Eagle TT4 Quick start guide



EAGLETUGS



PARTS&SERVICEMANUAL




VehicleTypes:TT‐4,TT‐5,TT‐6,&TT‐8
EngineType:Chrysler2.5L4CylinderEngineModel




2
REVISIONDATE3‐16‐09


3
INTRODUCTION
FromeveryoneatEagleIndustrialTruckManufacturing,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%satis‐
fied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.
CONTACTINFORMATION
EagleCorporateOffice
26111NorthlineRd
Taylor,MI48180
(800)671‐0431
www.eagletugs.com
CustomerService Parts&Service TechnicalSupport
[e-mail] [e-mail] [e-mail]
(734)442‐1000‐‐(800)671‐0431 (734)442‐1000‐‐ (800)671‐0431 (734)442‐1000‐‐(800)671‐0431


4
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OFCONTENTS


5

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OFCONTENTS


6
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DISTR IBUTOR #


7
WARRANTY
WARRANTYREGISTRATION
Pleasefillouttheenginewarrantyregistrationcardthatcomeswithyourvehicle.Thisinformationisneededfor
completingwarrantyworkonyourengineifaproblemoccurs.SeeVehicleIDInformationonpreviouspage.
STANDARDWARRANTY
EagleIndustrialTruckManufacturing,LLC(EAGLE)warrantsthatEAGLEtowtractorswillbefreefromdefectsin
materialandworkmanshipforaperiodof12monthsor2,000operatinghours(whichevercomesfirst),beginningatthe
dateofdelivery.The12‐month/2,000hourWarrantycoverseverythingexceptfortheelectricalandcoolingsystems,
whicharecoveredfor3monthsor500hours(whichevercomesfirst).Writtennoticeofanyclaimeddefect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EAGLEʹselection,anypartorpartsdeemeddefectiveafter
examinationbyEAGLEoranAuthorizedServiceRepresentative.AnyEAGLEtowtractororanyofitspartsreturnedby
thecustomertoEAGLEoranAuthorizedServiceRepresentativeviaprepaidtransportation,andwhichisfoundtobe
defective,willberepairedorreplacedandreturnedto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.
Thiswarrantydoesnotextendtotiresandbatteriesasthesearewarranteddirectlytotheuserbytheirrespective
manufacturerandnotbyEAGLEoranAuthorizedServiceRepresentative.
ThiswarrantydoesnotapplytoanyEAGLEtowtractor,orcomponentpartsthathavebeensubjectedtomisuse,
accident,orimproperhandling,maintenanceorapplication;nordoesitextendtotheEAGLEtowtractorand/orparts
whichhavebeenrepairedoralteredoutsideofEAGLEʹsplantorthefacilityofanAuthorizedServiceRepresentative.
Thiswarrantydoesnotapplytoroutinemaintenance,ignitioncomponents,orwearablepartsoftheEAGLEtowtractor
suchasfilters,seals,plugs,hoses,belts,brakepads,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.
Ifawarrantyproblemoccurswithyourengine,pleasecontactanauthorizedenginedistributorforassistance.(Alistof
FordPowerProductsServiceorganizationscanbefoundatthebackofthismanual)

EXCEPTASSETFORTHABOVE,ALLWARRANTIES,CONDITIONS,REPRESENTATIONS,INDEMNITIESAND
GUARANTEES,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THECUSTOMER,
DISTRIBUTOR,DEALERORANYREPRESENTATIVE,AREHEREBYOVERWRITTENANDEXCLUDED,ANDNO
LIABILITYSHALLATTACHTOEAGLE,EITHERINCONTRACTORINTORT,ORSTRICTLIABILITYINTORT,
FORANYDAMAGETOPROPERTY,LOSSOFPROFITS,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TOWTRACTORORTHESUPPLYOFSERVICES.
SUBJECTTOCHANGEWITHOUTNOTICE
*Theabovewarrantyisonlyvalidfornewlymanufacturedtowtractors.PleasecontactEagleTugsdirectlyforwarranty
termsregardinganyUSEDtowtractorsbythroughEagleTugsdirectly.


8
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


9
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‐
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‐



10
POWERTRAIN
ENGINEDRESS