Remove all snap rings by pinching ears together with a pair of pliers, and prising with a screw driver. If ring does not snap out of groove readily, tap end of bearing race lightly to relieve the pressure against ring.
- Page 45 Keep joint in this position so as to avoid dropping the needle rollers. Repeat this operation for opposite bearing. The splined sleeve yoke or flange yoke can now be removed. Rest the two exposed trunnions on wood or lead blocks, then tap yoke with soft hammer to remove the two remaining bearing races.
- Page 46 EXAMINE AND CHECK FOR WEAR The parts most likely to show signs of wear after long usage are bearing races and spider journals. Should looseness in the fit of these parts load markings or distortion be observed, they should be renewed complete as a unit, i.e. because worn needle bearings used with a new spider journal, or new needle bearings used with a worn spider journal, will wear more rapidly, making another replacement necessary in a short time.
- Page 47 This can be checked by observing that arrows marked on splined sleeve yoke and splined stub shaft are in line. See that all drilled holes in journals are cleaned out and filled with grease. With the rollers in position fill the races about one-third full with grease (see next page).
- Page 48 SERVICE INSTRUCTIONS LUBRICATION Prior to 1939 all small type joints had no lubricator fitted to the spider for lubrication, the spider being packed with lubricant on assembly and this lasted till general overhaul. Later it became necessary to make lubrication a simpler operation, and a lubricator was added to the spider on the small type series of propeller shafts, and since 1945 the majority of these joints have been supplied with a lubricator.
- Page 50 STEERING GEAR T7903 (TYPE 462 LONG) - NIMBUS & SPRITE MODELS ADJUSTMENTS: The major adjustments are accomplished by shims and are three in number:- Adjustment of bearings between which the cam revolves. Adjustment of end play of rocker shaft (item 26). Adjustment of engagement between roller (item 26) and cam (item 6).
- Page 51 OLD TYPE (TAPER) STEERING COLUMN CHANGE NEW TYPE (SPLINED)
- Page 52 OIL BATH AIR CLEANER AND FITTINGS STANDARD AIR CLEANER Item Part No. Qty. Description T8078 Clip T8328 Hose T8283 Air Cleaner T8279 Mounting Bracket T8758 Dust Cap T8095 Inlet Manifold T5124 Air Cleaner T5125 Air Cleaner Cartridge OIL BATH AIR CLEANER - MAINTENANCE INSTRUCTIONS GENERAL: Basic servicing involves removal of the easily detachable oil base, draining off the dirty oil and scraping out any sediment, filling the base to the indicated level with...
- Page 53 Date of repair or maintenance ----------------------------------- THWAITES SPRITE & NIMBUS MODELS 250 HOUR SERVICE OR 4/6 WEEK SERVICE SCHEDULE -------------- 1. Carry out 250 hour service on Engine unit as recommended in Petter handbook. -------------- 2. Change oil in Gearbox. (See Chart) -------------- 3.
- Page 54 CORRECT MAINTENANCE SAVES MONEY In our experience clean machines work better and successful plant operation depends largely on the operator; his skill and efficiency Influence the speed of the work and the safety of others. The operator must be allowed time for maintenance and should be encouraged to take pride in his machine.
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Questions and answers
My break drum keeps tightening on Thwaites nimbus dumper. And on looking inside with the drum off I can see the expander which is operated by the rods moves. Should this. And if not how is it fixed please
The expander in the brake drum of a Thwaites Nimbus dumper should be adjusted by turning the square-headed screw on the brake back plate clockwise until tight, then turning it back until the wheel revolves freely. If the expander is not functioning correctly, the brakes should be stripped and cleaned—especially in dirty conditions—by jacking up and removing the wheels, releasing the brakes, and removing the brake drum. Regular maintenance, such as weekly cleaning, helps prevent malfunction.
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@Mr. Anderson Thanks. But that side is the adjuster assembly. The other side which moves up and down is the expander assembly connected to the brake rods and I think it shouldn’t move but don’t know . Should it be fixed . And how.
Question not any
Are there clips to hold brake expander mine moves also I think someone has put the shoes on the wrong way round . The reason I ask is my wheel keeps braking as I drive and I can’t work out why.
The context does not mention the availability of clips for the Thwaites NIMBUS brake expander. To determine if the brake shoes are installed correctly, adjust the square-headed screw on the brake back plate clockwise until tight, then turn it back until the wheel revolves freely. This ensures proper brake adjustment. If done correctly and the wheel rotates freely after adjustment, the brake shoes are likely installed properly.
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