TUSKER DIGGER MK. 4 THWAITES LTD

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3 TUSKER DIGGER MK. 4 THWAITES LTD The copyright in this publication and its illustrations are vested in Thwaites Ltd. and action will be taken where unauthorised copies are made. WHEN ORDERING SPARES PLEASE QUOTE MACHINE SERIAL NUMBER... SPARES FAX: (01926) T0089

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5 Thwaites THWAITES ENGINEERING COMPANY LIMITED LEAMINGTON SPA ENGLAND Digger Mk 4

6 Thwaites Digger Mk 4 OPERATOR INSTRUCTIONS FOR THWAITES DIGGER DUMPER The Thwaites Digger Dumper is a very powerful excavator for its size and extremly simple to operate. Read carefully the following operation and maintenance instructions, which will help to familarise oneself with the machine. 1. It is important to remember the sequence of controls and what each lever does. The diagram below shows this when operator is in seated position. Dipper Slew Boom Bucket Away Right Lower Open Towards Left Raise Close Make sure first that this is in the most comfortable position for you. 2. LOWER STABILIZERS: It is always best to drop the right hand stabilizer first. Slew boom to right approximately 45 from centre with the Dipper extended halfway and bucket almost closed, it is then only a question of pushing the boom lever forward raising the driving wheel off the ground. With the wheel approximately 1/3rd of a metre off the ground, kick the plunger release of the stabilizer, which will then drop. Now BEFORE lifting the boom and slewing to lower the left stabilizer down, make absolutely sure the plunger has gone 100% home in one of the locating holes. THIS IS MOST IMPORTANT. 3. PRACTICE PROCEDURE: With the Digger Dumper now level and raised ready for digging, we come to the most important section of all, CONTROL: place both hands on the two outside levers, Dipper and Bucket. The engine should be set for ¼ to ½ speed (it is very seldom more than ¾ throttle is ever required). With the palm of your right hand resting on the bucket lever using thumb and forefinger only, push the boom lever forward, this is best done with bucket and dipper fully extended. Absolute control must be mastered of the boom to produce a quick smooth raise and lower action. Control of the levers actuating the bucket slew and dipper will be found straightforward once boom control is mastered. DO NOT cross hands over during the digging operation. The right hand must work the bucket and boom, the left hand the dipper and slew. 4. IMPORTANT THE SECRET of all efficient high output digging is to TAKE A LONG and THIN SLICE AT A TIME and always lift out with a full bucket even if this means taking another bite. 5. INITIAL PENETRATION is always the most difficult but once a depth of about 1/3rd of a metre has been reached, digging becomes easier. 6. DIGGING PROCEDURE: Extend dipper to ¾ of its maximum reach, bucket ¼ open, lower boom, bucket teeth just biting the surface with the throttle set at half speed. Pull back the dipper lever and the bucket will inbed itself into the ground. The pressure release valve will then blow off (a distinct hissing noise) as the dipper stops. Keeping the dipper lever back, bring the boom lever towards you VERY gently. As the dipper comes to the end of its travel, bring the bucket lever towards you, all things being equal the result should be a full bucket. This is only intended as a guide and practice is the only way that will make a fine excavator driver. 7. MOVING THE DIGGER DUMPER BACKWARDS: when trenching instead of driving, make absolutely sure your rear wheels are straight. Lift front end of the machine with the aid of boom and dipper until both stabilizers are clear of ground. By pushing the dipper lever forward (WITH CAUTION until fully experienced) the machine will move back. This is best practised on smooth ground first. 8. RAISING STABILIZERS: You will find it necessary to get over the top of these and lift in a quick sharp upward movement. It is no use trying to remain seated while attempting this. Changing Digger to Dumper The first thing to be done is find a reasonably flat piece of ground. Concrete is best but that cannot always be found. One has to use a little common sense when placing the Digger stand and a fairly level surface can usually be located somewhere on site. The procedure is as follows: 1. Drive Digger Dumper on to stand, this has to be done with plenty of gusto. It is impossible to drive too far owing to the stops fitted. It is essential that the dumper sits 100% squarely on the stand, this is MOST IMPORTANT. For this operation the back hoe must be slewed into the dead ahead position. With the machine now on its stand, lower the boom until the lowest part of the bucket is not less than 18 above the ground and not more than 24.

7 Thwaites Digger Mk 4 2. Stop engine (using pump rack and NOT decompressor). Remove spring clips from the 2-1 tapered pins located on either side of machine behind hydraulic tank, noting that the tapered end faces outwards. Remove both pins, placing them in a safe place with the spring clips. Now making sure the throttle lever on Digger is fully closed (backwards when sitting on Digger). At the point where the linkage joins the throttle mechanism on the Petter engine, grip and lift upwards pushing linkage forward and out of the way so that it rests in the vertical position. Now all that remains is to disconnect the hydraulic drive, this is done by grasping the male portion of the coupling (from the nearside of machine) then twisting it towards you as far as it will go and at the same time pull away from the engine it will then separate. These three operations will be much simpler if a liberal coating of oil is applied to the above mentioned parts namely, throttle linkage, hydraulic quick release coupling and the two tapered pins. They will of course ease up with use. Fig 1. Remove both pins and stow clips Fig 2. Lift the link clear Fig 3. Lift flap and turn coupling as shown 3. Restart engine and reverse dumper away from digger unit. It is a good idea before doing this to check that EVERYTHING has been properly disconnected. As soon as you have done this the whole unit will tip forward on the stand, the bucket resting on the ground. At this stage, should the digger unit not be required for a day or so, it is a good idea to place a support under the hydraulic tank. This stops the back end of the unit dropping down should anyone touch the boom lever by mistake. (Safeguard for children). 4. With the digger dumper skip in the near upright position, held there by the special skip prop, drive the dumper up to the skip leaving the handbrake OFF. Connect up skip straps by pulling or pushing on the driving wheels of dumper to reduce or increase cleanance. You will find the connecting up procedure very simple. Attach both check chains. Changing Dumper to Digger 1. Reverse procedure (4) remembering not to lose clevis pins from check chains. 2. Drive machine SQUARELY onto stand as far as it will go. You will note that the two hooks on the front end of the digger unit hit the front chassis cross member (channel) of the dumper, this is correct. Be very careful when driving in to make sure that the back end of the digger is high enough to enable the hydraulic drive prop shaft to clear the front chassis member. This is MOST IMPORTANT as damage can be done to hydraulic pump if the drive shaft is hit. 3. When you are satisfied that the dumper is absolutely square to the digger unit, AND NOT UNTIL THEN, push the lever second from the right (when the digger driving position) FORWARD. This will drop the back end. It is then only a question of driving the machine forward about 6-9, in any case as far as it will go. 4. The 1 holes on digger unit and dumper will now be level with each other, replace tapered pins (spring clip on the outside). Connect hydraulic drive and throttle linkage, restart engine, raise boom, close dipper. The machine is now ready to commence digging. Should you have any difficulty in changing digger to dumper or vice versa please contact our distributor in your area or the Sales Department of Thwaites Engineering Co., Ltd., Leamington Spa. Tel No. Leamington

8 Thwaites Digger Mk 4 MAINTENANCE INSTRUCTIONS It is extremely important that the machine be kept clean, if cleaned regularly it facilitates easy greasing and maintenance. NO adjustments should be required to the Hydraulics as these are pre-set at the works, should you feel that the Hydraulics are not working correctly, do not attempt to alter them yourself, contact your nearest THWAITES agent or THWAITES ENGINEERING CO. LTD., Service Department. All Hydraulic Pipe Connections should be checked periodically to ensure that the Hydraulic Oil is not leaking. DO NOT allow the machine to run without sufficient Hydraulic Oil in the tank. If the oil level is allowed to drop below the filter, damage will be caused to the Pump. THE CORRECT GRADE OF HYDRAULIC OIL IS: MOBIL D.T.E.LIGHT Maintenance Daily Grease Machine. Check Oil in Hydraulic Tank. Oil all Working Parts. Weekly Check all Bolts for tightness. Inspect All Hydraulic Connections for Leaks. Tighten if necessary. Monthly Remove Hydraulic Filter, clean, replace cartridge. Greasing points are as follows: Propshaft King Post Rams Top & Bottom Leg Locking Pins Slewing Arms Bucket Linkage Feet Pivot Boom Top & Bottom Pin Bucket Swivel Pin

9 Thwaites Digger Mk 4 INDEX PAGE CONTENTS Operation & Maintenance Instructions 1-2 Digger Chassis & Fittings 3-4 Boom, Rams & Bucket 5-6 Boom Ram & Mounting Assy. 7-8 Hyd. Control Valve & Oil Filter 9 Hyd. Control Valve with Control Fittings 10 Oil Circuit Oil Pump Assembly (Up to m/c no Unit no ) & Oil Pump - Drive Shaft Assembly 13 Oil Pump Assembly (Up to m/c no Unit no ) (Replaced Oil Pump illustrated on Page 11)

10 DIGGER CHASSIS AND FITTINGS Thwaites Digger Mk 4 1

11 DIGGER CHASSIS AND FITTINGS Thwaites Digger Mk 4 Item Part No. Qty. Description Item Part No. Qty. Description 1 T Connecting Link 2 T Clevis Pin 3 T Washer 4 T Split Pin 5 T Bolt 6 T Washer 7 T Spring 8 T Friction Pad 9 T Hand Throttle Lever 10 T Hyd. Tank Filler Cap 11 T Hyd. Tank Filler Strainer 12 T Bolt 13 T Spring Washer 14 T Plate for Filler Cap 15 T Gasket (Filler Cap Plate to Tank) 16 T Hydraulic Tank 17 T Bolt 18 T Washer 19 T Rubber Spacer 20 T Nyloc Nut 21 T Tank Breather c/w T9351 Element 22 T Seat Frame 23 T Seat Back 24 T Seat Cushion T Seat Assembly 25 T Seat Mounting Pin 26 T Split Pin 27 T Prop Shaft Cover 28 T Split Pin 29 T Jubilee Clip 30 T Rubber Elbow 31 T Union 32 T Copper Washer 33 T Micronic Filter 34 T Banjo 35 T Banjo Bolt 36 T Rubber Hose 37 T Suction Filter 38 T Drain Plug 39 T Connecting Pin 40 T Lynch Pin 41 T Digger Chassis 42 T Pedal Rubbers 43 T Foot Pedal L/H N/S 44 T Foot Pedal R/H O/S 45 T Link 46 T Locking Peg 47 T Clevis Pin 48 T Spring 49 T Stabiliser Leg Roller 50 T Washer 51 T Nyloc Nut 52 T Bolt 53 T Bolt 54 T Stabiliser Leg L/H 55 T Stabiliser Leg R/H 56 T Stabiliser Feet 57 T Pin 58 T Hyd. Ram (Slew Ram) 59 T Bush 60 T Bush 61 T Hinge Pin 62 T Split Pin 63 T Bolt 64 T Nyloc Nut 65 T Hyd. Pipe L/H 66 T Hyd. Pipe R/H 67 T Hyd. Pipe R/H 68 T Hyd. Pipe L/H 69 T Hyd. Pipe R/H 70 T Hyd. Pipe L/H 71 T Bolt 72 T Nut 73 T Spring Washer 74 T Bolt 75 T Nut 76 T Straight Grease Nipple 77 T King Pin (Valve Op. Lever) 78 T Washer 79 T Adaptor 80 T Spacer 81 T Pin 82 T Split Pin 83 T Foot Pedal N/S 84 T Foot Pedal O/S 85 T Locking Peg 86 T Nut 87 T Spring Washer 88 T Set Screw 89 T Split Pin 90 T Bush 91 T Grease Nipple 2

12 BOOM, RAMS & BUCKET Thwaites Digger Mk 4 3

13 BOOM, RAMS & BUCKET Thwaites Digger Mk 4 Item Part No. Qty. Description Item Part No. Qty. Description 1 T Boom 2 T Bush 3 T Pin 4 T Rubber Buffer 5 T Bolt 6 T Bolt 7 T Washer 8 T Nyloc Nut 9 T Hyd. Hose 10 T Hyd. Hose 11 T Adaptor 12 T Pipe Clamp 13 T Bolt 14 T Spring Washer 15 T Bolt 16 T Pipe Clamp 17 T Hyd. Pipe 18 T Hyd. Hose 19 T Ram Pin 20 T Ram Pin 21 T Collar 22 T Bolt 23 T Locknut 24 T ¼ BSF St. Grease Nipple 25 T Pipe Clip 26 T Hyd. Pipe 27 T Hyd. Pipe 28 T /8 BSF Angled Grease Nipple 29 T Nut 30 T Hinge Pin 31 T Hyd. Ram 32 T Bush 33 T Bush 34 T ¼ BSF 90 Grease Nipple 35 T Hyd. Hose 36 T Hyd. Hose 37 T /8 BSF St. Grease Nipple 38 T Hyd. Hose 39 T Hinge Pin 40 T Dipper Arm 41 T Bush 42 T Arm R/H 43 T Arm L/H 44 T Hinge Pin 45 T Bucket Connecting Link 46 T Bush 47 T Bush 48 T Bucket Pin (superseded by item 52) 49 T Spring Lynch Pin 50 T Bucket T Bucket T Bucket 51 T Bucket Teeth 52 T Pin 53 T Bolt 54 T Nut 55 T c/snk sq. Head Bolt 56 T Hyd. Washer 57 T Bucket Teeth (superseded by item 51) T Adaptor 60 T Tension Pin 61 T Spacer 62 T Boom Ram 63 T Bolt 64 T Nut 65 T Bush 4

14 BOOM RAM & MOUNTING ASSEMBLY Thwaites Digger Mk 4 5

15 BOOM RAM & MOUNTING ASSEMBLY Thwaites Digger Mk 4 Item Part No. Qty. Description 1 T King Post Pin 2 T Oil Seal 3 T Bearing 4 T King Post 5 T Nut - King Post 6 T Split Pin 7 T Pin 8 T Slewing Arm L/H 9 T Slewing Arm R/H 10 T ¼ BSF St. Grease Nipple 11 T Bush 12 T Pin (Ram to King Post) 13 T Split Pin T Tension Pin 16 T Bush 17 T Tension Pin 18 T /8 BSF Angle Grease Nipple 19 T Bush T Piston Rod 22+ T Wiper Seal 23 T Gland Nut 24+ T Gland Seal 25+ T Gland O Ring 26 T Gland Housing 27 T Piston Head Retainer 28+ T Piston Seal 29+ T Piston O Seal 30 T Piston Head 31 T Piston Nut 32 T Boom Ram (complete) 33 T Washer T8785+ Seal Kit comprising items 22, 24, 25, 28 & 29. Note: Internal parts of Hyd. Boom Ram as shown are fitted also to Hyd. Ram T

16 HYD. CONTROL VALVE & OIL FILTER Thwaites Digger Mk 4 7

17 HYD. CONTROL VALVE & OIL FILTER Thwaites Digger Mk 4 Item Part No. Qty. Description Item Part No. Qty. Description T Oil Filter 1+ 1 Head Assembly 2 T Seal 3+ 1 Spring 4+ 1 Valve Body 5+ 1 Valve 6+ 1 Guide Element (Top) 7+ 1 Centre Tube 8 T Element 9+ 1 Sump Circlip Guide Element (Bottom) Seal (Centre Bolt) Washer Spring Seal Sump (Bottom) Reinforcing Collar Centre Bolt T Hyd. Control Valve 18 T Port Plate 19 T Valve Body & Spool Boom & Dipper 20 T Valve Body & Spool Bucket & Slewing 21 T End Plate 22 T O Ring 23 T O Ring 24 T Washer 3/8 25 T O Ring + Not available as spare parts 26 T Tie Bolt 27 T Washer Spring 28 T Relief Valve Assembly 29 T Back Up Washer 30 T O Ring 31 T O Ring 32 T Relief Valve Assembly 33 T Plug 34 T Back Up Washer 35 T O Ring 36 T Deep Washer 37 T Washer 38 T Spool Spring 39 T Shallow Washer 40 T Clip Ring 41 T O Ring 42 T O Ring 43 T Lift Check Body 44 T Back Up Washer 45 T O Ring 46 T Lift Check Spring 47 T Plunger Lift Check Note: T Seal Kit (Comprising items 40, 41, 42, 44 & 45) T Seal Kit (Comprising items 42, 35, 41, 34, 45, 44 & 40) T Seal Kit (Comprising items 22, 23 & 25) 8

18 Thwaites Digger Mk 4 HYD. CONTROL VALVE WITH CONTROL FITTINGS NOTE: PIPE (ITEM 27) and ADAPTOR (ITEM 18) ARE FITTED TO PORT AS SHOWN WITH O RING (T7558). ALL OTHER PORTS AS SHOWN REQUIRE SMALLER O RING (T6942) Item Part No. Qty. Description Item Part No. Qty. Description 1 T Control Valve 2 T Bolt 3 T Spring Washer 4 T Link Pin 5 T Split Pin 6 T Link 7 T Lever - Outer 8 T Lever - Inner 9 T Lever Pin 10 T Split Pin 11 T Rubber Hose 12 T Jubilee Clip 13 T Banjo 14 T Banjo Bolt 15 T Hyd. Washer 16 T Hyd. Union 17 T Hyd. Union 18 T Hyd. Union 19 T Hyd. Pipe 20 T Hyd. Pipe 21 T Hyd. Hose 22 T Hyd. Hose 23 T Hyd. Pipe 24 T Hyd. Pipe 25 T Hyd. Pipe 26 T Hyd. Pipe 27 T Hyd. Pipe 28 T Lever Knob 29 T Washer 9

19 Thwaites Digger Mk 4 OIL CIRCUIT HYDRAULIC CIRCUIT COMPONENTS: BUCKET RAM DIPPER RAM BOOM RAM SLEWING RAM HYD. CONTROL VALVE HYD. PUMP OIL FILTER SUCTION FILTER T6515 T6515 T6436 T6515 T6661 T8271 T6048 T

20 Thwaites Digger Mk 4 OIL PUMP ASSEMBLY (Up to m/c no Unit no ) & OIL PUMP - DRIVE SHAFT ASSEMBLY 11

21 Thwaites Digger Mk 4 OIL PUMP ASSEMBLY (Up to m/c no Unit no ) & OIL PUMP - DRIVE SHAFT ASSEMBLY Item Part No. Qty. Description 1 T Rubber Elbow 2 T Jubilee Clip 3 T Inlet Elbow 4 T Inlet Elbow Cap Screw 5 T Inlet Elbow Spring Washer 6 T O Ring 7 T Bolt 8 T Spring Washer 9 T Nyloc Nut 10 T Hyd. Pipe 11 T Hyd. Union 12 T Sealing Washer 13 T Outlet Elbow 14 T Outlet Elbow Cap Screw 15 T Body - Hyd. Pump 16 T Spring Dowel 17 T O Ring 18 T O Ring 19 T pr C Bushes (matched pair) 20 T pr Drive Gear & Driven Gear (matched pair) 21 T Assembly Sleeve 22 T Key 23 T pr A Bushes (matched pair) 24 T O Ring 25 T Sealing Ring 26 T Support Ring 27 T Body Cover 28 T Cap Screw 29 T Shaft Seal 30 T Baffle Washer 31 T Set Screw 32 T Spring Washer 33 T Retaining Washer 34 T Drive Flange 35 T /8 BSF Grub Screw 1 long 36 T Key 37 T Hook Flange 38 T Spring Washer 39 T /16 BSF Set Screw ¾ long 40 T ¼ BSF Long Grease Nipple 41 T ¼ BSF Str. Grease Nipple 42 T Prop Shaft Unit Pack 43 T Prop Shaft Joint Assy - Female End Complete 44 T Prop Shaft Joint Assy - Male End Complete 45 T Hydraulic Pump Flange 46 T Bolt 47 T Nyloc Nut OIL PUMP T6046 (used on machines up to no Unit ) NOTE: T6046 is now replaced by T8271, see page

22 Thwaites Digger Mk 4 OIL PUMP ASSEMBLY (From m/c no Unit no ) (Replaced Oil Pump illustrated on Page 11) OIL PUMP - T8271 (From m/c Unit no ) Item Part No. Qty. Description 1 T Oil Pump Assembly 2 T Seal Kit 3 T Hydraulic Pipe - Outlet 4 T Cap Screw 5 T Spring Washer 6 T Elbow - Inlet 7 T O Ring 8 T Elbow - Outlet 9 T Hydraulic Hose - Inlet 10 T Key 11 T Nut 12 T O Ring 13 T Bolt 14 T Hydraulic Seal 15 T Adaptor 16 T Cap Screw 17 T Jubilee Clip 13