Eagle TT4 Quick start guide

REV30 8.4.15TT4-8 4TNV98
EAGLE TUGS
Parts and Service Manual
Vehicle Type s: TT-4, TT-5, TT-6, & TT-8
Engine Type: Yanmar Diesel 4TNV98 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-4, TT-5, TT-6, and TT-8 tow tractor models. This manual includes part numbers and descriptions to assist the
reader in ordering component spare/service parts. The manual also outlines the Scheduled Maintenance Intervals
recommended by Eagle in order to keep your vehicle running properly. In this manual you will also find the Eagle
Standard Warranty on all of the TT-series tow tractors. However, for more detailed information on the Eagle
Warranty and procedure, as well as information pertaining to the safe operation of your Eagle product, please see
the Eagle Operations Manual that was also included with your vehicle.
TECHNICAL ASSISTANCE
When addressing a repair procedure or operational problem, please remember that Eagle technical support is only a
phone call away. Eagle technicians are available to assist you in vehicle diagnostics and recommended repair proce-
dures. We encourage you to use this service to reduce machine down-time and to gain a better understanding of
proper repair procedures.
ORDERING SPARE/SERVICE PARTS
Eagle inventories most of the component parts found in its TT-series tow tractors, and most spare/service parts can
be shipped the same day the order is received. Parts orders need to be received at Eagle by 12:00 pm (Noon) EST in
order for the parts to be shipped that same day. Parts ordered after 12:00 pm EST will most likely be shipped the
following day.
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................................................................................................................................ 9
WARRANTY INFORMATION ...................................................................................................................................... 9
SAFETY INFORMATION............................................................................................................................................ 10
VEHICLE ID INFORMATION..................................................................................................................................... 11
WARRANTY REGISTRATION ................................................................................................................................... 12
YANMAR WARRANTY REGISTRATION .................................................................................................................... 12
AUTHORIZED YANMAR DISTRIBUTOR INFORMATION........................................................................................... 12
EAGLE TUGS SERVICE BULLETIN ESB-02-08............................................................................................................ 13
SERVICE PARTS ILLUSTRATIONS & DETAIL............................................................... 15
IDENTIFICATION KEY.............................................................................................................................................. 15
POWER TRAIN......................................................................................................................................................... 16
Engine Dress –Yanmar Tier II & Tier III Engines........................................................................................ 16
Alternator Yanmar Tier III Engine ................................................................................................................. 21
Alternator Yanmar Tier II Engine .................................................................................................................. 22
Alternator Yanmar Tier II & III Engine With Cab or Transit Pro Option................................................ 23
Head Cover Assembly Yanmar Tier II & Tier III Engines .......................................................................... 24
Cylinder Block Assembly Yanmar Tier II Engine ........................................................................................ 26
Cylinder Block Assembly Yanmar Tier III Engine....................................................................................... 28
Crankshaft & Piston Yanmar Tier II Engine ................................................................................................. 30
Crankshaft & Piston Yanmar Tier III Engine................................................................................................ 32
Camshaft & Driving Gear Yanmar Tier II Engine ....................................................................................... 34
Camshaft & Driving Gear Yanmar Tier III Engine ...................................................................................... 36
Governor Assembly Yanmar Tier III Engine Only ...................................................................................... 38
Oil Pan Assembly Yanmar Tier II & Tier III Engines .................................................................................. 39
Lube, Oil System Yanmar Tier II & Tier III Engines.................................................................................... 40
Gear Housing Yanmar Tier II & Tier III Engines ......................................................................................... 42
Engine Gaskets Yanmar Tier II Engine.......................................................................................................... 44
Engine Gaskets Yanmar Tier III Engine ...................................................................................................... 46
COOLING SYSTEM................................................................................................................................................... 48
Engine Cooling System.................................................................................................................................... 48
Radiator (Copper) ............................................................................................................................................ 50
Radiator (Aluminum) ...................................................................................................................................... 52
DRIVELINE .............................................................................................................................................................. 54
Drive Shaft Assembly—Front......................................................................................................................... 54
Drive Shaft Assembly—Rear .......................................................................................................................... 55
TRANSMISSION........................................................................................................................................................ 56
Transaxle Mounting & Misc. Parts................................................................................................................. 57
Transaxle Case Extension & Retainer ........................................................................................................... 58

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TABLE OF CONTENTS
AXLES...................................................................................................................................................................... 61
Axle Assembly—Dana Front Non-Drive (2WD) only ............................................................................... 61
Axle Assembly—Brierton Front Non-Drive (2WD) only .......................................................................... 62
Axle Assembly—Front Drive (All Wheel Drive) ......................................................................................... 63
Axle Assembly—Rear...................................................................................................................................... 64
Recommended Dana Axle Torque Specs ...................................................................................................... 65
Axle Assembly Breakdown—Brierton Front Non-Drive (2WD)............................................................... 66
Axle Assembly Breakdown—Dana Front Non-Drive (2WD) .................................................................... 68
Axle Assembly Breakdown—Front Drive (All Wheel Drive).................................................................... 70
Axle Assembly Breakdown—Rear Drive...................................................................................................... 74
BRAKES.................................................................................................................................................................... 78
Parking Brake Actuator Assembly................................................................................................................. 78
Drum Brake Assembly - Rear ........................................................................................................................ 80
Brake Actuator Assembly ............................................................................................................................... 82
Brake System Hydraulic.................................................................................................................................. 84
Hydraulic Assist With Prince Pump ............................................................................................................. 86
Hydraulic Assist With Metaris Pump ........................................................................................................... 88
Hydraulic Tank Subassembly......................................................................................................................... 90
Hydraulic Assist Schematic ............................................................................................................................ 93
STEERING SYSTEM................................................................................................................................................... 94
Steering System Breakdown ........................................................................................................................... 94
FUEL SYSTEM ......................................................................................................................................................... 96
Fuel System Yanmar Tier II & Tier III ........................................................................................................... 96
Fuel Injection Pump Yanmar Tier II .............................................................................................................. 98
Engine Fuel Lines Yanmar Tier II ................................................................................................................. 99
Engine Fuel Injection Lines & Nozzle Yanmar Tier II............................................................................... 100
Fuel Injection Pump Yanmar Tier III ........................................................................................................... 102
Engine Fuel Line Yanmar Tier III................................................................................................................. 103
Engine Fuel Injection Lines & Nozzle Yanmar Tier III ............................................................................. 104
AIR CLEANER ....................................................................................................................................................... 106
Air Cleaner Assembly –Diesel..................................................................................................................... 106
EXHAUST & INTAKE SYSTEM ............................................................................................................................... 107
Exhaust System Yanmar Tier II & Tier III Engines.................................................................................... 107
Exhaust Manifold Yanmar Tier II Engine ................................................................................................... 108
Intake Manifold Yanmar Tier II Engine ...................................................................................................... 109
Exhaust Manifold Yanmar Tier III Engine.................................................................................................. 110
Intake Manifold Yanmar Tier III Engine..................................................................................................... 112
OPERATOR COMPARTMENT ................................................................................................................................. 114
Accelerator Pedal Assembly Yanmar Tier III Engine ............................................................................... 114
Accelerator Pedal Assembly Yanmar Tier II Engine ................................................................................. 115
Instrument Panel (Sauer Danfoss Display/Controller) ............................................................................. 116
Quick Start Guide (Sauer Danfoss Display/Controller)............................................................................ 117
Instrument Panel (H30 Display/Controller) ............................................................................................... 118
Quick Start Guide (H30 Display/Controller).............................................................................................. 119
Transmission Control .................................................................................................................................... 120

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TABLE OF CONTENTS
ELECTRIAL SCHEMATICS .....................................................................................................................................121
Dash Wiring Diagram ...................................................................................................................................121
Yanmar Engine Wire Harness Tier II Engine..............................................................................................122
Yanmar Engine Wire Harness Tier III Engine ............................................................................................124
Vehicle Wiring Harness Yanmar Tier II Engine .........................................................................................126
Vehicle Wiring Harness Yanmar Tier III Engine (Through 9/2013).........................................................128
Vehicle Wiring Harness Yanmar Tier III Engine (10/2013 through 9/2014)............................................130
Vehicle Wiring Harness Yanmar Tier III Engine (9/2014 and Later) .......................................................132
Vehicle Logic Controller ................................................................................................................................134
Vehicle Logic Controller Wire Harness ......................................................................................................135
CE Option-Operator Presence Circuit Wiring Diagram ...........................................................................136
Cab Option Wiring Diagram........................................................................................................................137
LIGHTS & ELECTRICAL.........................................................................................................................................138
Headlights, taillights & Spotlight Assembly...............................................................................................139
OTHER ASSEMBLIES ..............................................................................................................................................146
Body Assembly................................................................................................................................................146
Seats ..................................................................................................................................................................147
WHEELS & TIRES ...................................................................................................................................................148
Wheel & Tire Assembly .................................................................................................................................148
Wheel & Tire Assembly—Dual Rear Wheel Model ...................................................................................149
OPTIONS ................................................................................................................................................................150
Hitch Options ..................................................................................................................................................150
Strobe, Beacon & Floor Mats .........................................................................................................................151
Cab Option.......................................................................................................................................................152
Cab Heater ......................................................................................................................................................154
Other Options Not Shown.............................................................................................................................155
MAINTENANCE ................................................................................................................... 156
Daily Operator Responsibilities ...................................................................................................................156
Lubrication Chart ..........................................................................................................................................157
Recommended Filter Guide ..........................................................................................................................158
Preventative Maintenance Schedule ............................................................................................................159
TT4—TT8 Specifications & Capacities .........................................................................................................160
Yanmar Engine Trouble Shooting ..............................................................................................................162
Recommended Tool List ..............................................................................................................................164
Tip For All Weather Traction ........................................................................................................................166
Front End Alignment Procedure ..................................................................................................................167
Dana Front Axle Maintenance ......................................................................................................................168
REVISION LOG..................................................................................................................... 170

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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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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.
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
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.
WARRANTY

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REV30 8.4.15TT4-8 4TNV98
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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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.
NOTE: At the time a warranty claim is filed it may be necessary for Eagle Tugs to request a copy 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.
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 tire warranty please contact Eagle directly by phone at 800-671-0431, by email at [e-mail] or
through our website at www.eagletugs.com .
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.
WARRANTY REGISTRATION INFORMATION
Please complete and return the Eagle Tugs Warranty Registration Card provided your tug or fill
out and submit on line at www.eagletugs.com.

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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
NOTE: THIS MANUAL COVERS PARTS & SERVICE FOR EAGLE TT4—TT8 2WD AND 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 III 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
ENGINE DRESS - FAN ASSEMBLY, PRINCE PUMP, AND MOTOR MOUNTS
*See page 20 to determine proper
spacer (item 10) needed
TORQUE
TO 37 ft-lb TORQUE
TO 100 ft-lb
TORQUE
TO 100 ft-lb
TORQUE
TO 37 ft-lb

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POWER TRAIN
Item Part Number Qty. Description
1 NPN 4 HCS, M8X1.25 X 45
2 NPN 13 LOCK WASHER, M8
3 NPN 9 FLAT WASHER, 1/4
4 A-TT8-00312 1 FAN
5 A-TT8-00360 1 FAN SPACER
6 129900-42450 1 PULLEY (INCLUDED WITH ENGINE)
7 NPN 4 HCS, M8X1.25 X 70
8 NPN 1 HCS, M8X1.25 X 60
9 A-TT8-00354 1 REMOTE FAN BRACKET
10 NPN 1 FAN BRACKET SPACER (SEE PG. 20)
11 NPN 4 HCS, M8X1.25 X 40
12 A-TT8-00353 1 WATER PUMP SHEAVE
13 A-TT8-00356 1 REMOTE FAN SHAFT
14 A-TT8-00357 2 REMOTE FAN BEARING
15 A-TT8-00355 1 REMOTE FAN SHAFT HOUSING
16 A-TT8-00358 1 REMOTE FAN SNAP RING
17 NPN 2 HCS, 1/2-13 UNC X 1.25
18 NPN 2 FLAT WASHER, 1/2
19 NPN 2 LOCK WASHER, 1/2
20 NPN 2 SHCS, M10X1.5 X 30
21 NPN 14 LOCK WASHER, 3/8
22 SP20PB11L145H9L 1 PRINCE PUMP
23 NPN 4 HCS, 3/4-10 UNC X 3.5
24 NPN 4 FLAT WASHER, 3/4
25 NPN 4 HCS, 5/8-11 UNC X 2.5, GR 8, ZN PLATED
26 A-TT4-00011 2 ENGINE MOUNT TRANS PLATE
27 A-TT5D-00013-1 4 ISOLATOR
28 A-TT5D-00010 4 LORD WASHER
29 NPN 4 LOCK NUT, 3/4-10 UNC
30 NPN 12 SHCS, M10X1.5 X 25, GR 10.9
31 A-TT4-00012 1 MOTOR MOUNT - B
32 A-TT4-00013 1 MOTOR MOUNT - A
33 24321-000850 1 PTO GASKET (INCLUDED WITH ENGINE)
34 NPN 4 LOCK NUT, 5/8-11 UNC

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POWER TRAIN
ENGINE DRESS - TRANSMISSION
A
B
C
TORQUE
TO 45 ft-lb
Used on engines not equipped with integrated rear crank seal.
Used on engines with integrated rear crank seal.
See ESB-01-15 Service Bulletin for proper transmission identification. Assembly as shown is current production.
Install with stamped “D” facing toward transmission.
A
B
C
TORQUE
TO 45 ft-lb
TORQUE
TO 45 ft-lb
TORQUE
TO 50 ft-lb
TORQUE
TO 70 ft-lb
TORQUE
TO 50 ft-lb
TORQUE
TO 55 ft-lb
D
TORQUE
TO 70 ft-lb
TORQUE
TO 45 ft-lb
D
TORQUE
TO 70 ft-lb

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POWER TRAIN
Item Part Number Qty. Description
1 NPN 4 SHCS, M12X1.75 X 40, GR 10.9
TT08-54-003-KA 1 TRANSMISSION - AWD2
TT08-54-005-KA 1 TRANSMISSION - 2WD2
3 NPN 8 HCS, M12X1.75 X 25, GR 10.9, ZN PLATED
4 TM27C00305-ID 1 FLEX PLATE WASHER
5 B-TT10TD-00016-ID 1 FLEX PLATE
6 NPN 3 HCS, M16X2.0 X 45
7 NPN 3 LOCK WASHER, M16
8 B-TT5D-00017-4TNV 1 FLEX PLATE ADAPTER
9 5240849 2 TRANS DOWEL PIN
10 NPN 12 FHCS, M10X1.50 X 45, GR 10.9
11 B-TT10TD-00001-4TNV 1 TRANS PLATE
12 129953-21570 1 FLY WHEEL ASSEMBLY (CONTAINS ITEM 13)
13 129900-21600 1 RING GEAR (INCLUDED IN ITEM 12)
14 B-TT10TD-00002 1 TRANS PLATE SPACER
15 129916-01790 1 OIL SEAL
16 NPN 3 HCS, M10X1.5 X 45, GR 10.9, ZN PLATED
17 TMD27B00521-4TNV 1 ENGINE PLATE
18 41HN28 3 ADJ PLATE DOWEL PIN, 3/8 X 2.5
19 NPN 9 HCS, M10X1.5 X 35, GR 10.9, ZN PLATED
20 129940-77010 1 STARTER
21 NPN 2 HCS, M12X1.75 X 25
22 TMD27B00521-T3SPEC 1 ENGINE PLATE
23 NPN 4 HCS, M10X1.5 X 12
24 NPN 6 HCS, M8X1.25 X 12
25 121850-21130 6 HCS, M14X1.5 X 35 (INCLUDED WITH ENGINE)

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POWER TRAIN
Choosing the Correct Fan Bracket Spacer
The fan bracket spacer shown above comes in two different versions. Version A-TT8-00361 is .625" thick. Ver-
sion A-TT8-00363 is .50" thick. Using this guide will make determining which version you need very easy.
Version A-TT8-00361: This part should be used if the cover circled below is a stamped part with a dome in the
center and a ridge around the outside as shown:
Version A-TT8-00363: This part should be used if the cover circled below is a flat sheet as shown: