Eagle Tugs MTT 2012 Series Quick start guide

QA014 REV06 08.04.12
EAGLE TUGS
Parts and Service Manual
Vehicle Type: MTT
Motor Type: A/C Electric

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QA014 REV06 08.04.12
INTRODUCTION
From everyone at Eagle Tugs, we would like to say Thank You for purchasing an Eagle MTT 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 MTT series tractor is functionally superior to any other prod-
ucts you have used. This also means that your Eagle product is continually supported in a professional, timely man-
ner.
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
MTT series 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 War-
ranty on all of the MTT 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 Opera-
tions 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 MTT 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.
NOTE: PLEASE CHECK OUR WEBSITE PERIODICALLY FOR MANUAL UPDATES
AS WELL AS SERVICE BULLETINS.
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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TABLE OF CONTENTS
INTRODUCTION ....................................................................................................................... 3
PURPOSE & USE OF THIS MANUAL ......................................................................................................................... 3
TECHNICAL ASSISTANCE ........................................................................................................................................... 3
ORDERING SPARE/SERVICE PARTS ........................................................................................................................... 3
CONTACT INFORMATION ......................................................................................................................................... 3
WARRANTY ................................................................................................................................ 6
SAFETY INFORMATION .............................................................................................................................................. 6
VEHICLE ID INFORMATION ...................................................................................................................................... 7
STANDARD WARRANTY INFORMATION ................................................................................................................... 8
WARRANTY REGISTRATION INFORMATION .............................................................................................................. 9
SERVICE PARTS ILLUSTRATIONS & DETAIL ............................................................... 11
IDENTIFICATION KEY .............................................................................................................................................. 11
AXLES ....................................................................................................................................................................... 12
Front Axle Install .............................................................................................................................................. 12
Front Axle-Tires, Springs & Shocks ............................................................................................................... 13
Front Axle Assembly Without Brakes............................................................................................................ 14
Front Axle Assembly With Brakes ................................................................................................................. 16
Front Axle With Brakes-Tie Rod Assembly .................................................................................................. 18
Front Axle With Brakes-Hub & Rotor Assembly ......................................................................................... 19
Rear Axle Install ................................................................................................................................................ 20
Rear Axle-Tires, Springs & Shocks ................................................................................................................. 21
Rear Axle Right Hand Reduction Unit .......................................................................................................... 22
Rear Axle Differential & Brakes ...................................................................................................................... 24
Rear Axle Left Hand Reduction Unit ............................................................................................................. 26
Rear Axle Halfshaft & Phonic Wheel ............................................................................................................. 28
Rear Axle Hand Brake Lever & Sensor .......................................................................................................... 30
PARKING BRAKE ................................................................................................................................................... 32
Parking Brake Cable Assembly ...................................................................................................................... 32
Parking Brake Handle Assembly .................................................................................................................. 34
HYDRAULIC SYSTEM ............................................................................................................................................... 36
Hydraulic System Fluid Level Check ............................................................................................................ 36
Hydraulic Pump Install ................................................................................................................................... 38
Hydraulic System Assembly With Single Brake Option ............................................................................. 40
Hydraulic Assist With Single Brake Option ................................................................................................. 42
Schematic Hydraulic Assist With Single Brake Option ............................................................................... 44
Hydraulic System Assembly With Dual Brake Option ............................................................................... 46
Hydraulic Assist With Dual Brake Option .................................................................................................... 48
Schematic Hydraulic Assist With Dual Brake Option ................................................................................. 50
OPERATOR COMPARTMENT .................................................................................................................................... 52
Steering Column ............................................................................................................................................... 52
Brake Pedal & Accelerator Pedal .................................................................................................................... 53
Under Dash Components ................................................................................................................................ 54
Dash Panel & Ignition Switch ......................................................................................................................... 56
Digital Display .................................................................................................................................................. 57

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TABLE OF CONTENTS
ELECTRICAL SYSTEM .............................................................................................................................................. 59
High Voltage Wires .......................................................................................................................................... 59
Electrical Sub Panel .......................................................................................................................................... 60
Electrical Box Install ......................................................................................................................................... 61
Buss Bars ............................................................................................................................................................ 62
AC Drive Install S/N 5M106 And Before ...................................................................................................... 65
AC Drive Install S/N 5M107 And After......................................................................................................... 66
Electrical Panel A Without Cab Option ......................................................................................................... 68
Electrical Panel A With Cab Option .............................................................................................................. 70
Electrical Schematic Drive LH S/N 5M106 And Before ............................................................................... 72
Electrical Schematic Drive RH S/N 5M106 And Before .............................................................................. 73
Electrical Schematic Drive LH S/N 5M107 And After ................................................................................. 74
Electrical Schematic Drive RH S/N 5M107 And After ................................................................................ 75
LIGHTS ..................................................................................................................................................................... 76
Headlights ......................................................................................................................................................... 76
Taillights ............................................................................................................................................................ 77
OTHER ASSEMBLY .................................................................................................................................................. 77
Body Panels ....................................................................................................................................................... 78
Charge Jack Assembly ..................................................................................................................................... 83
Heater Module .................................................................................................................................................. 84
Heater Schematic .............................................................................................................................................. 86
Floor Mats .......................................................................................................................................................... 87
Seat Assembly ................................................................................................................................................... 88
Hitch Options .................................................................................................................................................... 89
E-hitch & Front Tie Down Rings .................................................................................................................... 90
Front Bumper Option ...................................................................................................................................... 91
E-hitch, Spot Light & Inching Switch ............................................................................................................ 92
Rear Bumper Option ........................................................................................................................................ 93
Cab Option ........................................................................................................................................................ 94
MAINTENANCE ........................................................................................................................................................ 97
Daily Operator Responsibilities, Maintenance Chart & Axle Maintenance Chart .................................. 97
Trouble Shooting .............................................................................................................................................. 98
Error Codes ....................................................................................................................................................... 99
Recommended Tool List ................................................................................................................................ 100
Cold Weather Care ......................................................................................................................................... 101
Battery Charging & Maintenance Quick Guide ......................................................................................... 104
Transporting Instructions .............................................................................................................................. 106
Accumulator Maintenance ............................................................................................................................ 107
Front Axle Maintenance ................................................................................................................................ 108
Rear Axle Maintenance-Oil Change ............................................................................................................ 109
Rear Axle Grease In Assembly ..................................................................................................................... 113
Rear Axle Maintenance-Torque Specifications........................................................................................... 116
Rear Axle Maintenance-Sensor Group Disassembly ................................................................................. 117
Rear Axle Maintenance-Sensor Group Assembly ...................................................................................... 119
Rear Axle Maintenance-Sensor Adjustment ............................................................................................... 120

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TABLE OF CONTENTS
Rear Axle Maintenance-RH Gear Reduction Group Disassembly .......................................................... 125
Rear Axle Maintenance-RH Gear Reduction Group Assembly ............................................................... 134
Rear Axle Maintenance-Brake Group Disassembly .................................................................................. 148
Rear Axle Maintenance-Brake Group Assembly ....................................................................................... 156
Rear Axle Maintenance-RH Housing Group Disassembly ...................................................................... 165
Rear Axle Maintenance-RH Housing Group Assembly ........................................................................... 168
Rear Axle Maintenance-RH Differential Group Disassembly ................................................................. 172
Rear Axle Maintenance-RH Differential Group Assembly ..................................................................... 174
Rear Axle Maintenance-LH Reduction Gear Group Disassembly .......................................................... 177
Rear Axle Maintenance-LH Reduction Gear Group Assembly ............................................................... 183
Rear Axle Maintenance-LH Housing & Electric Motor Disassembly ..................................................... 194
Rear Axle Maintenance-LH Housing & Electric Motor Assembly .......................................................... 198
Rear Axle Maintenance-Brake Control Group Disassembly .................................................................... 202
Rear Axle Maintenance-Brake Control Group Assembly ......................................................................... 206
Rear Axle Maintenance-Trouble Shooting .................................................................................................. 211
Rear Axle Maintenance-Special Tools ......................................................................................................... 213
ADDEMDUM .......................................................................................................................................................... 215

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The following list contains some general WARNINGS that you should follow when you work on equipment:
Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you to be under the equipment.
Be sure that the ignition switch is always in the OFF position, and battery is disconnected unless otherwise re-
quired 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.
Keep yourself and your clothing away from moving parts when the motor is running.
Do not smoke while working on the equipment.
To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to
work on the equipment. Tie long hair securely behind the head.
When disconnecting the MTT from the battery to perform service, a residual charge may still exist in the sys-
tem. To drain the system of all power, turn the keyswitch on after disconnecting the battery. This will drain
any remaining electricity in the system and ensure that the truck is safe to perform work on.
Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all indus-
trial equipment as well as the personal safety of the individual performing the work. This Service Manual provides
general directions for accomplishing service and repair work with tested and effective techniques. Following them
will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for servicing equipment, as well as in the
skill of the individual doing the work. This Manual cannot possibly anticipate all such variations and provide
advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must
first establish he compromises his/her personal safety, and/or the equipment integrity by his/her choice of methods,
tools or parts.
WARNINGS
IMPORTANT SAFETY NOTICE
WARRANTY
For more information regarding safety please refer to the operations manual provided with your tug. This manual
can also be found on the Eagle Tugs website at www.eagletugs.com.

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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 _________________________________________
Data Plate Location

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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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WARRANTY
NOTE: At the time a warranty claim is filed it may be necessary for Eagle Tugs to request a copy of the maintenance
records kept on your tug. For your convenience a printable Preventative Maintenance Schedule page is available in
the Maintenance section of this manual.
WARRANTY REGISTRATION INFORMATION
Please complete the Eagle Tugs Warranty Registration found on line at www.eagletugs.com.
Battery
Refertothebatterymanufacturer’sdocumentationforthetractionbatterywarranty.

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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
TO HELP US SERVICE YOU BETTER. HAVE TUG MODEL AND SERIAL NUMBER AVAILABLE
WHEN ORDERING PARTS

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FRONT AXLE INSTALL
AXLES
1
2 3
4
5

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FRONT AXLE ASSEMBLY
Item Part Number Qty. Description
106-13144 10 1/2-20 UNF TAPERED WHEEL NUT
2 A-MTT5-0430 1 FRONT AXLE (WITHOUT BRAKES)
3 A-TT10-00826 1 CYLINDER BEARING
4 A-TT10-00803A 1 HYD CYL PIVOT & COTTER PIN SET
5 A-TT4-00116 2 LEAF SPRING
6 A-MTT5-0510 4
U-BOLT KIT
(INCLUDES BOLT, NUT & WASHER)
7 A-TT10-00803-1 1 STEERING CYLINDER
8 A-MTT5-0212 2 FRONT U-BOLT PLATE
9 A-MTT5-0520B 1 FRONT TIRE
10 A-MTT5-0520A 1 FRONT RIM
11 A-MTT5-0520C 1 TIRE TUBE
12 A-MTT5-0520 1 FRONT TIRE AND RIM ASSEMBLY
AXLES
1
2
3
4
6
5
10
7
8
6
6
9
11

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AXLES
FRONT AXLE WITHOUT BRAKES
AXLES
1 2
3
4 5
6 7 8
10
11
12
14
15
16,22
17,18
19
20,21
23
24
2 3
25
26 27
1/2-20 wheel studs (5) on
5.50 BC

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Item Part Number Qty. Description
103-30860 1 AXLE BEAM WELDMENT
203-30861 1 RH KNUCKLE WELDMENT
303-30682 1 LH KNUCKLE WELDMENT
402-21004 1 TIE ROD TUBE ASSY
502-20322 2 #623 HUB ASSY
6130355100 2 OUTER CONE #15123
706-13108 2 TONGUED SPINDLE WASHER
806-62085 2 NUT, 1-14 SPINDLE, 12 SLOTTED
9324604160 2 COTTER PIN, 3/16 X 2 1/2
10 06-12016 2GREASE CAP
11 06-62415 2KING PIN
12 06-60498 2 THRUST BEARING
13 06-60603 2KING PIN SHIM
14 06-61721 4 KING PIN BUSHING
15 390406410 4GREASE ZERK
16 06-60547 4KING PIN CAP
17 06-61080 8 SCREW, 10-24 X 5/8 BHC
18 06-61081 8 WASHER, #10 LOCK
19 06-60811 83/8-16 SHSC
20 321800090 2 NUT, 1/2- HX JAM
21 320224100 2SCREW, 1/2-13 X 2 HX HD
22 06-61376 4KING PIN COVER GASKET
23 06-13144 10 NUT, 1/2-20 UNF TAPERED WHEEL
24 02-21005 1 FRONT TIE ROD ASSY
25 06-60332 1 CYLINDER TIE ROD END
26 A-TT4-00402 1 LEFT TIE ROD END
27 A-TT4-00403 1 RIGHT TIE ROD END
AXLES
FRONT AXLE WITHOUT BRAKES

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AXLES
FRONT AXLE WITH BRAKES
AXLES
1
2 3
3
4
5
5 5
6
7
8 & 9
10
11
12
13
14
15
16 & 22
17 & 18
19
20 & 21 23
24 25
Apply locktite blue (2.42)
Torq to 35 FT Lbs 1/2-20 wheel studs (5) on
5.50 BC

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Item Part Number Qty. Description
103-30865 1 AXLE BEAM WELDMENT
203-30866 1 RH KNUCKLE WELDMENT
303-30687 1 LH KNUCKLE WELDMENT
402-21012 1 TIE ROD TUBE ASSY
502-20643 2 HUB & ROTOR ASSY
602-21013 2 FRONT TIE ROD ASSY
706-13108 2 TONGUED SPINDLE WASHER
806-62085 2 NUT, 1-14 SINDLE, 12 SLOTTED
9324604160 2 COTTER PIN, 3/16 X 2 1/2
10 06-12016 2GREASE CAP
11 06-62415 2KING PIN
12 06-60498 2 THRUST BEARING
13 06-60603 2KING PIN SHIM
14 06-61721 4 KING PIN BUSHING
15 390406410 4GREASE ZERK
16 06-60547 4KING PIN CAP
17 06-61080 8 SCREW, 10-24 X 5/8 BHC
18 06-61081 8 WASHER, #10 LOCK
19 06-60811 83/8-16 SHSC
20 321800090 2 NUT, 1/2-13 JAM
21 320224100 2SCREW, 1/2-13 X 2 HX HD
22 06-61376 4KING PIN COVER GASKET
23 06-13144 10 NUT, 1/2-20 UNF TAPERED WHEEL
24 06-63022 1 RH CALIPER W/ MINERAL OIL SEAL
25 06-63023 1 LH CALIPER W/ MINERAL OIL SEAL
AXLES
FRONT AXLE WITH BRAKES

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AXLES
FRONT AXLE WITH BRAKES -TIE ROD
AXLES
Item Part Number Qty. Description
106-63016 1 TIE ROD TUBE
2 A-TT4-00402 1 TIE ROD END LEFT
306-60359 1 LEFT JAM NUT 3/4-16 UNF HEX
4 A-TT4-00403 1 TIE ROD END RIGHT
506-60361 1 RIGHT JAM NUT 3/4-16 UNF HEX
606-60332 1 CYLINDER TIE ROD END
706-63017 1 TIE ROD TUBE
806-61772 1 SPLIT COLLAR 1 1/4 ID
1
2
3
4
5
6 7
8

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AXLES
FRONT AXLE WITH BRAKES-HUB & ROTOR ASSY
AXLES
Item Part Number Qty. Description
102-03916b 1 HUB #623 CUPPED & STUDDED
1A 130400100 1INNER CONE #24780
1B 02-03207 1 GREASE SEAL #623
1C 130355100 1 OUTER CONE #15123
1D 06-12016 1 GREASE CAP #523
206-61448M 1 ROTOR SPACER
306-51459 1 ROTOR, 10.75 DIA
406-12104 10 WASHER, 1/2 LOCK
506-61570 5 SCREW, 1/2-13 HX HD X 1.00 LG GR8
606-61511 5 WHEEL STUD, 1/2-20
1
2 1A
1B 1C 1D
3
4 5
6

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AXLES
REAR AXLE INSTALL
AXLES
1 2
3
4
5
6 7