EAGLE TUGS

Parts and Service Manual

V e hicle T ype s: U SA TS
En gi ne T ype : Isuzu Diesel 4JG1 Engine Models

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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 informa-
tion pertaining to the safe operation of your Eagle product, please see the Eagle Operations Manual that was also in-
cluded 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 proce-
dures. We encourage you to use this service to reduce machine down-time and to gain a better understanding of proper
repair procedures.

O RDERING S PARE /S ERVICE P ARTS

Eagle inventories most of the component parts found in its USAT series tow tractors, and most spare/service parts can be
shipped the same day the order is received. Parts orders need to be received at Eagle by 12:00 pm (Noon) EST in order
for the parts to be shipped that same day. Parts ordered after 12:00 pm EST will most likely be shipped the following
day.

C ONTACT I NFORMATION

Eagle Corporate Office

26111 Northline Rd
Taylor, MI 48180
(800) 671-0431
www.eagletugs.com

Customer Service Parts & Service Technical Support

customerservice@eagletugs.com parts@eagletugs.com support@eagletugs.com
(734) 442-1000 -- (800) 671-0431 (734) 442-1000 -- (800) 671-0431 (734) 442-1000 -- (800) 671-0431

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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

SAFETY INFORMATION ....................................................................................................... 12

ISUZU SERVICE & PARTS BULLETIN (J-SERIES ENGINE OIL FILL PROCEDURES) .................................................. 12
IMPORTANT SAFETY NOTICE AND WARNING ....................................................................................................... 14

SERVICE PARTS ILLUSTRATIONS & DETAIL............................................................... 15

IDENTIFICATION KEY .............................................................................................................................................. 15
POWER TRAIN ......................................................................................................................................................... 16
Engine Dress – Isuzu Diesel ............................................................................................................................ 16
Engine Dress— Isuzu Diesel—Detail............................................................................................................. 17
COOLING SYSTEM ................................................................................................................................................... 18
Cooling System—Diesel Engine .................................................................................................................... 18
Cooling System-Transmission ........................................................................................................................ 18
DRIVELINE ............................................................................................................................................................... 22
Drive Shaft Assembly-Front ............................................................................................................................ 22
Drive Shaft Assembly-Rear ............................................................................................................................. 23
TRANSMISSION ........................................................................................................................................................ 24
Transaxle Mounting & Misc. Parts ................................................................................................................. 24
Transaxle Mounting & Misc. Parts—Detail ................................................................................................. 25
Transaxle Case Extension & Retainer ........................................................................................................... 26
Transaxle Case Extension & Retainer - Detail.............................................................................................. 27
AXLES ...................................................................................................................................................................... 28
Axle Assembly—Front Drive (4WD) ............................................................................................................. 28
Axle Assembly—Rear ...................................................................................................................................... 29
Axle Assembly Breakdown—Front Drive (4WD) ........................................................................................ 30
Axle Assembly Breakdown—Front Drive –Detail ....................................................................................... 31
Axle Assembly Breakdown—Front Drive—Detail ...................................................................................... 33
Axle Assembly Breakdown—Rear Drive ...................................................................................................... 34
Axle Assembly Breakdown—Rear Drive—Detail........................................................................................ 35

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T ABLE OF CONTENTS

BRAKES.................................................................................................................................................................... 36
Brake Assembly - Rear .................................................................................................................................... 36
Brake Assembly - Rear—Detail ..................................................................................................................... 37
Brake Actuator Assembly............................................................................................................................... 39
Brake System Hydraulic .................................................................................................................................. 40
Brake System Hydraulic—Detail ........................................................................................................................ 41
Parking Brake Actuator Assembly ................................................................................................................. 42
Parking Brake Actuator Assembly—Detail .................................................................................................. 43
HYDRAULIC SYSTEM............................................................................................................................................... 45
Hydraulic Assist ............................................................................................................................................... 45
STEERING SYSTEM................................................................................................................................................... 46
Steering System Breakdown ........................................................................................................................... 46
Steering System Breakdown—Detail ............................................................................................................. 47
AIR CLEANER, FUEL SYSTEM & EXHAUST ............................................................................................................ 48
Air Cleaner Assembly – Diesel ....................................................................................................................... 48
Air Cleaner Sub-Assembly .............................................................................................................................. 49
Fuel System—Diesel ........................................................................................................................................ 50
Exhaust System—Diesel .................................................................................................................................. 51
OPERATOR COMPARTMENT ................................................................................................................................... 52
Accelerator Pedal Assembly ......................................................................................................................... 52
Transmission Control ...................................................................................................................................... 53
Instrument Panel .............................................................................................................................................. 54
Instrument Panel—Detail ................................................................................................................................ 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 Option—Detail....................................................................................................................................... 65
USATS DEISEL MAINTENANCE .............................................................................................................................. 66
Lubrication Chart ............................................................................................................................................ 66
Preventative Maintenance ............................................................................................................................... 67
Daily Operator Responsibilities .................................................................................................................... 68
Specifications & Capacities ............................................................................................................................. 69

REVISION LOG ........................................................................................................................ 71

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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
POURPOSE
V ID TH E W& UASE
A RR Y OM
NTOF 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
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
servicing ID I NFORMATION
recommendations of the manufacturer.

This information can be found on the tractor’s I.D. Plate located on the firewall next to the driver’s seat. Additionally,
theredescriptions
The is a permanent
andserial number located
specifications on in
contained thethis
rear bulkhead
manual inside
were the engine
in effect compartment.
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.

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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.

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A UTHORIZED I SUZU D ISTRIBUTOR M AP

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A UTHORIZED I SUZU D ISTRIBUTOR D IRECTORY

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A UTHORIZED I SUZU D ISTRIBUTOR D IRECTORY

Isuzu Motors Limited - Worldwide Distributor Network
Asia / Pacific
Japan Isuzu Motors Limited Tawain Leanmark Co.
3-1, Kamigo, 4-Chome, Ebina 9F-1, No.201 Sec 2
Kanagawa-Ken, 243-0434, Japan Keelung Road, Taipei, Taiwan
(Non-Automotive Engines) Fax: 1437-0308
Phone: 81-46-234-6180
Phone: 81-46-234-6093

Europe
Belgium / The NetherlandsDBH Division of MACME
Rivierdijk 452, 3372 BW Boomsesteenweg 42B
Hardinxveld-Giessendam B-2630 Aartselaar
The Netherlands Phone: +32-3-870-8180
Phone: +31 184 613066 Fax: +32-3-870-8188
Fax: +31 184 618002

Denmark 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

France Penven Germany Lopke Diesel Gmbh

281, Chaussee Jules Cesar Ferdinand-Zeppelin-Strasse 19
F-95250 Beauchamp 47445 Moers
Phone: 1-34135432 Germany
Fax: 1-39957659 Phone: 0049 (0) 2841-99 90 445
Fax: 0049 (0) 2841-99 90 185

Greece Petros Petropoulos S.A. Italy Pitteri Violini S.P.A.

Lera Odos 96-102 20021 Baranzate de Bollate
P.O.B. 41018 12210 Milano, Via I Maggio, 25/57 Italy
Athens Phone: +39-02-382209-220
Phone: 347-3300 Fax: +39-02-3561674
Fax: 347-3404

Norway Diesel Power A/S Portugal Motolusa

Industriveien 7, P.O.B. 144 Estrada da Circunvalacao
N-3430 Spikkostad Portela da Ajuda
Phone: 3129-1940 P-1495 Lisboa
Fax: 3129-1958 Phone: 1214-241823
Fax: 1214-171927

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A UTHORIZED I SUZU D ISTRIBUTOR D IRECTORY

Isuzu Motors Limited - Worldwide Distributor Network
Spain Transdiesel Div. de Casli, S.A. Automoviles Utilitarios, S.A. (AUSA)
c/Viguetas Castilla, 26 CRA.DE VIC, KM. 2,8 - P.O.B. 194
E-28820 Coslada - Madrid 08240 Manresa, (Barcelona)
Phone: 1-6737012 Phone: 93-874 7311
Fax: 1-6737412 Fax: 93-874 1211

Sweden 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 HM Isuzu Isuzu Motors Europe Limited

Unit 5A, Babdown Airfield Suite 24, The Courtyards
Nr Tetbury, Gloucestershire GL8 8YL Croxley Business Park
United Kingdom Hatters Lane, Watford
Phone: 44+1666500843 Hertfordshire, WD1 8YH
Fax: 44+1666500844 - FAX United Kingdom
Phone: 1923-231-580

Middle East
General Navigation
and Commerce
Oman General Engineering Service Est. U.A.E. Company
C.R. 1/27447/3 P.O.B.5690 Za'abeel Place Road
Ruwi, Sultanate Of Oman P.O. Box 5563, Dubai
Fax: +968-591802 Phone: +971-370065
Fax: +971-370308

Oceania
Australia Isuzu Australia Limited New ZealandHolden New Zealand Limited
Building 1, Brooklyn Estate Plant No.1, Private Bag
77 Millers Road Upper Hut
Brooklyn, Victoria 3025 Phone: 4-528-1200
Australia Fax: 4-528-1125
Phone: 61 3 9931 9977
Fax: 61 3 9315 2370

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S AFETY INFORMATION

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S AFETY I NFORMATION

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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 di-
rections for accomplishing service and repair work with tested and effective techniques. Following them will help as-
sure 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 cau-
tions 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, cata-
lytic 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.

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S ERVICE P ARTS I LLUSTRATIONS & D ETAIL

I DENTIFICATION K EY

The following abbreviations are used throughout the parts lists in this section.

Abbreviation Meaning Purpose

Part required but not shown on diagram
NL Not Listed
NPN No Part Number Parts shown and numbered, but not stocked and sold by Eagle. Typi-
cally used for bolts, clamps, etc…
AR As required

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P OWER TRAIN

ENGINE DRESS—ISUZU DIESEL

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P OWER TRAIN

ENGINE DRESS—ISUZU DIESEL—DETAIL

Item Part Number Qty Description

1 B-TT10TD-00017-1 1 FLYWHEEL
2 B-TT10TD-00016-ID 1 FLEX PLATE
3 TM27C00305-ID 1 FLEX PLATE WASHER
4 B-TT10TD-00001-ID 1 TRANS PLATE
5 NPN 4 3/4" LOCK NUT
6 A-TT5D-00010 4 LORD WASHER
7 A-TT5D-00013-1 4 ISOLATOR
8 B-TT5D-0009 2 TRANS MOUNT
9 B-TT5D-00009 1 ENGINE MOUNT
10 NPN 4 3/4-16X3.5 BOLT & 3/4" WHASHER
11 8-94430-983-1 1 OIL FILTER ELEMENT
12 A-TT4-000651 1 OIL PRESSURE SENDING UNIT
13 8971138000 1 ISUZU MOTOR MOUNT
14 1136714360 1 BELT
15 TMD27B00521-ID 1 ENGINE PLATE
16 8970848770 1 STARTER
18 897213-4720 1 FUEL FILTER ELEMENT
19 A-TT4-000652 1 COOLANT TEMP SENDING UNIT
20 5136603081 1 FAN
21 894423-7450 1 ALTERNATOR BRACKET
22 5812003470 1 ALTERNATOR - 50AMP
23 8943881780 1 BOLT, ALT
24 8970862281 1 SLIDING ADJUSTMENT BOLT
25 8971842640 1 ALTERNATOR ADJUSTING BRACKET
26 1099851770 1 LOCK WASHER, ALT
27 9091105080 1 NUT, ALT
28 5240849 2 DOWEL PINS
29 13MM-ID 8 M-13 BOLTS
30 8970186640 1 THERMOSTAT HOUSING
NL 8972112090 1 THERMOSTAT
NL 894365-6741 1 THERMOSTAT GASKET
NL 8970908790 1 THERMOSTAT HOUSING GASKET

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C OOLING S YSTEM
COOLING SYSTEM—USATS 4JG1 ENGINE MODELS ONLY

COOLING SYSTEM—DETAIL

Item Part Number Qty Description

1 A-TT10-00323 2 RADIATOR HOSE BOTTOM
2 A-USAT5-00100 1 LOWER COOLING TUBE
3 BULK HOSE 1 BOTTOM HOSE 1 1/2 IN X 3IN

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C OOLING S YSTEM
COOLING SYSTEM—USATS 4JG1 ENGINE MODELS ONLY

1
3

COOLING SYSTEM—DETAIL

Item Part Number Qty Description

1 A-TT10TD-00322 1 SURGE TANK
2 A-USAT5-00311-1 1 RADIATOR
3 A-USAT5-00330 1 RADIATOR CAP
4 A-USAT5-50-15-1 1 UPPER SHROUD ( NOT SHOWN)
5 A-USAT5-50-16-1 1 BOTTOM SHROUD (NOT SHOWN)

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C OOLING S YSTEM

COOLING SYSTEM— TRANSMISSION

COOLING SYSTEM—TRANSMISSION DETAIL

Item Part Number Qty Description

1 A-USAT5-00311-1 1 RADIATOR
2 A-TT4-00221-1 2 TRANSMISSION COOLER
3 A-USAT5-00330 1 RADIATOR CAP

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D RIVELINE
DRIVE SHAFT ASSEMBLY—FRONT

DRIVE SHAFT ASSEMBLY— FRONT DETAIL

Item Part Number Qty Description

1 A-TT8-00201-1 1 TRANSMISSION OUTPUT YOKE SHAFT-FRONT
2 A-TT4-00132-1 1 CROSS BEARING FRONT D/S NEW STYLE
3 A-TT4-00134 1 DRIVE SHAFT SPRING
4 A-TT8-00202-4 1 DRIVE SHAFT
5 A-TT4-00130 2 END YOKE STRAP AND BOLT KIT
6 A-TT4-00137-1 1 CROSS BEARING FRONT D/S NEW STYLE
7 2-4-1921 1 END YOKE
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D RIVELINE
DRIVESHAFT ASSEMBLY—REAR

2
3

1
5

DRIVE SHAFT ASSEMBLY—REAR DETAIL

Item Part Number Qty Description

1 A-TT8-00201-2 1 TRANSMISSION OUTPUT YOKE SHAFT-REAR
2 A-TT4-00134 1 DRIVE SHAFT SPRING
3 A-TT4-00132-1 1 CROSS BEARING FRONT D/S NEW STYLE
4 AB-TT4-00130-1 1 DRIVE SHAFT
5 A-TT4-00130 2 END YOKE STRAP KIT
6 A-TT4-00137 1 CROSS BEARING REAR D/S NEW STYLE
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T RANSMISSION
TRANSAXLE MOUNTING & MISC. PARTS

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T RANSMISSION
TRANSAXLE MOUNTING & MISC. PARTS DETAIL

Item Part Number Qty Description

1 A-TT5D-0018-1 1 TRANSAXLE
2 A-TN4-00707 1 GROUND STRAP
3 3747361 1 SWITCH-NEUTRAL STARTER & BACK UP LIGHT
4 4856444 1 INDICATOR-TRANSAXLE FLUID
5 5240849 2 DOWEL PIN-TRANSAXLE TO ENGINE ALIGNMENT
6 4778718 1 TORQUE CONVERTER
7 A-TT4-00419 1 TRANSAXLE SHIFT LEVER-MANUAL CONTROL
8 6501741 * SCREW-HEX CAP-WITH WASHER M12-1.75 X 30
9 85705 * GASKET & FILTER MAINTENANCE PACKAGE
* CALL EAGLE PARTS DEPT. FOR DETAILS

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T RANSMISSION
TRANSAXLE CASE EXTENTION & RETAINER

18

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T RANSMISSION
TRANSAXLE CASE EXTENSION & RETAINER - DETAIL

Item Part Number Qty Description

1 6501474 10 SCREW-HEX CAP-W/WASHER M8-1.25 X 16
2 4471573 1 PAN
3 NPN 1 CUP(NOT SOLD SEPARATELY)
4 4504568 1 SPACER KIT
5 4269787 1 RETAINER, OIL
6 4567493 1 RETAINER, BEARING
6500368 6 SCREW-HEX CAP-M8 X 1.25 X 23
7 NPN 6 SCREW-HEX CAP-WASHER HEAD M8-1.25 X
8 NPN 10 SCREW-HEX CAP M8-1.25 X 15
9 4659342 1 COVER, TRANS. END
82180 1 RTV SEALANT
6501474 10 SCREW-HEX CAP W/WASHER M8-1.25 X 16
10 3878447 1 SEAL, MANUAL VALVE SHAFT
11 4471573 1 PAN, TRANSAXLE OIL
12 6501474 12 SCREW-HEX CAP W/WASHER M8-1.25 X 16
6101285 1 SCREW-HEX CAP-W/WASHER M6-1 X 16
13 4567022 1 CUP
14 4567494 1 RETAINER
15 6500111 1 O-RING
16 4549219 1 OUTPUT HOUSING
6500511 4 SCREW-HEX CAP-W/WASHER M8-1.25 X 33
17 NPN 2 M8 HEX HEAD SCREW
18 4412522 2 SEAL
19 NPN 1 BUSHING (SERVICED IN EXT.)
20 NPN 4 SCREW-HEX CAP WASHER HEAD M8-1.25 X
21 5212151 1 O-RING
22 4295857 1 SPEEDOMETER CABLE ADAPTOR
23 NPN 1 SCREW-FLAT HEAD HEX SOCKET M8-1.25 X
24 NPN 1 SCREW-HEX CAP-WASHER HEAD M6-1.0 X
25 A-TT5D-00021 1 DIFFERENTIAL-WELDED SPIDER GEAR
26 A-TT4-00657 1 TRANSMISSION PLUG (2WD ONLY)

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A XLES
AXLE ASSEMBLY—FRONT DRIVE (4WD)

AXLE ASSEMBLY—FRONT DRIVE—DETAIL

6 A-TT4-00119 12 NYLON WASHER

7 NPN 4 SCREW-HEX CAP 3/8-16X3.5
8 NPN 3 NUT 9/16-18 GR8
9 3965138 3 BUSHING
10 A-TT4-00365 8 *NUT, AXLE U-BOLT
11 A-TT4-00118-3 2 MACHINED AXLE CLAMP PLATE
12 A-TT4-00116 2 LEAF SPRING
13 A-TT4-00366 8 *WASHER, AXLE U-BOLT
* INCLUDED IN #4 U-BOLT KIT

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A XLES
AXLE ASSEMBLY— REAR

AXLE ASSEMBLY—REAR—DETAIL

Item Part Number Qty Description

1 A-TT4-00361 1 REAR AXLE ASSEMBLY
2 A-TT4-00116 2 LEAF SPRING
3 A-TT4-00362-1 4 U-BOLT KIT *INCLUDES ITEMS 5 AND 6
4 A-TT4-00363 2 AXLE CLAMP PLATE
5 A-TT4-00366 8 WASHER
6 A-TT4-00365 8 NUT
7 4313905 1 LEFT HAND BACKING PLATE

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A XLES
AXLE ASSEMBLY BREAKDOWN—FRONT DRIVE (4WD)

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A XLES
AXLE ASSEMBLY BREAKDOWN—FRONT DRIVE—DETAIL

Item Part Number Qty Description

1 A-TT8-00371 1 COMPLETE AXLE ASSEMBLY
2 22404X 1 GEAR & PINION ASSEMBLY
3 30764 1 SLINGER-PINION OIL INNER
4 706031X KIT INNER PINION BEARING
5 706617X KIT SHIM-PINION ADJUSTING
6 30765 1 BAFFLE-PINION OIL
7 706617X KIT SHIM-PINION BEARING ADJUSTING
8 706030 KIT OUTER PINION BEARING
9 13575 1 SLINGER-PINION OIL OUTER
10 39118 1 SEAL-OIL
11 345761X 1 END YOKE ASSEMBLY
12 30186 1 WASHER-PINION NUT
13 30185 1 NUT-PINION
15 82180 AR RTV SEALANT
15a 34685 1 GASKET
17 36472 1 PLUG-COVER PLATE
18 34279 10 SCREW-FLANGE HD
19 N/A 2 CAP DIFFERENTIAL BEARING
20 48632-1 2 1/2-13 X 2.25 GRD8 HEX BOLT
21 706032X KIT DIFFERENTIAL BEARING
22 706618X KIT DIFFERENTIAL SHIM
23 25806X 1 CASE-DIFFERENTIAL ASSY
32684 1 CASE-DIFFERENTIAL
24 41221 10 BOLT-DRIVE GEAR
25 17717 2 PINION-DIFFERENTIAL
26 706027X 2 GEAR-DIFFERENTIAL KIT (KIT INCLUDES 15a
AND 24-29)
27 13338-3 2 THRUST WASHER DIFFERENTIAL PINION
28 32121 2 THRUST WASHER DIFFERENTIAL GEAR
29 39194 1 SHAFT-DIFFERENTIAL
30 13449 1 PIN-ROLL
31 16979 1 VENT
32 36352 2 SEAL & GUIDE-SHAFT
33 44101 2 NUT-SLOTTED
34 500024-8 2 PIN-COTTER
35 35417 2 RING-ADJUSTING
36 40112 1 SOCKET ASSEMBLY-UPPER
37 35566 2 NUT-LOCK
38 40113 1 SOCKET ASSEMBLY-LOWER
39 35928 1 RING-SNAP
40 310026-2 2 BOLT-STOP
44 500024-4 2 PIN-COTTER
45 044TR115-16X 1 TIE ROD ASSEMBLY

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QA028 REV03 11.18.13

 33

A XLES
AXLE ASSEMBLY BREAKDOWN—FRONT DRIVE—DETAIL (CONT.)

Item Part Number Qty Description

45 044TR115-16X 1 TIE ROD ASSEMBLY
46 660091-18 2 SHAFT & JOINT ASSEMBLY
47 36364 1 SLINGER
48 38128 2 SEAL-OIL
49 38106 2 SPACER
50 550759 2 BEARING-NEEDLE
52 35704 12 NUT-LOCK
57 21588X 2 SPINDLE NUT
58 36569 2 LOCK-RETAINING NUT
59 31139 2 NUT-SPINDLE
62 31624 2 RING-SNAP
68 31552 2 CAP-HUB
69 42667 2 GEAR-AXLE DRIVE
70 35218 2 SPRING PRESSURE
71 32589 2 PLATE-SPRING RETAINING
72 706111X KIT OUTER WHEEL BEARING
73 044HU103 2 HUB & ROTOR ASSEMBLY
74 706690-X KIT INNER WHEEL BEARING
75 36366 2 AXLE SEAL
76 706570 KIT SPINDLE ASSEMBLY
7065227X KIT SPINDLE SEAL & BEARING
77 36361 1 SEAL-OIL
78 RD52 1 SET BRAKE PAD SET
79 18-4167 1 CALIPER ASSY LEFT
79 18-4166 1 CALIPER ASSY RIGHT
80 5468226 1SET ANCHOR BOLTS

QA028 REV03 11.18.13

34

A XLES
AXLE ASSEMBLY BREAKDOWN—REAR DRIVE

QA028 REV03 11.18.13

 35

A XLES
AXLE ASSEMBLY BREAKDOWN—REAR DRIVE—DETAIL
Item Part Number Qty Description
A-TT4-00361 1 COMPLETE AXLE ASSEMBLY
2 706033-10X KIT DRIVE GEAR & PINION
3 706046X KIT INNER PINION BEARING
4 706672X KIT SHIM-DRIVE PINION ADJUSTING
5 30765 1 BAFFLE-PINION BEARING
6 706672X KIT SHIM-PINION BEARING ADJUSTING
7 706045X KIT OUTER PINION BEARING
8 30273 1 SLINGER-PINION BEARING
9 38427 1 SEAL-PINION
10 345731X 1 END YOKE ASSEMBLY
11 30275 1 WASHER-PINION NUT
12 30271 1 NUT-PINION
14 73597 1 COVER ASSEMBLY
15 82180 RTV SEALANT
15a 39697 1 AXLE GASKET
16 98785 1 PLUG-PIPE SLOTTED
17 34822 10 SCREW-FLANGE HD
18 N/A 1 CAP DIFFERENTIAL BEARING
19 48632-1 2 1/2-13 x 2.25 GRD8 BOLT BEARING CAP
20 706047X KIT BEARING
21 706673X KIT SHIM-DIFFERENTIAL BEARING
22 706669X KIT CASE-DIFFERENTIAL
23 30266 10 BOLT-DRIVE GEAR
24 SEE KIT KIT PINION-DIFFERENTIAL
25 SEE KIT KIT GEAR-DIFFERENTIAL
26 SEE KIT KIT THRUST WASHER-PINION
27 SEE KIT KIT THRUST WASHER-GEAR
28 SEE KIT KIT SHAFT-DIFFERENTIAL
29 500598-21 1 LOCK-DIFFERENTIAL
30 36253 8 BOLT-BRAKE MANUFACTURING
31 36805 8 NUT-BRAKE MANUFACTURING
32 36240 2 SEAL-OIL
33 706071X KIT INNER WHEEL BEARING
34 706072X KIT OUTER WHEEL BEARING
35 36241 2 HUB & DRUM ASSEMBLY
36 36847 8 STUD-HUB
37 30636 4 NUT-SPINDLE
38 30637 2 LOCK WASHER WHEEL BEARING
39 34887-7 1 SHAFT-AXLE FLANGE LONG
34887-10 1 SHAFT-AXLE FLANGE SHORT
40 31534 16 ADAPTER-STUD
41 36805 24 NUT-LOCK
16979 1 VENT
060WD100 1 BRAKE ASSEMBLY-SHOE TYPE-RIGHT
060WD101 1 BRAKE ASSEMBLY-SHOE TYPE-LEFT
KIT 706671X 1 DIFFERENTIAL PARTS (STANDARD)
INCLUDES 15, 21-23, 29
KIT 707084X 1 DIFFERENTIAL PARTS (LIMITED SLIP)
INCLUDES 15, 21, 23, 24, 26, 28, 29, 43-48

QA028 REV03 11.18.13

36

B RAKES
DRUM BRAKE ASSEMBLY—REAR

29
28
30

21

QA028 REV03 11.18.13

 37

B RAKES
DRUM BRAKE ASSEMBLY—REAR –DETAIL

Item Part Number Qty Description

060WD101 1 BRAKE ASSEMBLY L/H
060WD100 1 BRAKE ASSEMBLY R/H
1 4313905 1 BACKING PLATE L/H
1 4313904 1 BACKING PLATE R/H
2 FR357 1 SET SHOE & LINING SET
4 2235585 1 CYLINDER ASSEMBLY L/H
4 2235586 1 CYLINDER ASSEMBLY R/H
5 315834 2 WHEEL CYLINDERS CONNECTING LINK
6 *SEE KIT BELOW 1 COVER
7 *SEE KIT BELOW 1 SPRING-UPPER
8 *SEE KIT BELOW 1 SPRING-LOWER
9 *SEE KIT BELOW 2 SPRING-HOLD DOWN
10 *SEE KIT BELOW 1 PIN
11 *SEE KIT BELOW 1 SPRING TENSION
12 *SEE KIT BELOW 1 BRAKE ADJUSTING LINK
13 *SEE KIT BELOW 1 CABLE GUIDE
14 *SEE KIT BELOW 1 CABLE ASSEMBLY
15 *SEE KIT BELOW 2 SPRING-HOLD DOWN
19 4383299 1 PARKING BRAKE CAM L/H
19 4383298 1 PARKING BRAKE CAM R/H
20 4383264 1 PARKING BRAKE LEVER (LEFT)
20 4383265 1 PARKING BRAKE LEVER (RIGHT)
21 4419698 1 BRAKE ANCHOR BOLT
24 *SEE KIT BELOW 1 BRAKE ADJUSTING SOCKET L/H
25 *SEE KIT BELOW 1 BRAKE ADJUSTING SCREW L/H
26 *SEE KIT BELOW 1 BRAKE ADJUSTING SOCKET
27 *SEE KIT BELOW 1 WASHER FLAT
28 3492670 1 WASHER
29 3492656 1 SPRING
30 4383600 1 SPACER
KIT H2588 LEFT BRAKE ADJUSTING KIT INCLUDES PART
6,10,11,12,14,13,20,24,25,26,27
KIT H2589 RIGHT BRAKE ADJUSTING KIT INCLUDES PART
6,10,11,12,14,13,20,24,25,26,27
KIT H7146 BRAKE SPRING KIT INCLUDES PART
7,8,9,15
*KIT PARTS NOT SOLD SEPERATELY

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 39

B RAKES
BRAKE ACTUATOR ASSEMBLY

12 14
6
7 6 2
8 6
8
3
8 3
2 9

10
8 3
7 1

7 1 4
3 6
1
6
5

11 3 3 1 7 8
2

1
13

BRAKE ACTUATOR—DETAIL

Item Part Number Qty Description

1 NPN 6 ¼-20 SET SCREW
2 NPN 3 ½-20 NUT
3 C-TT4-10188 5 THOMSON NYLINER BEARING
4 A-USAT5-50-13 1 BELL CRANK SHORT
5 A-USAT5-50-11 1 BELL CRANK LONG
6 A-TT4-00193 5 CLEVIS PIN
7 NPN 5 COTTER PIN
8 A-TT4-10192 5 CLEVIS
9 NPN 1 1/2-20 X 33 ADJUSTING ROD
10 NPN 1 1/2-20 X 3 1/2 ADJUSTING ROD
11 C-TT4-10182 1 BRAKE PEDAL PIVOT SHAFT
12 C-USAT5-10181 1 BRAKE PEDAL
13 C-TT4-10187-8.5 1 BELL CRANK PIVOT SHAFT 8.5 "
14 C-TT4-10187-13 1 BELL CRANK PIVOT SHAFT 13"

QA028 REV03 11.18.13

40

B RAKES
BRAKE SYSTEM HYDRAULIC

3
1
4 2
5
6
14

19
9
7
8 20
12
10

11

13

15
14

18
16

8 17

QA028 REV03 11.18.13

 41

B RAKES
BRAKE SYSTEM HYDRAULIC

BRAKE SYSTEM HYDRAULIC—DETAIL

Item Part Number Qty Description

1 A-USAT5-00175 1 BRAKE LINE FRONT RIGHT
2 A-TT4-00174 1 CROSS TEE
3 A-USAT5-00177 1 BRAKE LINE FRONT LEFT
4 NPN 6 LINE CLAMP
5 A-USAT5-00162 1 BRAKE LINE FRONT
6 A-USAT5-00171 1 BRAKE LINE FIRST REAR
7 A-TT5-00181 1 FITTING ADAPTER MASTER CYLINDER
8 A-TT4-00167 2 BRAKE LINE
9 A-TT5-00180 1 FITTING ADAPTER MASTER CYLINDER
10 A-TT4-00173 1 BRAKE LIGHT SWITCH
11 A-TT4-00163 1 BRAKE LIGHT TEE
12 NPN 1 3/16 BRAKE LINE UNION
13 A-USAT5-00164 1 BRAKE LINE SECOND HALF REAR
14 A-TT4-00165 3 BRAKE HOSE CLIP
15 A-TT4-00170 1 BRAKE LINE LEFT REAR
16 A-TT4-00166 1 BRAKE HOSE REAR
17 A-TT4-00168 1 CROSS TEE REAR
18 A-TT4-00169 1 BRAKE LINE RIGHT REAR
19 A-TT4-00176-1 2 CALIPER HOSE

QA028 REV03 11.18.13

42

B RAKES
PARKING BRAKE ACTUATOR ASSEMBLY

10

QA028 REV03 11.18.13

 43

B RAKES
PARKING BRAKE ACTUATOR ASSEMBLY—DETAIL

Item Part Number Qty Description

1 A-TT4-00141 1 HAND BRAKE
2 NPN 4 SCREW-HEX CAP-5/16-18 X 1
3 NPN 4 WASHER-FLAT-5/16
4 NPN 4 NUT-LOCK-5/16-18
5 B-TT4-00145 1 CABLE PRIMARY
6 A-TT4-00146 1 BAR EQUALIZER
7 A-TT4-00193 3 CLEVIS PIN
8 NPN 3 COTTER PIN
10 A-TT4-00150 2 PARKING BRAKE CABLE REAR LONG
11 NPN 1 SCREW-HEX CAP-14-20 X 1
12 NPN 1 WASHER-FLAT-1/4
13 NPN 1 NUT-LOCK-1/4-20
14 NPN 1 SCREW-HEX CAP-1/4-28 X 1
15 NPN 1 CABLE CLAMP PLATE
16 NPN 1 CABLE CLAMP HANDLE
17 NPN 2 NUT-LOCK-1/4-28
18 NPN 2 CABLE CLAMP

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 45

H YDRAULIC ASSIST

HYDRAULIC ASSIST SYSTEM

11

12
1

HYDRAULIC ASSIST SYSTEM—DETAIL

Item Part Number Qty Description

1 05712B-108 5 NIPPLE
2 C3269X12X8 2 BUSHING
3 C5515X6 1 90 DEGREE SWIVEL FITTING
4 06U-606-56-B67 1 HOSE
5 NPN 1 CUT TO FIT, BULK HOSE - 3/8" 350 PSI
6 A-TT4-00207 1 RETURN LINE TEE
7 A-TT4-00161-1 1 MASTER CYLINDER
8 F81Z3A697AB 1 POWER STEERING RESERVOIR TANK
9 A-TT4-00606-1 1 Y FITTING (BLACK IRON)
10 A-TT4-00606-1A *COMPLETE ASSEMBLY 1 Y FITTING (BLACK MALE COUPLING)
11 SP20PB11L145H3R 1 PRINCE PUMP
12 12GMV MEGAVAC 1 CUT TO FIT, BULK HOSE 3/4" SUCTION

QA028 REV03 11.18.13

46

S TEERING S YSTEM
STEERING SYSTEM BREAKDOWN

16

20

10

12 13

8 9

11 18
14

15

17

QA028 REV03 11.18.13

 47

S TEERING S YSTEM
STEERING SYSTEM BREAKDOWN—DETAIL

Item Part Number Qty Description

1 A-TT10-00809 1 STEERING WHEEL
2 A-TT10-00807-1 1 STEERING COLUMN
3 A-TT10-00811 1 HORN BUTTON
4 A-TU-00801 1 CHARLYNN CONTROL PUMP
5 A-TT10-00831 6 FITTING - ADAPTOR
6 A-TT10-0001 1 FITTING 90 DEGREE
7 06U-606-101-366 1 LINE-MASTER CYLINDER TO STEER PUMP
8 *NPN (NOT SOLD SERPERATELY, INCLUDED 1 HYDRAULIC CYLINDER PIVOT PIN
WITH ITEM #18)
9 A-TT10-00826 1 BEARING (AFTER 7/99)
10 NPN 7 HOSE CLAMP
11 A-TT10-00817 1 DRAG LINK
12 06U-666-66-606 1 LINE -STEERING LEFT TURN
13 06U-666-69-686 1 LINE-STEERING RIGHT TURN
14 A-TT10-00406 1 JAM NUT
15 A-TT10-00407 1 TIE ROD END
16 NPN 1 HIGH PRESSURE HOSE 3/8 ID 350 PSI
17 NPN 1 NUT HEX SLOTTED
18 A-TT10-00803 1 HYDRAULIC CYLINDER
19 NPN(Not Shown) 2 CLIP
20 A-TT10-00813 1 WHEEL NUT 13/16 - 20
21 06U-606-56-B67 1 LINE- ENGINE TO MASTER CYLINDER

QA028 REV03 11.18.13

48

A IR C LEANER
AIR CLEANER ASSEMBLY—DIESEL

6
8

AIR CLEANER ASSEMBLY—DETAIL

Item Part Number Qty Description

1 A-TT4-00091-1 1 AIR CLEANER ASSEMBLY 3"
2 A-TT4-00092 2 AIR CLEANER BRACKET (NOT SHOWN)
3 NPN 3 NUT-LOCK 3/8-16
4 NPN 3 WASHER-FLAT 3/8
5 NPN 3 SCREW-HEX CAP 3/8-16 X 1 GR.5
6 NPN 4 HOSE CLAMPS
8 A-TT4-00097-1 2 90 DEGREE ELBOW INTAKE TUBE
9 NPN 1 BULK-INTAKE TUBE - 3"
QA028 REV03 11.18.13
 49

A IR C LEANER
AIR CLEANER SUB-ASSEMBLY

AIR CLEANER SUB-ASSEMBLY—DETAIL

Item Part Number Qty Description

1 A-TT4-00091-1 1 AIR CLEANER ASSEMBLY 3"
2 P549271 1 AIR CLEANER ELEMENT

QA028 REV03 11.18.13

50

F UEL S YSTEM
FUEL SYSTEM—DIESEL

FUEL SYSTEM—DETAIL

Item Part Number Qty Description

1 A-TT4-00276 1 FUEL SENDING UNIT
2 A-TT4-00271-1 1 FUEL CAP
3 A-TT4-00272 1 NIPPLE
4 A-USAT5-00273-2 1 FUEL TANK
5 A-TT4-00274 6 90 DEGREE ELBOW FITTING
6 NPN 1 BULK-5/16 FUEL LINE
7 NPN 4 3/8-16 X 1 1/4 HCS
8 NPN 6 3/8 FLAT WASHER
9 NPN 4 3/8 LOCK NUT
10 NPN 5 SCREW-HEX CAP-10-32 X3/4
11 A-TT4-00280 2 BULK HEAD FITTING (NOT SHOWN)

QA028 REV03 11.18.13

 51

E XHAUST
EXHAUST SYSTEM– DIESEL

EXHAUST SYSTEM—DETAIL

Item Part Number Qty Description

1 A-USAT-00253 1 DIESEL EXHAUST PIPE
2 A-TT12-00251 1 EXHAUST GASKET
3 NPN 2 SCREW-HEX-CAP 3/8-16 X 1-1/4
4 NPN 2 WASHER FLAT 3/8
5 NPN 2 NUT-HEX 3/8-10
6 A-TT4-00260 2 PIPE HANGER
7 A-TT4-00254 3 2” MUFFLER CLAMPS
8 A-TT4-00258-1 1 MUFFLER
9 A-TT4-00259-1 2 90 DEGREE TAIL PIPE

QA028 REV03 11.18.13

 52

O PERATOR C OMPARTMENT
ACCELERATOR PEDAL ASSEMBLY

ACCELERATOR PEDAL ASSEMBLY—DETAIL

Item Part Number Qty Description

1 A-TT4-00281-1 1 FOOT PEDAL ASSEMBLY
2 NPN 3 SCREW-HEX CAP-1/4-20 X 1.00 G8
3 NPN 3 WASHER-FLAT-1/4
4 NPN 3 NUT-LOCK-1/4-20
5 A-TT4-00285* 1* CABLE CLASP*
6 A-TT4-00287 1 BALL JOINT KIT - NUT INCLUDED
7 A-USAT5-00282 1 ACCELERATOR CABLE ASSEMBLY
8 A-TT4-00247 1 ACCELERATOR U-BOLT KIT
9 A-TT4-00283-1 1 ACCELERATOR CLEVIS-PIN KIT
*CLASP MUST BE WELDED TO BRACKET

QA028 REV03 11.18.13

 53

O PERATOR C OMPARTMENT
TRANSMISSION CONTROL

TRANSMISSION CONTROL—DETAIL

Item Part Number Qty Description

1 A-TT4-00245 1 TRANSMISSION SHIFT CONTROL
2 A-USAT5-00246 1 TRANSMISSION SHIFT CABLE 120'
3 A-TT4-00248 1 TRANSMISSION CABLE BRACKET ASSEMBLY
4 A-TT4-00247 1 U-BOLT KIT
5 A-TT4-00249 1 BALL JOINT KIT
6 A-TT4-00419 1 TRANSMISSION LEVER

QA028 REV03 11.18.13

54

O PERATOR C OMPARTMENT
INSTRUMENT PANEL

14

15

#15. 12V Accessory outlet found directly under

QA028 REV03 11.18.13

 55

O PERATOR C OMPARTMENT
INSTRUMENT PANEL—DETAIL

Item Part Number Qty Description

1 C-TT4-00411 1 DASH PANEL (NO INSTRUMENTS)
2 A-TT4-00412 1 OIL PRESSURE GAUGE
3 A-TT4-00415 1 FUEL GAUGE
4 A-TT4-00416 1 VOLT-AMP GAUGE
5 A-TT4-00417 1 TEMP GAUGE
6 A-TT4-00418 1 HOUR METER
7 A-TT4-00422-2 1 IGNITION SWITCH (KEYED OPTION)
7 A-TT4-00422-3 1 IGNITION SWITCH (KEYLESS OPTION)
8 A-TT6-0015 1 PLATE, MOUNTING IGNITION SWITCH
9 TMD27M00200 1 GLOW PLUG SWITCH
10 A-TT4-00423-1 1 HEAD LIGHT SWITCH
11 A-TT4-00428 1 HORN BUTTON
12 A-TT4-00609 1 HEATER FAN SWITCH(OPTIONAL)
13 A-TT4-00608 1 TEMP CONTROL CABLE(OPTIONAL)
NS A-TT4-00434-1 1 WIRE HARNESS (DASH ONLY)
NS A-TT4-00435-1 1 80 AMP CIRCUIT BREAKER
14 AE-OPT-0066 1 EMERGENCY STOP(OPTIONAL)
15 AE-OPT-0094 2 12V ACCESSORY OUTLET
16 A-TT4-00306 1 WARNING LIGHT ISUZU FUEL(NOT

QA028 REV03 11.18.13

56

L IGHTS & E LECTRICAL

ELECTRICAL BOARD

4
1

10

11

3 2 10

ELECTRICAL BOARD—DETAIL

Item Part Number Qty Description

1 B-TT4-00301 1 MOUNTING BRACKET
2 A-TT4-00302 1 STARTER RELAY
3 A-TT4-00303-1 1 HORN RELAY
4 A-TT4-00435-1 1 FUSE (80 AMP)
5 98253-00410 1 GLOW PLUG RESISTOR
6 A-TT4-00308 1 RELAY
7 A-TT4-00299 1 FUSE BLOCK (NOT SHOWN)
8 A-TT4-00300 1 TERMINAL BLOCK (NOT SHOWN)
9 A-TT3-0010 4 25 AMP ROUND FUSE (NOT SHOWN)
10 NPN 10 SELF DRILLING SCREWS
11 NPN 2 LOCK NUT 10-32

QA028 REV03 11.18.13

 57

L IGHTS & E LECTICAL

HORN ASSEMBLY

HORN—DETAIL

Item Part Number Qty Description

1 A-TT4-0052 1 HORN ASSEMBLY

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QA028 REV03 11.18.13

 59

L IGHTS & E LECTRICAL

HEADLIGHT & TAILLIGHT ASSEMBLY

HEADLIGHT & TAILLIGHT ASSEMBLY—DETAIL

Item Part Number Qty Description

1 ATT4-00291-5 2 HEADLIGHT
1a H3 2 REPLACEMENT HEADLIGHT BULB
2 A-TT4-00292 2 TAILLIGHT
2a 1157 1 BRAKE / TAIL LAMP
2b 1156 1 BACKUP LAMP
3 NPN 2 WASHER-FLAT-1/2
4 NPN 6 WASHER-FLAT-1/4
5 NPN 2 NUT-1/2-13
6 NPN 6 NUT-1/4-20

QA028 REV03 11.18.13

60

L IGHTS & E LECTRICAL

WIRING HARNESS

QA028 REV03 11.18.13

 61

L IGHTS & E LECTRICAL

WIRING SCHEMATIC

QA028 REV03 11.18.13

62

W HEELS & T IRES

WHEEL & TIRE ASSEMBLY

WHEEL & TIRE ASSEMBLY—DETAIL

Item Part Number Qty Description
1 A-TT8/2-00121-1 4 TIRE 16"
2 A-TT4-00122-1 4 RIM 16"
3 A-TT4-00123 32 LUG NUT
* AE-OPT-0068 4 SNOW TIRE (OPTION)

* All current models now equipped with standard 16” tire & rim

QA028 REV03 11.18.13

 63

O THER A SSEMBLY
BODY ASSEMBLY

1
2

BODY ASSEMBLY—DETAIL

Item Part Number Qty Description

1 A-TT4-0048-1 1 SINGLE SEAT
2 A-TT10-00048 1 BENCH SEAT
3 AE-OPT-0033 1 E-HITCH (OPTION)

QA028 REV03 11.18.13

64

O THER A SSEMBLY
BODY ASSEMBLY

BODY ASSEMBLY—DETAIL

Item Part Number Qty Description

1 D-TT4-0009-1 2 SIDE ACCESS DOOR
2 62-10-603-20 2 LATCH SIDE ACCESS DOOR

QA028 REV03 11.18.13

 65

O THER A SSEMBLY
HITCH OPTIONS

2 1

HITCH OPTION—DETAIL

Item Part Number Qty Description

1 AE-OPT-0033 1 E-HITCH 1 1/2 " PIN-COMPLETE ASSEMBLY
2 B-TT3-0008 DET2 1 E-HITCH GUIDE 1 1/2" GUIDE PIN WITH RING
3 B-TT3-0008A 1 E-HITCH SPRING
4 B-TT3-0008 DET5 1 LOCKING COLLAR
5 AE-OPT-0028 1 PINTLE HOOK

* The above are standard hitch options. Please call for special hitch options information

QA028 REV03 11.18.13

 66

USATS D IESEL M AINTENANCE

LUBRICATION CHART

Type
Item Identification Service Lubricant
1 Steering Linkage Lube EP Multipurpose Grease
2 Transmission Oil* Check Dextron III
3 Engine Oil Change OE/HDO (MIL-L-2104)
4 Drive Axles Check GO 80-90 (MIL-L-2105)
5 Power Steering Pump Check Power Steering Fluid
6 Drive Shaft Lube EP Multipurpose Grease
7 Brake Master Cylinder Check Dot 3
8 Engine Coolant Check MIL-A-46153 (Ethylene Glycol)
*Check when engine is at operating temperature

QA028 REV03 11.18.13

 67

USATS D IESEL M AINTENANCE

PREVENTATIVE MAINTENANCE SCHEDULE

NO Description of Check/Service Operational Hours

X-Check * - Requires Service Daily 50 100 250 500 750 1000 1500
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 x x x
11 Inlet & Exhaust Pipes to Manifold x x x x x x
12 Throttle Controls x x x x x x
13 Coolant Hoses x x x x x x
14 Belt Drives x x x x x x
15 Fuel System Leak Check x x x x x x
16 Electrical Wires and Connections x x x x x x
17 Suspension U-Bolts *
18 Battery Cables x
19 Air Cleaner Element *every 250 hours * * * *
20 Brake Pads (Front) x x
21 Drum Brake Lining (Rear) x x
22 Brake Lines and Hoses x x
23 Flush Cooling System *
24 Clean Feed Pump Strainer *
25 Check Injection Nozzles x x x
26 Cylinder Compression Pressure x
27 Valve Clearance Check x
Position Crankcase Ventilation
28 Valve Cleaning x
29 Rotate Tires *every 500 hours * *

QA028 REV03 11.18.13

68

USATS D IESEL M AINTENANCE

DAILY OPERATOR RESPONSIBILITIES

Proper Fluid Checks

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 be-
tween 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 remov-
ing 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 dip-
stick 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.

Power Steering Fluid

Check power steering fluid with key in “OFF” position, the shifter position in “PARK” and the parking brake
applied. Open hood, set hood prop remove cap from power steering reservoir. Fluid level should be between
the arrows on the indicator stick. DO NOT OVERFILL.
Recommended Filters:
Engine oil Isuzu 8-94430-983-1 Fuel Filter Isuzu 897213-4720
Carquest 85390 Carquest 86128
Fleetgard LF3528 Wix 33128
Air Cleaner Donaldson P549271 Transmission Wix 58705
Lubricity Filter Fleetgard FS20000

QA028 REV03 11.18.13

 69

USATS D IESEL M AINTENANCE

SPECIFICATIONS & CAPACITIES

MODEL # ISUZU 4JG1

DESCRIPTION: Standard diesel, 2.8 Liter, Isuzu four cylinder, direct injection engine

# OF CYLINDERS 4 IN-LINE, 4 CYCLE

BORE & STROKE INCHES (mm) 3.66 X 4.01 (93 X 102)
DISPLACEMENT, CUBIC INCHES (L) 171 (2.8)
COMPRESSION RATIO 18.60
FUEL No 2 DIESEL
ALTERNATOR 50 AMP, 12 VOLT, NEG GROUND
ENGINE WEIGHT FULLY DRESSED LB (KG) (PROX) 557 (253)

ENGINE CRANKCASE CAPACITIES

ENGINE U.S. QUARTS IMPERIAL QUARTS LITRES

2.8 L (171 CID) DIESEL*** 10.00 8.33 9.46
**10W30(5W20 ARCTIC)
***15W40CD IN CONTINENTAL U.S.

FUEL TANK REFILL CAPACITIES

U.S. GALLONS IMPERIAL GALLONS LITERS

16.0
13.3 60.6

SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) NO. 2-D

JIS (JAPANESE INDUSTRIAL STANDARD) NO 2
DIN (DEUTSCHE INDUSTRIE NORMEN) 51601
BS (BRITISH STANDARD) CLASS A-1
*Please refer to Isuzu Engine Instruction Manual IDE– 6053 for further information

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USATS D IESEL M AINTENANCE

SPECIFICATIONS & CAPACITIES

TRANSMISSION REFILL CAPACITIES

ENGINE U.S. PINTS IMPERIAL PINTS LITRES

2.8 L (171 CID) DIESEL 8.00 6.60 3.80
* USE DEXTRON III TYPE TRANSMISSION FLUID OR EQUIVALENT
**ADD 9 PINTS, 7.5 IMPERIAL PINTS OR 4.25 LITERS IF TORQUE CONVERTOR HAS BEEN DRAINED

ENGINE COOLING SYSTEM REFILL CAPACITIES

ENGINE U.S. QUARTS IMPERIAL QUARTS LITRES

2.8 L (171 CID) DIESEL 16.00 13.30 15.10
* A 50/50 MIXTURE OF GLYCOL AND CLEAN WATER

BRAKE SYSTEM

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 U.S. PINTS IMPERIAL PINTS LITRES

FRONT STEER – NON
N/A N/A N/A
DRIVE
FRONT DRIVE AXLE
5.20 4.37 2.48
REAR DRIVE AXLE 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

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R EVISION L OG
Rev Date Description Appr.
3 18-Nov-2013 Removed warranty statement SEB

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