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
[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................................................................................................................................ 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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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
[e-mail]. Please see warranty terms and conditions on the previous page.