Eagle TT4 Quick start guide

QA022 REV05 01.27.12
EAGLE TUGS
PARTS & SERVICE MANUAL
Vehicle Types: TT-4, TT-5, TT-6, & TT-8
Engine Type: Chrysler 2.5L 4 Cylinder Engine Model

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QA022 REV05 01.27.12

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QA022 REV05 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 Ea-
gle 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 War-
ranty 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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QA022 REV05 01.27.12
INTRODUCTION....................................................................................................................... 3
PURPOSE & USE OF THIS MANUAL......................................................................................................................... 3
TECHNICAL ASSISTANCE.......................................................................................................................................... 3
ORDERING SPARE/SERVICE PARTS .......................................................................................................................... 3
CONTACT INFORMATION......................................................................................................................................... 3
TABLE OF CONTENTS................................................................................................................................................ 4
WARRANTY................................................................................................................................ 6
VEHICLE ID INFORMATION ..................................................................................................................................... 6
WARRANTY INFORMATION...................................................................................................................................... 7
SAFETY INFORMATION ............................................................................................................................................. 8
SERVICE PARTS ILLUSTRATIONS & DETAIL................................................................. 9
IDENTIFICATION KEY............................................................................................................................................... 9
POWER TRAIN..........................................................................................................................................................10
Engine Dress......................................................................................................................................................10
Engine Mounts ..................................................................................................................................................12
Engine Oil ..........................................................................................................................................................14
Cylinder Head ...................................................................................................................................................16
Cylinder Block...................................................................................................................................................18
Crankshaft Piston & Torque Converter .........................................................................................................20
Camshaft & Valves ...........................................................................................................................................22
Timing Belt, Covers & Intermediate Shaft.....................................................................................................24
Manifolds, Intake & Exhaust ..........................................................................................................................26
Drive Pulleys ....................................................................................................................................................27
Crankcase Ventilation .....................................................................................................................................28
Distributor Spark Plugs & Cables ..................................................................................................................29
Carburetor .........................................................................................................................................................30
Belt-Drive ..........................................................................................................................................................31
Starter ................................................................................................................................................................32
Alternator ..........................................................................................................................................................33
Power Steering Pump.......................................................................................................................................34
Water Pump ......................................................................................................................................................35
COOLING SYSTEM....................................................................................................................................................36
Cooling System.................................................................................................................................................36
DRIVELINE ...............................................................................................................................................................38
Drive Shaft Assembly—Front .........................................................................................................................38
Drive Shaft Assembly—Rear...........................................................................................................................39
STEERING SYSTEM ...................................................................................................................................................40
Steering System ................................................................................................................................................40
TRANSMISSION ........................................................................................................................................................43
Cooling System—Transmission......................................................................................................................43
Transaxle Mounting & Misc. Parts ................................................................................................................44
Transaxle Case Extension & Retainer ............................................................................................................46
AXLES ......................................................................................................................................................................48
Axle Assembly—Front Non-Drive (2WD) ....................................................................................................48
TABLE OFCONTENTS

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Axle Assembly—Front Drive ALL Wheel Drive ........................................................................................ 49
Axle Assembly—Rear...................................................................................................................................... 50
Axle Torque Specifications ............................................................................................................................. 51
Axle Assembly Breakdown—Front Non-Drive (2WD) .............................................................................. 52
Axle Assembly Breakdown—Front Drive ALL Wheel Drive.................................................................... 54
Axle Assembly Breakdown —Rear Drive ................................................................................................... 58
BRAKES ................................................................................................................................................................... 62
Parking Brake Actuator Assembly ................................................................................................................ 62
Rear Drum Brake Assembly ........................................................................................................................... 64
Brake Actuator Assembly ............................................................................................................................... 66
Hydraulic Actuation System .......................................................................................................................... 68
Brake System Hydraulic.................................................................................................................................. 70
FUEL SYSTEM ......................................................................................................................................................... 72
Fuel System Gasoline....................................................................................................................................... 72
Fuel System LP ................................................................................................................................................. 74
EXHAUST SYSTEM................................................................................................................................................... 76
OPETRATOR COMPARTMENT................................................................................................................................. 78
Accelerator Pedal ............................................................................................................................................. 78
Transmission Control ...................................................................................................................................... 79
Instrument Panel .............................................................................................................................................. 80
ELECTRICAL SYSTEM ............................................................................................................................................ 83
Electrical Panel ................................................................................................................................................. 83
Electrical Schematics........................................................................................................................................ 84
Ignition Module Wiring .................................................................................................................................. 87
Shutdown Module Wiring.............................................................................................................................. 88
Cab Option Wiring........................................................................................................................................... 89
Headlight, Taillight & Spotlight..................................................................................................................... 91
AIR CLEANER ASSEMBLY....................................................................................................................................... 92
OTHER ASSEMBLIES................................................................................................................................................ 94
Body Assembly................................................................................................................................................. 94
Seat & Safety Light Options............................................................................................................................ 95
Exhaust Assembly............................................................................................................................................ 89
Exhaust Assembly—Detail ............................................................................................................................. 90
WHEELS & TIRES.................................................................................................................................................... 94
Wheel & Tires Standard .................................................................................................................................. 96
Wheel & Tire Dual Rear Wheels .................................................................................................................... 97
OPTIONS ................................................................................................................................................................. 98
Cab Option........................................................................................................................................................ 98
Cab Heater ...................................................................................................................................................... 100
Hitch Options ................................................................................................................................................. 101
MAINTINANCE .................................................................................................................................................... 102
Scheduled Maintenance ................................................................................................................................ 102
Lubrication Chart (2WD) .............................................................................................................................. 103
Lubrication Chart ALL Wheel Drive........................................................................................................... 104
Tips For Increased All Weather Traction During Aircraft Pushback...................................................... 105
Front End Alignment Procedure.................................................................................................................. 106
TABLE OFCONTENTS

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QA022 REV05 01.27.12
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 #
MFG DATE
ENGINE TYPE
ENGINE SERIAL #
CHRYSLER 2.5L DISTRIBUTOR #

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QA022 REV05 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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The following list contains some general WARNINGS that you should follow when you work on equipment:
Always wear safety glasses for eye protection.
Use safety stands whenever a procedure requires you to be under the equipment.
Be sure that the ignitions switch is always in the OFF position, unless otherwise required by the procedure.
Set the parking brake (if equipped) when working on the equipment. Place wood blocks (4” x 4” or larger)
to the front and rear surfaces of the tires to provide further restraint from inadvertent equipment movement.
Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.
Keep yourself and your clothing away from moving parts when the engine is running, especially the fan
and belts.
To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail
pipe, catalytic converter and muffler.
Do not smoke while working on the equipment.
To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning
to work on the equipment. Tie long hair securely behind the head.
SAFETY INFORMATION
Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all indus-
trial engines as well as the personal safety of the individual performing the work. This Service Manual provides
general directions for accomplishing service and repair work with tested and effective techniques. Following them
will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for servicing equipment, as well as in the
skill of the individual doing the work. This Manual cannot possibly anticipate all such variations and provide
advice or cautions as to each. Accordingly, anyone who departs from the instructions provided in this Manual must
first establish he compromises his/her personal safety, and/or the equipment integrity by his/her choice of methods,
WARNINGS
IMPORTANT SAFETY NOTICE

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QA022 REV05 01.27.12
SERVICE PARTS ILLUSTRATIONS & DETAIL
IDENTIFICATION KEY
The following abbreviations are used throughout the parts lists in this section.
Abbreviation Meaning Purpose
NS 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…

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POWER TRAIN
ENGINE DRESS

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QA022 REV05 01.27.12
Item Part Number Qty Description
1 A-TT4-00651 1 OIL PRESSURE SENDING UNIT
2 A-TT4-00652 1 WATER TEMPERATURE SENDING UNIT
3 A-TT4-00653 1 FAN SWITCH
8 A-TT4-00304 1 IGNITION MODULE
9 A-TT6-00012-1 1 BRACKET-IGNITION MODULE
10 A-TT6-00011-2 1 ADAPTER PLATE CARBURETOR
11 A-TT5-00012 1 CARBURETOR
12 A-TT5-00710 1 GOVERNOR
13 B-TT5-00708 1 SPACE PLATE-CARBURETOR
14 B-TT5-00709-1 1 ACCELERATOR CABLE MTG. BRACKET
15 4324411 1 CARBURETOR GASKET
15A 1001 3 GASKET
16 NPN 2 SCREW-HEX CAP-1/4-20 X 3/4
17 NPN 1 WASHER-FLAT-1/4
18 NPN 2 NUT-1/4-20
19 NPN 1 SCREW-HEX HEAD-M8-1 1/4 X 20
20 NPN 3 SCREW-HEX CAP-M8-1 1/4 X 40
21 NPN 2 STUD-5/16-18 X 2 1/4
22 NPN 2 SCREW-HEX CAP-1/4-20 X 3/4
23 NPN 2 NUT-LOCK-1/4-20
24 NPN 2 NUT-5/16-18
25 NPN 2 WASHER-FLAT-5/16
26 31078 1 THERMOSTAT
27 4179895 1 GASKET
28 5281063 1 CONNECTOR-CYLINDER WATER OUTLET
29 6500559 2 STUD & WASHER
30 NPN 2 SCREW-HEX CAP-M10 - 1 1/2 X 30
31 4417478 1 HARNESS WIRE-IGN MODULE TO DISTR
32 4176009 1 IGNITION COIL
33 5226575 1 DISTRIBUTOR (IGNITION CAP & ROTOR
34 5227251 1 COIL MOUNTING BRACKET
POWER TRAIN
ENGINE DRESS

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ENGINE MOUNTS
POWER TRAIN

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Item Part Number Qty Description
1 B-TT4-00052-1 1 FIRE WALL MOUNT
2 NPN 6 SCREW-HEX CAP-1/2-13 X 1 1/2
3 NPN 9 WASHER-FLAT-1/2
4 NPN 9 NUT-LOCK-1/2-13
5 NPN 1 SCREW-HEX CAP-1/2-13 X 4
6 B-TT4-00051-1 1 MOUNT-TRANSMISSION
7 NPN 4 SCREW-HEX CAP-M10-1.5 X 35
8 A-TT4-00067 1 ENGINE SUPPORT SIDE
9 NPN 1 SCREW-HEX CAP-1/2-13 X 4 1/2 GR5
10 NPN 2 SCREW-HEX CAP-M12-1.75 X 28
11 NPN 2 SCREW-HEX CAP-M12-1.75 X 60
12 A-TT4-00068 1 ENGINE SUPPORT
13 A-TT4-00069 1 INSULATOR
14 NPN 1 SCREW-HEX CAP-M10-1.5 X 90
15 NPN 1 SCREW-HEX CAP-1/2-13 X 2 1/2
16 A-TT5-00065-1 1 FIRE WALL MOUNT REAR
17 NPN 2 SCREW-HEX CAP-3/8-16 X 2 1/2 GR5
18 NPN 7 WASHER-FLAT-3/8
19 NPN 2 NUT-LOCK-3/8-16
20 5252351 1 ENGINE MOUNT BRACKET
ENGINE MOUNTS
POWER TRAIN

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1
34
5
8
10
11
12
15
16
14
9
13
18
17
6
ENGINE OIL
POWER TRAIN

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QA022 REV05 01.27.12
Item Part Number Qty Description
14387478 1 SEAL-OIL PAN TO RETAINER FRONT
25203778 1 SEAL-OIL PAN TO RETAINER REAR(NS)
36032145 1 OIL PAN DRAIN PLUG(NOW 1 PIECE)
44621160 1 PAN-OIL PARTIAL WITH LINERS PAINTED
56501990 12 SCREW-HEX HEAD-M8-1.25 X 18
64387575 1 TUBE & CLIP-OIL LEVEL INDICATOR
76101445 1 NUT-OIL LEVEL INDICATOR TUBE(NS)
84397768 1 GASKET PACKAGE OIL PAN
94536073 1
VALVE-ANTI-DRAIN BACK OIL FILTER
ADAPTER
10 4387675 1 TUBE-OIL PUMP PICKUP
11 1407748 1 O-RNG FILTER ADAPTER
12 6500070 1 SCREW & WASHER OIL PICKUP TUBE
13 4397746 1 PUMP-OIL
14 4387305 1 OIL COOLER-ENGINE
15 4387822 1 CONNECTOR-OIL COOLER ENGINE
16 4740294 1 SEAL-OIL COOLER
17 85085 1 OIL FILTER
18 4483102 1 DIPSTICK OIL INDICATOR
ENGINE OIL
POWER TRAIN

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CYLINDER HEAD
POWER TRAIN

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Item Part Number Qty Description
14728218 1 GASKET PACKAGE STEEL HEAD(NS)
24773063 1 GASKET PACKAGE ALUMINUM HEAD(NS)
35241066 1 CYLINDER HEAD COVER
34739918 1 ALUMINUM CYLINDER HEAD COVER
44667303 1 RESTRICTOR
54621012 CAP-OIL FILTER
66100276 5 SCREW-HEX CAP-W/ WASHER M6-20
74343882 1 GASKET
84105395 1 SEAL-CAMSHAFT FRONT OIL
9 NPN 10 SCREW-HEX CAP M8-1.25 X 45
10 4343627 1 HEAD-CYLINDER WITH EDM INJECTION
6500267 1 SCREW-HEX CAP-W/ WASHER M10-1.25 X 16
11 4105295 1 NIPPLE-THERMOSTAT WATER BY-PASS
12 5281065 1 GASKET-CYLINDER HEAD
13 4556020 2 PLUG-CORE HOLE CUP (1.25") X .065
13 4556021 AR PLUG-CORE HOLE CUP (5/8) X .065
14 4556018 2 PLUG-OIL GALLERY HOLE (5/8)
14 4556019 AR PLUG-OIL GALLERY HOLE (.065"O.S.)
15 6500435 2 STUD-W/ FLAT WASHER M6
6100276 5 SCREW-HEX CAP-W/ WASHER
15A 6500274 2 NUT-LOCK-M6-1.00
16 6501435 10 WASHER-CYLINDER HEAD SCREW
17 6501433 10 SCREW-HEX CAP-M11-122.5
18 NPN AR NUT-CAMSHAFT BEARING CAP STUD
19 NPN 5 CAPS-CAMSHAFT BEARING
20 4105396 1 SEAL-CAMSHAFT REAR OIL
CYLINDER HEAD
POWER TRAIN

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CYLINDER BLOCK
POWER TRAIN

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Item Part Number Qty Description
4626450 1 GASKET PACKAGE LOWER ENGINE
14556431 1 ENGINE INJECTOR
26500402 2 DOWEL-CYLINDER BLOCK TO HEAD
3 NPN 1
PLUG-CYLINDER BLOCK WATER JACKET
DRAIN (1/4)
4 NPN 4
DOWEL-CYLINDER BLOCK TO CRANKSHAFT
RETAINER
66100276 3 SCREW-HEX CAP W/ WASHER
6100271 1 SCREW-HEX CAP W/ WASHER
72473275 1 SEAL CRANKSHAFT FRONT OIL
85203778 1 SEAL OIL PAN TO RETAINER
84387478 1 SEAL OIL PAN TO RETAINER
94556018 2 PLUG-CYLINDER BLOCK OIL GALLERY (5/8")
10 4556022 5
PLUG-CYLINDER BLOCK CORE HOLE CUP
(1.625" O/S)
11 5240849 2
DOWEL-CYLINDER BLOCK TO TRANSAXLE
CASE
12 5203590 1 SEAL-CRANKSHAFT REAR OIL
13 6100276 4
SCREW-HEX CAP W/ WASHER
CRANKSHAFT REAR OIL SEAL RETAINER
14 5214784 1 RETAINER-CRANKSHAFT REAR OIL SEAL
15 6015327 2 CLIP-ENGINE BLOCK HEATER CORD
16 4687405 1 CORD-ENGINE BLOCK HEATER
16 6015756 AR STRAP-ENGINE BLOCK HEATER
17 4740197 1 HEATER PACKAGE-ENGINE BLOCK
18 6501445 1
O-RING ENGINE BLOCK HEATER (1-11/32 DIA
11/64 WIDTH)
18 6501446 1
O-RING ENGINE BLOCK HEATER (1-1132 DIA
9/64 WIDTH)
19 4323808 1 RESTRICTOR-CYLINDER HEAD OIL
CYLINDER BLOCK
POWER TRAIN

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13
25
24
19
18
7
11
12
14
26
15
24
CRANKSHAFT, PISTON & TORQUE CONVERTOR
POWER TRAIN