Eagle TT4 Quick start guide

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EAGLETUGS
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PARTS&SERVICEMANUAL
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VehicleTypes:TT‐4,TT‐5,TT‐6,&TT‐8
EngineType:Chrysler2.5L4CylinderEngineModel
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REVISIONDATE3‐16‐09

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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

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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
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TABLEOFCONTENTS

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

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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.
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MODEL
SERIAL#
MFGDATE
ENGINETYPE
ENGINESERIAL#
CHRYSLER2.5LDISTR IBUTOR #

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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)
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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.

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


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

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


12
20
ENGINEMOUNTS
POWERTRAIN


13
Item PartNumber Qty Description
1B‐TT4‐00052‐11FIREWALLMOUNT
2NPN6SCREW‐HEXCAP‐1/2‐13X11/2
3NPN9WASHER‐FLAT‐1/2
4NPN9NUT‐LOCK‐1/2‐13
5NPN1SCREW‐HEXCAP‐1/2‐13X4
6B‐TT4‐00051‐11MOUNT‐TRANSMISSION
7NPN4SCREW‐HEXCAP‐M10 ‐1.5X35
8A‐TT4‐00067 1 ENGINESUPPORTSIDE
9NPN1SCREW‐HEXCAP‐1/2‐13X41/2GR5
10 NPN 2 SCREW‐HEXCAP‐M12‐1.75X28
11 NPN 2 SCREW‐HEXCAP‐M12‐1.75X60
12 A‐TT4‐00068 1 ENGINESUPPORT
13 A‐TT4‐00069 1 INSULATOR
14 NPN 1 SCREW‐HEXCAP‐M10‐1.5X90
15 NPN 1 SCREW‐HEXCAP‐1/2‐13X21/2
16 A‐TT5‐00065‐11FIREWALLMOUNTREAR
17 NPN 2 SCREW‐HEXCAP‐3/8‐16X21/2GR5
18 NPN 7 WASHER‐FLAT‐3/8
19 NPN 2 NUT‐LOCK‐3/8‐16
20 5252351 1 ENGINEMOUNTBRACKET
ENGINEMOUNTS
POWERTRAIN


14
1
34
5
8
10
11
12
15
16
14
9
13
18
17
6
ENGINEOIL
POWERTRAIN


15
Item PartNumber Qty Description
1 4387478 1 SEAL‐OILPANTORETAINERFRONT
2 5203778 1 SEAL‐OILPANTORETAINERREAR(NS)
3 6032145 1 OILPANDRAINPLUG(NOW1PIECE)
4 4621160 1 PAN‐OILPARTIALWITHLINERSPAINTED
5 6501990 12 SCREW‐HEXHEAD‐M8‐1.25X18
6 4387575 1 TUBE&CLIP‐OILLEVELINDICATOR
7 6101445 1 NUT‐OILLEVELINDICATORTUBE(NS)
8 4397768 1 GASKETPACKAGEOILPAN
9 4536073 1 VALVE‐ANTI‐DRAINBACKOILFILTER
ADAPTER
10 4387675 1 TUBE‐OILPUMPPICKUP
11 1407748 1 O‐RNGFILTERADAPTER
12 6500070 1 SCREW&WASHEROILPICKUPTUBE
13 4397746 1 PUMP‐OIL
14 4387305 1 OILCOOLER‐ENGIN
E
15 4387822 1 CONNECTOR‐OILCOOLERENGINE
16 4740294 1 SEAL‐OILCOOLER
17 85085 1 OILFILTER
18 4483102 1 DIPSTICKOILINDICATOR
ENGINEOIL
POWERTRAIN


16
20
CYLINDERHEAD
POWERTRAIN


17
Item PartNumber Qty Description
1 4728218 1 GASKETPACKAGESTEELHEAD(NS)
2 4773063 1 GASKETPACKAGEALUMINUMHEAD(NS)
3 5241066 1 CYLINDERHEADCOVER
3 4739918 1 ALUMINUMCYLINDERHEADCOVER
4 4667303 1 RESTRICTOR
5 4621012 CAP‐OILFILTER
6 6100276 5 SCREW‐HEXCAP‐W/WASHERM6‐20
7 4343882 1 GASKET
8 4105395 1 SEAL‐CAMSHAFTFRONTOIL
9NPN10SCREW‐HEXCAPM8‐1.25X45
10 4343627 1 HEAD‐CYLINDERWITHEDMINJECTION
6500267 1 SCREW‐HEXCAP‐W/WASHERM10‐1.25X16
11 4105295 1 NIPPLE‐THERMOSTATWATERBY‐PASS
12 5281065 1 GASKET‐CYLINDERHEAD
13 4556020 2 PLUG‐COREHOLECUP(1.25ʺ)X.065
13 4556021 AR PLUG‐COREHOLECUP(5/8)X.065
14 4556018 2 PLUG‐OILGALLERYHOLE(5/8)
14 4556019 AR PLUG‐OILGALLERYHOLE(.065ʺO.S.)
15 6500435 2 STUD‐W/FLATWASHERM6
6100276 5 SCREW‐HEXCAP‐W/WASHER
15A 6500274 2 NUT‐LOCK‐M6‐1.00
16 6501435 10 WASHER‐CYLINDERHEADSCREW
17 6501433 10 SCREW‐HEXCAP‐M11‐122.5
18 NP
N
A
R
NUT‐CAMSHAFTBEARINGCAPSTUD
19 NP
N
5CAPS‐CAMSHAFTBEARING
20 4105396 1 SEAL‐CAMSHAFTREAROIL
CYLINDERHEAD
POWERTRAIN


18
CYLINDERBLOCK
POWERTRAIN


19
Item PartNumber Qty Description
4626450 1 GASKETPACKAGELOWERENGINE
1 4556431 1 ENGINEINJECTOR
2 6500402 2 DOWEL‐CYLINDERBLOCKTOHEAD
3NPN1PLUG‐CYLINDERBLOCKWATERJACKET
DRAIN(1/4)
4NPN4DOWEL‐CYLINDERBLOCKTOCRANKSHAFT
RETAINER
6 6100276 3 SCREW‐HEXCAPW/WASHER
6100271 1 SCREW‐HEXCAPW/WASHER
7 2473275 1 SEALCRANKSHAFTFRONTOIL
8 5203778 1 SEALOILPANTORETAINER
8 4387478 1 SEALOILPANTORETAINER
9 4556018 2 PLUG‐CYLINDERBLOCKOILGALLERY(5/8ʺ)
10 4556022 5 PLUG‐CYLINDERBLOCKCOREHOLECUP
(1.625ʺO/S)
11 5240849 2 DOWEL‐CYLINDERBLOCKTOTRANSAXLE
CASE
12 5203590 1 SEAL‐CRANKSHAFTREAROIL
13 6100276 4 SCREW‐HEXCAPW/WASHER
CRANKSHAFTREAROILSEALRETAINER
14 5214784 1 RETAINER‐CRANKSHAFTREAROILSEAL
15 6015327 2 CLIP‐ENGINEBLOCKHEATERCORD
16 4687405 1 CORD‐ENGINEBLOCKHEATER
16 6015756 AR STRAP‐ENGINEBLOCKHEATER
17 4740197 1 HEATERPACKAGE‐ENGINEBLOCK
18 6501445 1 O‐RINGENGINEBLOCKHEATER(1‐11/32DIA
11/64WIDTH)
18 6501446 1 O‐RINGENGINEBLOCKHEATER(1‐1132DIA
9/64WIDTH)
19 4323808 1 RESTRICTOR‐CYLINDERHEADOIL
CYLINDERBLOCK
POWERTRAIN


20

13
25
24
19
18
7
11
12
14
26
15
24
CRANKSHAFT,PISTON&TORQUECONVERTOR
POWERTRAIN