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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

QA028 REV03 11.18.13

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QA028 REV03 11.18.13

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.

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

Parts & Service


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

QA028 REV03 11.18.13

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

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 DieselDetail............................................................................................................. 17
COOLING SYSTEM ................................................................................................................................................... 18
Cooling SystemDiesel 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. PartsDetail ................................................................................................. 25
Transaxle Case Extension & Retainer ........................................................................................................... 26
Transaxle Case Extension & Retainer - Detail.............................................................................................. 27
AXLES ...................................................................................................................................................................... 28
Axle AssemblyFront Drive (4WD) ............................................................................................................. 28
Axle AssemblyRear ...................................................................................................................................... 29
Axle Assembly BreakdownFront Drive (4WD) ........................................................................................ 30
Axle Assembly BreakdownFront Drive Detail ....................................................................................... 31
Axle Assembly BreakdownFront DriveDetail ...................................................................................... 33
Axle Assembly BreakdownRear Drive ...................................................................................................... 34
Axle Assembly BreakdownRear DriveDetail........................................................................................ 35

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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

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

QA028 REV03 11.18.13

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.

QA028 REV03 11.18.13

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.

QA028 REV03 11.18.13

A UTHORIZED I SUZU D ISTRIBUTOR M AP

QA028 REV03 11.18.13

A UTHORIZED I SUZU D ISTRIBUTOR D IRECTORY

QA028 REV03 11.18.13

10

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

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

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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11

A UTHORIZED I SUZU D ISTRIBUTOR D IRECTORY


Isuzu Motors Limited - Worldwide Distributor Network
Spain

Sweden

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

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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12

S AFETY

INFORMATION

QA028 REV03 11.18.13

13

S AFETY I NFORMATION

QA028 REV03 11.18.13

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.

QA028 REV03 11.18.13

15

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

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

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16

P OWER

TRAIN
ENGINE DRESSISUZU DIESEL

QA028 REV03 11.18.13

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

FLEX PLATE WASHER

B-TT10TD-00001-ID

TRANS PLATE

NPN

3/4" LOCK NUT

A-TT5D-00010

LORD WASHER

A-TT5D-00013-1

ISOLATOR

B-TT5D-0009

TRANS MOUNT

B-TT5D-00009

ENGINE MOUNT

10

NPN

3/4-16X3.5 BOLT & 3/4" WHASHER

11

8-94430-983-1

OIL FILTER ELEMENT

12

A-TT4-000651

OIL PRESSURE SENDING UNIT

13

8971138000

ISUZU MOTOR MOUNT

14

1136714360

BELT

15

TMD27B00521-ID

ENGINE PLATE

16

8970848770

STARTER

18

897213-4720

FUEL FILTER ELEMENT

19

A-TT4-000652

COOLANT TEMP SENDING UNIT

20

5136603081

FAN

21

894423-7450

ALTERNATOR BRACKET

22

5812003470

ALTERNATOR - 50AMP

23

8943881780

BOLT, ALT

24

8970862281

SLIDING ADJUSTMENT BOLT

25

8971842640

ALTERNATOR ADJUSTING BRACKET

26

1099851770

LOCK WASHER, ALT

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

THERMOSTAT HOUSING GASKET

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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

QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

Description
SURGE TANK
RADIATOR
RADIATOR CAP
UPPER SHROUD ( NOT SHOWN)
BOTTOM SHROUD (NOT SHOWN)

20

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QA028 REV03 11.18.13

21

C OOLING S YSTEM
COOLING SYSTEM TRANSMISSION

COOLING SYSTEMTRANSMISSION DETAIL

Item

Part Number

Qty

A-USAT5-00311-1

RADIATOR

A-TT4-00221-1

TRANSMISSION COOLER

A-USAT5-00330

RADIATOR CAP

QA028 REV03 11.18.13

Description

22

D RIVELINE
DRIVE SHAFT ASSEMBLYFRONT

DRIVE SHAFT ASSEMBLY FRONT DETAIL

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

QA028 REV03 11.18.13

23

D RIVELINE
DRIVESHAFT ASSEMBLYREAR

6
2

3
1

DRIVE SHAFT ASSEMBLYREAR DETAIL

Item

Part Number

Qty

Description

A-TT8-00201-2

TRANSMISSION OUTPUT YOKE SHAFT-REAR

A-TT4-00134

DRIVE SHAFT SPRING

A-TT4-00132-1

CROSS BEARING FRONT D/S NEW STYLE

AB-TT4-00130-1

DRIVE SHAFT

A-TT4-00130

END YOKE STRAP KIT

A-TT4-00137

CROSS BEARING REAR D/S NEW STYLE

QA028 REV03 11.18.13

24

T RANSMISSION
TRANSAXLE MOUNTING & MISC. PARTS

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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

* CALL EAGLE PARTS DEPT. FOR DETAILS

QA028 REV03 11.18.13

26

T RANSMISSION
TRANSAXLE CASE EXTENTION & RETAINER

18

QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

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)

AXLE ASSEMBLYFRONT DRIVEDETAIL

A-TT4-00119

12

NYLON WASHER

NPN

SCREW-HEX CAP 3/8-16X3.5

NPN

NUT 9/16-18 GR8

3965138

BUSHING

10

A-TT4-00365

*NUT, AXLE U-BOLT

11

A-TT4-00118-3

MACHINED AXLE CLAMP PLATE

12

A-TT4-00116

LEAF SPRING

13

A-TT4-00366

*WASHER, AXLE U-BOLT

* INCLUDED IN #4 U-BOLT KIT

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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

QA028 REV03 11.18.13

REAR AXLE ASSEMBLY


LEAF SPRING
U-BOLT KIT *INCLUDES ITEMS 5 AND 6
AXLE CLAMP PLATE
WASHER
NUT
LEFT HAND BACKING PLATE

30

A XLES
AXLE ASSEMBLY BREAKDOWNFRONT DRIVE (4WD)

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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

GEAR-DIFFERENTIAL KIT (KIT INCLUDES 15a


AND 24-29)

27

13338-3

THRUST WASHER DIFFERENTIAL PINION

28

32121

THRUST WASHER DIFFERENTIAL GEAR

29

39194

SHAFT-DIFFERENTIAL

30

13449

PIN-ROLL

31

16979

VENT

32

36352

SEAL & GUIDE-SHAFT

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

TIE ROD ASSEMBLY

QA028 REV03 11.18.13

32

This page was intentionally left blank

QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

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

DIFFERENTIAL PARTS (LIMITED SLIP)


INCLUDES 15, 21, 23, 24, 26, 28, 29, 43-48

QA028 REV03 11.18.13

36

B RAKES
DRUM BRAKE ASSEMBLYREAR

29
28
30

21

QA028 REV03 11.18.13

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

*KIT PARTS NOT SOLD SEPERATELY

QA028 REV03 11.18.13

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

This page was intentionally left blank

QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

41

B RAKES
BRAKE SYSTEM HYDRAULIC

BRAKE SYSTEM HYDRAULICDETAIL


Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

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

QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

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

This page was intentionally left blank

QA028 REV03 11.18.13

45

H YDRAULIC

ASSIST
HYDRAULIC ASSIST SYSTEM

11

12
1

1
1

HYDRAULIC ASSIST SYSTEMDETAIL


Item

Part Number

Qty

Description

05712B-108

NIPPLE

C3269X12X8

BUSHING

C5515X6

90 DEGREE SWIVEL FITTING

06U-606-56-B67

HOSE

NPN

CUT TO FIT, BULK HOSE - 3/8" 350 PSI

A-TT4-00207

RETURN LINE TEE

A-TT4-00161-1

MASTER CYLINDER

F81Z3A697AB

POWER STEERING RESERVOIR TANK

A-TT4-00606-1

Y FITTING (BLACK IRON)

10

A-TT4-00606-1A *COMPLETE ASSEMBLY

Y FITTING (BLACK MALE COUPLING)

11

SP20PB11L145H3R

PRINCE PUMP

12

12GMV MEGAVAC

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

8
14

11

18

15
17

QA028 REV03 11.18.13

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

WITH ITEM #18)


A-TT10-00826
NPN
A-TT10-00817

1
7
1

BEARING (AFTER 7/99)


HOSE CLAMP
DRAG LINK

12

06U-666-66-606

LINE -STEERING LEFT TURN

13

06U-666-69-686

LINE-STEERING RIGHT TURN

14

A-TT10-00406

JAM NUT

15

A-TT10-00407

TIE ROD END

16

NPN

HIGH PRESSURE HOSE 3/8 ID 350 PSI

17

NPN

NUT HEX SLOTTED

18

A-TT10-00803

HYDRAULIC CYLINDER

19

NPN(Not Shown)

CLIP

20

A-TT10-00813

WHEEL NUT 13/16 - 20

21

06U-606-56-B67

LINE- ENGINE TO MASTER CYLINDER

QA028 REV03 11.18.13

48

A IR C LEANER
AIR CLEANER ASSEMBLYDIESEL

8
6
6

6
8

AIR CLEANER ASSEMBLYDETAIL

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

AIR CLEANER SUB-ASSEMBLYDETAIL

Item
1
2

Part Number
A-TT4-00091-1
P549271

Qty
1
1

QA028 REV03 11.18.13

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

SCREW-HEX CAP-10-32 X3/4


BULK HEAD FITTING (NOT SHOWN)

QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

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

ACCELERATOR PEDAL ASSEMBLYDETAIL


Item
1

Part Number
A-TT4-00281-1

Qty
1

Description
FOOT PEDAL ASSEMBLY

NPN

SCREW-HEX CAP-1/4-20 X 1.00 G8

NPN

WASHER-FLAT-1/4

NPN

NUT-LOCK-1/4-20

A-TT4-00285*

1*

CABLE CLASP*

A-TT4-00287

BALL JOINT KIT - NUT INCLUDED

A-USAT5-00282

ACCELERATOR CABLE ASSEMBLY

A-TT4-00247

ACCELERATOR U-BOLT KIT

A-TT4-00283-1

ACCELERATOR CLEVIS-PIN KIT

*CLASP MUST BE WELDED TO BRACKET


QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

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

#15. 12V Accessory outlet found directly under

QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

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

L IGHTS & E LECTRICAL


ELECTRICAL BOARD

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

L IGHTS & E LECTICAL


HORN ASSEMBLY

HORNDETAIL

Item
1

Part Number
A-TT4-0052

Qty
1

QA028 REV03 11.18.13

Description
HORN ASSEMBLY

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QA028 REV03 11.18.13

59

L IGHTS & E LECTRICAL


HEADLIGHT & TAILLIGHT ASSEMBLY

HEADLIGHT & TAILLIGHT ASSEMBLYDETAIL

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

QA028 REV03 11.18.13

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

L IGHTS & E LECTRICAL


WIRING HARNESS

QA028 REV03 11.18.13

61

L IGHTS & E LECTRICAL


WIRING SCHEMATIC

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62

W HEELS & T IRES


WHEEL & TIRE ASSEMBLY

WHEEL & TIRE ASSEMBLYDETAIL

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

QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

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

QA028 REV03 11.18.13

SIDE ACCESS DOOR


LATCH SIDE ACCESS DOOR

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

USATS D IESEL M AINTENANCE


LUBRICATION CHART

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)

*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
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

QA028 REV03 11.18.13

500

750 1000 1500

*
*
*

*
*

*
*
*

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

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 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.

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

Lubricity Filter

Fleetgard FS20000

Transmission

QA028 REV03 11.18.13

Wix 58705

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

10.00

8.33

9.46

2.8 L (171 CID) DIESEL***


**10W30(5W20 ARCTIC)
***15W40CD IN CONTINENTAL U.S.

FUEL TANK REFILL CAPACITIES

U.S. GALLONS

IMPERIAL GALLONS

LITERS

13.3

60.6

16.0

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

QA028 REV03 11.18.13

70

USATS D IESEL M AINTENANCE


SPECIFICATIONS & CAPACITIES
TRANSMISSION REFILL CAPACITIES

ENGINE
2.8 L (171 CID) DIESEL

U.S. PINTS

IMPERIAL PINTS

LITRES

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
2.8 L (171 CID) DIESEL

U.S. QUARTS

IMPERIAL QUARTS

LITRES

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
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

QA028 REV03 11.18.13

71

R EVISION L OG
Rev

Date

18-Nov-2013

Description

Appr.

Removed warranty statement

QA028 REV03 11.18.13

SEB

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QA028 REV03 11.18.13