Thwaites SPRITE NIMBUS Manual Download Page 3

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SERVICING INSTRUCTIONS
NIMBUS & SPRITE MODELS

CONTENTS:
A

OPERATION & ROUTINE MAINTENANCE

SERVICING POINTS

CLUTCH

GEARBOX

AXLES

DRIVE SHAFT

STEERING GEAR

OIL BATH AIR CLEANER

MAINTENANCE CHECK OFF LIST

Summary of Contents for SPRITE NIMBUS

Page 1: ...SPRITE NIMBUS...

Page 2: ...HEY MAY MAKE THE DUMPER UNSTABLE AND MAKE IT DIFFICULT FOR THE DRIVER TO SEE THE ROAD AHEAD REMEMBER THE LOWER THE POSITION OF THE LOAD THE SAFER THE DUMPER TAKE CARE WHEN USING STARTING HANDLE WRONG...

Page 3: ...ING INSTRUCTIONS NIMBUS SPRITE MODELS CONTENTS A OPERATION ROUTINE MAINTENANCE B SERVICING POINTS 1 CLUTCH 2 GEARBOX 3 AXLES 4 DRIVE SHAFT 5 STEERING GEAR 6 OIL BATH AIR CLEANER 7 MAINTENANCE CHECK OF...

Page 4: ...knob The pedal positions are the same as a car i e clutch pedal to the left of the steering column brake pedal to the right of the steering column throttle pedal to the right of the brake pedal The ha...

Page 5: ...i e at least once per week To do this jack up and remove wheels release brakes and remove brake drum The wheel and wheel nuts hold the brake drum on the hub GENERAL MAINTENANCE It is extremely importa...

Page 6: ...B...

Page 7: ...Turn square headed screw in clutch back plate for adjustment 1 1...

Page 8: ...CLUTCH AND HOUSING 1 2...

Page 9: ...26 now fit the clutch spring item 28 and slide an easy way of fitting the clutch spring is to compress the clutch spring in a vice and wire it up The wire must be cut and removed after the conical nut...

Page 10: ...SLIDE Item 102 CLUTCH SLIDE NUT OR CONICAL NUT Item 91 LOCKING WIRE SPRING Item 101 SLIDE ROD TO BACK PLATE BEARING Item 104 CLUTCH THRUST CHAINCASE Item 109 CLUTCH OPERATING ARM OR LEVER A 1 64 ALL...

Page 11: ...closes to on the 2 ton Alldrive and 1 8 on all other models To adjust the clutch on site a special clutch adjusting spanner is provided with each machine Two people are required one to sit on the mach...

Page 12: ...GEARBOX ASSEMBLY T5260 SPRITE NIMBUS...

Page 13: ...on as the shaft has left the fork close the ends of the hole in the fork with the fingers and remove complete from the gearbox Now undo the split pins in the clevis pins item 48 remove the clevis pins...

Page 14: ...th a suitable drift and then reamed in position with a 5 8 diameter reamer The pilot diameter of the mainshaft should be a free running fit without undue shake 3 The shafts and gears in the gearbox ar...

Page 15: ...l and spring in position The fork with the rod in place is passed into the box and the selector shaft is then pushed through from the rear of the case and the fork pushing out the piece of rod in the...

Page 16: ...ring item 18 may pass through and by using a drift slightly smaller than the bore of the housing the bearing and oil seal may be pressed out 4 The bearing item 23 can be removed from the input shaft b...

Page 17: ...nd BEARINGS 3 2 1 PARA 12 REMOVAL OF PINION 3 2 2 PARA 16 REMOVAL OF OIL SEAL and BEARINGS 3 2 5 PARA 19 DISMANTLING OF THE DIFFERENTIAL 3 2 5 PARA 20 RE ASSEMBLY OF THE DIFFERENTIAL 3 2 6 PARA 21 RE...

Page 18: ...eted under workshop conditions using correct equipment as recommended Certain components should always be renewed when servicing axles these are stated in the text however any component which is found...

Page 19: ...Axle Shaft End Float Measurement dial gauge shims 3 b...

Page 20: ......

Page 21: ...3 1 10...

Page 22: ...which control the shaft end float 4 Remove the axle shaft with its taper roller bearing using the Service Tool 4a To remove a broken axle shaft make a loop at one end of a length of stiff wire slide...

Page 23: ...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 Remove the axle shafts as previously detailed 2 Not...

Page 24: ...NT Do not overstretch See instructions 7 Remove differential assembly complete with ring gear It may be necessary to lever the case out of the carrier In order to prevent damage do not lever against s...

Page 25: ...ew parts 17 Remove outer pinion bearing cone part item 26 18 Remove inner and outer bearings cups from carrier Extraction slots are provided in the carrier for ease of removal purposes Carefully note...

Page 26: ...3 2 3...

Page 27: ...he back face Fit the shaft spacer in the cross pin if originally fitted Refit the cross pin with the pinion mates and shaft spacer thrust washers This will ensure correct meshing of pinion mates and s...

Page 28: ...DIAGRAMS TO SHOW THE PROCEDURE IN REMOVING THE INNER AND OUTER BEARINGS Z Z Y X Y X Fig 8 3 2 4...

Page 29: ...to serial number have no significance in service 22 Assemble inner bearing cone onto pinion using service tool or suitable press 23 Select new shim pack the size of that removed from the inner bearing...

Page 30: ...er of bearings whilst assembling iii Both bearing cups may be assembled together if the appropriate service tool is available 25 Insert pinion and inner pinion bearing cone into housing and support in...

Page 31: ...ptor locating near the outer diameter of the seal 29 Fit companion flange If it is necessary to press or tap the flange into position do not let flange react against bearing but react against support...

Page 32: ...xle model 4HA Nominal cone distance 2 625 2 625 Marked variation 3 003 2 002 Actual required distance 2 628 2 623 iv Read the differential bearing seat diameter from chart 1 Which is 3 4392 Mean v Sub...

Page 33: ...ked Zero will be at the zero cone setting distance dimension B in figure 15 from the centre line of the gear to the face on the small end of the pinion a pinion marked Plus Two 2 should be adjusted to...

Page 34: ...3 2 11...

Page 35: ...Drive Gear Bolt 21 3 8 U N F X 49 56 Ib f ft 7 16 U N F X 70 88 Ib f ft Diff Bearing Cap Bolt 6 1 2 U N C R 63 72 Ib f ft Gear Carrier Cover Screw 3 5 16 U N C S 18 20 Ib f ft Diff Case Bolt 11 3 8 U...

Page 36: ...d 37 Repeat operation on other differential bore 38 Add the two readings and halve the result in order to obtain the mean figure If the pinion is set correctly a mean reading of zero should be obtaine...

Page 37: ...oad will lead to pitting and failure of the bearings To rectify the preload adjust the shim pack between the outer bearing cone and the pinion shank or spacer but do not touch the shims behind the inn...

Page 38: ...10 and 030 NOTE When using new bearings rotate differential assembly approximately six times whilst pressing assembly towards each bearing in turn this is in order to settle bearings Following this ad...

Page 39: ...orce assembly into position as this could cause damage to bearings 49 Fit bearing caps noting that markings match with markings on carrier 50 Tighten bearing cap bolts to torque given in chart 2 with...

Page 40: ...53 Re fit carrier cover using new gasket Tighten cover bolts to torque figure given in chart 2 Fig 23 3 2 17...

Page 41: ...s from between the pinion bearing spacer or the shoulder of the pinion shank and the outer bearing cone This correction has a tendency to move the tooth bearing towards the heel on drive and toe on co...

Page 42: ...ed is not satisfactory Diff Preload Shim Alice 007 on All Models Backlash As etched on Drive Gear Minimum 004 E Heel Contact Figure E shows an example of heel contact which is indicated by the concent...

Page 43: ...Drive Shaft Assembly Servicing...

Page 44: ...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 Support the shaft and with the yoke lug on to...

Page 45: ...screws and bearing cap Use a soft nosed drift slightly smaller than the outside diameter of the bearing race to drive out from the top the underneath bearing race Keep joint in this position enabling...

Page 46: ...ther parts likely to show signs of wear are the splined sleeve yoke or splined stub A total of 004 circumferential movement measured on the outside diameter of the splined should not be exceeded Shoul...

Page 47: ...skets and gasket retainers on the journal or spider assembly Using the tubular drift as shown on illustration The journal shoulders should be shellaced prior to fitting to ensure a good lubricant seal...

Page 48: ...of the Needle Bearings As a guide for type the following are suitable and all are equally recommended ESSO MULTIPURPOSE GREASE H and T S D 1110 GULFSIL GREASE G 78 2 and G 64A 2 SUPER LITHIUM FILTRAT...

Page 49: ...5 1...

Page 50: ...cam item 6 When this adjustment has been correctly made it should be such that after the bottom cap item 16 is again fastened securely to the box casting by the screws item 18 the cam and steering wh...

Page 51: ...OLD TYPE TAPER STEERING COLUMN CHANGE NEW TYPE SPLINED 5 3...

Page 52: ...filling the base to the indicated level with clean sump oil and re fitting to the air cleaner body In the case of the OBAR type units the lower filtering medium section may also be removed and washed...

Page 53: ...Adjust cables if necessary 10 Check Propshaft bolts for tightness 18 21 Ibs f ft 11 Check Wheel Nuts for tightness Drum Brakes 150 Ibs f ft Disc Brakes 200 Ibs f ft 12 Check Engine Gearbox and Steeri...

Page 54: ...pare grease should be kept covered never use dirty grease 2 Use the correct grade of lubricating oil as recommended and see that funnels and containers used are clean and dry Do not mix different grad...

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