Eagle TT Series Quick start guide
REV23 4.14.15TT10-12 4TNV98T
EAGLE TUGS
Parts and Service Manual
Vehicle Type s: TT-10 & TT-12
Engine Type: Yanmar Turbo Diesel 4TNV98T Tier II & Tier III Engine Models
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INTRODUCTION
From everyone at Eagle Tugs, we would like to say Thank You for purchasing an Eagle TT-series tow tractor. We
take a lot of pride in the quality of the products that we build, as well as our continued customer service. Our goal is
to build a long term relationship with our customers. We want you, the customer, to be 100% satisfied with your
Eagle experience. To us, this means that your Eagle TT-series tractor is functionally superior to any other products
you have used. This also means that your Eagle product is continually supported in a professional, timely manner.
PURPOSE & USE OF THIS MANUAL
This manual is designed as a reference guide to make the reader more familiar with the components of the Eagle
TT-10 and TT-12 tow tractor models. This manual includes part numbers and descriptions to assist the reader in
ordering component spare/service parts. The manual also outlines the Scheduled Maintenance Intervals recom-
mended 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.
NOTE: PLEASE CHECK OUR WEBSITE PERIODICALLY FOR MANUAL UPDATES
AS WELL AS SERVICE BULLETINS.
Eagle Corporate Office
26111 Northline Rd
Taylor, MI 48180
(800) 671-0431
www.eagletugs.com
Customer Service Parts & Service Technical Support
customerservice@eagletugs.com parts@eagletugs.com support@eagletugs.com
(734) 442-1000 -- (800) 671-0431 (734) 442-1000 -- (800) 671-0431 (734) 442-1000 -- (800) 671-0431
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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................................................................................................................................ 8
VEHICLE ID INFORMATION ..................................................................................................................................... 8
WARRANTY INFORMATION...................................................................................................................................... 9
Eagle Warranty Registration ..........................................................................................................................10
Yanmar warranty registration.........................................................................................................................10
Authorized Yanmar Distributor information ...............................................................................................10
EAGLE TUGS SERVICE BULLETIN ESB-02-08 ............................................................................................................11
SAFETY INFORMATION ............................................................................................................................................12
SERVICE PARTS ILLUSTRATIONS & DETAIL............................................................... 13
IDENTIFICATION KEY ..............................................................................................................................................13
POWER TRAIN .........................................................................................................................................................14
Engine Dress –Yanmar Tier II & Tier III Engines ........................................................................................14
Alternator Yanmar Tier II Engine...................................................................................................................16
Alternator Yanmar Tier III Engine .................................................................................................................17
Alternator (High Output) Yanmar Tier II Engine with Cab or Accessory Options...............................18
Alternator (High Output) Yanmar Tier III Engine with Cab or Accessory Options ..............................19
Head Cover Assembly Yanmar Tier II & Tier III Engines...........................................................................20
Cylinder Block Assembly Yanmar Tier II Engine ........................................................................................22
Cylinder Block Assembly Yanmar Tier III Engine .......................................................................................24
Crankshaft & Piston Yanmar Tier II Engine..................................................................................................26
Crankshaft & Piston Yanmar Tier III Engine ................................................................................................28
Camshaft & Driving Gear Yanmar Tier II Engine ........................................................................................30
Camshaft & Driving Gear Yanmar Tier III Engine.......................................................................................32
Governor Assembly Yanmar Tier III Engine Only.......................................................................................34
Oil Pan Assembly Yanmar Tier II & Tier III Engines...................................................................................35
Lube, Oil System Yanmar Tier II & Tier III Engines ....................................................................................36
Lube Oil Lines Yanmar Tier II Engine ...........................................................................................................38
Lube Oil Lines Yanmar Tier III Engine .........................................................................................................40
Gear Housing Yanmar Tier II Engine ............................................................................................................42
Gear Housing Yanmar Tier III Engine ...........................................................................................................44
Turbo Charger Yanmar Tier II Engine ...........................................................................................................46
Turbo Charger Yanmar Tier III Engine..........................................................................................................47
Engine Gaskets Yanmar Tier II Engine ..........................................................................................................48
Engine Gaskets Yanmar Tier III Engine.......................................................................................................50
COOLING SYSTEM....................................................................................................................................................52
Engine Cooling System Yanmar Tier II .........................................................................................................52
Engine Cooling System Yanmar Tier III ........................................................................................................54
Radiator and Transmission Cooler Yanmar Tier II & Tier III .....................................................................56
TRANSMISSION ........................................................................................................................................................58
Transaxle Mounting & Misc. Parts .................................................................................................................58
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TABLE OF CONTENTS
Transaxle Case Extension & Retainer ............................................................................................................60
DRIVELINE...............................................................................................................................................................62
Driveshaft Assembly-Front .............................................................................................................................62
Driveshaft Assembly-Rear ..............................................................................................................................63
AXLES ......................................................................................................................................................................64
Axle Assembly—Front Drive .........................................................................................................................64
Axle Assembly Breakdown-Front Drive .......................................................................................................66
Axle Assembly—Rear ......................................................................................................................................72
Axle Assembly Breakdown—Rear Drive Dually .........................................................................................74
Axle Assembly Breakdown—Rear Single Wheel .........................................................................................78
Recommended Axle Torque Specs.................................................................................................................80
BRAKES ....................................................................................................................................................................81
Caliper Brake Assembly-Front........................................................................................................................81
Drum Brake Assembly-Rear Dually...............................................................................................................82
Caliper Brake Assembly-Rear Single Wheel .................................................................................................84
Parking Brake Actuator Assembly .................................................................................................................86
Brake Actuator Assembly ...............................................................................................................................88
Service Brake Assembly Dually ......................................................................................................................90
Service Brake Assembly Single Rear Wheel..................................................................................................92
HYDRAULIC SYSTEM ...............................................................................................................................................94
Hydraulic Steering System Breakdown With Prince Pump .......................................................................94
Hydraulic Steering System Breakdown With Metaris Pump .....................................................................96
Hydraulic Tank Assembly...............................................................................................................................98
Hydraulic Assist Schematic...........................................................................................................................101
FUEL SYSTEM ........................................................................................................................................................102
Fuel System Yanmar Tier II & Tier III..........................................................................................................102
Fuel Injection Pump Yanmar Tier II.............................................................................................................104
Fuel Injection Lines & Nozzle Yanmar Tier II ............................................................................................105
Fuel Injection Pump Yanmar Tier III ...........................................................................................................106
Fuel Injection Lines & Nozzle Yanmar Tier III ...........................................................................................107
Engine Fuel Line Yanmar Tier II...................................................................................................................108
Engine Fuel Line Yanmar Tier III .................................................................................................................110
AIR CLEANER........................................................................................................................................................112
Air Cleaner Assembly –Diesel .....................................................................................................................112
EXHAUST & INTAKE SYSTEM................................................................................................................................113
Exhaust System Yanmar Tier II & Tier III Engines ....................................................................................113
Exhaust Manifold Yanmar Tier II Engine....................................................................................................114
Intake Manifold Yanmar Tier II Engine.......................................................................................................115
Exhaust Manifold Yanmar Tier III Engine ..................................................................................................116
Intake Manifold Yanmar Tier III Engine .....................................................................................................118
OPERATOR COMPARTMENT..................................................................................................................................120
Accelerator Pedal Assembly Yanmar Tier III Engine ...............................................................................120
Accelerator Pedal Assembly Yanmar Tier II Engine..................................................................................121
Instrument Panel (Sauer Danfoss Display/Controller) .............................................................................122
Quick Start Guide (Sauer Danfoss Display/Controller) ...........................................................................123
Instrument Panel (H30 Display/Controller) ...............................................................................................124
Quick Start Guide (H30 Display/Controller) .............................................................................................125
Transmission Control.....................................................................................................................................126
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TABLE OF CONTENTS
Yanmar Engine Wire Harness Tier III Engine ............................................................................................130
Yanmar Vehicle Wire Harness Tier II Engine .............................................................................................132
Yanmar Vehicle Wire Harness Tier III Engine (Prior to 10/2013).............................................................134
Yanmar Vehicle Wire Harness Tier III Engine (10/2013 through 09/2014)..............................................136
Yanmar Vehicle Wire Harness Tier III Engine (09/2014 and Later) .........................................................138
Vehicle Logic Controller ................................................................................................................................140
Vehicle Logic Controller Harness.................................................................................................................141
CE Option-Operator Presence Circuit Wiring Diagram ...........................................................................142
Cab Option Wiring Diagram........................................................................................................................142
LIGHTS & ELECTRICAL.........................................................................................................................................144
Headlights, taillights & Spotlight Assembly...............................................................................................144
OTHER ASSEMBLIES ..............................................................................................................................................146
Body & Seat Assembly ...................................................................................................................................146
WHEELS & TIRES ...................................................................................................................................................147
Wheel & Tire Assembly .................................................................................................................................147
OPTIONS ................................................................................................................................................................148
Hitch Options ..................................................................................................................................................148
Strobe, Beacon & Floor Mats .........................................................................................................................149
Cab Option.......................................................................................................................................................150
Cab Heater ......................................................................................................................................................150
MAINTENANCE ................................................................................................................... 154
Daily Operator Responsibilities ...................................................................................................................154
Lubrication Chart ..........................................................................................................................................155
Recommended Filter Guide ..........................................................................................................................156
Preventative Maintenance Schedule ............................................................................................................157
TT10—TT12 Specifications & Capacities ....................................................................................................158
Yanmar Engine Trouble Shooting ..............................................................................................................158
Tool List ..........................................................................................................................................................162
Tips for All Weather Traction .......................................................................................................................164
Front End Alignment Procedure ..................................................................................................................165
REVISION LOG...................................................................................................................... 166
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ELECTRIAL SCHEMATICS 123
Dash Wiring Diagram 123
Yanmar Engine Wire Harness Tier II Engine 124
Yanmar Engine Wire Harness Tier III Engine 120
Vehicle Wiring Harness Yanmar Tier II Engine 122
Vehicle Wiring Harness Yanmar Tier III Engine 124
WARRANTY
VEHICLE ID INFORMATION
This information can be found on the tractor’s I.D. Plate located on the firewall next to the driver’s seat.
Additionally, there is a permanent serial number located on the rear bulkhead inside the engine compartment.
MODEL _________________________________________
SERIAL NO _________________________________________
MFG DATE _________________________________________
ENGINE TYPE _________________________________________
ENGINE SERIAL NO _________________________________________
Data Plate Location
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REV23 4.14.15TT10-12 4TNV98T
WARRANTY
WARRANTY INFORMATION
Please read the Eagle Tugs warranty statement (available on our website) carefully.
When contacting Eagle Tugs for warranty or parts service, please have the following
information ready:
Tractor model number
Tractor serial number
Current hour reading
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YANMAR ENGINE WARRANTY REGISTRATION INFORMATION
The following pertains to warranty regarding the Yanmar engine only. For warranty issues not related to the engine
in your tug please contact Eagle Tugs directly at 800-671-0431.
The Purchaser should register the Product as soon as possible after purchase. Registration may allow Yanmar to
provide Product updates, Product improvements and other important information to the Purchaser. Registration
will also make processing a future warranty claim more efficient and convenient for the Purchaser and Yanmar. A
Purchaser should register the Product on-line by entering the required information into the Customer Registration
screens found on Yanmar’s website at http://www.yanmar.co.jp. To register product, click on the Customer
Registration link. Go to Industrial Engines and then click on the Industrial Engine link. Enter the registration
information in the necessary fields.
AUTHORIZED YANMAR DISTRIBUTOR INFORMATION
The Yanmar Distributor Information can be found on the Yanmar website at
www.yanmar.com/industrial/dealerlocatormainmap.asp. If you need help finding a distributor in your
area please call Eagle Tugs at 800-671-0431.
WARRANTY
Tires
For pneumatic tires, contact your nearest Power King (Kelly-Springfield) brand dealer who will adjust your claim
based on the remaining tread wear as a percent of total new tread.
For solid tires, contact Eagle directly.
Battery
In the U.S. and Canada, call 1-888-823-0954 or 1-877-255-2287
Outside the Continental U.S. and Canada please contact Eagle directly.
EAGLE WARRANTY REGISTRATION INFORMATION
In order for Eagle to provide the most efficient warranty repair service please fill out and return the Warranty
Registration Card included with your vehicle. This form may either be mailed to Eagle or e-mailed to
support@eagletugs.com. Please see warranty terms and conditions on the previous page.
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WARRANTY
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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.
Keep hands and other objects clear of the radiator and blades.
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,
tools or parts.
WARNINGS
IMPORTANT SAFETY NOTICE
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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
NOTE: THIS MANUAL COVERS PARTS & SERVICE FOR EAGLE TT10 and TT1 2 ALL WHEEL DRIVE
MODELS WITH BOTH THE YANMAR TIER II AND TIER III ENGINES. PLEASE BE SURE TO CHECK THE
HEADING ON EACH PAGE TO SEE IF THE PARTS REFERENCED ARE FOR A :
YANMAR TIER II DIESEL
OR
YANMAR TIER III DIESEL
ALL PAGES WITHOUT THE ABOVE IN THE DESCRIPTION DENOTE PARTS ARE USED ON MODELS
POWERED WITH BOTH A YANMAR TIER II AND YANMAR TIER III ENGINE.
TO DETERMINE IF YOUR TUG IS POWERED BY A TIER II OR TIER II ENGINE YOU CAN CHECK THE
DISPLAY LOCATED ON THE DASHBOARD BY THE FOLLOWING.
1. TURN DISPLAY “ON”
2. PRESS ENTER
3. SCROLL TO “EAGLE SET UP”
4. PRESS ENTER
5. YOU WILL SEE “SELECT ENGINE : YANMAR TIER II OR YANMAR TIER III” ON YOUR SCREEN
TO DETERMINE IF YOUR TUG IS POWERED BY A TIER II OR TIER III ENGINE WITHOUT TURNING ON
DISPLAY.
ALL TIER II TUGS ARE EQUIPPED WITH A MANUAL ALUMINUM FOOT PEDAL AND ALL TIER III TUGS
ARE EQUIPEED WITH A BLACK PLASTIC ELECTRONIC FOOT PEDAL.
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POWER TRAIN
12
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 1.5 M16 x 1.5
in-lb 87-105
ft-lb 17-21 32-40 58-72 94-108 160-174
N-m 9.8-11.8 22.6-28.4 45-54.8 78.5-98.10 127.2-146.8 216.2-235.8
kgf/m 1.1 2.03-2.09 4.5-5.5 8.0-10.0 12.5-15.5 21-25
Thread Size x Pitch mm
Tightening Torque
STANDARD TORQUE CHART
Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise specified.
CAUTION: The tightening torque in the above Standard Torque Chart should be applied only to the bolts with a “7”
head. (JIS strength classification 71).
*Apply 60% torque to bolts that are not listed.
*Apply 80% torque when tightened to aluminum alloy.
ENGINE DRESS
22
3
23
24
25
26
27
28
29
30
31
32
21
33
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ENGINE DRESS
POWER TRAIN
Item Part Number Qty Description
1 NPN 4 3/4-16 X 3 1/2 BOLT & 3/4" FLAT WASHER
2 B-TT5D-00008-1 1 ENGINE MOUNT
3 A-TT5D-00013-1 4 ISOLATOR
4 A-TT5D-00010 4 LORD WASHER
5 NPN 4 3/4" LOCK NUT
6 A-TT8-00312 1 FAN
7 A-TT8-00360 1 FAN SPACER
8 SP20PB11L145H9L 1 PRINCE PUMP
9 B-TT5D-00006-1 1 FRONT ENGINE MOUNT
10 TM27C00305-ID 1 FLEX PLATE WASHER
11 B-TT10TD-00016-ID 1 FLEX PLATE
12 B-TT5D-00017-4TNV 1 FLEX PLATE ADAPTER
13 129953-21570 1 FLYWHEEL WITH RING GEAR
14 B-TT10TD-00001-4TNV 1 TRANS PLATE
15 B-TT10TD-00002 1 TRANS PLATE SPACER
16 129900-01780 1 OIL SEAL TIER II
16 129900-01790 1 OIL SEAL TIER III
17 41HN28 3 ADJ PLATE DOWEL PINS 3/8 X 2.5
18 TMD27B00521-4TNV 1 ENGINE PLATE
19 129940-77010 1 HIGH OUTPUT STARTER
20 26116-120302 2 BOLT, M12 X 30 PLATED
21 A-TT4-00011 2 ENGINE MOUNT TRANS PLATE
22 129900-21600 1 RING GEAR
23 5240849 2 TRANSMISSION DOWEL PIN
24 A-TT8-00361 1 FAN BRACKET SPACER
25 A-TT10-00354 1 REMOTE FAN BRACKET TURBO TIER III
25 A-TT10-00354-MOD 1 REMOTE FAN BRACKET TURBO TIER II
26 A-TT8-00358 1 REMOTE FAN SNAP RING
27 A-TT8-00355 1 REMOTE FAN SHAFT HOUSING
28 A-TT8-00357 2 REMOTE FAN BEARING
29 A-TT8-00356 1 REMOTE FAN SHAFT
30 A-TT8-00362 1 REMOTE FAN BELT TIER III
30 9510 1 REMOTE FAN BELT TIER II
31 129916-21680 1 CRANK PULLEY, DOUBLE GROOVE
32 A-TT10-00353 1 WATER PUMP SHEAVE TIER III
32 A-TT8-00353 1 WATER PUMP SHEAVE TIER II
33 A-TT4-00405 4 SPACER (QTY 2 ON TIER II MODEL)
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POWER TRAIN
Item Part Number Qty Description
1 129795-01900 1 STUD, ALTERNATOR
2 26306-100002 2 NUT, ALTERNATOR
3 26014-080252 1 BOLT, M8 X 25 PLATED
4 119810-77340 1 BOLT ,ADJUSTING
5 129900-77330 1 ADJUSTER BRACKET, ALTERNATOR 40 AMP
6 129423-77200 1 ALTERNATOR 40 AMP(BLUE ID TAG)
7 119643-66900 1 DIODE
8 119650-77910 1 RELAY, GLOW
9 128300-77920 1 TIMER
10 129211-77920 1 TIMER
2
34
5
6
7
8
9
1
40 AMP ALTERNATOR ASSEMBLY—YANMAR TIER II
*Most commonly used on Models TT-10 and TT-12.
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Item Part Number Qty Description
1 129795-01900 1 STUD, ALTERNATOR 55 AMP ALT
1 26116-101202 1 STUD, ALTERNATOR 80 AMP ALT
2 26306-100002 2 NUT, ALTERNATOR 55 AMP ALT
2 26366-100002 2 NUT, ALTERNATOR 80 AMP ALT
3 26106-080222 1 BOLT, M8 X 22 PLATED 55 AMP ALT
3 26014-080252 2 STUD 80 AMP ALT
4 129972-77341 1 BOLT ,ADJUSTING
5 129972-77330 1 ADJUSTER BRACKET 55 AMP ALT
5 129900-77330 1 ADJUSTER BRACKET 80 AMP ALT
6 119940-77270 1 SPACER 55 AMP ALT (RED ID TAG)
6 129470-77340 1 SPACER 80 AMP ALT
7 119626-77210 1 ALTERNATOR 55 AMP
7 129612-77290 1 ALTERNATOR 80 AMP
55 AND 80 AMP ALTERNATOR ASSEMBLY—YANMAR TIER II AND III DIESEL
POWER TRAIN
2
34
5
6
7
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Item Part Number Qty Description
1 AE-OPT-0021 1 105A ALTERNATOR
2 NPN 1 1.40 SPACER
3 NPN 1 .23 SPACER
4 NPN 1 M10-1.5 x 130
5 NPN 1 .92 SPACER
6 26306-100002 1 M10-1.5 LOCK NUT
7 26014-080252 1 BOLT M8-1.25 x 45 PLATED
8 26106-080222 1 BOLT ADJUSTING
9 129900-77330 1 ADJUSTING BRACKET
10 A-TT8-00362 1 ALTERNATOR BELT(NOT SHOWN)
TIER II 105 AMP HIGH OUTPUT ALTERNATOR ASSEMBLY
TUGS WITH CAB OPTION OR AS REQUIRED BY ENGINEERING DUE TO ADDED OPTIONS
POWER TRAIN
1
2
3
4
5
6
7
8
9
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1
2
3
4
5
6
7
Item Part Number Qty Description
1 AE-OPT-0021 1 105A ALTERNATOR
2 NPN 1 1.40 SPACER
3 NPN 1 .23 SPACER
4 NPN 1 M10-1.5 x 130
5 NPN 2 5/16 FLAT WASHER
6 119940-77270 1 SPACER
7 26306-100002 1 M10-1.5 LOCK NUT
89440 1 ALTERNATOR BELT(NOT SHOWN)
9 119810-77340 1 BOLT M8 X 22 PLATED
10 26014-080252 1 BOLT ADJUSTING
11 129972-77330 1 ADJUSTING BRACKET
POWER TRAIN
TIER III 105 AMP HIGH OUTPUT ALTERNATOR ASSEMBLY
TUGS WITH CAB OPTION OR AS REQUIRED BY ENGINEERING DUE TO ADDED OPTIONS
9
10
11
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HEAD COVER ASSEMBLY YANMAR TIER II & TIER III
1
2
3
13
5
4
6
7
8
9
10
11
12
14
7
6
15
16
POWER TRAIN
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