EAGLE TUGS PARTS & SERVICE MANUAL. Engine Type: Isuzu Turbo Diesel Engine Models QA017 REV

Transcription

1 EAGLE TUGS PARTS & SERVICE MANUAL Vehicle Types: TT-10, TT-12 Engine Type: Isuzu Turbo Diesel Engine Models

2 2

3 3 INTRODUCTION From everyone at Eagle Tugs, we would like to say Thank You for purchasing an Eagle TT-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 TT-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 & USE OF THIS MANUAL This manual is designed as a reference guide to make the reader more familiar with the components of the Eagle TT-10- TT-12 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 TT-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. 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 procedures. 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 TT-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 Northline Rd Taylor, MI (800) Customer Service Parts & Service Technical Support customerservice@eagletugs.com parts@eagletugs.com support@eagletugs.com (734) (800) (734) (800) (734) (800)

4 4 TABLE OF CONTENTS 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... 7 STANDARD WARRANTY... 7 AUTHORIZED ISUZU DISTRIBUTOR MAP... 8 AUTHORIZED ISUZU DISTRIBUTOR DIRECTORY... 9 ISUZU SERVICE & PARTS BULLETIN (J-SERIES ENGINE OIL FILL PROCEDURES)...12 SERVICE PARTS ILLUSTRATIONS & DETAIL IDENTIFICATION KEY...15 POWER TRAIN...16 Engine Dress Isuzu Turbo Diesel...16 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 Cooling System Transmission...28 COOLING SYSTEM...29 Cooling System Turbo Diesel...29 AXLES...30 Axle Assembly Front Drive (All Wheel Drive)...30 Axle Assembly Rear...31 Axle Assembly Breakdown Front Drive (All Wheel Drive)...32 Axle Assembly Breakdown Front Drive Detail...33 Axle Assembly Breakdown Rear Drive...36 Axle Assembly Breakdown Rear Drive Detail...37 BRAKES...40 Drum Brake Assembly Rear...40 Brake Caliper Assembly Front...41 Brake System Hydraulic...42 Brake Actuator Assembly...44 Brake Pedal Assembly...45 Parking Brake Actuator Assembly...46 Parking Brake Actuator Assembly Detail...47 STEERING SYSTEM...48 Steering System Breakdown (For Serial Numbers Starting After & Above)...48 Steering System Breakdown Detail...49

5 5 TABLE OF CONTENTS Steering System Breakdown (For Serial Numbers Starting Before & Below) Steering System Breakdown Detail AIR CLEANER, FUEL SYSTEM & EXHAUST Air Cleaner Assembly Diesel Air Cleaner Sub-Assembly Fuel System Diesel Exhaust System Diesel OPERATOR COMPARTMENT Transmission Control Accelerator Pedal Assembly Instrument Panel Instrument Panel Detail LIGHTS & ELECTRIAL Electrical Board Headlight & Taillight Assembly Wiring Harness Wiring Schematic Shutdown Option Wiring Cab Option Wiring OTHER ASSEMBLIES Body Assembly Body Assembly With Split Hood Wheel & Tire Assembly Dual Rear Wheel Model Hitch Options Cab Option Cab Option Detail Cab Heater Detail Strobe, Beacon & Floor Mats Other Options SCHEDULED MAINTENANCE Lubrication diagram - TT Series-All Wheel Drive Preventative Maintenance schedule Daily operator responsibilities Specifications & capacities Tips for All Weather Traction Front End Alignment Procedure... 83

6 6 WARRANTY VEHICLE ID INFORMATION This information can be found on the tractor s I.D. 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 NO MFG DATE ENGINE TYPE ENGINE SERIAL NO Data Plate Location

7 7 WARRANTY 3-Year Limited Warranty Information* The Eagle Tugs (Eagle) 3-Year Warranty covers all TT-series, ett-series, XL-series, exl-series and USATS tow tractors, used in aviation applications. Eagle Tugs warrants that these tractors will be free from defects in material and workmanship for a period of 3 years or 3,000 operating hours, with the exception of the electrical system (see electrical component warranty below), from date of delivery to the first customer (or first use), whichever comes first. Written notice of any claimed defect must be given to Eagle within the warranty period and within thirty (30) days after such defect is discovered. Liability under this warranty is limited to either replacing or repairing, at Eagle s election, any part or parts deemed defective after examination by Eagle or an Authorized Service Representative. Any Eagle tractor or any of its parts returned by the customer to Eagle or an Authorized Service Representative via prepaid transportation, and which is found to be defective, will be repaired or replaced and returned to the customer prepaid. On the other hand, should a part be found not defective, inspection and handling charges may be charged to the customer or Authorized Service Representative by Eagle. Electrical Component Warranty: Electrical components including but not limited to display, starters, alternators and electric fans shall be covered under the respective original manufacturers warranty for each individual component. Copies of the respective warranties are available upon request. This warranty does not extend to the tires, batteries, and battery chargers as these are warranted directly to the user by their respective manufacturer and not by Eagle or an Authorized Service Representative. This warranty does not apply to any Eagle tow tractor, or component part(s) that have been subjected to misuse, accident, vandalism, environmental conditions, improper handling or application, maintenance neglect, including lack of lubricants or fluids; nor does it extend to the Eagle tow tractor and/or parts which have been repaired or altered outside of Eagle's plant or the facility of an Authorized Service Representative without the permission of Eagle. This warranty does not apply to routine maintenance or wearable parts of the Eagle tow tractor such as filters, seals, plugs, hoses, belts, brake pads or shoes, light bulbs, fuses or similar items. Moreover, this warranty does not extend beyond its original term for any Eagle tow tractor or part replaced or repaired under warranty. This warranty does not cover or provide credit for the following: tractor rental or other substitute equipment; lodging; loss of time, income, sales or profits; loss of the use of tractor; telephone calls or communication expense; lift truck; storage fees; injury or death to persons or damage or destruction of property; or consequential, incidental or punitive damages. Labor Allowance: A labor allowance may be issued upon request at Eagle s discretion. Allowable labor hours and a per hour labor rate will be determined by Eagle according to reasonable automotive standards. Warranty Claim Procedure: When a warranty situation arises, it is essential that the customer contact Eagle s Warranty Department at The customer will need to provide Eagle with the tow tractor serial number and engine hours. A customer service representative will analyze the problem and determine the next steps. In many cases Eagle s technical support personnel will be able to analyze the problem and recommend adjustments that will solve the problem and reduce down time. If further service is required, an Eagle customer service representative will work with customer personnel to arrange a service provider and/or parts be sent to your facility for the repair as quickly as possible. EXCEPT AS SET FORTH ABOVE, ALL WARRANTIES, CONDITIONS, REPRESENTATIONS, INDEMNITIES AND GUARAN- TEES, EXPRESS OR IMPLIED, WHETHER ARISING BY STATUTE, CUSTOM OF TRADE OR UNDER ORAL OR WRITTEN STATEMENTS MADE BY OR ON BEHALF OF EAGLE NEGOTIATIONS WITH CUSTOMER, DISTRIBUTOR, DEALER OR ANY REPRESENTATIVE, ARE HEREBY OVERWRITTEN AND EXCLUDED, AND NO LIABILITY SHALL ATTACH TO EAGLE, EI- THER IN CONTRACT OR IN TORT, OR STRICT LIABILITY IN TORT, FOR ANY DAMAGE TO PROPERTY, LOSS OF PROFITS, DAMAGES, COSTS, CHARGES, LIABILITY OR EXPENSES, WHETHER DIRECT OR INDIRECT, CONSEQUENTIAL OR OTH- ERWISE, WHICH ARISE OUT OF OR IN CONNECTION WITH THE SALE OR USE OF ANY EAGLE MACHINE OR THE SUP- PLY OF SERVICES. SUBJECT TO CHANGE WITHOUT NOTICE Please check our website periodically for service bulletins and manual updates. *Note - The Eagle Tugs 3-Year Warranty covers TT-series, ett-series, XL-series, exl-series and USATS tow tractors used in aviation applications. All MTT and RTT-series, and Transit Pro tow tractors, and all Eagle models which are used in industrial applications, are covered under the Eagle Standard Warranty of 1 Year or 2,000 hours. Eagle Bob Tails are covered under Ford Motor Company's Standard Warranty for each respective Ford truck model.

8 8 A UTHORIZED I SUZU D ISTRIBUTOR M AP

9 9 AUTHORIZED ISUZU DISTRIBUTOR DIRECTORY

10 10 AUTHORIZED ISUZU DISTRIBUTOR DIRECTORY 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, , Japan Keelung Road, Taipei, Taiwan (Non-Automotive Engines) Fax: Phone: Phone: Europe Belgium / The NetherlandsDBH Division of MACME Rivierdijk 452, 3372 BW Boomsesteenweg 42B Hardinxveld-Giessendam B-2630 Aartselaar The Netherlands Phone: Phone: Fax: Fax: Denmark Holm-Denmark Finland Finmotor Sydvestvej Palvitie 3 DK-2600 Glostrup FIN Vantaa Phone: Phone: Fax: Fax: France Penven Germany Lopke Diesel Gmbh 281, Chaussee Jules Cesar Ferdinand-Zeppelin-Strasse 19 F Beauchamp Moers Phone: Germany Fax: Phone: 0049 (0) Fax: 0049 (0) Greece Petros Petropoulos S.A. Italy Pitteri Violini S.P.A. Lera Odos Baranzate de Bollate P.O.B Milano, Via I Maggio, 25/57 Italy Athens Phone: Phone: Fax: Fax: Norway Diesel Power A/S Portugal Motolusa Industriveien 7, P.O.B. 144 Estrada da Circunvalacao N-3430 Spikkostad Portela da Ajuda Phone: P-1495 Lisboa Fax: Phone: Fax:

11 11 AUTHORIZED ISUZU DISTRIBUTOR DIRECTORY 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 Coslada - Madrid Manresa, (Barcelona) Phone: Phone: Fax: Fax: Sweden Swed Motor AB Switzerland Sterki AG Box 4 Zinkereistrasse 35 S Vasterhaninge CH-8633 Wolfhausen Phone: Phone: Fax: Fax: United Kingdom HM Isuzu Unit 5A, Babdown Airfield Nr Tetbury, Gloucestershire GL8 8YL United Kingdom Phone: Fax: FAX Isuzu Motors Europe Limited Suite 24, The Courtyards Croxley Business Park Hatters Lane, Watford Hertfordshire, WD1 8YH United Kingdom Phone: Middle East Oman General Engineering Service Est. U.A.E. General Navigation and Commerce Company C.R. 1/27447/3 P.O.B.5690 Za'abeel Place Road Ruwi, Sultanate Of Oman P.O. Box 5563, Dubai Fax: Phone: Fax: 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: Australia Fax: Phone: Fax:

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13 13 WARNING DO NOT USE JET A FUEL IN THIS ENGINE. ANY USE OF JET A FUEL WILL VOID THE WARRANTY ON THE ENGINE AND WILL RESULT IN VIOLATION OF EPA EMISSIONS REGULATIONS

14 14 NOTES:

15 15 SERVICE PARTS ILLUSTRATIONS & DETAIL IDENTIFICATION KEY The following abbreviations are used throughout the parts lists in this section. Abbreviation Meaning Purpose NL Not Listed Part required but not shown on diagram NPN No Part Number Parts shown and numbered, but not stocked and sold by Eagle. Typically used for bolts, clamps, etc AR As required

16 16 POWER TRAIN ENGINE DRESS ISUZU TURBO DIESEL 21

17 17 POWER TRAIN ENGINE DRESS ISUZU TURBO DIESEL DETAIL

18 18 POWER TRAIN ENGINE DRESS ISUZU TURBO DIESEL

19 19 POWER TRAIN ENGINE DRESS ISUZU TURBO DIESEL DETAIL Item Part Number Qty Description OIL PAN OIL PAN GASKET OIL LEVEL GAUGE GASKET, DRAIN PLUG DRAIN PLUG EXHAUST MANIFOLD GASKET, EXHAUST MANIFOLD #1 FUEL INJECTION LINE #2 FUEL INJECTION LINE #3 FUEL INJECTION LINE #4 FUEL INJECTION LINE GASKET, INTAKE MANIFOLD INTAKE MANIFOLD GASKET, CYLINDER HEAD GASKET, CYLINDER HEAD COVER CYLINDER HEAD COVER OIL FILLER CAP GASKET, OIL FILLER CAP CAP, HEAD COVER GASKET, CAP HEAD COVER

20 20 POWER TRAIN ENGINE DRESS ISUZU TURBO DIESEL 1 *Includes all gaskets with asterisk

21 21 POWER TRAIN ENGINE DRESS ISUZU TURBO DIESEL DETAIL Item Part Number Qty Description ENGINE OVERHAUL GASKET SET ENGINE HEAD OVERHAUL GASKET SET *Item 1 includes all gaskets with asterisk in items 1 and 2

22 22 DRIVELINE DRIVE SHAFT ASSEMBLY FRONT 7 DRIVE SHAFT ASSEMBLY FRONT DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A-TT TRANSMISSION OUTPUT YOKE SHAFT-FRONT 2 A-TT CROSS BEARING FRONT D/S NEW STYLE 3 A-TT DRIVE SHAFT SPRING 4 A-TT DRIVE SHAFT 5 A-TT END YOKE STRAP AND BOLT KIT 6 A-TT CROSS BEARING FRONT D/S NEW STYLE END YOKE

23 23 DRIVELINE DRIVESHAFT ASSEMBLY REAR DRIVE SHAFT ASSEMBLY REAR DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A-TT TRANSMISSION OUTPUT YOKE SHAFT-REAR 2 A-TT DRIVE SHAFT SPRING 3 A-TT CROSS BEARING FRONT D/S NEW STYLE 4 AB-TT10D DRIVE SHAFT 5 A-TT END YOKE STRAP KIT 6 A-TT CROSS BEARING REAR D/S NEW STYLE

24 24 TRANSMISSION TRANSAXLE MOUNTING & MISC. PARTS

25 25 TRANSMISSION TRANSAXLE MOUNTING & MISC. PARTS DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A-TT5D TRANSAXLE 2 A-TN GROUND STRAP SWITCH-NEUTRAL STARTER & BACK UP LIGHT INDICATOR-TRANSAXLE FLUID DOWEL PIN-TRANSAXLE TO ENGINE ALIGNMENT 6 TT582YTTLS 1 TORQUE CONVERTER 7 A-TT TRANSAXLE SHIFT LEVER-MANUAL CONTROL 8 NPN 5 SCREW-HEX CAP-WITH WASHER M X GASKET & FILTER MAINTENANCE PACKAGE

26 26 TRANSMISSION TRANSAXLE CASE EXTENTION & RETAINER ALL WHEEL DRIVE 3

27 27 TRANSMISSION TRANSAXLE CASE EXTENSION & RETAINER ALL WHEEL DRIVE - DETAIL Item Part Number Qty Description SCREW-HEX CAP-W/ WASHER M X PAN GASKET (USE SILICONE ADHESIVE) 4 NPN 1 CUP(NOT SOLD SEPARATELY) SPACER KIT RETAINER, OIL RETAINER, BEARING SCREW-HEX CAP-M8 X 1.25 X SEAL, DIFFERENTIAL BRG.RET COVER, TRANS. END GASKET (USE SILICONE ADHESIVE) SCREW-HEX CAP W/WASHER M X SEAL, MANUAL VALVE SHAFT PAN, TRANSAXLE OIL SCREW-HEX CAP-W/ WASHER M6-1 X CUP RETAINER O-RING OUT PUT HOUSING SCREW-HEX CAP-W/ WASHER M X NPN 1 BUSHING (SERVICED IN EXT.) SEAL SCREW-HEX CAP M X NPN 1 SCREW-HEX CAP-WASHER HEAD M6-1.0 X O-RING SPEEDOMETER CABLE ADAPTOR 23 NPN 1 SCREW-FLAT HEAD HEX SOCKET M X 24 NPN 6 SCREW-HEX CAP-WASHER HEAD M X 26 A-TT5D DIFFERENTIAL-WELDED SPIDER GEAR 27 NPN 4 SCREW-HEX CAP WASHER HEAD M X

28 28 TRANSMISSION COOLING SYSTEM TRANSMISSION 3 COOLING SYSTEM TRANSMISSION DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 B-TT10TD RADIATOR 2 A-TT TRANSMISSION COOLER RADIATOR CAP

29 29 COOLING SYSTEM COOLING SYSTEM TURBO DIESEL COOLING SYSTEM TURBO DIESEL DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A-TT10TD SURGE TANK 2 B-TT10TD RADIATOR 3 A-TT BOTTOM RADIATOR HOSE 4 A-TT TOP RADIATOR HOSE

30 30 AXLES AXLE ASSEMBLY FRONT DRIVE (ALL WHEEL DRIVE) AXLE ASSEMBLY FRONT DRIVE DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A-TT FRONT DRIVE AXLE ASSEMBLY 2 A-TT CLEVIS 3 NPN 4 COTTER PIN 4 A-TT U BOLT 5/8-18 TREAD 5 NPN 4 WASHER FLAT 3/8 6 A-TT CLEVIS-PIN 7 A-TT WASHER-NYLON 8 NPN 2 THREADED ROD 9 NPN 2 SCREW HEX CAP 3/8-16 X 3-1/2 10 NPN 2 NUT HEX LOCK 3/ NPN 2 SCREW HEX CAP 9/16-18 X 3 1/2 12 A-TT AXLE CLAMP PLATE 13 NPN 2 NUT HEX LOCK 9/ A-TT WASHER, U-BOLT 15 A-TT NUT, U BOLT 16 A-TT LEAF SPRING 17 A-TT JAM NUT TR115-24X 1 TIE ROD ASSEMBLY 19 NPN 2 WASHER FLAT 9/16

31 31 AXLES AXLE ASSEMBLY REAR AXLE ASSEMBLY REAR DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A-TT AXLE ASSEMBLY REAR DRIVE 2 A-TT LEAF SPRING 3 NPN 2 SCREW-HEX CAP 9/16-18 X 3 1/2 GR8 4 NPN 2 WASHER-FLAT 9/ NPN 2 NUT-LOCK 9/ A-TT U-BOLT 5/8-18 THREAD 7 NPN 4 SCREW-HEX CAP 3/8-16 X 2-1/2 8 A-TT WASHER-NYLON 9 NPN 4 WASHER-FLAT 3/8 10 A-TT AXLE CLAMP PLATE 11 A-TT WASHER FLAT SPECIAL 3/16" THICK 12 A-TT NUT-HEX-HIGH SPECIAL 5/ HU247X 2 BRAKE DRUM-REAR 14 NPN 2 NUT-HEX-LOCK 3/ NPN 2 THREADED ROD 16 A-TT CLEVIS 17 A-TT CLEVIS PIN 18 NPN 4 COTTER PIN 19 A-TT JAM NUT

32 32 AXLES AXLE ASSEMBLY BREAKDOWN FRONT DRIVE (ALL WHEEL DRIVE)

33 33 AXLES AXLE ASSEMBLY BREAKDOWN FRONT DRIVE (ALL WHEEL DRIVE) Item Part Number Qty Description 1 A-TT COMPLETE AXLE ASSEMBLY X 1 GEAR & PINION ASSEMBLY 3 *SEE KIT 1 SLINGER-PINION OIL INNER X KIT INNER PINION BEARING 5 *SEE KIT KIT SHIM-PINION ADJUSTING 6 *SEE KIT 1 BAFFLE-PINION OIL 7 *SEE KIT KIT SHIM-PINION BEARING ADJUSTING X KIT OUTER PINION BEARING 9 *SEE KIT 1 SLINGER-PINION OIL OUTER SEAL-OIL X 1 END YOKE ASSY WASHER-PINION NUT NUT-PINION X 1 COVER - CARRIER RTV SEALANT 16A GASKET PLUG-PIPE SQ DRIVE SCREW-FLANGE HD 19 NOT SOLD SEPERATELY 2 CAP DIFFERENTIAL BEARING /2-13 X 2.25 GRD8 HEX BOLT X KIT DIFFERENTIAL BEARING 22 *SEE KIT KIT DIFFERENTIAL SHIM 23 *SEE KIT 1 CASE-DIFFERENTIAL ASSY SCREW-HEX 25 *SEE KIT 2 PINION-DIFFERENTIAL 26 *SEE KIT 2 GEAR-DIFFERENTIAL KIT 27 *SEE KIT 2 THRUST WASHER DIFFERENTIAL PINION 28 *SEE KIT 2 THRUST WASHER DIFFERENTIAL GEAR 29 *SEE KIT 1 SHAFT-DIFFERENTIAL PIN-ROLL VENT PLUG SEAL & GUIDE-SHAFT 33 SEE KIT X 2 SEAL-KING PIN 34 SEE KIT X 2 RETAINER 35 SEE KIT X 2 BEARING KING PIN OIL SEAL TR115-24X 2 TIE ROD ASSY BOLT STOP 39 05QE 2 JAM NUT RETAINER- COMPRESSION SPRING COMPRESSION SPRING LOCK WASHER BOLT-KING PIN BEARING CAP FITTING - LUBRICATION KING PIN CAP GASKET - KING PIN CAP BUSHING - KING PIN KING PIN X 1 (3)RIGHT HAND STEERING KNUCKLE

34 34 AXLES AXLE ASSEMBLY BREAKDOWN FRONT DRIVE DETAIL SK193-X 1 (3)LEFT HAND STEERING KNUCKLE CAP - KING PIN BEARING COTTER PIN NUT (1) SHAFT AND JOINT ASSY 30 TOOTH (1) SHAFT AND JOINT ASSY 35 TOOTH SLINGER OIL SEAL 56 *SEE KIT 2 SPACER 57 *SEE KIT 2 SEAL 58 *SEE KIT 2 BEARING ASSY - NEEDLE 59 *SEE KIT 2 WHEEL BEARING SPINDLE ASSY SPINDLE NUT SEAL X 2 INNER WHEEL BEARING HU109-X 2 WHEEL HUB X 2 OUTER WHEEL BEARING NUT LOCK-WHEEL BEARING ADJUSTING NUT NUT SPACER - DRIVE GEAR GEAR - DRIVE HUB CAP KIT X KIT DRIVE GEAR AND PINION ASSY INCLUDES 2-10, 12,13,16,22,24 KIT 72162X KIT DRIVE GEAR AND PINION INCLUDES 2,13 KIT X KIT DIFFERENTIAL PARTS (STANDARD) 16,24-30 KIT X KIT DIFFERENTIAL PARTS (LIMITED SLIP) INCLUDES 16,24,74-81 KIT X KIT DIFFERENTIAL DISC AND PLATES(LIMITED SLIP) INCLUDES KIT X KIT PINION AND BEARING ADJUSTING SHIMS INCLUDES 5,7,12,13,16 KIT X KIT DIDDERENTIAL ADJUSTING SHIMS INCLUDES 16,22 KIT X KIT DIFFERENTIAL AND PIONION SHIMS 5,7,12,13,16,22 KIT KIT SPINDLE ASSY INCLUDES KIT KIT SPINDLE SEAL AND BEARING INCLUDES 55-58

35 35 NOTES: (1) Due to engineering change by Dana axles. Your tug may have either a 30 or 35 tooth shaft and joint assembly. All tugs with continental engines will have (35 tooth). It may be necessary for you to count the teeth on your shaft and joint assembly to correctly identify the part you require. RECOMMENDED TORQUE SPECIFICATIONS DANA 70 AXLE POSITION THREAD WRENCH TORQUE (LBS.-FT) Drive Pinion Nut 7/ Differential Bearing Cup Cap Screws 1/ Ring Gear Cap Screws 1/ Cover Screws 3/ Differential Case Cap Screws 7/ Brake Retainer Nuts 1/ Axle Shaft Flange Nuts 7/ Upper Kingpin 1 1/ Kingpin Cap Cap Screws 1/ Spindle Mounting Nuts 1/ Tie Rod Stud Nut 5/ Min (2) Tie Rod Clamp Nuts 1/ Steering Arm Nuts 1/ Steering Arm Stop Screw & Jam Nut 1/ (2) Note If cotter pin cannot be installed after minimum torque is attained, the nut must be advanced until cotter pin can be installed. (3) When replacing steering knuckles be sure that upon installation your steering cylinders (see pages 48-51) must be adjusted so when in full turn to the right and them full turn to the left the cylinder does not pull steering arm more than 3/16 of an inch. If you have any questions please call Eagle Tugs technical department.

36 36 AXLES AXLE ASSEMBLY BREAKDOWN REAR DRIVE *41-51 Special order limited slip kit call EAGLE for replacement

37 37 AXLES AXLE ASSEMBLY BREAKDOWN REAR DRIVE DETAIL Item Part Number Qty Description 1 A-TT COMPLETE AXLE ASSEMBLY X KIT DRIVE GEAR & PINION X KIT INNER PINION BEARING 4 *SEE KIT KIT SHIM-DRIVE PINION ADJUSTING BAFFLE-PINION BEARING 6 *SEE KIT KIT SHIM-PINION BEARING ADJUSTING X KIT OUTER PINION BEARING SLINGER-PINION BEARING SEAL-PINION X 1 END YOKE ASSEMBLY WASHER-PINION NUT NUT-PINION X 1 COVER ASSEMBLY RTV SEALANT 14A GASKET PLUG-PIPE SLOTTED SCREW-FLANGE HD 17 N/A 1 CAP DIFFERENTIAL BEARING /2-13 x 2.25 GRD8 BOLT BEARING CAP X KIT BEARING 20 *SEE KIT KIT SHIM-DIFFERENTIAL BEARING 21 *SEE KIT KIT CASE-DIFFERENTIAL KIT BOLT-DRIVE GEAR 23 *SEE KIT KIT PINION-DIFFERENTIAL 24 *SEE KIT KIT GEAR-DIFFERENTIAL 25 *SEE KIT KIT THUST WASHER-PINION 26 *SEE KIT KIT THRUST WASHER-GEAR 27 *SEE KIT KIT SHAFT-DIFFERENTIAL LOCK-DIFFERENTIAL BOLT-BRAKE MANUFACTURING NUT-BRAKE MANUFACTURING SEAL-OIL X KIT INNER WHEEL BEARING X KIT OUTER WHEEL BEARING HU247-X 2 HUB & DRUM ASSEMBLY STUD-HUB NUT-SPINDLE LOCK WASHER WHEEL BEARING SR SHAFT-AXLE FLANGE LONG ADAPTER-STUD NUT-LOCK VENT KIT X 2 PINION & BEARING ADJ SHIMS 4,6,11,12,14 KIT X 2 DIFFERENTIAL CASE ASSY (STAND) 14,19-28

38 38 AXLES AXLE ASSEMBLY BREAKDOWN REAR DRIVE DETAIL Item Part Number Qty Description 41 SEE KIT LIMITED SLIP 1 FLANGE HALF - DIFFERENTIAL CASE 42 SEE KIT LIMITED SLIP 1 CAP HALF - DIFFERENTIAL CASE 43 SEE KIT LIMITED SLIP 1 SHAFT - DIFFERENTIAL 44 SEE KIT LIMITED SLIP 1 PINION - DIFFERENTIAL 45 SEE KIT LIMITED SLIP 1 GEAR - DIFFERENTIAL 46 SEE KIT LIMITED SLIP 1 RING - DIFFERENTIAL GEAR 47 SEE KIT LIMITED SLIP 1 PLATE - DIFFERENTIAL 48 SEE KIT LIMITED SLIP 1 DISC - DIFFERENTIAL 49 SEE KIT LIMITED SLIP 1 DISC 50 SEE KIT LIMITED SLIP 1 PLATE BOLT - DIFFERENTIAL CASE KIT X 2 DRIVE GEAR AND ;PINION ASSY 2-9, 11-12, KIT 72165X 2 DRIVE GEAR AND PINION 2,12 KIT X 2 DIFFERENTIAL CASE (STANDARD) 14A, 20-22, KIT X 2 DIFFERENTIAL INNER PARTS (STANDARD) 28 14A, KIT X 2 DIFFERENTIAL INNER PARTS (LIMITED SLIP) 14A, KIT X 2 DIFFERENTIAL DISC AND PLATES (LIMITED SLIP) KIT X 2 DIFFERENTIAL ADJUSTING SHIMS 14A, 20 KIT X 2 DIFFERENTIAL AND PINION SHIMS 4, 6, 11-12, 14A, 20

39 39 NOTES: RECOMMENDED TORQUE SPECIFICATIONS DANA 70 AXLE POSITION THREAD WRENCH TORQUE (LBS.-FT) Drive Pinion Nut 7/ Differential Bearing Cup Cap Screws 1/ Ring Gear Cap Screws 1/ Cover Screws 3/ Differential Case Cap Screws 7/ Brake Retainer Nuts 1/ Axle Shaft Flange Nuts 7/ Upper Kingpin 1 1/ Kingpin Cap Cap Screws 1/ Spindle Mounting Nuts 1/ Tie Rod Stud Nut 5/ Min (Note) Tie Rod Clamp Nuts 1/ Steering Arm Nuts 1/ Steering Arm Stop Screw & Jam Nut 1/ Note If cotter pin cannot be installed after minimum torque is attained, the nut must be advanced until cotter pin can be installed.

40 40 BRAKES DRUM BRAKE ASSEMBLY REAR 7 6 BRAKE ASSEMBLY REAR DETAIL Item Part Number Qty Description 070WD BRAKE ASSY LEFT COMPLETE 070WD BRAKE ASSY RIGHT COMPLETE 1 RS358R 1 SHOES-REAR AXLE SET 2 EW CYL. WHEEL - LEFT EW CYL. WHEEL - RIGHT 3 H KIT - ADJUSTER - LEFT H KIT - ADJUSTER - RIGHT 4 H KIT - SPRING REAR AXLE SET LEFT BACKING PLATE RIGHT BACKING PLATE BRAKE ANCHOR BOLT PARKING BRAKE LEVER (LEFT) PARKING BRAKE LEVER (RIGHT)

41 41 BRAKES BRAKE CALIPER ASSEMBLY FRONT DRUM BRAKE ASSEMBLY FRONT DETAIL Item Part Number Qty Description ASSEMBLY - CALIPER L/H ASSEMBLY - CALIPER R/H 2 RMP KIT - DISK PADS FRONT

42 42 BRAKES BRAKE SYSTEM HYDRAULIC

43 43 BRAKE SYSTEM DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A-TT BRAKE LINE 2 A-TT BRAKE LINE 3 302X3 1 UNION 4 A-TT BRAKE LINE 5 A-TT BRAKE LINE 6 A-TT REAR BRAKE HOSE 7 A-TT BRAKE LINE 8 A-TT REAR BRAKE TEE 9 A-TT BRAKE LINE 10 A-TT BRAKE LINE CLIP 12 A-TT BANJO BOLT 13 A-TT BRAKE LINE HOSE 14 A-TT BRAKE LINE 15 A-TT BRAKE LINE TEE 16 **A-TT BRAKE LINE 16A A-TT BRAKE LINE (MODELS BUILT PREVIOUS TO **A-TT BRAKE LINE 17A A-TT BRAKE LINE(MODELS BUILT PREVIOUS TO ) 18 A-TT FITTING 19 A-TT FITTING 20 A-TT BRAKE LIGHT SWITCH TEE 21 A-TT BRAKE LIGHT SWITCH 22 A-TT MASTER CYLINDER **MASTER CYLINDER A-TT WAS IMPLEMENTED APPROXIMATELY IF YOU ARE REPLACING A MASTER CYLINDER ON A TUG BUILT PREVIOUS TO THIS DATE YOU WILL ALSO NEED ITEMS 16 AND 17.

44 44 BRAKES HYDRAULIC ACTUATION BRAKING SYSTEM HYDRAULIC ACTUATION BRAKING SYSTEM DETAIL Item Part Number Qty Description 1 A-TT A 5 NIPPLE 2 C3269X12X8 2 BUSHING 3 C5515X DEGREE SWIVEL FITTING 4 06UB U606 1 CUT TO FIT, BULK HOSE 5 NPN 1 CUT TO FIT, BULK HOSE - 3/8" 350 PSI 6 A-TT RETURN LINE TEE 7 A-TT MASTER CYLINDER 8 F81Z3A697AB 1 POWER STEERING RESERVOIR TANK 9 A-TT Y FITTING 10 SP20PB11L145H3R 1 PUMP 11 12GMV MEGAVAC 1 BULK HOSE 3/4" SUCTION 51" 12 12GMV MEGAVAC 1 BULK HOSE 3/4" SUCTION 3" 13 12GMV MEGAVAC 1 BULK HOSE 3/4" SUCTION 37" 14 NPN 1 CUT TO FIT, BULK HOSE - 3/8" 350 PSI 15 NPN 1 CUT TO FIT, BULK HOSE - 3/8" 350 PSI

45 45 BRAKES BRAKE PEDAL ASSEMBLY BRAKE ACTUATOR ASSEMBLY DETAIL Item Part Number Qty Description 1 C-TT BRAKE PEDAL 2 C-TT BRAKE PEDAL PIVOT SHAFT 3 C-TT BEARING 4 A-TT CLEVIS PIN 5 A-TT CLEVIS 6 NPN 1 ½-20 X 12 ADJUSTING ROD 7 NPN 1 ½-20 NUT 8 NPN 1 COTTER PIN

46 46 BRAKES PARKING BRAKE ACTUATOR ASSEMBLY

47 47 BRAKES PARKING BRAKE ACTUATOR ASSEMBLY DETAIL Item Part Number Qty Description 1 A-TT 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/ B-TT CABLE PRIMARY 6 A-TT BAR EQUALIZER 7 NPN 3 CLEVIS PIN 8 NPN 3 COTTER PIN 9 A-TT PARKING BRAKE CABLE LEFT REAR 10 A-TT PARKING BRAKE CABLE RIGHT REAR 11 NPN 1 SCREW-HEX CAP X 1 12 NPN 1 WASHER-FLAT-1/4 13 NPN 1 NUT-LOCK-1/ 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/ NPN 2 CABLE CLAMP THE FOLLOWING ITEMS ARE NOT SHOWN 19 AE-OPT-0069 HAND BRAKE "ON" WARNING (OPTION) 20 AE-OPT-0069 SHUTDOWN HAND BRAKE "ON" SHUTDOWN (OPTION) BUZZ LITE FOR PARKING BRAKE CONTACT PIN PROXIMITY SENSOR MOUNTING SCREW RELAY 26 A-TT NEUTRAL SAFETY SWITCH

48 48 STEERING SYSTEM STEERING SYSTEM BREAKDOWN * YOUR TUG MAY HAVE 2 HYDRAULIC CYLINDERS, IF SO SEE PAGE 48

49 49 STEERING SYSTEM STEERING SYSTEM BREAKDOWN DETAIL Item Part Number Qty Description 1 A-TT STEERING WHEEL 2 A-TT STEERING COLUMN 3 A-TT HORN BUTTON 4 A-TU CHARLYNN CONTROL PUMP 5 A-TT FITTING - ADAPTOR 6 A-TT FITTING 90 DEGREE 7 A-TT HYDRAULIC STEERING LINE 22" 9 NPN 1 HYDRAULIC CYLINDER PIVOT PIN 11 A-TT BEARING (AFTER 7/99) 12 NPN 7 HOSE CLAMP 14 A-TT DRAG LINK 15 A-TT HYDRAULIC STEERING LINE 46" 16 A-TT HYDRAULIC STEERING LINE 43" 17 A-TT JAM NUT 18 A-TT TIE ROD END 19 NPN 1 HIGH PRESSURE HOSE 23 NPN 1 NUT HEX SLOTTED 25 A-TT *HYDRAULIC STEERING CYLINDER 27 NPN 2 CLIP 28 A-TT WHEEL NUT 13/ AE-OPT-0160 (OPTION) 1 STEERING COLUMN TURN SIGNAL SWITCH 30 AE-OPT-0160-A (OPTION) 1 12V FLASHER TURN SIGNAL *Steering cylinder must be adjusted so when in full turn to the right and them full turn to the left the cylinder does not pull steering arm more than 3/16 of an inch. If you have any questions please call Eagle Tugs technical department.

50 50 STEERING SYSTEM STEERING SYSTEM BREAKDOWN * YOUR TUG MAY HAVE ONLY 1 HYDRAULIC CYLINDER, IF SO SEE PAGE 46

51 51 STEERING SYSTEM STEERING SYSTEM BREAKDOWN DETAIL Item Part Number Qty Description 1 A-TT STEERING WHEEL 2 A-TT STEERING COLUMN 3 A-TT HORN BUTTON 4 A-TT CHARLYNN CONTROL PUMP 5 A-TT FITTING - ADAPTOR 6 A-TT FITTING 90 DEGREE 7 A-TT HYDRAULIC STEERING LINE 22" 8 A-TT HYDRAULIC STEERING LINE 43" 9 NPN 2 HYDRAULIC CYLINDER PIVOT PIN 10 A-TT HYDRAULIC STEERING LINE 32" 11 A-TT BEARING (AFTER 7/99) 12 NPN 7 HOSE CLAMP 13 A-TT STEERING MOUNTING BLOCK 14 A-TT DRAG LINK 15 A-TT HYDRAULIC STEERING LINE 22.5" 16 A-TT HYDRAULIC STEERING LINE 32' 17 A-TT JAM NUT 18 A-TT TIE ROD END 19 NPN 1 HIGH PRESSURE HOSE 20 NPN 8 SCREW HEX CAP 1/2-20 X 2 1/4 21 NPN 8 WASHER FLAT 1/2 22 A-TT STEERING ARM ( MACHINED) 23 NPN 2 NUT HEX SLOTTED 24 C-5707X6 2 FITTING -TEE 25 A-TT HYDRAULIC CYLINDER 26 NPN 2 SET SCREW 5/16 18 X 3/8 27 NPN 4 CLIP 28 A-TT WHEEL NUT 13/16-20 *Steering cylinder must be adjusted so when in full turn to the right and them full turn to the left the cylinder does not pull steering arm more than 3/16 of an inch. If you have any questions please call Eagle Tugs technical department.

52 52 AIR CLEANER AIR CLEANER ASSEMBLY DIESEL AIR CLEANER ASSEMBLY DETAIL Item Part Number Qty Description 1 A-TT AIR CLEANER BRACKET 2 A-TT AIR CLEANER ASSEMBLY 3" A-TT AIR CLEANER ASSEMBLY 2" 3 NPN 7 HOSE CLAMPS 4 A-TT DEGREE ELBOW 5 A-TT PIPE HANGAR 6 A-TT " EXHAUST CLAMP 7 NPN 1 BULK-INTAKE TUBE 8 A-TT DEGREE ELBOW 9 NPN 3 BULK-INTAKE TUBE - 3"

53 53 AIR CLEANER AIR CLEANER SUB-ASSEMBLY 2 1 AIR CLEANER SUB-ASSEMBLY DETAIL Item Part Number Qty Description 1 A-TT A-TT AIR CLEANER 2" AIR CLEANER 3" 2 P P AIR CLEANER ELEMENT 2" AIR CLEANER ELEMENT 3"

54 54 FUEL SYSTEM FUEL SYSTEM DIESEL FUEL SYSTEM DETAIL Item Part Number Qty Description 1 A-TT FUEL SENDING UNIT 2 A-TT FUEL CAP 3 A-TT NIPPLE 4 A-TT FUEL TANK 5 A-TT DEGREE ELBOW FITTING 6 NPN 1 BULK-5/16 FUEL LINE 7 NPN 4 BOLT 8 NPN 6 WASHER 9 NPN 4 LOCK NUT 10 NPN 5 SCREW-HEX CAP X3/4

55 55 EXHAUST EXHAUST SYSTEM DIESEL EXHAUST SYSTEM DETAIL Item Part Number Qty Description 1 A-TT " MUFFLER CLAMPS 2 A-TT10TD DIESEL EXHAUST PIPE 3 A-TT PIPE HANGER 4 A-TT MUFFLER 5 A-TT & DEGREEE TAIL PIPE 6 A-TT EXHAUST WRAP 7 NPN 2 3/8-16 X 1 HEX CAP SCREW 8 NPN 2 3/8 FLAT WASHER 9 NPN 2 3/8 LOCK NUT 10 AE-OPT SPARK ARRESTING MUFFLER (OPTION) 11 AE-OPT DIESEL SCRUBBER (OPTION)

56 56 OPERATOR COMPARTMENT TRANSMISSION CONTROL TRANSMISSION CONTROL DETAIL Item Part Number Qty Description 1 A-TT TRANSMISSION SHIFT CONTROL 2 A-TT TRANSMISSION SHIFT CABLE 3 A-TT TRANSMISSION CABLE BRACKET ASSEMBLY 4 A-TT U-BOLT KIT 5 A-TT BALL JOINT KIT 6 A-TT TRANSMISSION LEVER INDICATOR STRIP REPAIR KIT HANDLE REPAIR KIT

57 57 OPERATOR COMPARTMENT ACCELERATOR PEDAL ASSEMBLY ACCELERATOR PEDAL ASSEMBLY DETAIL ITEM PART NUMBER QTY. DESCRIPTION 1 A-TT 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/ A-TT * 1* CABLE CLASP* 6 A-TT BALL JOINT KIT - NUT INCLUDED 7 A-TT ACCELERATOR CABLE ASSEMBLY 8 A-TT ACCELERATOR U-BOLT KIT 9 A-TT ACCELERATOR CLEVIS-PIN KIT *CLASP MUST BE WELDED TO BRACKET

58 58 OPERATOR COMPARTMENT INSTRUMENT PANEL

59 59 OPERATOR COMPARTMENT INSTRUMENT PANEL DETAIL Item Part Number Qty Description 1 C-TT DASH PANEL (NO INSTRUMENTS) 2 A-TT OIL PRESSURE GAUGE 3 A-TT FUEL GAUGE 4 A-TT VOLT-AMP GAUGE 5 A-TT TEMP GAUGE 6 A-TT HOUR METER 7 A-TT IGNITION SWITCH (KEYED OPTION) 7 A-TT IGNITION SWITCH (KEYLESS OPTION) 8 A-TT PLATE, MOUNTING IGNITION SWITCH 9 TMD27M GLOW PLUG SWITCH 10 A-TT HEAD LIGHT SWITCH 11 A-TT HORN BUTTON 12 A-TT HEATER FAN SWITCH 13 A-TT TEMPERATURE CONTROL CABLE NS A-TT WIRE HARNESS (DASH ONLY) NS A-TT AMP CIRCUIT BREAKER NS AE-OPT AMMETER(OPTION) NS AE-OPT TRANSMISSION FLUID TEMP The following optional items are NOT SHOWN 14 AE-OPT HI TEMP-LO OIL SHUTDOWN (OPTION) 15 9B SHUTDOWN MODULE LOW OIL BUZZ LITE HI TEMP BUZZ LITE F 2 LENS COVER BUZZ LITES

60 60

61 61 LIGHTS & ELECTRICAL ELECTRICAL BOARD ELECTRICAL BOARD DETAIL Item Part Number Qty Description 1 B-TT MOUNTING BRACKET 2 NPN 2 LOCK NUT NPN 5 SELF DRILLING SCREWS 4 A-TT STARTER RELAY 5 A-TT HORN RELAY 6 A-TT GLOW PLUG RESISTER 7 A-TT RELAY

62 62 LIGHTS & ELECTRICAL HEADLIGHT & TAILLIGHT ASSEMBLY

63 63 LIGHTS & ELECTRICAL HEADLIGHT & REAR SPOT LIGHT ASSEMBLY DETAIL Item Part Number Qty Description 1 A-TT HEADLIGHT 2 NPN 2 NUT-1/ NPN 6 NUT-1/4-20 4A AE-OPT (TEAR DROP STYLE) 2 HEADLIGHT WITH TURN SIGNAL (OPTION) 4B A-TT (RETANGULAR STYLE) 2 HEADLIGHT WITH TURN SIGNAL (OPTION) 5 A-TT (NOT SHOWN) 1 REAR FACING SPOT LIGHT TAILLIGHT ASSEMBLY DETAIL Item Part Number Qty Description 6 A-TT TAILLIGHT 7 NPN 2 WASHER-FLAT-1/2 8 NPN 6 WASHER-FLAT-1/ TAIL LENS COVER REPLACEMENT BULBS Item Part Number Qty Description 10 H4 REPL BULB ITEMS 1 AND 4A 11 H3 REPL BULB ITEM REPL BULB BRAKE LIGHT ITEM 6 & TURN SIGNAL ITEM 4B REPL BULB REVERSE LIGHT ITEM NA REPL BULB TURN SIGNAL ITEM 4 15 H6545 SEALED BEAM FOR ITEM 4B OPTIONS NOT SHOWN Item Part Number Qty Description 15 AE-OPT ROOF MOUNTED TURN SIGNAL LAMP *DUE TO ENGINEERING IMPROVEMENTS YOU MAY HAVE HEADLIGHTS OTHER THAT THE ONES LISTED **IF YOUR TUG HAS GAS TANK REV C A-TT (OLDER MODELS) YOU CAN USE ITEMS 1, 4A OR 5. **IF YOUR TUG HAS GAS TANK REV D A-TT (NEW TANK WITH NOTCHED CORNER) YOU CAN USE ITEMS 1, 4A, 4B OR 5.

64 64 LIGHTS & ELECTRICAL WIRING HARNESS

65 65 LIGHTS & ELECTRICAL WIRING SCHEMATIC

66 66 LIGHTS & ELECTRICAL SHUTDOWN OPTION WIRING Item Part Number Qty Description 1a AE-OPT-0080(COMPLETE ASSY) 1 LOW OIL/HI TEMP SHUTDOWN DIESEL ENG 1b AE-OPT (COMPLETE ASSY) 1 LOW OIL/HI TEMP SHUTDOWN GASOLINE 2 9B SHUTDOWN MODULE 3 W WIRE HARNESS F 1 OIL PRESSURE LIGHT F 1 TEMPERATURE LIGHT LENS COVER SHROUD(NOT SHOWN) 7 H PRESSURE SWITCH /8 MALE/FEMALE ADAPTER(NOT SHOWN) /4 X 1/8 ADAPTER

67 67 LIGHTS & ELECTRICAL CAB OPTION WIRING

68 68 OTHER ASSEMBLY BODY ASSEMBLY BODY ASSEMBLY DETAIL Item Part Number Qty Description 1 NPN 1 HOOD PROP 2 NPN 1 HOOD PROP ASSEMBLY 3 C-TT T-HANDLE LATCH 3 C-TT LOCKING T-HANDLE LATCH 4 A-TT HORN ASSEMBLY 5 A-TT HEAT SHIELD 6 D-TT GRILL GUARD/ACCESS DOOR LATCH FOR ACCESS DOOR 8 B-TT HOOD

69 69 OTHER ASSEMBLY BODY ASSEMBLY WITH SPLIT HOOD BODY ASSEMBLY DETAIL Item Part Number Qty Description 1 B-TT L 1 HOOD LEFT 2 C-TT LOCKING T-HANDLE LATCH LEFT DOOR 3 B-TT R 1 HOOD RIGHT 4 C-TT T-HANDLE LATCH RIGHT DOOR 5 A-TT BENCH SEAT 6 AE-OPT-0055-C 1 BENCH SEAT BACK CUSHION 7 AE-OPT-0055-B 1 BENCH SEAT BOTTOM CUSHION 8 AE-OPT BENCH SEAT WITH KILL SWITCH( OPTION)

70 70 WHEELS & TIRES WHEEL & TIRE ASSEMBLY DUAL REAR WHEEL MODELS WHEEL & TIRE ASSEMBLY DUAL REAR WHEEL MODELS DETAIL Item Part Number Qty Description 1 A-TT STANDARD 16.5 IN TIRE 2 A-TT STANDARD 16.5 IN RIM-FRONT 3 A-TT STANDARD 16.5 IN RIM-REAR 4 A-TT WHEEL LUG NUT 5 A-TT WHEEL LUG NUT 6 AE-OPT OPTIONAL ALL SEASON MUD & SNOW TIRE REQUIRES OPTIONAL 16 IN RIM 7 A-TT OPTIONAL FRONT 16 IN RIM FOR AE-OPT A-TT OPTIONAL REAR 16 IN RIM FOR AE-OPT AE-OPT OPTIONAL FRONT ALUMINUM 16 IN RIM 10 AE-OPT OPTIONAL REAR ALUMINUM 16 IN RIM 11 AE-OPT OPTIONAL TIRE FOR ALUMINUM RIM 12 AE-OPT OPTIONAL SNOW CABLES * Tires listed above do not include foam fill option.

71 71 OPTIONS HITCH OPTIONS HITCH OPTION DETAIL Item Part Number Qty Description 1 AE-OPT E-HITCH 1 1/2 " PIN-COMPLETE ASSEMBLY 2 B-TT DET2 1 E-HITCH GUIDE 1 1/2" GUIDE PIN WITH RING 3 B-TT3-0008A 1 E-HITCH SPRING 4 B-TT DET5 1 LOCKING COLLAR 5 AE-OPT PINTLE HOOK 6 AE-OPT AIRLINE HITCH 3" PIN WITH CABLE(NOT SHOWN) 7 AE-OPT AIRLINE HITCH 2 3/8" PIN (NOT SHOWN) * The above are standard hitch options. Please call for special hitch options information

72 72 OPTIONS CAB OPTION

73 73 OPTIONS CAB OPTION DETAIL Item Part Number Qty Description 1 AE-OPT CAB ASSEMBLY COMPLETE DOOR ASSEMBLY COMPLETE 3 A-TT DOME LITE 4 A-TT ROOF VENT 5 A-TT WIPER MOTOR 6 A-TT DEFROST FAN 7 A-TT HEATER FAN SWITCH WIPER ARM WIPER BLADE DOOR HINGE STRIKER PLATE INSIDE DOOR HANDLE OUTSIDE DOOR HANDLE DOOR STRAP DOOR WINDOW WINDSHEILD REAR WINDOW SLIDING WINDOW FRONT QUARTER WINDOW

74 74 OPTIONS CAB HEATER DETAIL ENGINE RETURN ENGINE SUPPLY Item Part Number Qty Description 1 A-TT HEATER ASSEMBLY 2 A-TT D 1 CONTROL VALVE A 2 Y CONNECTOR 4 A-TT HEATER FAN SWITCH 5 A-TT TEMPERATURE CONTROL CABLE 6 NPN 5/8 HEATER HOSE (NOT SHOWN)

75 75 OPTIONS STROBE, BEACON & FLOOR MAT OPTIONS 1 OR 2 3 Item Part Number Qty Description 1 AE-OPT AMBER ROTATING BEACON 1A R5024BH 1 REPLACEMENT BULB 24VDC 1B R5012BH 1 REPLACEMENT BULB 12VDC 2 AE-OPT STROBE 2A REPLACEMENT BULB FOR STROBE 2B AE-OPT /2 COVER FOR STROBE 3 A-TT BASIC FLOOR MAT(NO SENSOR) 3A A-TT OPERATOR SWITCH MAT (WITH SENSOR) 3B A-TT SWITCHMAT DELAY TIMER

76 76 OPTIONS OTHER OPTIONS LISTED NOT SHOWN Item Part Number Qty Description 1 AE-OPT LUBRICITY FILTER SYSTEM 2 FS LUBRICITY REPLACEMENT ELEMENT 3 AE-OPT BACK UP ALARM 4 AE-OPT MASTER BATTERY DISCONNECT SWITCH 5 AE-OPT-0099A 1 MASTER BATTERY DISCONNECT SWITCH- LOCKOUT LEVER KIT 6 AE-OPT INTECOM JACK 7 AE-OPT V ACCESSORY OUTLET

77 77 TT DIESEL MAINTENANCE LUBRICATION DIAGRAM TT SERIES-ALL WHEEL DRIVE Type Item Identification Service Lubricant 1 STEERING LINKAGE LUBE EP MULTIPURPOSE GREASE 2 TRANSMISSION OIL CHECK DEXTRON III TYPE TRANSMISSION FLUID 3 ENGINE OIL CHANGE 15W40 CD OE/HDO (MIL-L-2104) 4 DRIVE AXLES CHECK GEAR OIL (MIL-L-2105) AXLE SHAFT U-JOINT CHECK EP MULTIPURPOSE GREASE 5 POWER STEERING PUMP CHECK AUTOMOTIVE POWER STEERING FLUID 6 DRIVE SHAFT LUBE EP MULTIPURPOSE GREASE 7 BRAKE MASTER CYLINDER CHECK DOT 3 BRAKE FLUID 8 ENGINE COOLANT CHECK ETHYLENE GLYCOL/ WATER (50/50 MIX) MIL-A ACCELERATOR CABLE LUBE **SUMMER MONTHS WD40 PENETRATING OIL WINTER MONTHS ANTI FREEZE *CHECK WHEN ENGINE IS AT OPERATING TEMPERATURE **IT IS RECOMMENDED BY MANUFACTURER TO PROLONG THE LIFE OF YOUR ACCELERATOR CABLE THAT THE ABOVE LUBRICATION BE FOLLOWED SEE PREVENTATIVE MAINTENANCE SCHEDULE NEXT PAGE

78 78 PREVENTATIVE MAINTENANCE SCHEDULE This section below has been added to for your record keeping convenience Date Service Performed Tug Serial Number Tug Hours Technician

79 79 DAILY OPERATOR RESPONSIBILITES 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 Fuel Filter Isuzu Carquest Fleetgard LF3528 Fleetgard FF5114 Air Cleaner Donaldson P Or P Transmission Wix Lubricity Filter Fleetgard FS20000

80 80 SPECIFICATIONS & CAPACITIES MODEL # DESCRIPTION: ISUZU 4JG1T 3.1 Liter, Isuzu four cylinder, equipped with turbo charger # OF CYLINDERS 4 IN-LINE, 4 CYCLE BORE & STROKE INCHES (mm) 3.74 X 4.21 (95.0 X 107.0) DISPLACEMENT, CUBIC INCHES (L) 189 (3.1) COMPRESSION RATIO FUEL ALTERNATOR No 1 or No 2 DIESEL 50 AMP, 12 VOLT, NEG GROUND ENGINE WEIGHT FULLY DRESSED LB (KG) (PROX) 610 (277) ENGINE CRANKCASE CAPACITIES ENGINE U.S. QUARTS IMPERIAL QUARTS LITRES 3.1 L (189 CID) DIESEL*** ***15W40CD IN CONTINENTAL U.S. FUEL TANK REFILL CAPACITIES U.S. GALLONS IMPERIAL GALLONS LITERS SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) NO. 2-D JIS (JAPANESE INDUSTRIAL STANDARD) NO 2 DIN (DEUTSCHE INDUSTRIE NORMEN) BS (BRITISH STANDARD) CLASS A-1 *Please refer to Isuzu Engine Instruction Manual IDE 6053 for further information

81 81 SPECIFICATIONS & CAPACITIES TRANSMISSION REFILL CAPACITIES ENGINE U.S. PINTS IMPERIAL PINTS LITRES 3.1 L (189 CID) DIESEL * 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 3.1L (189 CID) DIESEL * 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 OR EQUIVALENT SPEC FOR GM, CHRYSLER AND FORD AUTO APPLICATIONS AXLE REFILL CAPACITIES AXLE U.S. PINTS IMPERIAL PINTS LITRES FRONT STEER NON DRIVE FRONT DRIVE AXLE N/A N/A N/A REAR DRIVE AXLE * SERVICE REFILL CAPACITIES ARE DETERMINED BY FILLING TO THE BOTTOM OF THE FILLER HOLE **USE 80W90 HYPOID GEAR LUBRICANT

82 82 TIPS FOR INCREASED ALL WEATHER TRACTION DURING AIRCRAFT PUSHBACK 1. Reduce air pressure in pneumatic tires from 60 PSI to as low as 25 PSI. (**restore air pressure to 60 psi as soon as weather emergency ends). 2. When pushing with All Wheel Drive tractors, make sure the towbar is level or slightly downhill toward tractor. 3. When towing with Rear Wheel Drive-raise hitch height. 4. When pushing with Rear Wheel Drive-lower hitch height. Note: These strategies(2, 3 and 4) maximize all weather traction. 5. When pushing aircraft on ice or icy snow with All Wheel Drive, a wheel may loose traction (wheel spin). To stop front wheel spin, apply some service brake gradually with left foot until wheel spin stops and hold, while continuing the pushback. Coordinate the left foot service brake pressure and the right foot accelerator, to maintain a smooth pushback. To stop rear wheel spin, apply parking brake with lever until it stops while continuing the pushback. 6. On ice or snow use chains or cables. If the use of chains is prohibited, there are traction cables that serve the same function as chains but are much easier to mount and are very kind in terms of abrasion to all surfaces. 7. Keep fuel tank full, as much as possible. 8. Consult with Eagle Tugs factory for additional assistance.

83 83 FRONT END ALIGNMENT PROCEDURE Find center line of tire front and back Check with tape measure to see difference The front should be 1/16 inch more that the rear 1/16 inch toe out, if less or greater loosen the two bolts on the tie rod clamp Turn clamp in or out to achieve desired setting 1/16 in toe out Retighten two bolts on the tie rod clamp + 1/16 TOE OUT TIE ROD CLAMP & BOLT FRONT TIRES