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Parts and Service Manual

1. AIR CLEANER FUEL SYSTEM amp EXHAUST 1 1 1 1 1 1 1 1 00000000 Air Cleaner Assembly Diesel see Air Cleaner Assembly ric titt t Fuel Systems Exhaust System Diesel aysasqa trt ertet n OPERATOR COMPARTMENT vise eres seine Fee ea qu pe FE Saa Accelerator Pedal Assembly tp tto arme Transmission Controls A e asses a Instrument Panelis 0 te are Instr ment Panel Detatl 1 00 LICHTS amp ELEGTRIAL 1 1000000 Board 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 00000000 Horn Headlight amp Taillight Assembly 508 02er eb nm Wining Harness ad Md RRS WHEELS E TRES Hitch Optuori Detail qata amia ee USATS MAINTENANCE 1 1 1 1 1 1 1 1 0000 Psubrieatior Chart AS Preventative 1 0000000 Daily Operator Responsibilities adt eo nee ee ne Specifications amp ios RSS REVISION TOC A QA028 11 18 13 6 WARRANTY WARNING DO NOT USE JET A FUEL IN THIS ENGINE ANY USE OF JET A F
2. COMPETE AXLE ASSEMBLY 22404X 30764 17717 706027 45 044 115 16 A CASE DIFFERENTIAL BOLT DRIVE GEAR PINION DIFFERENTIAL GEAR DIFFERENTIAL KIT KIT INCLUDES 15a AND 24 29 TIE ROD ASSEMBLY ale I g o Kan gt O IN QA028 REV03 11 18 13 QA028 11 18 13 This page was intentionally left blank 32 33 5 AXLE ASSEMBLY BREAKDOWN FRONT DRIVE DETAIL CONT 45 044 11546 1 TIERODASSEMBLY 46 6600918 2 SHAFT amp JOINTASSEMBLY 36364 SLINGER 48 50 52 35704 57 21588X NUT LOCK 36569 e 316024 d 2 RING SNAP CGFARAXIEDRVE KIT OUTER WHEEL BEARING 2 KIT 36366 AXLESEAL SPINDLE ASSEMBLY SEAL OIL 1 SET 7 18 4167 80 is SE ANCHORBOLIS A NIN IN 70 71 72 73 74 KIT KIT 1 1 76 77 78 9 QA028 11 18 13 AXLES AXLE ASSEMBLY BREAKDOWN REAR DRIVE QA028 11 18 13 35 AXLES AXLE ASSEMBLY BREAKDOWN REAR DRIVE DETAIL 00361 11 COMPLETEAXLEASSEMBLY 2 PDRIVEGEAR amp PINION O a 760 INNERPINIONBEARING 30765 8 Jj J 3023 11 SLINGER PINION BEARING 9 3807 o 1 SEAL PINON 1 1 34731X 1 ENDYOKEASSEMBLY 1 325 1 WASHER PINIONNUT O 12 az 1 NUT PI
3. TRANSAXLE CASE EXTENTION amp RETAINER QA028 11 18 13 27 TRANSMISSION TRANSAXLE CASE EXTENSION amp RETAINER DETAIL 1 6500368 RETAINER BEARING 0 SCREW HEX CAP WASHER HEAD 8 1 25 X 10 SCREW HEX CAP M8 1 25 X 15 4659342 0 1 2 1 1 1 1 SCREW HEX 8 X 1 25 X 23 10 11 12 12 60 9 13 4702 71 CUP 14 15 16 160171 4 SCREW HEXCAP W WASHER 8 1 25 X33 17 NN 2 M8HEXHEADSCREW 19 1 BUSHING SERVICED IN EXT 2201 4 __ SCREW HEXCAP WASHER HEAD 8 1 25 X 1 SCREW FLAT HEAD HEX SOCKET 8 1 25 X I 24 NN 1 SCREWHEXCAP WASHER HEAD M6 1 0 X QA028 11 18 13 28 AXLES AXLE ASSEMBLY FRONT DRIVE 4WD AXLE ASSEMBLY FRONT DRIVE DETAIL 5 amos NYLON WASHER N ore E s SCN OT 11 MACHINED AXLE CLAMP PLATE 5 WASHER AXLEU BOLT INCLUDEDIN U BOLT KIT ee QA028 11 18 13 29 AXLES AXLE ASSEMBLY REAR Part Number x T REARAXLEASSEVBLY A TT4 00116 a LEAF SPRING x 5 x 6 SC NUT 7 4313905 1 LEFT HAND BACKING PLATE QA028 11 18 13 AXLES AXLE ASSEMBLY BREAKDOWN FRONT DRIVE 4WD QA028 11 18 13 31 5 AXLE ASSEMBLY BREAKDOWN FRONT DRIVE DETAIL E l1 PartNumber Description 1
4. 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 DRIVE FRONT DRIVE AXLE REAR DRIVE AXLE SERVICE REFILL CAPACITIES DETERMINED BY FILLING TO THE BOTTOM OF THE FILLER HOLE USE 80W90 HYPOID GEAR LUBRICANT QA028 11 18 13 71 Appr SEB REVISION LOG Rev Date Description 3 18 Nov 2013 Removed warranty statement QA028 11 18 13 QA028 11 18 13 This page was intentionally left blank 72
5. SEKITBLOW 1 BRAKEADJUSTINGSOCKET 27 SEEKITBEOW 1 WASHERFLAT 3492670 W ASHER 2 __________34926566 LI 1 LEFT 1 640111214132024252627 610111214132024252627 KT BRAKESPRINGKITINCLUDESPART Zu 7 89 15 KIT PARTS NOT SOLD SEPERATELY A m Irch linia ja ID errr d QA028 11 18 13 QA028 11 18 13 This page was intentionally left blank 38 39 BRAKES BRAKE ACTUATOR ASSEMBLY BRAKE ACTUATOR DETAIL 1 NEN 6 20SEISCREW NPN 20 NUT 3 C TT4 10188 5 THOMSON NYLINER BEARING 4 06 5 5043 1 BELLCRANKSHORT 5 A USATS 50 11 1 00193 CLEVIS 7 5 COTTER al __________ 10192 15 cs NPN 1 2 20X 33 ADJUSTINGROD ooo NN 92 20 X 3 1 2 ADJUSTINGROD 11 gt CTT4108 11 BRAKEPEDALPIVOTSHAFT 12 CUSATS10180 1 BRAKEPEDAL 13 CTT41018 85 1 BELLCRANKPIVOTSHAFT85 314 CITT41018713 1 BELLCRANKPIVOTSHAFT13 a lo la Ja o QA028 REV03 11 18 13 40 BRAKES BRAKE SYSTEM HYDRAULIC QA028 11 18 13 41 BRAKES BRAKE SYSTEM HYDRAULIC BRAKE SYSTEM HYDRAULIC DETAIL 1 6 3 7 BRAKELINE A TT5 00180 1 F
6. 1 1 1 ex 3 3 872590 3 FUELFILTERELEMENT 1 1 COOLANTTEMPSENDINGUNI x seal 1 ma m sa 1 AUTERNATORBRACKET m 1 ALTERNATOR SDAMP m EE m 1 SUPINGADIUSTMENTBOLT a5 ALTERNATOR ADJUSTING BRACKET a 1 1OCKWASHERALT xm seme l m sume m omo s moos 3 TERMOSTATO USING N 1 N 1 THERMOSTATGASKET NL 8970908790 1 THERMOSTAT HOUSING CASKET QA028 11 18 13 18 COOLING SYSTEM COOLING SYSTEM USATS 4JG1 ENGINE MODELS ONLY COOLING SYSTEM DETAIL Description 10 00323 RADIATOR HOSE BOTTOM hsc I 1 2 A USAT5 00100 1 LOWER COOLING TUBE BULK HOSE OTTOM HOSE 1 1 2 IN X 3IN QA028 11 18 13 COOLING SYSTEM COOLING SYSTEM USATS 4JG1 ENGINE MODELS ONLY COOLING SYSTEM DETAIL 1 A TTIOTD 00322 SURGETANK A USAT5 00311 1 RADIATOR A USAT5 00330 RADIATOR CAP 4 A USAT5 50 15 1 UPPER SHROUD NOT SHOWN 5 A USAT5 50 16 1 BOTTOM SHROUD NOT SHOWN QA028 11 18 13 QA028 11 18 13 This page was intentionally left blank 20 21 COOLING SYSTEM COOLING SYS
7. Fuel Filter every 250 hours Lubricity Filter every 250 hours Oil Leak Check Engine Rubber Mounts Inlet amp Exhaust Pipes to Manifold Throttle Controls Coolant Hoses N elt Drives System Leak Check lectrical Wires and Connections uspension U Bolts attery Cables Air Cleaner Element every 250 hours Brake Pads Front Drum Brake Lining Rear Brake Lines and Hoses Flush Cooling System Clean Feed Pump Strainer 5 Check Injection Nozzles 6 Cylinder Compression Pressure 27 Valve Clearance Check Position Crankcase Ventilation 28 Valve Cleaning Rotate Tires every 500 hours 00 w 4 WIN el x S lt lt gt x lt gt x O x 6 QA028 11 18 13 68 USATS DIESEL MAINTENANCE 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
8. TAILLIGHT ASSEMBLY HEADLIGHT TAILLIGHT ASSEMBLY DETAIL Description HEADLIGHT SS wa REPLACEMENT HEADLIGHT BULB TAILLIGHT BRAKE TAIL LAMP BACKUP LAMP W ASHER FLAT 1 2 NUT 1 2 13 NN NUT 1 4 20 5 H3 WASHER FLAT 1 4 NPN QA028 11 18 13 QA028 11 18 13 Ivg AINO Larp GION31OS 730 19 9 NOLLOSFNI 192 IN3WAINDZ 2 140 TIY OL MOVA b SLHDIT 831315 014 51911 8519001 S8IM 31182 es L A349 LNO 4901 TL NMOY8 SL 034 WIRING HARNESS 111 3079 EA 31 die 5530 10 Pr LIGHTS amp ELECTRICAL 60 QA028 11 18 13 YOLOW 9314915 GION310S 311 8 00103105 HOLIMS AO15 HOLIMS NOLLINSI 4 WIRING SCHEMATIC LIGHTS amp ELECTRICAL 61 62 WHEELS amp TIRES WHEEL amp TIRE ASSEMBLY WHEEL amp ASSEMBLY DETAIL Park Number A TT8 2 00121 1 TIRE 16 4 00122 1 RIM 16 LUG NUT AE OPT 0068 SNOW TIRE OPTION A TT4 00123 current models now equipped with standard 16 tire amp rim QA028 11 18 13 63 OTHER ASSEMBLY BODY ASSEMBLY BODY ASSEMBLY DETAIL Description 4 0048 1 SINGLESEAT 1 A
9. TT10 00048 BENCH SEAT AE OPT 0033 E HITCH OPTION QA028 11 18 13 64 OTHER ASSEMBLY BODY ASSEMBLY BODY ASSEMBLY DETAIL Item Part Number D TT4 0009 1 SIDE ACCESS DOOR 62 10 603 20 LATCH SIDE ACCESS DOOR QA028 11 18 13 65 OTHER ASSEMBLY HITCH OPTIONS HITCH OPTION DETAIL 1 0033 E HITCH 1 1 2 PIN COMPLETE ASSEMBLY B TT3 0008 DET2 E HITCH GUIDE 1 1 2 GUIDE PIN WITH RING LOCKING COLLAR PINTLE HOOK B TT3 0008 DET5 AE OPT 0028 The above are standard hitch options Please call for special hitch options information QA028 11 18 13 66 USATS DIESEL MAINTENANCE LUBRICATION CHART Type Item Identification Service Lubricant 1 Steering Linkage Transmission Oil Engine Oil Drive Axles Power Steering Pump Drive Shaft Brake Master Cylinder Engine Coolant Check when engine is at operating temperature QA028 11 18 13 67 WE s NN NM 20 E USATS DIESEL MAINTENANCE PREVENTATIVE MAINTENANCE SCHEDULE Description of Check Service Operational Hours 5 Requires Service Engine Oil and filter first 50 and every 100hours thereafter ransmission Fluid every 500 hours Power Steering Fluid Brake Fluid Coolant Level Fuel Filter every 500 hours Drain Water
10. 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 11 18 13 69 USATS DIESEL MAINTENANCE SPECIFICATIONS amp CAPACITIES MODEL ISUZU 4JG1 DESCRIPTION Standard diesel 2 8 Liter Isuzu four cylinder direct injection engine OF CYLINDERS 4 IN LINE 4 CYCLE NES EA ENGINE CRANKCASE CAPACITIES IMPERIAL QUARTS LITRES FUEL TANK REFILL CAPACITIES U S GALLONS IMPERIAL GALLONS LITERS gt mm a 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 11 18 13 70 USATS DIESEL MAINTENANCE SPECIFICATIONS amp CAPACITIES TRANSMISSION REFILL CAPACITIES ENGINE U S PINTS IMPERIAL PINTS LITRES 281 an lt ss USE DEXTRON 111 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
11. 972 1836 801 975 7316 fax www dessco com ENGINE CENTER 2351 Hilton Road Ferndale 0 248 399 0002 800 726 8870 248 399 3142 fax info enginecenter com FLINT POWER SYSTEMS 408 South Westover Blvd Albany GA 31707 229 888 1900 800 821 4025 229 435 2946 fax www flintpower com HAMILTON ENGINE SALES INC 5540 NE Columbia Blvd Portland OR 97218 503 288 6714 800 437 3644 503 287 8289 fax www hamiltonengine com HUSKER POWER PRODUCTS 2955 West Highway 6 Hastings NE 68901 402 463 1531 800 752 0888 402 463 1313 fax www huskerpowerproducts com 10 AUTHORIZED ISUZU DISTRIBUTOR DIRECTORY Leanmark Co 9F 1 201 Sec 2 Keelung Road Taipei Taiwan Fax 1437 0308 Division of MACME Boomsesteenw eg 42B B 2630 Aartselaar Phone 32 3 870 8180 Fax 32 3 870 8188 Finmotor Palvitie 3 FIN 01390 Vantaa Phone 35 8987 00970 Fax 35 8987 009770 Lopke Diesel Gmbh Ferdinand Zeppelin Strasse 19 47445 Moers Germany Phone 0049 0 2841 99 90 445 Fax 0049 0 2841 99 90 185 Pitteri Violini S P A 20021 Baranzate de Bollate Milano Via I Maggio 25 57 Italy Phone 39 02 382209 220 Fax 39 02 3561674 Motolusa Estrada da Circunvalacao Portela da Ajuda P 1495 Lisboa Phone 1214 241823 Fax 1214 171927 Isuzu Motors Limited Worldwide Distributor Network Asia Pacific Japan Isuzu Motors Limited 3 1 Kamigo 4 Chome Ebina Kanagawa Ken 243 0434 Japan Tawain Automotive
12. EAGLE 5 THE POWER MOVE YOU Parts and Service Manual Vehicle Types USATS Engine Type Isuzu Diesel 4JG1 Engine Models QA028 11 18 13 This page was intentionally left blank QA028 11 18 13 INTRODUCTION 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 PURPOSE amp USE OF THIS MANUAL 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 operatio
13. EL MIDWEST 3141 39 Street SW Fargo ND 58104 701 282 7915 877 831 7915 701 282 2472 fax joelck3 aol com amp L ENGINE LLC 1212 St Charles Street Houma LA 70360 985 857 8000 800 960 0068 985 851 0006 fax www mlengine com sales mlengine com MACK BORING amp PARTS CO 48 Leona Drive Middleborough MA 02346 508 946 9200 800 622 5364 ext 3 508 946 0779 fax www mackboring com MACK BORING amp PARTS CO 4500 Northchase Parkway NE Wilmington NC 28405 910 792 1900 800 622 5364 ext 2 910 792 6266 fax www mackboring com carolina mackboring com MACK BORING amp PARTS CO 2365 Route 22 West Union 07083 908 964 0700 800 622 5364 ext 1 908 964 8475 fax www mackboring com sales mackboring com NORTH COAST FORD INDUSTRIAL 11885 Bellaire Road Cleveland OH 44135 216 251 5800 800 423 1316 216 251 8675 fax www northcoastford com mail northcoastford com PITT AUTO ELECTRIC CO 1241 Freedom Road Cranberry Township PA 16066 724 778 8200 800 245 0711 724 778 8206 fax www pittauto com infoGpittauto com QA028 11 18 13 BLUE RIDGE DIESEL INJECTION INC 1016 Delaware Street Salem VA 24153 0867 540 389 7296 800 476 0456 540 387 2792 fax www blueridgediesel com CK POWER PRODUCTS 1100 Research Blvd St Louis MO 63132 314 868 8620 314 868 9314 fax www ckpower com jcostello ckpower com DIESEL ELECTRIC SERVICE amp SUPPLY CO 652 West 1700 South Salt Lake City UT 84104 801
14. Engines Phone 81 46 234 6180 Phone 81 46 234 6093 Europe Belgium The Netherlands DBH Rivierdijk 452 3372 BW Hardinxveld Giessendam The Netherlands Phone 31 184 613066 Fax 31 184 618002 Holm Denmark Finland Sydvestvej 142 144 DK 2600 Glostrup Phone 45 43 633700 Fax 45 43 631403 Denmark France Penven Germany 281 Chaussee Jules Cesar F 95250 Beauchamp Phone 1 34135432 Fax 1 39957659 Greece Petros Petropoulos S A Italy Lera Odos 96 102 P O B 41018 12210 Athens Phone 347 3300 Fax 347 3404 Diesel Power A S Industriveien 7 P O B 144 N 3430 Spikkostad Phone 3129 1940 Fax 3129 1958 Norway Portugal QA028 11 18 13 AUTHORIZED ISUZU DISTRIBUTOR DIRECTORY Automoviles Utilitarios S A AUSA CRA DE VIC KM 2 8 P O B 194 08240 Manresa Barcelona Phone 93 874 7311 Fax 93 874 1211 Switzerland Sterki AG Zinkereistrasse 35 CH 8633 W olfhausen Phone 55 253 2600 Fax 55 253 2609 Isuzu Motors Europe Limited Suite 24 The Courtyards Croxley Business Park Hatters Lane Watford Hertfordshire WD1 8YH United Kingdom Phone 1923 231 580 General Navigation and Commerce Company Za abeel Place Road P O Box 5563 Dubai Phone 971 370065 Fax 971 370308 New Zealanc Holden New Zealand Limited Plant No 1 Private Bag Upper Hut Phone 4 528 1200 Fax 4 528 1125 Isuzu Motors Limited Worldwide Distributor Network Transdiesel Div de Casli S A c Vigu
15. ING SPARE SERVICE PARTS ionen eraan nane 1 1 1 1 1 00 3 CONTACT INFORMATION deelen 3 WARRANT Y n 6 VEHICLE TD INFORMATION 0 01010101 6 WARRANTY REGISTRATION 6 WARRANTY INFORMATION 2 00001010010 7 AUTHORIZED ISUZU DISTRIBUTOR MAP US AND 002222 160 8 AUTHORIZED ISUZU DISTRIBUTOR DIRECTORY 0006066060006 6066 9 SAFETY INFORMATION sentia a Ra 12 ISUZU SERVICE PARTS BULLETIN J SERIES ENGINE OIL FILL PROCEDURES ee 12 IMPORTANT SAFETY NOTICE AND WARNING EEN 14 SERVICE PARTS ILLUSTRATIONS amp DETAILIA 15 IDENTIFICATION KEY EE 15 EE 16 Engine Dress Isuzu aaa aa 16 Engine Dress Is u Dies el Detail 17 E RRE Ee 18 Cooling System Diesel a 18 Cooling Syste 8 18 DRIVELINE iei ad 22 Drive Shaft Assembly Ptont 2 ttn a a ee E ER 22 Drive Shaft Assembly Rear cnica nado ela 23 TRANSMISSION iaa tana uma Di 24 Transaxle Mounting amp Misc Barten 24 Transaxle
16. ITTING ADAPTER MASTER CYLINDER BRAKE HOSE CLIP A TT4 00165 18 19 Raja ja je a Im QA028 11 18 13 42 BRAKES PARKING BRAKE ACTUATOR ASSEMBLY QA028 11 18 13 43 BRAKES PARKING BRAKE ACTUATOR ASSEMBLY DETAIL Qy Description Part Number A TT4 00141 P P P B TT4 00145 A TT4 00146 A TT4 00193 NPN 00150 NPN NPN P NPN P 18 NPN 2 2 2 5 4 4 4 f 4 4 f f 4 2 2 2 N Z Z Z Z CD 2 2 2 7 QA028 11 18 13 QA028 11 18 13 This page was intentionally left blank 44 45 HYDRAULIC ASSIST HYDRAULIC ASSIST SYSTEM TO TRANSMISSION COOLER HYDRAULIC ASSIST SYSTEM DETAIL x C x G TTT SRE SWIVEL TING HOE NPN 10 ATT4 00606 COMPLETE ASSEMBLY 1 YFIIING GLACKMALECOUPLING un 1 CUTTOHI BULKHOSESH SUCTON QA028 REV03 11 18 13 46 STEERING SYSTEM STEERING SYSTEM BREAKDOWN To Cooler High Pressure 16 gt QA028 REV03 11 18 13 47 STEERING SYSTEM STEERING SYSTEM BREAKDOWN DETAIL HYDRAULIC CYLINDER PIVOT PIN BEARING AFTER 7 99 HOSECLAMP NPN NOT SOLD SERPERATELY INCLUDED WITHITEM 18 1 7 10 11 E E i i i i 19 20 21 NPN Not Sh
17. Mounting amp Misc Parts Detail 25 Transaxle Case Extension Retainer lt RA RR AAS 26 Transaxle Case Extension amp Retainer Detail 27 AXLES 1 1 1 1 1 1 1 1 1 1 1 1 1 1 en 4 00 28 Axl Assembly Eront Drive icon rada ic 28 Axl Assembly A RE 29 Axle Assembly Breakdown Front Drive AWD 0 06 6606 66 666 30 Axle Assembly Breakdown Front Drive 31 Axle Assembly Breakdown Front 33 Axle Assembly Breakdown Rear Driv sse 34 Axle Assembly Breakdown Rear 35 QA028 11 18 13 TABLE CONTENTS EIER EE Brake Assembly Detail Brake Actuator A NAAA Brake System Hydraulic Detail sau a nern ensemble Parking Brake Actuator Assembly 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 nennen Parking Brake Actuator Assembly Detail HYDRAULIC SYSTEM ater th ds t diis dad Hydraulic ASSIST tian Qua dante hinein ls ab RR STEERING OYSTEM Pa mere eb iiti p ivt E de aei Steering System Breakdown NENNEN Steering System Breakdown Detail sse
18. NION 14 73597 1 2552 2402 7 17 34822 18 19 BEARING 30 1 30258 8 4 BOLT BRAKEMANUFACTURING 31 236800 NUT BRAKEMANUFACTURING SEAL OIL aa3687 La STUD HUB 30636 39 40 36805 24 1 CD 92 oo N 060W 2100 1 BRAKEASSEMBLY SHOE TYPE RIGHT 060WD101 BRAKE ASSEMBLY SHOE TYPE LEFT 706671X DIFFERENTIAL PARTS STANDARD INCLUDES 15 21 23 24 26 28 29 43 48 16979 VENT 707084X QA028 11 18 13 36 BRAKES DRUM BRAKE ASSEMBLY REAR QA028 11 18 13 37 BRAKES DRUM BRAKE ASSEMBLY REAR DETAIL LI 06098001 1 BRAKEASSEMBLYLH 060WDI00 1 1 y 491490 1 BACKINGPLATELH FR357 7 9 SEKITBEOW 2 SPRINC HOLDDOWN 10 SEEKITBELOW 1 PIN 11 SEKITBEOW IL j 12 SEKITBEOW 1 BRAKEADJGTINGLINK 13 SEEKITBELOW 1 CABLEGUDE 14 SEKITBEOW 1 15 SEEKTBEIOW 2 SPRINC HOLDDOWN 1 438329 1 PARKINGBRAKECAML H 1 48098 1 PARKINGBRAKECAMR H 20 498364 1 PARKINGBRAKELEVER LEFT 20 438325 1 PARKINGBRAKELEVER RIGHT 21 446 8 1 BRAKEANCHORBOLT 24 SEEKITBEOW 1 BRAKEADJUSTINGSOCKETI H 25 SEEKITBELOW 1 BRAKEADJUSTNGSCREWL H 26
19. RATOR PEDAL ASSEMBLY DETAIL NPN NPN x 5 A 6 E 9 CLASP MUST BE WELDED TO BRACKET QA028 11 18 13 53 OPERATOR COMPARTMENT TRANSMISSION CONTROL A TT4 00245 A USAT5 00246 A TT40047 1 U BOLT KIT 0 1 BALL JOINT KIT TRANSMISSION LEVER Qt QA028 11 18 13 54 OPERATOR COMPARTMENT INSTRUMENT PANEL 12 15 15 12V Accessory outlet found directly under QA028 11 18 13 55 OPERATOR COMPARTMENT INSTRUMENT PANEL DETAIL FUEL GAUGE A TT4 00416 ATT 015 1 MOUNTING IGNITION SWITCH 2 9 TMD7M020 1 GLOWPLUGSWITCH HORN BUTTON 4 00609 QA028 11 18 13 56 LIGHTS amp ELECTRICAL ELECTRICAL BOARD ELECTRICAL BOARD DETAIL Description 2 po 0 2 1 STARTERREAY 1 HORN RELAY 4 AT 1 5 98253 00 1 GLOW PLUG RESISTOR 6 A IT40008 1 RELAY 8 40 0 1 TERMINALBLOCK NOTSHOWN op 000 4 25AMPROUNDFUSE NOTSHOWN 1 LOCK NUT 10 32 1 QA028 11 18 13 57 LIGHTS amp ELECTICAL HORN ASSEMBLY HORN DETAIL A TT4 0052 HORN ASSEMBLY QA028 11 18 13 QA028 11 18 13 This page was intentionally left blank 58 59 LIGHTS amp ELECTRICAL HEADLIGHT amp
20. TEM TRANSMISSION COOLING SYSTEM TRANSMISSION DETAIL 05 A USAT5 00311 1 RADIATOR A TT4 00221 1 TRANSMISSION COOLER 3 A USAT5 00330 1 RADIATOR CAP QA028 11 18 13 22 DRIVELINE DRIVE SHAFT ASSEMBLY FRONT DRIVE SHAFT ASSEMBLY FRONT DETAIL 1 TRANSMISSION OUTPUT YORESHAFT FRONT I ROSS BEARING PRONT DB NEW SIYE T 0 A TT8 00202 4 1 DRIVESHAFT A TT4 00130 END YOKESTRAP ANDBOLT KIT 7 A TT4 00137 1 CROSS BEARING FRONT DJS NEW STYLE QA028 11 18 13 23 DRIVELINE DRIVESHAFT ASSEMBLY REAR DRIVE SHAFT ASSEMBLY REAR DETAIL 3 1 BEARING FRONT DS NEW STYLE AB TT4 00130 1 DRIVESHAFT 5 A TT4 00130 END YOKE STRAP KIT 6 A TT4 00137 CROSS BEARING REAR D S NEW STYLE QA028 REV03 11 18 13 24 TRANSMISSION TRANSAXLE MOUNTING amp MISC PARTS QA028 11 18 13 25 TRANSMISSION TRANSAXLE MOUNTING amp MISC PARTS DETAIL 3 34741 1 SWITCHNEUTRALSTARTER 8 BACK UP LIGHT 5 52404 2 DOWELPIN TRANSAXEE TO ENGINE ALIGNMENT 6 4778718 TORQUE CONVERTER 7 A TT4 00419 TRANSAXLE SHIFT LEVER MANUAL CONTROL 6501741 SCREW HEX CAP WITH WASHER M12 1 75 X 30 85705 ASKET amp FILTER MAINTENANCE PACKAGE CALL EAGLE PARTS DEPT FOR DETAILS QA028 REV03 11 18 13 26 TRANSMISSION
21. UEL WILL VOID THE WARRANTY ON THE ENGINE AND WILL RESULT IN VIOLATION OF EPA EMISSIONS REGULATIONS VEHICLE ID INFORMATION This information can be found on the tractor s Plate located on the firewall next to the driver s seat Additionally there is a permanent serial number located on the rear bulkhead inside the engine compartment MODEL SERIAL MFG DATE ENGINE TYPE ENGINE SERIAL WARRANTY REGISTRATION Please take time to fill out the warranty registration information found at our website www eagletugs com 028 11 18 13 WARRANTY 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 eTractor model number eTractor serial number eCurrent 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 11 18 13 8 AUTHORIZED ISUZU DISTRIBUTOR AUTHORIZED ISUZU DISTRIBUTOR DIRECTORY Ausus UNITED STATES TOTAL ENERGY SYSTEMS 8525 North 87 Street Milwaukee WI 53224 414 357 7900 800 236 6626 414 357 6278 fax www totalenergysystems com wschmidt totalenergysystems com TUBAN INDUSTRIAL PRODUCTS CO 2003 Leghorn Mt View CA 94043 650 968 2431 800 648 4726 650 969 1267
22. etas Castilla 26 E 28820 Coslada Madrid Phone 1 6737012 Fax 1 6737412 Swed Motor AB Box 4 5 13721 Vasterhaninge Phone 8 50012140 Fax 8 50026800 HM Isuzu Unit 5A Babdown Airfield Nr Tetbury Gloucestershire GL8 8YL United Kingdom Phone 44 1666500843 Fax 44 1666500844 FAX General Engineering Service Est U A E CR 1 27447 3 P O B 5690 Ruwi Sultanate Of Oman Fax 968 591802 Isuzu Australia Limited Building 1 Brooklyn Estate 77 Millers Road Brooklyn Victoria 3025 Australia Phone 61 3 9931 9977 Fax 61 3 9315 2370 QA028 11 18 13 Spain Sweden United Kingdom Middle East Oman Oceania Australia 12 SAFETY INFORMATION SERVICE amp PARTS BULLETIN SVS 21 07 8 9 2007 To ALL DISTRIBUTOR amp DEALER SERVICE PERSONNEL SUBJECT J SERIES ENGINE FILL PROCEDURES BACKGROUND INFORMATION Improper engine oil fill rate and crankcase venting while filling may allow oil to enter the crank case ventilation system intake manifold and combustion chamber which may cause engine damage at startup ACTION REQUIRED Follow the Oil Fill Procedure provided below or refer to the appropriate engine Instruction Manual to prevent this non warnantable failure mode OIL FILL PROCEDURE 1 Before adding engine oil remove the engine oil dipstick to provide crankcase ventilation 2 Use an engine oil fill device that is smaller than the oil fill hole so that air is allo
23. fax www tubanonline org info tubanonline org LUNENBURG FOUNDRY amp ENGINEERING LTD 53 Falkland Street Lunenburg 5 80 2 0 902 634 8827 902 634 8886 fax head office 902 634 8889 fax sales parts amp service www lunenburgfoundry com M K POWER PRODUCTS 5641 McAdam Road Mississauga ON L4Z 1N9 905 890 5323 800 263 5011 905 890 6660 fax 800 430 0344 fax www m k com WESTQUIP DIESEL SALES ALTA LTD 11720 181 Street Edmonton AB T5S 1M6 780 486 2645 780 486 2676 fax gdumont westquip ca Pub SL 4010 06 08 04 SOUTHWEST PRODUCTS CORP 5143 W Roosevelt Phoenix AZ 85043 602 269 3581 877 779 3581 602 269 8448 fax www southwestproducts com SOUTHWEST PRODUCTS CORP 2760 Junipero Signal Hill CA 90755 562 424 0913 877 779 3581 562 424 4517 fax www southwestproducts com TiPCO B440 C Belvedere Avenue Sacramento CA 95826 916 383 1956 800 458 4726 916 383 4296 fax www tubanonline org info tubanonline org ADF DIESEL 1790 route de l Aeroport Ste Foy G2E 319 418 681 0631 800 265 6720 Canada 418 681 3686 fax www adfdiesel com ADF DIESEL 2355 Boul Hymus Dorval 118 514 684 0440 800 517 1489 Canada 514 684 2417 fax www adfdiesel com marc fontaine adfdiesel com DIESELTECH 100 Otter Street Winnipeg MB R3T 0M8 204 452 4334 800 665 7665 Canada 204 452 7984 fax www dieseltech mb ca info dieseltech mb ca Branch Office ISUZU DIES
24. 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 amp 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
25. n of your Eagle product please see the Eagle Operations Manual that was also in cluded with your vehicle TECHNICAL ASSISTANCE 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 ORDERING SPARE SERVICE PARTS 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 CONTACT INFORMATION Eagle Corporate Office 26111 Northline Rd Taylor MI 48180 800 671 0431 www eagletugs com Customer Service Parts amp Service Technical Support customerserice 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 QA028 11 18 13 TABLE OF CONTENTS INTRODUCTION 00000 3 PURPOSE USE MANUAL 1 1 1 1 1 1 1 1000000 3 TECHNICAL ASSISTANCE Sau Suman 3 ORDER
26. own A TT10 00813 06U 606 56 B67 PN PN PN 6 ER 41271 QA028 11 18 13 48 AIR CLEANER AIR CLEANER ASSEMBLY DIESEL AIR CLEANER ASSEMBLY DETAIL 1 A TT4 00091 1 A TT4 00092 Description AIR CLEANER ASSEMBLY 3 AIR CLEANER BRACKET NOT SHOWN NUT LOCK 3 8 16 SCREW HEX CAP 3 8 16 X 1 GR 5 HOSE CLAMPS 90 DEGREE ELBOW INTAKE TUBE BULK INTAKE 3 QA028 11 18 13 W ASHER FLAT 3 8 49 AIR CLEANER AIR CLEANER SUB ASSEMBLY AIR CLEANER SUB ASSEMBLY DETAIL Description Part Number 2 P549271 AIR CLEANER ELEMENT QA028 11 18 13 50 FUEL SYSTEM FUEL SYSTEM DIESEL Feed Line Return Line FUEL SYSTEM DETAIL 1 A TT 0076 gt 1 FELSENDNGUNT a 002711 FUEL CAP BULK 5 16 FUEL LINE 3 8 16 X 1 1 4 HCS S 8FLATWASHER 3 8 FLAT W ASHER 3 8 LOCK NUT N SCREW HEX 10 32 X3 4 PN 11 A TT4 00280 BULK HEAD FITTING NOT SHOWN QA028 11 18 13 21 EXHAUST EXHAUST SYSTEM DIESEL EXHAUST SYSTEM DETAIL 2 po 0 1 NPN 4 gt WASHERFLAT38 5 NN 2 X NUFHEX3 E10 6 Arroo 2 ___ le A TT40058 1 MUFFLER 9 ATT4 0059 1 2 90DEGREETAILPPE QA028 11 18 13 52 OPERATOR COMPARTMENT ACCELERATOR PEDAL ASSEMBLY ACCELE
27. ssential 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 WARNINGS The following list contains some general WARNINGS that you should follow when you work on equipment eAlways wear safety glasses for eye protection Use safety stands whenever a procedure requires you to be under the equipment 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 eOperate the engine only in a well ventilated area to avoid the danger of carbon monoxide eKeep yourself and
28. wed to pass along the side of the fill hole 3 Add engine oil slowly at a rate that does not flood the valve cover Be very careful when using automatic oil ill pumps adjust to a slow rate if possible 4 When changing the engine oil add the exact amount specified in the manual 5 Allow 10 20 minutes for the oil to drain into the oil pan Confirm this checking the oil level with the stick repeatedly until it stabilizes Service_Bulletin_SVS 21 07 doc Page 1 of 2 QA028 11 18 13 SAFETY INFORMATION SERVICE amp PARTS BULLETIN 6 Check if the oil level is low accounting for the oil filter oil capacity 7 Ifthe oil is low oil may have entered the Closed Crankcase Ventilation CCV system and into the intake manifold and cylinder If so the oil must be removed before cranking the engine PROCEDURE FOR EVACUATING OIL FROM THE CCV SYSTEM 1 If oil entered the CCV system it may be found in the intake manifold Remove the intake manifold for verification 2 Oil that has entered the CCV system be removed from the cylinders by removing all fuel injection nozzles If you should have any questions please contact your service and parts representative Best Regards The 151 Service d Parts Seam Service Bulletin SVS 21 07 doc Page 2 of 2 QA028 11 18 13 14 SAFETY INFORMATION IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are e
29. your clothing away from moving parts when the engine is running especially the fan and belts 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 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 eKeep 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 11 18 13 SERVICE PARTS ILLUSTRATIONS amp DETAIL IDENTIFICATION KEY The following abbreviations are used throughout the parts lists in this section Abbreviation Part required but not shown on diagram No Part Number Parts shown and numbered but not stocked and sold by Eagle Typi used for bolts clamps etc 77 QA028 11 18 13 16 ENGINE DRESS ISUZU DIESEL QA028 11 18 13 POWER TRAIN ENGINE DRESS ISUZU DIESEL DETAIL ag 1 7 NPN 3 4 16X3 5 BOLT amp 3 4 WHASHER 12 1 2 SUZUMOTOR MOUNT 4 o

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