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V e hicle T ype s:
U SA TS
I NTRODUCTION
From everyone at Eagle Tugs, we would like to say Thank You for purchasing an Eagle USATS series tow tractor. We
take a lot of pride in the quality of the products that we build, as well as our continued customer service. Our goal is to
build a long term relationship with our customers. We want you, the customer, to be 100% satisfied with your Eagle
experience. To us, this means that your Eagle USATS series tractor is functionally superior to any other products you
have used. This also means that your Eagle product is continually supported in a professional, timely manner.
P URPOSE & U SE
OF
T HIS M ANUAL
This manual is designed as a reference guide to make the reader more familiar with the components of the Eagle USATS
tow tractor models. This manual includes part numbers and descriptions to assist the reader in ordering component
spare/service parts. The manual also outlines the Scheduled Maintenance Intervals recommended by Eagle in order to
keep your vehicle running properly. In this manual you will also find the Eagle Standard Warranty on all of the USATS
series tow tractors. However, for more detailed information on the Eagle Warranty and procedure, as well as information pertaining to the safe operation of your Eagle product, please see the Eagle Operations Manual that was also included with your vehicle.
T ECHNICAL A SSISTANCE
When addressing a repair procedure or operational problem, please remember that Eagle technical support is only a
phone call away. Eagle technicians are available to assist you in vehicle diagnostics and recommended repair procedures. We encourage you to use this service to reduce machine down-time and to gain a better understanding of proper
repair procedures.
C ONTACT I NFORMATION
Technical Support
support@eagletugs.com
(734) 442-1000 -- (800) 671-0431
T ABLE
OF
C ONTENTS
INTRODUCTION ....................................................................................................................... 3
PURPOSE & USE OF THIS MANUAL ......................................................................................................................... 3
TECHNICAL ASSISTANCE........................................................................................................................................... 3
ORDERING SPARE/SERVICE PARTS ........................................................................................................................... 3
CONTACT INFORMATION ......................................................................................................................................... 3
WARRANTY ................................................................................................................................ 6
VEHICLE ID INFORMATION ...................................................................................................................................... 6
WARRANTY REGISTRATION ...................................................................................................................................... 6
WARRANTY INFORMATION ...................................................................................................................................... 7
AUTHORIZED ISUZU DISTRIBUTOR MAP US AND CANADA .................................................................................. 8
AUTHORIZED ISUZU DISTRIBUTOR DIRECTORY....................................................................................................... 9
T ABLE
OF CONTENTS
BRAKES.................................................................................................................................................................... 36
Brake Assembly - Rear .................................................................................................................................... 36
Brake Assembly - RearDetail ..................................................................................................................... 37
Brake Actuator Assembly............................................................................................................................... 39
Brake System Hydraulic .................................................................................................................................. 40
Brake System HydraulicDetail ........................................................................................................................ 41
Parking Brake Actuator Assembly ................................................................................................................. 42
Parking Brake Actuator AssemblyDetail .................................................................................................. 43
HYDRAULIC SYSTEM............................................................................................................................................... 45
Hydraulic Assist ............................................................................................................................................... 45
STEERING SYSTEM................................................................................................................................................... 46
Steering System Breakdown ........................................................................................................................... 46
Steering System BreakdownDetail ............................................................................................................. 47
AIR CLEANER, FUEL SYSTEM & EXHAUST ............................................................................................................ 48
Air Cleaner Assembly Diesel ....................................................................................................................... 48
Air Cleaner Sub-Assembly .............................................................................................................................. 49
Fuel SystemDiesel ........................................................................................................................................ 50
Exhaust SystemDiesel .................................................................................................................................. 51
OPERATOR COMPARTMENT ................................................................................................................................... 52
Accelerator Pedal Assembly ......................................................................................................................... 52
Transmission Control ...................................................................................................................................... 53
Instrument Panel .............................................................................................................................................. 54
Instrument PanelDetail ................................................................................................................................ 55
LIGHTS & ELECTRIAL ............................................................................................................................................ 56
Electrical Board ................................................................................................................................................. 56
Horn Assembly ................................................................................................................................................. 57
Headlight & Taillight Assembly..................................................................................................................... 59
Wiring Harness ................................................................................................................................................. 60
Wiring Schematic ............................................................................................................................................. 61
WHEELS & TIRES .................................................................................................................................................... 62
Wheels & Tires .................................................................................................................................................. 62
OTHER ASSEMBLIES ................................................................................................................................................ 63
Seats ................................................................................................................................................................... 63
Side Access Door .............................................................................................................................................. 64
Hitch OptionDetail....................................................................................................................................... 65
USATS DEISEL MAINTENANCE .............................................................................................................................. 66
Lubrication Chart ............................................................................................................................................ 66
Preventative Maintenance ............................................................................................................................... 67
Daily Operator Responsibilities .................................................................................................................... 68
Specifications & Capacities ............................................................................................................................. 69
I NTRODUCTION
W
ARRANTY
*W ARNING DO NOT U SE J E T A FU E L I N TH IS E N GI NE . A N Y U SE O F J E T A FU E L WI L L
V
ID TH E W&
A RR
NTOF
Y OM
N TH
E E N GI NE A ND WILL RES ULT I N V IOLA TIO N O F EPA E M ISSI O NS
POURPOSE
UASE
ANUAL
R E GU LAT IO NS
This manual is designed as a quick guide to familiarize you with part numbers and descriptions of component spare
parts, as well as to inform you of how to order spare parts and service packages for preventative maintenance and
V
EHICLE
ID I NFORMATION
servicing
recommendations
of the manufacturer.
This information can be found on the tractors I.D. Plate located on the firewall next to the drivers seat. Additionally,
theredescriptions
is a permanent
number located
on in
thethis
rear
bulkhead
inside
the engine
compartment.
The
andserial
specifications
contained
manual
were
in effect
at the time
the manual was printed. Eagle
Industrial Truck Manufacturing, LLC. reserves the right to discontinue models at any time and/or to change
specifications, designs or components used without notice and without incurring obligations.
MODEL
C ONTACT I NFORMATION
Customer Service
27250
Kitty
SERIAL
# hawk
Grosse Ile, MI 48138
customerservice@eagletugs.com
(734)
MFG671-8181
DATE
Parts & Service Sales
27250 Kitty hawk
ENGINE TYPE
Grosse Ile, MI 48138
customerservice@eagletugs.com
(734) 671-8181
ENGINE SERIAL #
Web-Site
www.eagletugs.com
W ARRANTY R EGISTRATION
Please take time to fill out the warranty registration information found at our website www.eagletugs.com.
W ARRANTY
WARRANTY INFORMATION
Please read the Eagle Tugs warranty statement (available on our website) carefully.
When contacting Eagle Tugs for warranty or parts service, please have the following
information ready:
Tractor model number
Tractor serial number
Current hour reading
This information can be found on the data plate located beside the driver seat with the exception of the hours which can
be read using the OPT10 display on the dash.
10
Tawain
Leanmark Co.
(Non-Automotive Engines)
Fax: 1437-0308
Phone: 81-46-234-6180
Phone: 81-46-234-6093
Europe
Belgium / The NetherlandsDBH
Division of MACME
Boomsesteenweg 42B
Hardinxveld-Giessendam
B-2630 Aartselaar
The Netherlands
Phone: +32-3-870-8180
Fax: +32-3-870-8188
France
Holm-Denmark
Finland
Finmotor
Sydvestvej 142-144
Palvitie 3
DK-2600 Glostrup
FIN-01390 Vantaa
Phone: +45-43-633700
Phone: +35-8987-00970
Fax: +45-43-631403
Fax: +35-8987-009770
Penven
Germany
Ferdinand-Zeppelin-Strasse 19
F-95250 Beauchamp
47445 Moers
Phone: 1-34135432
Germany
Fax: 1-39957659
Greece
Italy
Athens
Phone: +39-02-382209-220
Phone: 347-3300
Fax: +39-02-3561674
Fax: 347-3404
Norway
Portugal
Motolusa
Estrada da Circunvalacao
N-3430 Spikkostad
Portela da Ajuda
Phone: 3129-1940
P-1495 Lisboa
Fax: 3129-1958
Phone: 1214-241823
Fax: 1214-171927
11
Sweden
c/Viguetas Castilla, 26
Phone: 1-6737012
Fax: 1-6737412
Swed Motor AB
Switzerland Sterki AG
Box 4
Zinkereistrasse 35
S-13721 Vasterhaninge
CH-8633 Wolfhausen
Phone: 8-50012140
Phone: 55-253-2600
Fax: 8-50026800
Fax: 55-253-2609
United Kingdom
Phone: 44+1666500843
United Kingdom
Phone: 1923-231-580
Middle East
General Navigation
and Commerce
Oman
U.A.E.
Company
Fax: +968-591802
Phone: +971-370065
Fax: +971-370308
Oceania
Australia
77 Millers Road
Upper Hut
Phone: 4-528-1200
Australia
Fax: 4-528-1125
12
S AFETY
INFORMATION
13
S AFETY I NFORMATION
14
S AFETY I NFORMATION
I MPORTANT S AFETY N OTICE
Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all industrial
engines as well as the personal safety of the individual performing the work. This Service Manual provides general directions for accomplishing service and repair work with tested and effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for servicing equipment, as well as in the skill
of the individual doing the work. This Manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must first establish he
compromises his/her personal safety, and/or the equipment integrity by his/her choice of methods, tools or parts.
W ARNINGS
The following list contains some general WARNINGS that you should follow when you work on equipment:
Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you to be under the equipment.
Be sure that the ignitions switch is always in the OFF position, unless otherwise required by the procedure.
Set the parking brake (if equipped) when working on the equipment. Place wood blocks (4 x 4 or larger) to the
front and rear surfaces of the tires to provide further restraint from inadvertent equipment movement.
Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.
Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts.
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.
Do not smoke while working on the equipment.
To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work
on the equipment. Tie long hair securely behind the head.
Keep hands and other objects clear of the radiator and blades. Electric cooling fan(s) can start to operate at any
time by an increase in under hood temperatures, even though the ignition is in the OFF position. Therefore, care
should be taken to ensure the electric cooling fan(s) are completely disconnected when working under the hood.
15
Abbreviation
Meaning
NL
Not Listed
NPN
No Part Number
AR
As required
Purpose
Part required but not shown on diagram
Parts shown and numbered, but not stocked and sold by Eagle. Typically used for bolts, clamps, etc
16
P OWER
TRAIN
ENGINE DRESSISUZU DIESEL
17
P OWER
TRAIN
ENGINE DRESSISUZU DIESELDETAIL
Item
Part Number
Qty
Description
B-TT10TD-00017-1
FLYWHEEL
B-TT10TD-00016-ID
FLEX PLATE
TM27C00305-ID
B-TT10TD-00001-ID
TRANS PLATE
NPN
A-TT5D-00010
LORD WASHER
A-TT5D-00013-1
ISOLATOR
B-TT5D-0009
TRANS MOUNT
B-TT5D-00009
ENGINE MOUNT
10
NPN
11
8-94430-983-1
12
A-TT4-000651
13
8971138000
14
1136714360
BELT
15
TMD27B00521-ID
ENGINE PLATE
16
8970848770
STARTER
18
897213-4720
19
A-TT4-000652
20
5136603081
FAN
21
894423-7450
ALTERNATOR BRACKET
22
5812003470
ALTERNATOR - 50AMP
23
8943881780
BOLT, ALT
24
8970862281
25
8971842640
26
1099851770
27
9091105080
NUT, ALT
28
5240849
DOWEL PINS
29
13MM-ID
M-13 BOLTS
30
8970186640
THERMOSTAT HOUSING
NL
8972112090
THERMOSTAT
NL
894365-6741
THERMOSTAT GASKET
NL
8970908790
18
C OOLING S YSTEM
COOLING SYSTEMUSATS 4JG1 ENGINE MODELS ONLY
COOLING SYSTEMDETAIL
Item
1
2
3
Part Number
A-TT10-00323
A-USAT5-00100
BULK HOSE
Qty
2
1
1
Description
RADIATOR HOSE BOTTOM
LOWER COOLING TUBE
BOTTOM HOSE 1 1/2 IN X 3IN
19
C OOLING S YSTEM
COOLING SYSTEMUSATS 4JG1 ENGINE MODELS ONLY
COOLING SYSTEMDETAIL
Item
1
2
3
4
5
Part Number
A-TT10TD-00322
A-USAT5-00311-1
A-USAT5-00330
A-USAT5-50-15-1
A-USAT5-50-16-1
Qty
1
1
1
1
1
Description
SURGE TANK
RADIATOR
RADIATOR CAP
UPPER SHROUD ( NOT SHOWN)
BOTTOM SHROUD (NOT SHOWN)
20
21
C OOLING S YSTEM
COOLING SYSTEM TRANSMISSION
Item
Part Number
Qty
A-USAT5-00311-1
RADIATOR
A-TT4-00221-1
TRANSMISSION COOLER
A-USAT5-00330
RADIATOR CAP
Description
22
D RIVELINE
DRIVE SHAFT ASSEMBLYFRONT
Item
1
2
3
4
5
6
Part Number
A-TT8-00201-1
A-TT4-00132-1
A-TT4-00134
A-TT8-00202-4
A-TT4-00130
A-TT4-00137-1
Qty
1
1
1
1
2
1
2-4-1921
Description
TRANSMISSION OUTPUT YOKE SHAFT-FRONT
CROSS BEARING FRONT D/S NEW STYLE
DRIVE SHAFT SPRING
DRIVE SHAFT
END YOKE STRAP AND BOLT KIT
CROSS BEARING FRONT D/S NEW STYLE
END YOKE
23
D RIVELINE
DRIVESHAFT ASSEMBLYREAR
6
2
3
1
Item
Part Number
Qty
Description
A-TT8-00201-2
A-TT4-00134
A-TT4-00132-1
AB-TT4-00130-1
DRIVE SHAFT
A-TT4-00130
A-TT4-00137
24
T RANSMISSION
TRANSAXLE MOUNTING & MISC. PARTS
25
T RANSMISSION
TRANSAXLE MOUNTING & MISC. PARTS DETAIL
Item
1
2
3
4
5
6
7
8
9
Part Number
A-TT5D-0018-1
A-TN4-00707
3747361
4856444
5240849
4778718
A-TT4-00419
6501741
85705
Qty
1
1
1
1
2
1
1
*
*
Description
TRANSAXLE
GROUND STRAP
SWITCH-NEUTRAL STARTER & BACK UP LIGHT
INDICATOR-TRANSAXLE FLUID
DOWEL PIN-TRANSAXLE TO ENGINE ALIGNMENT
TORQUE CONVERTER
TRANSAXLE SHIFT LEVER-MANUAL CONTROL
SCREW-HEX CAP-WITH WASHER M12-1.75 X 30
GASKET & FILTER MAINTENANCE PACKAGE
26
T RANSMISSION
TRANSAXLE CASE EXTENTION & RETAINER
18
27
T RANSMISSION
TRANSAXLE CASE EXTENSION & RETAINER - DETAIL
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Part Number
6501474
4471573
NPN
4504568
4269787
4567493
6500368
NPN
NPN
4659342
82180
6501474
3878447
4471573
6501474
6101285
4567022
4567494
6500111
4549219
6500511
NPN
4412522
NPN
NPN
5212151
4295857
NPN
NPN
A-TT5D-00021
A-TT4-00657
Qty
10
1
1
1
1
1
6
6
10
1
1
10
1
1
12
1
1
1
1
1
4
2
2
1
4
1
1
1
1
1
1
Description
SCREW-HEX CAP-W/WASHER M8-1.25 X 16
PAN
CUP(NOT SOLD SEPARATELY)
SPACER KIT
RETAINER, OIL
RETAINER, BEARING
SCREW-HEX CAP-M8 X 1.25 X 23
SCREW-HEX CAP-WASHER HEAD M8-1.25 X
SCREW-HEX CAP M8-1.25 X 15
COVER, TRANS. END
RTV SEALANT
SCREW-HEX CAP W/WASHER M8-1.25 X 16
SEAL, MANUAL VALVE SHAFT
PAN, TRANSAXLE OIL
SCREW-HEX CAP W/WASHER M8-1.25 X 16
SCREW-HEX CAP-W/WASHER M6-1 X 16
CUP
RETAINER
O-RING
OUTPUT HOUSING
SCREW-HEX CAP-W/WASHER M8-1.25 X 33
M8 HEX HEAD SCREW
SEAL
BUSHING (SERVICED IN EXT.)
SCREW-HEX CAP WASHER HEAD M8-1.25 X
O-RING
SPEEDOMETER CABLE ADAPTOR
SCREW-FLAT HEAD HEX SOCKET M8-1.25 X
SCREW-HEX CAP-WASHER HEAD M6-1.0 X
DIFFERENTIAL-WELDED SPIDER GEAR
TRANSMISSION PLUG (2WD ONLY)
28
A XLES
AXLE ASSEMBLYFRONT DRIVE (4WD)
A-TT4-00119
12
NYLON WASHER
NPN
NPN
3965138
BUSHING
10
A-TT4-00365
11
A-TT4-00118-3
12
A-TT4-00116
LEAF SPRING
13
A-TT4-00366
29
A XLES
AXLE ASSEMBLY REAR
AXLE ASSEMBLYREARDETAIL
Item
Part Number
1
2
3
4
5
6
7
Qty
A-TT4-00361
A-TT4-00116
A-TT4-00362-1
A-TT4-00363
A-TT4-00366
A-TT4-00365
4313905
Description
1
2
4
2
8
8
1
30
A XLES
AXLE ASSEMBLY BREAKDOWNFRONT DRIVE (4WD)
31
A XLES
AXLE ASSEMBLY BREAKDOWNFRONT DRIVEDETAIL
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
15
15a
17
18
19
20
21
22
23
24
25
Part Number
A-TT8-00371
22404X
30764
706031X
706617X
30765
706617X
706030
13575
39118
345761X
30186
30185
82180
34685
36472
34279
N/A
48632-1
706032X
706618X
25806X
32684
41221
17717
Qty
1
1
1
KIT
KIT
1
KIT
KIT
1
1
1
1
1
AR
1
1
10
2
2
KIT
KIT
1
1
10
2
Description
COMPLETE AXLE ASSEMBLY
GEAR & PINION ASSEMBLY
SLINGER-PINION OIL INNER
INNER PINION BEARING
SHIM-PINION ADJUSTING
BAFFLE-PINION OIL
SHIM-PINION BEARING ADJUSTING
OUTER PINION BEARING
SLINGER-PINION OIL OUTER
SEAL-OIL
END YOKE ASSEMBLY
WASHER-PINION NUT
NUT-PINION
RTV SEALANT
GASKET
PLUG-COVER PLATE
SCREW-FLANGE HD
CAP DIFFERENTIAL BEARING
1/2-13 X 2.25 GRD8 HEX BOLT
DIFFERENTIAL BEARING
DIFFERENTIAL SHIM
CASE-DIFFERENTIAL ASSY
CASE-DIFFERENTIAL
BOLT-DRIVE GEAR
PINION-DIFFERENTIAL
26
706027X
27
13338-3
28
32121
29
39194
SHAFT-DIFFERENTIAL
30
13449
PIN-ROLL
31
16979
VENT
32
36352
33
44101
NUT-SLOTTED
34
500024-8
PIN-COTTER
35
35417
RING-ADJUSTING
36
40112
SOCKET ASSEMBLY-UPPER
37
35566
NUT-LOCK
38
40113
SOCKET ASSEMBLY-LOWER
39
35928
RING-SNAP
40
310026-2
BOLT-STOP
44
500024-4
PIN-COTTER
45
044TR115-16X
32
33
A XLES
AXLE ASSEMBLY BREAKDOWNFRONT DRIVEDETAIL (CONT.)
Item
45
46
47
48
49
50
52
57
58
59
62
68
69
70
71
72
73
74
75
76
77
78
79
79
80
Part Number
044TR115-16X
660091-18
36364
38128
38106
550759
35704
21588X
36569
31139
31624
31552
42667
35218
32589
706111X
044HU103
706690-X
36366
706570
7065227X
36361
RD52
18-4167
18-4166
5468226
Qty
1
2
1
2
2
2
12
2
2
2
2
2
2
2
2
KIT
2
KIT
2
KIT
KIT
1
1 SET
1
1
1SET
Description
TIE ROD ASSEMBLY
SHAFT & JOINT ASSEMBLY
SLINGER
SEAL-OIL
SPACER
BEARING-NEEDLE
NUT-LOCK
SPINDLE NUT
LOCK-RETAINING NUT
NUT-SPINDLE
RING-SNAP
CAP-HUB
GEAR-AXLE DRIVE
SPRING PRESSURE
PLATE-SPRING RETAINING
OUTER WHEEL BEARING
HUB & ROTOR ASSEMBLY
INNER WHEEL BEARING
AXLE SEAL
SPINDLE ASSEMBLY
SPINDLE SEAL & BEARING
SEAL-OIL
BRAKE PAD SET
CALIPER ASSY LEFT
CALIPER ASSY RIGHT
ANCHOR BOLTS
34
A XLES
AXLE ASSEMBLY BREAKDOWNREAR DRIVE
35
A XLES
AXLE ASSEMBLY BREAKDOWNREAR DRIVEDETAIL
Item
2
3
4
5
6
7
8
9
10
11
12
14
15
15a
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
KIT
Part Number
A-TT4-00361
706033-10X
706046X
706672X
30765
706672X
706045X
30273
38427
345731X
30275
30271
73597
82180
39697
98785
34822
N/A
48632-1
706047X
706673X
706669X
30266
SEE KIT
SEE KIT
SEE KIT
SEE KIT
SEE KIT
500598-21
36253
36805
36240
706071X
706072X
36241
36847
30636
30637
34887-7
34887-10
31534
36805
16979
060WD100
060WD101
706671X
Qty
1
KIT
KIT
KIT
1
KIT
KIT
1
1
1
1
1
1
1
1
10
1
2
KIT
KIT
KIT
10
KIT
KIT
KIT
KIT
KIT
1
8
8
2
KIT
KIT
2
8
4
2
1
1
16
24
1
1
1
1
Description
COMPLETE AXLE ASSEMBLY
DRIVE GEAR & PINION
INNER PINION BEARING
SHIM-DRIVE PINION ADJUSTING
BAFFLE-PINION BEARING
SHIM-PINION BEARING ADJUSTING
OUTER PINION BEARING
SLINGER-PINION BEARING
SEAL-PINION
END YOKE ASSEMBLY
WASHER-PINION NUT
NUT-PINION
COVER ASSEMBLY
RTV SEALANT
AXLE GASKET
PLUG-PIPE SLOTTED
SCREW-FLANGE HD
CAP DIFFERENTIAL BEARING
1/2-13 x 2.25 GRD8 BOLT BEARING CAP
BEARING
SHIM-DIFFERENTIAL BEARING
CASE-DIFFERENTIAL
BOLT-DRIVE GEAR
PINION-DIFFERENTIAL
GEAR-DIFFERENTIAL
THRUST WASHER-PINION
THRUST WASHER-GEAR
SHAFT-DIFFERENTIAL
LOCK-DIFFERENTIAL
BOLT-BRAKE MANUFACTURING
NUT-BRAKE MANUFACTURING
SEAL-OIL
INNER WHEEL BEARING
OUTER WHEEL BEARING
HUB & DRUM ASSEMBLY
STUD-HUB
NUT-SPINDLE
LOCK WASHER WHEEL BEARING
SHAFT-AXLE FLANGE LONG
SHAFT-AXLE FLANGE SHORT
ADAPTER-STUD
NUT-LOCK
VENT
BRAKE ASSEMBLY-SHOE TYPE-RIGHT
BRAKE ASSEMBLY-SHOE TYPE-LEFT
DIFFERENTIAL PARTS (STANDARD)
INCLUDES 15, 21-23, 29
KIT
707084X
36
B RAKES
DRUM BRAKE ASSEMBLYREAR
29
28
30
21
37
B RAKES
DRUM BRAKE ASSEMBLYREAR DETAIL
Item
1
1
2
4
4
5
6
7
8
9
10
11
12
13
14
15
19
19
20
20
21
24
25
26
27
28
29
30
KIT
Part Number
060WD101
060WD100
4313905
4313904
FR357
2235585
2235586
315834
*SEE KIT BELOW
*SEE KIT BELOW
*SEE KIT BELOW
*SEE KIT BELOW
*SEE KIT BELOW
*SEE KIT BELOW
*SEE KIT BELOW
*SEE KIT BELOW
*SEE KIT BELOW
*SEE KIT BELOW
4383299
4383298
4383264
4383265
4419698
*SEE KIT BELOW
*SEE KIT BELOW
*SEE KIT BELOW
*SEE KIT BELOW
3492670
3492656
4383600
H2588
Qty
1
1
1
1
1 SET
1
1
2
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
LEFT
KIT
H2589
RIGHT
KIT
H7146
Description
BRAKE ASSEMBLY L/H
BRAKE ASSEMBLY R/H
BACKING PLATE L/H
BACKING PLATE R/H
SHOE & LINING SET
CYLINDER ASSEMBLY L/H
CYLINDER ASSEMBLY R/H
WHEEL CYLINDERS CONNECTING LINK
COVER
SPRING-UPPER
SPRING-LOWER
SPRING-HOLD DOWN
PIN
SPRING TENSION
BRAKE ADJUSTING LINK
CABLE GUIDE
CABLE ASSEMBLY
SPRING-HOLD DOWN
PARKING BRAKE CAM L/H
PARKING BRAKE CAM R/H
PARKING BRAKE LEVER (LEFT)
PARKING BRAKE LEVER (RIGHT)
BRAKE ANCHOR BOLT
BRAKE ADJUSTING SOCKET L/H
BRAKE ADJUSTING SCREW L/H
BRAKE ADJUSTING SOCKET
WASHER FLAT
WASHER
SPRING
SPACER
BRAKE ADJUSTING KIT INCLUDES PART
6,10,11,12,14,13,20,24,25,26,27
BRAKE ADJUSTING KIT INCLUDES PART
6,10,11,12,14,13,20,24,25,26,27
BRAKE SPRING KIT INCLUDES PART
7,8,9,15
38
39
B RAKES
BRAKE ACTUATOR ASSEMBLY
12
14
10
8
7
3
6
5
11
8
2
1
13
BRAKE ACTUATORDETAIL
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part Number
NPN
NPN
C-TT4-10188
A-USAT5-50-13
A-USAT5-50-11
A-TT4-00193
NPN
A-TT4-10192
NPN
NPN
C-TT4-10182
C-USAT5-10181
C-TT4-10187-8.5
C-TT4-10187-13
Qty
6
3
5
1
1
5
5
5
1
1
1
1
1
1
Description
-20 SET SCREW
-20 NUT
THOMSON NYLINER BEARING
BELL CRANK SHORT
BELL CRANK LONG
CLEVIS PIN
COTTER PIN
CLEVIS
1/2-20 X 33 ADJUSTING ROD
1/2-20 X 3 1/2 ADJUSTING ROD
BRAKE PEDAL PIVOT SHAFT
BRAKE PEDAL
BELL CRANK PIVOT SHAFT 8.5 "
BELL CRANK PIVOT SHAFT 13"
40
B RAKES
BRAKE SYSTEM HYDRAULIC
3
4
14
19
9
20
12
10
11
13
15
14
18
16
8
17
41
B RAKES
BRAKE SYSTEM HYDRAULIC
Part Number
A-USAT5-00175
A-TT4-00174
A-USAT5-00177
NPN
A-USAT5-00162
A-USAT5-00171
A-TT5-00181
A-TT4-00167
A-TT5-00180
A-TT4-00173
A-TT4-00163
NPN
A-USAT5-00164
A-TT4-00165
A-TT4-00170
A-TT4-00166
A-TT4-00168
A-TT4-00169
A-TT4-00176-1
Qty
1
1
1
6
1
1
1
2
1
1
1
1
1
3
1
1
1
1
2
Description
BRAKE LINE FRONT RIGHT
CROSS TEE
BRAKE LINE FRONT LEFT
LINE CLAMP
BRAKE LINE FRONT
BRAKE LINE FIRST REAR
FITTING ADAPTER MASTER CYLINDER
BRAKE LINE
FITTING ADAPTER MASTER CYLINDER
BRAKE LIGHT SWITCH
BRAKE LIGHT TEE
3/16 BRAKE LINE UNION
BRAKE LINE SECOND HALF REAR
BRAKE HOSE CLIP
BRAKE LINE LEFT REAR
BRAKE HOSE REAR
CROSS TEE REAR
BRAKE LINE RIGHT REAR
CALIPER HOSE
42
B RAKES
PARKING BRAKE ACTUATOR ASSEMBLY
10
43
B RAKES
PARKING BRAKE ACTUATOR ASSEMBLYDETAIL
Item
1
2
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18
Part Number
A-TT4-00141
NPN
NPN
NPN
B-TT4-00145
A-TT4-00146
A-TT4-00193
NPN
A-TT4-00150
NPN
NPN
NPN
NPN
NPN
NPN
NPN
NPN
Qty
1
4
4
4
1
1
3
3
2
1
1
1
1
1
1
2
2
Description
HAND BRAKE
SCREW-HEX CAP-5/16-18 X 1
WASHER-FLAT-5/16
NUT-LOCK-5/16-18
CABLE PRIMARY
BAR EQUALIZER
CLEVIS PIN
COTTER PIN
PARKING BRAKE CABLE REAR LONG
SCREW-HEX CAP-14-20 X 1
WASHER-FLAT-1/4
NUT-LOCK-1/4-20
SCREW-HEX CAP-1/4-28 X 1
CABLE CLAMP PLATE
CABLE CLAMP HANDLE
NUT-LOCK-1/4-28
CABLE CLAMP
44
45
H YDRAULIC
ASSIST
HYDRAULIC ASSIST SYSTEM
11
12
1
1
1
Part Number
Qty
Description
05712B-108
NIPPLE
C3269X12X8
BUSHING
C5515X6
06U-606-56-B67
HOSE
NPN
A-TT4-00207
A-TT4-00161-1
MASTER CYLINDER
F81Z3A697AB
A-TT4-00606-1
10
11
SP20PB11L145H3R
PRINCE PUMP
12
12GMV MEGAVAC
46
S TEERING S YSTEM
STEERING SYSTEM BREAKDOWN
16
20
10
12
8
14
11
18
15
17
13
47
S TEERING S YSTEM
STEERING SYSTEM BREAKDOWNDETAIL
Item
1
2
3
4
5
6
7
8
Part Number
A-TT10-00809
A-TT10-00807-1
A-TT10-00811
A-TU-00801
A-TT10-00831
A-TT10-0001
06U-606-101-366
*NPN (NOT SOLD SERPERATELY, INCLUDED
Qty
1
1
1
1
6
1
1
1
Description
STEERING WHEEL
STEERING COLUMN
HORN BUTTON
CHARLYNN CONTROL PUMP
FITTING - ADAPTOR
FITTING 90 DEGREE
LINE-MASTER CYLINDER TO STEER PUMP
HYDRAULIC CYLINDER PIVOT PIN
9
10
11
1
7
1
12
06U-666-66-606
13
06U-666-69-686
14
A-TT10-00406
JAM NUT
15
A-TT10-00407
16
NPN
17
NPN
18
A-TT10-00803
HYDRAULIC CYLINDER
19
NPN(Not Shown)
CLIP
20
A-TT10-00813
21
06U-606-56-B67
48
A IR C LEANER
AIR CLEANER ASSEMBLYDIESEL
8
6
6
6
8
Item
1
2
3
4
5
6
8
9
Part Number
A-TT4-00091-1
A-TT4-00092
NPN
NPN
NPN
NPN
A-TT4-00097-1
NPN
Qty
1
2
3
3
3
4
2
1
QA028 REV03 11.18.13
Description
AIR CLEANER ASSEMBLY 3"
AIR CLEANER BRACKET (NOT SHOWN)
NUT-LOCK 3/8-16
WASHER-FLAT 3/8
SCREW-HEX CAP 3/8-16 X 1 GR.5
HOSE CLAMPS
90 DEGREE ELBOW INTAKE TUBE
BULK-INTAKE TUBE - 3"
49
A IR C LEANER
AIR CLEANER SUB-ASSEMBLY
Item
1
2
Part Number
A-TT4-00091-1
P549271
Qty
1
1
Description
AIR CLEANER ASSEMBLY 3"
AIR CLEANER ELEMENT
50
F UEL S YSTEM
FUEL SYSTEMDIESEL
FUEL SYSTEMDETAIL
Item
1
2
3
4
5
6
7
8
9
10
11
Part Number
A-TT4-00276
A-TT4-00271-1
A-TT4-00272
A-USAT5-00273-2
A-TT4-00274
NPN
NPN
NPN
NPN
Qty
1
1
1
1
6
1
4
6
4
Description
FUEL SENDING UNIT
FUEL CAP
NIPPLE
FUEL TANK
90 DEGREE ELBOW FITTING
BULK-5/16 FUEL LINE
3/8-16 X 1 1/4 HCS
3/8 FLAT WASHER
3/8 LOCK NUT
NPN
A-TT4-00280
5
2
51
E XHAUST
EXHAUST SYSTEM DIESEL
EXHAUST SYSTEMDETAIL
Item
1
2
3
4
5
6
7
8
9
Part Number
A-USAT-00253
A-TT12-00251
NPN
NPN
NPN
A-TT4-00260
A-TT4-00254
A-TT4-00258-1
A-TT4-00259-1
Qty
1
1
2
2
2
2
3
1
2
Description
DIESEL EXHAUST PIPE
EXHAUST GASKET
SCREW-HEX-CAP 3/8-16 X 1-1/4
WASHER FLAT 3/8
NUT-HEX 3/8-10
PIPE HANGER
2 MUFFLER CLAMPS
MUFFLER
90 DEGREE TAIL PIPE
52
O PERATOR C OMPARTMENT
ACCELERATOR PEDAL ASSEMBLY
Part Number
A-TT4-00281-1
Qty
1
Description
FOOT PEDAL ASSEMBLY
NPN
NPN
WASHER-FLAT-1/4
NPN
NUT-LOCK-1/4-20
A-TT4-00285*
1*
CABLE CLASP*
A-TT4-00287
A-USAT5-00282
A-TT4-00247
A-TT4-00283-1
53
O PERATOR C OMPARTMENT
TRANSMISSION CONTROL
TRANSMISSION CONTROLDETAIL
Item
1
2
3
4
5
6
Part Number
A-TT4-00245
A-USAT5-00246
A-TT4-00248
A-TT4-00247
A-TT4-00249
A-TT4-00419
Qty
1
1
1
1
1
1
Description
TRANSMISSION SHIFT CONTROL
TRANSMISSION SHIFT CABLE 120'
TRANSMISSION CABLE BRACKET ASSEMBLY
U-BOLT KIT
BALL JOINT KIT
TRANSMISSION LEVER
54
O PERATOR C OMPARTMENT
INSTRUMENT PANEL
14
15
55
O PERATOR C OMPARTMENT
INSTRUMENT PANELDETAIL
Item
1
2
3
4
5
6
7
7
8
9
10
11
12
13
NS
NS
14
15
16
Part Number
C-TT4-00411
A-TT4-00412
A-TT4-00415
A-TT4-00416
A-TT4-00417
A-TT4-00418
A-TT4-00422-2
A-TT4-00422-3
A-TT6-0015
TMD27M00200
A-TT4-00423-1
A-TT4-00428
A-TT4-00609
A-TT4-00608
A-TT4-00434-1
A-TT4-00435-1
AE-OPT-0066
AE-OPT-0094
A-TT4-00306
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
Description
DASH PANEL (NO INSTRUMENTS)
OIL PRESSURE GAUGE
FUEL GAUGE
VOLT-AMP GAUGE
TEMP GAUGE
HOUR METER
IGNITION SWITCH (KEYED OPTION)
IGNITION SWITCH (KEYLESS OPTION)
PLATE, MOUNTING IGNITION SWITCH
GLOW PLUG SWITCH
HEAD LIGHT SWITCH
HORN BUTTON
HEATER FAN SWITCH(OPTIONAL)
TEMP CONTROL CABLE(OPTIONAL)
WIRE HARNESS (DASH ONLY)
80 AMP CIRCUIT BREAKER
EMERGENCY STOP(OPTIONAL)
12V ACCESSORY OUTLET
WARNING LIGHT ISUZU FUEL(NOT
56
4
1
10
11
3
10
ELECTRICAL BOARDDETAIL
Item
1
2
3
4
5
6
7
8
9
10
11
Part Number
B-TT4-00301
A-TT4-00302
A-TT4-00303-1
A-TT4-00435-1
98253-00410
A-TT4-00308
A-TT4-00299
A-TT4-00300
A-TT3-0010
NPN
NPN
Qty
1
1
1
1
1
1
1
1
4
10
2
QA028 REV03 11.18.13
Description
MOUNTING BRACKET
STARTER RELAY
HORN RELAY
FUSE (80 AMP)
GLOW PLUG RESISTOR
RELAY
FUSE BLOCK (NOT SHOWN)
TERMINAL BLOCK (NOT SHOWN)
25 AMP ROUND FUSE (NOT SHOWN)
SELF DRILLING SCREWS
LOCK NUT 10-32
57
HORNDETAIL
Item
1
Part Number
A-TT4-0052
Qty
1
Description
HORN ASSEMBLY
58
59
Item
1
1a
2
2a
2b
3
4
5
6
Part Number
ATT4-00291-5
H3
A-TT4-00292
1157
1156
NPN
NPN
NPN
NPN
Qty
2
2
2
1
1
2
6
2
6
Description
HEADLIGHT
REPLACEMENT HEADLIGHT BULB
TAILLIGHT
BRAKE / TAIL LAMP
BACKUP LAMP
WASHER-FLAT-1/2
WASHER-FLAT-1/4
NUT-1/2-13
NUT-1/4-20
60
61
62
Item
1
2
3
*
Part Number
A-TT8/2-00121-1
A-TT4-00122-1
A-TT4-00123
AE-OPT-0068
Qty
4
4
32
4
* All current models now equipped with standard 16 tire & rim
Description
TIRE 16"
RIM 16"
LUG NUT
SNOW TIRE (OPTION)
63
O THER A SSEMBLY
BODY ASSEMBLY
1
2
BODY ASSEMBLYDETAIL
Item
1
2
3
Part Number
A-TT4-0048-1
A-TT10-00048
AE-OPT-0033
Qty
1
1
1
Description
SINGLE SEAT
BENCH SEAT
E-HITCH (OPTION)
64
O THER A SSEMBLY
BODY ASSEMBLY
BODY ASSEMBLYDETAIL
Item
Part Number
1
2
Qty
D-TT4-0009-1
62-10-603-20
Description
2
2
65
O THER A SSEMBLY
HITCH OPTIONS
HITCH OPTIONDETAIL
Item
1
2
3
4
5
Part Number
AE-OPT-0033
B-TT3-0008 DET2
B-TT3-0008A
B-TT3-0008 DET5
AE-OPT-0028
Qty
1
1
1
1
1
Description
E-HITCH 1 1/2 " PIN-COMPLETE ASSEMBLY
E-HITCH GUIDE 1 1/2" GUIDE PIN WITH RING
E-HITCH SPRING
LOCKING COLLAR
PINTLE HOOK
* The above are standard hitch options. Please call for special hitch options information
QA028 REV03 11.18.13
66
Item
Identification
Type
Service
Lubricant
1
2
3
4
5
6
7
8
Steering Linkage
Transmission Oil*
Engine Oil
Drive Axles
Power Steering Pump
Drive Shaft
Brake Master Cylinder
Engine Coolant
Lube
Check
Change
Check
Check
Lube
Check
Check
EP Multipurpose Grease
Dextron III
OE/HDO (MIL-L-2104)
GO 80-90 (MIL-L-2105)
Power Steering Fluid
EP Multipurpose Grease
Dot 3
MIL-A-46153 (Ethylene Glycol)
67
NO Description of Check/Service
Operational Hours
X-Check * - Requires Service
Daily
50 100 250
Engine Oil and filter *first 50 and
1 every 100 hours thereafter
x
*
*
2 Transmission Fluid *every 500 hours
x
3 Power Steering Fluid
x
4 Brake Fluid
x
5 Coolant Level
x
6 Fuel Filter *every 500 hours
7 Drain Water/Fuel Filter *every 250 hours
*
8 Lubricity Filter *every 250 hours
*
9 Oil Leak Check
x
10 Engine Rubber Mounts
x
x
x
11 Inlet & Exhaust Pipes to Manifold
x
x
x
12 Throttle Controls
x
x
x
13 Coolant Hoses
x
x
x
14 Belt Drives
x
x
x
15 Fuel System Leak Check
x
x
x
16 Electrical Wires and Connections
x
x
x
17 Suspension U-Bolts
*
18 Battery Cables
x
19 Air Cleaner Element *every 250 hours
*
20 Brake Pads (Front)
21 Drum Brake Lining (Rear)
22 Brake Lines and Hoses
23 Flush Cooling System
24 Clean Feed Pump Strainer
25 Check Injection Nozzles
26 Cylinder Compression Pressure
27 Valve Clearance Check
Position Crankcase Ventilation
28 Valve Cleaning
29 Rotate Tires *every 500 hours
500
*
*
*
*
*
*
*
*
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
*
x
x
x
*
*
x
x
x
x
x
x
*
x
x
*
68
Engine Oil
Check engine oil with the unit on a level surface, the key in the OFF position, the shifter position in PARK
and parking brake applied. Open side access door. Remove dipstick from crankcase, wipe it with a cloth. Insert
it fully and take out it gently again. Check the oil level by the marks on the dipstick. The oil level must be between the Max level and the Min level. DO NOT OVERFILL! SEE PAGES 12 & 13 FOR SAFETY BULLETIN!
Coolant
DO NOT remove recovery tank cap or check coolant level while engine is hot! With engine cool, the key in the
OFF position, the shifter position in PARK and the parking brake applied, open hood, set hood prop and
look at left side of recovery tank. The reservoir tank is translucent, so the fluid is readily visible without removing the cap. Fluid level should be at the Cold fill level.
Transmission Fluid
With unit in park and parking brake set in the ON position, start engine. Open side access door. Remove dipstick from transmission case, wipe it with a cloth. Insert it fully and take it out gently again. Check the fluid level
by the marks on the dipstick. The transmission fluid level must be between the Max level and the Min level
on the dipstick. DO NOT OVERFILL.
Brake Fluid
Check brake fluid with the unit on a level surface, the key in the OFF position, the shifter position in PARK
and parking brake applied. Open hood, set hood prop and locate master cylinder reservoir. Remove spring clips
and take off lid. Brake fluid level should be at the top of reservoir.
Isuzu 8-94430-983-1
Fuel Filter
Isuzu 897213-4720
Carquest 85390
Carquest 86128
Fleetgard LF3528
Wix 33128
Air Cleaner
Donaldson P549271
Lubricity Filter
Fleetgard FS20000
Transmission
Wix 58705
69
ISUZU 4JG1
DESCRIPTION:
Standard diesel, 2.8 Liter, Isuzu four cylinder, direct injection engine
# OF CYLINDERS
4 IN-LINE, 4 CYCLE
171 (2.8)
COMPRESSION RATIO
18.60
FUEL
No 2 DIESEL
ALTERNATOR
557 (253)
ENGINE
U.S. QUARTS
IMPERIAL QUARTS
LITRES
10.00
8.33
9.46
U.S. GALLONS
IMPERIAL GALLONS
LITERS
13.3
60.6
16.0
70
ENGINE
2.8 L (171 CID) DIESEL
U.S. PINTS
IMPERIAL PINTS
LITRES
8.00
6.60
3.80
ENGINE
2.8 L (171 CID) DIESEL
U.S. QUARTS
IMPERIAL QUARTS
LITRES
16.00
13.30
15.10
The brake system is power assisted hydraulic, front disc type and rear drum type. USE DOT 3 BRAKE FLUID.
STEERING SYSTEM
The steering system is power assisted hydrostatic type. USE TEXACO FLUID PART NO. 11872 OR EQUIVALENT.
AXLE REFILL CAPACITIES
AXLE
FRONT STEER NON
DRIVE
FRONT DRIVE AXLE
REAR DRIVE AXLE
U.S. PINTS
IMPERIAL PINTS
LITRES
N/A
N/A
N/A
5.20
4.37
2.48
8.50
7.00
3.75
* SERVICE REFILL CAPACITIES ARE DETERMINED BY FILLING TO THE BOTTOM OF THE FILLER HOLE
**USE 80W90 HYPOID GEAR LUBRICANT
71
R EVISION L OG
Rev
Date
18-Nov-2013
Description
Appr.
SEB
72