Eagle Tugs TT-4 Quick start guide

QA025 REV02 01.27.12
EAGLE TUGS
Parts and Service Manual
Vehicle Types: TT-4, TT-5, TT-6, & TT-8
Engine Type: Wiscon Diesel TMD27 Engine Model

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QA025 REV02 01.27.12
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-4,
TT-5, TT-6, and TT-8 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 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 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
26111 Northline Rd
Taylor, MI 48180
[phone]
www.eagletugs.com
Customer Service Parts & Service Technical Support
[e-mail] [e-mail] [e-mail]
[phone] -- [phone] [phone] -- [phone] [phone] -- [phone]

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QA025 REV02 01.27.12
TABLE OF CONTENTS
INTRODUCTION ................................................................................................................................................................................................. 2
PURPOSE & USE OF THIS MANUAL ..................................................................................................................................................................... 2
TECHNICAL ASSISTANCE ...................................................................................................................................................................................... 2
ORDERING SPARE/SERVICE PARTS ...................................................................................................................................................................... 2
CONTACT INFORMATION ..................................................................................................................................................................................... 2
WARRANTY .......................................................................................................................................................................................................... 5
VEHICLE ID INFORMATION ................................................................................................................................................................................. 5
WARRANTY REGISTRATION ................................................................................................................................................................................. 6
STANDARD WARRANTY ....................................................................................................................................................................................... 6
Scheduled Maintenance ......................................................................................................................................................................................... 7
TT-4, 5, 6, & 8 DIESEL MAINTENANCE INTERVALS ............................................................................................................................................ 7
LUBRICATION CHART - TT SERIES-ALL WHEEL DRIVE ..................................................................................................................................... 8
LUBRICATION CHART - TT SERIES-REAR WHEEL DRIVE .................................................................................................................................. 9
SERVICE PARTS ILLUSTRATIONS & DETAIL .......................................................................................................................................... 10
IDENTIFICATION KEY ......................................................................................................................................................................................... 10
POWER TRAIN .................................................................................................................................................................................................... 11
Belt-Drive Accessory .................................................................................................................................................................................. 11
Diesel Engine Dress .................................................................................................................................................................................... 12
Diesel Engine Dress—Detail ...................................................................................................................................................................... 13
CONTINENTAL PARTS CATALOG ....................................................................................................................................................................... 14
Service Facilities .......................................................................................................................................................................................... 15
Introduction & Table of Contents ............................................................................................................................................................. 16
Engine Service Kits ..................................................................................................................................................................................... 17
Crankcase, Bearing Caps & Oil Filter ....................................................................................................................................................... 18
Crankcase, Bearing Caps & Oil Filter—Detail ......................................................................................................................................... 19
Cylinder Head, Cover & Valves ................................................................................................................................................................ 20
Cylinder Head, Cover & Valves—Detail ................................................................................................................................................. 21
Camshaft & Rocker Arm ............................................................................................................................................................................ 22
Camshaft & Rocker Arm—Detail ............................................................................................................................................................. 23
Crankshaft & Pulley ................................................................................................................................................................................... 24
Crankshaft & Pulley —Detail .................................................................................................................................................................... 25
Piston & Connecting Rods ......................................................................................................................................................................... 26
Piston & Connecting Rods —Detail .......................................................................................................................................................... 27
Oil Pump ...................................................................................................................................................................................................... 28
Oil Pump —Detail ...................................................................................................................................................................................... 29
Gear Cover ................................................................................................................................................................................................... 30
Gear Cover —Detail ................................................................................................................................................................................... 31
Flywheel, Rep, Flex Plates & Starter ......................................................................................................................................................... 32
Flywheel, Rep, Flex Plates & Starter—Detail ........................................................................................................................................... 33
Intake & Exhaust Manifold ........................................................................................................................................................................ 34
Intake & Exhaust Manifold—Detail ......................................................................................................................................................... 35
Water Pump Assembly .............................................................................................................................................................................. 36
Water Pump Assembly—Detail ................................................................................................................................................................ 37
Water Header & Thermostat ..................................................................................................................................................................... 38
Water Header & Thermostat—Detail ....................................................................................................................................................... 39
Alternator, PCV, Engine Heater & Air Intake ......................................................................................................................................... 40
Alternator, PCV, Engine Heater & Air Intake—Detail ........................................................................................................................... 41
Oil Cooler ..................................................................................................................................................................................................... 42
Oil Cooler —Detail ..................................................................................................................................................................................... 43
Injector Pump, Fuel Filter, Electric Fuel Pump, & Injector Nozzles & Lines ....................................................................................... 44
Injector Pump, Fuel Filter, Electric Fuel Pump, & Injector Nozzles & Lines —Detail ........................................................................ 45
Injector Pump, Fuel Filter, Electric Fuel Pump, & Injector Nozzles & Lines ....................................................................................... 46
Injector Pump, Fuel Filter, Electric Fuel Pump, & Injector Nozzles & Lines —Detail ........................................................................ 47
Ship Loose .................................................................................................................................................................................................... 48
ACCESSORIES SECTION....................................................................................................................................................................................... 49
Starter ........................................................................................................................................................................................................... 50
Starter—Detail ............................................................................................................................................................................................. 51

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Alternator & Alternator & Detail .............................................................................................................................................................. 52
Water Pump Installation Tool ................................................................................................................................................................... 53
SERVICE & PARTS (WIS-CON TOTAL POWER) ................................................................................................................................................... 54
DRIVELINE .......................................................................................................................................................................................................... 55
Drive Shaft Assembly—Front ................................................................................................................................................................... 55
Drive Shaft Assembly—Rear ..................................................................................................................................................................... 56
TRANSMISSION ................................................................................................................................................................................................... 57
Cooling System—Transmission ................................................................................................................................................................ 57
Transaxle Mounting & Misc. Parts ........................................................................................................................................................... 58
Transaxle Mounting & Misc. Parts—Detail ............................................................................................................................................ 59
Transaxle Case Extension & Retainer ....................................................................................................................................................... 60
Transaxle Case Extension & Retainer—Detail ......................................................................................................................................... 61
AXLES ................................................................................................................................................................................................................. 62
Axle Assembly—Front Non-Drive (2WD) ............................................................................................................................................... 62
Axle Assembly—Front Drive (4WD) ........................................................................................................................................................ 63
Axle Assembly—Rear ................................................................................................................................................................................ 64
Notes ............................................................................................................................................................................................................ 65
Axle Assembly Breakdown—Front Non-Drive (2WD) .......................................................................................................................... 66
Axle Assembly Breakdown—Front Non-Drive—Detail ........................................................................................................................ 67
Axle Assembly Breakdown—Front Drive (4WD) ................................................................................................................................... 68
Axle Assembly Breakdown—Front Drive—Detail ................................................................................................................................. 69
Axle Assembly Breakdown—Front Drive—Detail ................................................................................................................................. 70
Notes ............................................................................................................................................................................................................ 71
Axle Assembly Breakdown—Rear Drive ................................................................................................................................................. 72
Axle Assembly Breakdown—Rear Drive—Detail .................................................................................................................................. 73
BRAKES ............................................................................................................................................................................................................... 74
Brake Caliper Assembly - Rear ................................................................................................................................................................. 74
Brake Caliper Assembly - Rear—Detail ................................................................................................................................................... 75
Brake System Hydraulic & Detail ............................................................................................................................................................. 76
Notes ............................................................................................................................................................................................................ 77
Brake Actuator Assembly .......................................................................................................................................................................... 78
Brake Actuator Assembly—Detail ............................................................................................................................................................ 79
Brake Actuator Assembly .......................................................................................................................................................................... 80
Brake Actuator Assembly—Detail ............................................................................................................................................................ 81
Parking Brake Assembly ............................................................................................................................................................................ 82
Parking Brake Assembly—Detail.............................................................................................................................................................. 83
WHEELS & TIRES ................................................................................................................................................................................................ 84
Wheel & Tire Assembly & Detail .............................................................................................................................................................. 84
Notes ............................................................................................................................................................................................................ 85
Cooling System (Diesel) ............................................................................................................................................................................. 86
Cooling System (Diesel)— Detail .............................................................................................................................................................. 87
Fuel System (Diesel) ................................................................................................................................................................................... 88
Fuel System (Diesel)— Detail .................................................................................................................................................................... 89
STEERING SYSTEM .............................................................................................................................................................................................. 90
Steering System Breakdown ...................................................................................................................................................................... 90
Steering System Breakdown—Detail ........................................................................................................................................................ 91
Accelerator Pedal Assembly ...................................................................................................................................................................... 92
Notes ............................................................................................................................................................................................................ 93
Instrument Panel ......................................................................................................................................................................................... 94
Instrument Panel—Detail .......................................................................................................................................................................... 95
OPERATOR COMPARTMENT & OTHER ASSEMBLIES ......................................................................................................................................... 96
Transmission Control & Detail .................................................................................................................................................................. 96
Air Cleaner Assembly & Detail ................................................................................................................................................................. 97
Electrical Components & Detail ................................................................................................................................................................ 98
Headlight & Taillight Assembly Detail .................................................................................................................................................... 99
Body Assembly ......................................................................................................................................................................................... 100
Body Assembly—Detail ........................................................................................................................................................................... 101
Exhaust System ......................................................................................................................................................................................... 102
Exhaust System—Detail ........................................................................................................................................................................... 103
Wiring Harness ......................................................................................................................................................................................... 104
Wiring Schematic ...................................................................................................................................................................................... 105

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QA025 REV02 01.27.12
INTRODUCTION
PURPOSE & USE OF MANUAL
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
servicing recommendations of the manufacturer.
The descriptions and specifications contained in this 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.
CONTACT INFORMATION
Customer Service
27250 Kitty hawk
Grosse Ile, MI 48138
[e-mail]
[phone]
Parts & Service Sales
27250 Kitty hawk
Grosse Ile, MI 48138
[e-mail]
[phone]
Web-Site
www.eagletugs.com
WARRANTY
*WARNING – DO NOT USE JET A FUEL IN THIS ENGINE. ANY US OF JET A FUEL 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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 #
MFG DATE
ENGINE TYPE
ENGINE SERIAL #

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QA025 REV02 01.27.12
EAGLE STANDARD WARRANTY
Standard Limited Warranty Information*
The Eagle Tugs (EAGLE) Standard Warranty covers all MTT, RTT-series and Transit Pro tow tractors, as well as all Eagle tow
tractor models used in industrial applications. Eagle Tugs warrants that these tractors will be free from defects in material and
workmanship for a period of 1 year or 2,000 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 de-
fect 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 Au-
thorized 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 re-
spective 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, vandal-
ism, 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Depart
ment at [phone]. The customer will need to provide Eagle with the tow tractor serial number and engine hours. A cus-
tomerservicerepresentativewillanalyzetheproblemanddeterminethenextsteps.InmanycasesEagle’stechnicalsupportper-
sonnel will be able to analyze the problem and recommend adjustments that will solve the problem and reduce down time. If fur-
ther 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 PROF-
ITS, DAMAGES, COSTS, CHARGES, LIABILITY OR EXPENSES, WHETHER DIRECT OR INDIRECT, CONSEQUENTIAL OR
OTHERWISE, WHICH ARISE OUT OF OR IN CONNECTION WITH THE SALE OR USE OF ANY EAGLE MACHINE OR THE
SUPPLY OF SERVICES.
SUBJECT TO CHANGE WITHOUT NOTICE
Please check our website www.eagletugs.com 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 which are
used in aviation applications. All MTT and RTT-series, and Transit Pro models, as well as all Eagle tow tractor 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.

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QA025 REV02 01.27.12
WARRANTY
TT 4, 5, 6, & 8 DIESEL MAINTENANCE INTERVALS
Part # Des cr ip t ion
-Engine Oil -Refill fluid levels as required
-Power Steering Fluid
-Transmission Fluid
-Brake Fluid (Master Cylinder)
All of the above, plus: -Components that show wear
-Valve Cover Gaskets or appear damaged
-Engine Rubber Mountings -Clean engine air cleaner
-Inlet & Exhaust Pipe
to Manifold
-Throttle Controls
-Coolant Levels
-All Hoses for deterioration
and/or chafing
-All Belt Drives for wear and
proper tension
-Steering arms bolts Re-torque to 120 Ft lbs.
-Fuel System for leaks
-Electrical System for frayed
wires and/or loose connections
All of the above, plus: -Components that show wear 85452 Oil Filter
-Battery Cables for Corrosion or appear damaged
-Steering arms bolts Re-torque to 120 Ft lbs.
-Change oil and replace oil filter
All of the above, plus: -Components that show wear P14-8966 Air Cleaner Element 3"
-Drum Brake Linings, Lines & or appear damaged
Hoses -Replace Air Cleaner Element 85705 Trans. Filter & Gasket
-Replace Fuel Filter TMD20F00400 Fuel Filter
-Steering arms bolts Re-torque to 120 Ft lbs. R20P Fuel Water Sep. Filter
-Replace Transmission Fluid BE-10-18 Power Steering Filter
& Filter
-Rotate Tires
All of the above -Components that show wear
or appear damaged
-Steering arms bolts Re-torque to 120 Ft lbs.
-Replace Hypoid Gear Lubricant
in Drive Axles
All of the above -Components that show wear RD52 Front Brake Pads
or appear damaged FR357 Rear Brake Shoes
-Steering arms bolts Re-torque to 120 Ft lbs. X27019530 Power Steering Belt
9490 Alternator Belt
A-TT4-00291-5 Headlight (Per 12/04)
A-TT10-00291 Headlight
1157 Tail Light Bulb
A-TT4-00282-1 Accelerator Cable
TM27K00325 Thermostat
X07854 Thermostat Gasket
N/A
Replace
Interval
Check/Inspect
Service
Ever y 100
Hour s
Ever y 2000
Hour s
Ever y 50
Hour s
N/A
N/A
Daily
N/A
Ever y 500
Hour s
Ever y 1000
Hour s
N/A
N/A

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QA025 REV02 01.27.12
LUBRICATION CHART—TT SERIES-ALL WHEEL DRIVE
Type
Service
1Steering Linkage Lube EP Multipurpose Grease
2Trans miss ion Oil* Check Dextron III
3Engine Oil Change OE/HDO (MIL-L-2104)
4Drive Axles Check GO 80-90 (MIL-L-2105)
5Power Steering Pump Check Power Steering Fluid
6Drive Shaft Lube EP Multipurpose Grease
7Brake Master Cylinder Check Dot 3
8Engine Coolant Check MIL-A-46153 (Ethylene Glycol)
*Check when engine is at operating temperature
Item
Identification
Lubricant

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QA025 REV02 01.27.12
LUBRICATION CHART—REAR WHEEL DRIVE
Type
Service
1Steering Linkage Lube EP Multipurpose Grease
2Trans miss ion Oil* Check Dextron III
3Engine Oil Change OE/HDO (MIL-L-2104)
4Drive Axles Check GO 80-90 (MIL-L-2105)
5Power Steering Pump Check Power Steering Fluid
6Drive Shaft Lube EP Multipurpose Grease
7Brake Master Cylinder Check Dot 3
8Engine Coolant Check MIL-A-46153 (Ethylene Glycol)
*Check when engine is at operating temperature
Item
Identification
Lubricant

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QA025 REV02 01.27.12
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. Typi-
callyusedforbolts,clamps,etc…
AR As required