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Parts and Service Manual

1. 84 M 84 FUELS SYSTEM VET ETHER aeq 86 Fuel System Yanmar Tier 5 86 Fuel Injection Pump Yanmar Tier 6 88 Engine Fuel Eines Yanmar 11 11 n t er 89 Engine Fuel Injection Lines amp Nozzle Yanmar 90 Fueliinjection Pump Yanmar Tier 92 Engine Fuel Line Yanmar Tier 93 Engine Fuel Injection Lines amp Nozzle Yanmar Tier 94 CLEANER 96 Air Cleaner Assembly Dieseli ninsori rno ttn etae Wen 96 EXHAUST amp INTAKE SYSTEM A tede pice Ree ee cuss cece m NER en B e Re EA fen eu teenie e er Ie NR 97 Exhaust System Yanmar Tier II amp Tier III 97 Exhaust Manifold Yanmar Tier Engine 98 Intake Manifold Yanmar Tier II 2 99 Exhaust Manifold Yanmar Tier 100 Intake Manifold Yanmar Tier
2. A Empty 41201 III B Battery C Empty 4 0 CC D Starter ALE Black 6 GND 7 gt gt gt 4 1819 1 4244 244 22i CAN 2 G ECU Power A2 1 Pin Jasa K Empty L Empty _ _ ___ M Throttle Power I N Empty 5 2 canas P Pressure Sender R Charge Lamp Empty T Empty CAN Low en CAN High Empty DPI ee V Empty 366 Engine Harness Connector ed 10C 18 E Battery Front Left Headlight Dark Brown 411 Front Left Running Light Hao Red 400 Front Lett Turn Signal m Red LET Front Right Headlight Dark Brown 411 Front Right Running Light 00 Front Right Turn signal m Red RFT PBG Black EEE Brake Pressure Hern Relay Ignition Relay Parking Brake Switch Vehicle Harness 4TNV98 QA027 REVO7 12 23 11 0 101619596 39 18 NOIINSI 6 vl IVW 5 st e y Z ZLV ELECTRICAL SCHEMATICS CE OPTION PRESENCE CIRCUIT WIRING DIAGRAM 118 e L ZLV en HOLMS 8O12313S 141 5 QA027 REVO7 12 23 11 119 ELECTRICAL SCHEMATICS CAB OPTION WIRING DIAGRAM ud 1 01 uoop g
3. Pressure Sender Foot Pedal GND C10 Empty Empty C12 H30 Connector Shifter iBlue Shitter Backlight Left Rear Indicator Aa es ut L 411 Dark Brown 1 1 Left Rear Reverse Light ec Right Rear 44 White Indicator and Brake Light p RR Black 41L Dark Brown Oo 1 Right Rear Reverse Light 418 Pink nm 251 d E Trans Plug Trans Temp Fuel Sender Horn Brake Pressure Hern 30 85 Vehicle Harness Tier3 4TNV QA027 REVO7 12 23 11 117 ELECTRICAL SCHEMATICS VEHICLE WIRING HARNESS YANMAR TIER III DIESEL Optional Turn Signal Lever LR RR and 44 are connected when not present Turn Signal Relay Turn Signal 2 4 5 6 7 I zon Accelerator Pedal gt 2 na A A12 D1 Reg D Power A2 D2 Red Be Power 8 Acc3 Yellow Ds Acc Power Tran4 Green D4 Trans Temp Spots White 55 Spotlight 644 85 Orange Horn Relay GND E 1 I I N 27 Empty WE 51000 C8 Lights Power 411 Brown D9 Lights Dio GND Heat Orange D10 Black Heater Low Heati2 Red 012 Heater High Dash Connector
4. 102 104 Accelerator Pedal Assembly Yanmar Tier see e 104 Accelerator Pedal Assembly Yanmar Tier Engine 105 Instrument cao che 106 Quick naa a i a a ia aaea a ein idani 107 Transmission Controlo 108 ELECTRIAL SCHEMATIES sa tese e ege 109 Dash Wiring Diagram ten e DET HEREIN 6 5 109 Yanmar Engine Wire Harness Tier II 11111 110 Yanmar Engine Wire Harness Tier III 112 Vehicle Wiring Harness Yanmar Tier 2 0 114 Vehicle Wiring Harness Yanmar Tier Engine 116 CE Option Operator Presence Circuit Wiring Diagram csse eee ns 118 Cab Option Wiring Diagram iie eoa rette tnbus it b a e 6 6 6 6 _ 119 120 Headlights taillights amp Spotlight Assembly 120 QA027 REVO7 12 23 11 TABLE OF CONTENTS OTHER ASSEMBLIES 0 sn 122 Body aa a BRENNER asi 122 hu 123 WHEELS amp TIRES 124 Wheel amp Tire ASSembl AA
5. 20 Alternator Yanmar Tier II III Engine With Cab or Transit Pro 21 Head Cover Assembly Yanmar Tier II amp Tier III Engines 22 Cylinder Block Assembly Yanmar Tier Engine 24 Cylinder Block Assembly Yanmar Tier Engine sese eee ener 26 Crankshaft amp Piston Yanmar Tier Engine 28 Crankshaft amp Piston Yanmar Tier III 2 30 Camshaft Driving Gear Yanmar Tier II Engine 32 Camshaft amp Driving Gear Yanmar Tier III Engine e nennen 34 Governor Assembly Yanmar Tier III Engine 36 Oil Pan Assembly Yanmar Tier II amp Tier III Engines see eene 37 Lube Oil System Yanmar Tier II amp Tier 38 Gear Housing Yanmar Tier II amp Tier III 10118 enne nn rene nnn 40 Engine Gaskets Yanmar Tier II Engine eene 42 Engine Gaskets Yanmar Tier 44 COOLING SYSTEM un in del X ETHER 46 Cooling SyStems i UU tette eto tte 48 DRIVELINE II V ER I OUR 50 Drive Shaft Assembly Front s saa yanasa a HEURE 50 Drive Shaft Assembly Rear eae ER 39904 51 TRANSMISSION cyan a A D 52 Transaxle Mountin
6. o9 5 22 Awg Lite Green 22 AWG Black 22 AWG Yellow 22 AWG Yellow 22 AWG Lite Green 22 AWG Black CANHigh E40A CANLow 0390 CANHigh 40 CANLow E39C QA027 REVO7 12 23 11 ELECTRICAL SCHEMATICS Actuator Relay YANMAR ENGINE WIRING HARNESS YANMAR TIER III DIESEL J20 B50 Air Heater Ex 14 Ring 8664 69 Starter 1 gt gt gt gt 114 PosLock 12 AWS RedBlack B66 Starter 2 E 0 Ring J1 22 AMS WhtteBlack 22 AWG Dark Blue 22 AWS Brack XC 22 AWG White 16 AWS VWwhite Black 22 AWG Grey 18 AWG Lite Blue 22 AWG Lite Blue 22 AWG Yellow 22 AWG YellovwwRed 22 AWG Yellow Black 22 AWG YellowwGreen 22 AWG Grey 22 AWG Tan Ignition 15 22 AWG Orange Black Stop Sw 1 22 AWG Lite GreervBlue 15 22 ANG Lite Green E24 22 AWG YellowiCrange E14 22 AWS Lite Green Red E05 22 AWG Lite GresvYeliow E13 22 AWG Lite GreervOrange E06 22 AWG Lite GreervBlack E09 22 AWG Lite Green Brown E17 22 AWG Yellow E40 22 AWG Lite Green X E39
7. n i NN NN i _ Oty HE _ 2 _ 1 _ EE 3 3 1 1 E BEE 2 __2 Welded to truck QA027 REV07 12 23 11 76 BRAKES BRAKE SYSTEM HYDRAULIC QA027 REVO7 12 23 11 77 BRAKES BRAKE SYSYEM HYDRAULIC Qy 7 1 BRAKELINEMASTERCYUNDER 1 1 BRAKELINERFAR 2nd HALF VERSION 4 BRAKELINEREAR2nd HALF VERSION 7 s cross TE 1 RAR QA027 REV07 12 23 11 78 HYDRAULIC ASSIST HYDRAULIC ASSIST SYSTEM WITH PRINCE PUMP QA027 REVO7 12 23 11 79 HYDRAULIC ASSIST HYDRAULIC ASSIST SYSTEM WITH PRINCE PUMP 2 SiS TER CYLINDER 4 RING GEAR BOX s HO 1711 38HYDRAULICHOSEWKPSI350 P A TT4 00606 1A A TT4 00606 1 9 Eu QA027 REVO7 12 23 11 80 HYDRAULIC ASSIST HYDRAULIC ASSIST SYSTEM WITH METARIS PUMP QA027 REVO7 12 23 11 81 HYDRAULIC ASSIST HYDRAULIC ASSIST SYSTEM WITH METARIS PUMP fen 7 16 y nno 4601 12 08 1 1 2 MSAE 3 4 SUCTION BARB 90 DEG FITTING 7033X14X12 1 7 8 M SAE 3 4 F SAE FITTIN
8. oy 1 3 SCT MKS PLATED 2 ORNGIAS4BU 3 3610606022 1 RO MERA 4 5 SEALWASHERINBOLT __ 1 Gs cra A CAR SENSOR 5 NULGOVENORWEGHT 5 BOXLMEXIPPLATD 0 7672 SENSOR QA027 REV07 12 23 11 37 POWER TRAIN OIL PAN ASSEMBLY __ 1 OILPAN ASSEMBLY INCLUDES TENS 4 amp 5 QA027 REVO7 12 23 11 POWER TRAIN LUBE OIL SYSTEM QA027 REVO7 12 23 11 39 POWER TRAIN LUBE OIL SYSTEM I 24311 240100 10 11 12 13 5 6 O RING DIPSTICK NOT SHOWN __ 5 7 11 _ 12 13 14 1 1 QA027 REVO7 12 23 11 POWER TRAIN GEAR HOUSING QA027 REVO7 12 23 11 41 POWER TRAIN GEAR HOUSING ay i QA027 REVO7 12 23 11 42 POWER TRAIN ENGINE GASKETS YANMAR TIER II QA027 REVO7 12 23 11 9770 01212 43 POWER TRAIN ENGINE GASKETS YANMAR TIER II i 129000 3200 _ 129000 40000 _ _ 129004870 y 1218804950 m 5 messa a O 2 emo aeneo 2490000 5 6 2 77 5 77
9. QA027 REVO7 12 23 11 113 114 ELECTRICAL SCHEMATICS Parking Brake Switch Gear Selector Switch Ignition Relay Fuel Sender Fuel Pump 10 Empty 11 H30 Power 12 Engine Harness VEHICLE WIRING HARNESS YANMAR TIER II DIESEL Spotlight Beacon Heater 1 i P L Empty 1 B2 Black Empty Empty gt Empty Empty 9 A2 D2 Red uE 5 3 C 8 2 3 LI 2 Ignitto BH A Shifter Backlight Lett Rear Indicator and Brake Light Left Rear Reverse Light Right Rear Indicator and Brake Light Right Rear Reverse Light I GES p Block q Dark Brown 0041812100 85 86 87 12 Trans Plug Trans Temp Fuel Sender Horn Brake ree Horn Relay Vehicle Harness Tier2 41MV98 QA027 REVO7 12 23 11 ELECTRICAL SCHEMATICS 115 Beacon VEHICLE WIRING HARNESS YANMAR TIER II DIESEL Heater Turn Signal Load Yellow Optional Turn Signal Lever RR and 44 are connected when not present 1 2 4 5 6 Turn Signat Relay ZowsLiRedll A12 D1 Red A2 D2 Red Accitvelewl y Tran4 Green D4 pots White D7 D8 L 09 Heat12 1 212 Switch Vehicle Harness Tier2 4TNV98 I Battery Bus M E H30 _ 30 85 86 87 30
10. 9 L a L FUEL WATER SEPERATOR COMPLETE ASSY BRACKET FUEL FILTER 4 HOSE CLAMP NPN BULK HEAD FITTING 5 16 HOSE SAE30R7 WKPK 17 5 16 HOSE SAE30R7 WKPK 14 5 16 HOSESAE30R7 WKPK OPTION LUBRICITY FILTER ASSY COMP OPTION 5 16 HOSESAE30R7 WKPK OPTION LUBRICITY FILTER ELEMENT Be jaa AE OPT 0091 05705 QA027 REVO7 12 23 11 88 FUEL SYSTEM FUEL INJECTION PUMP YANMAR TIER II DIESEL DA S gt AS In SS gt 1 ARES RX gr Vx CE 7 RL QR 4 129907 01950 26106 080222 26106 080162 26106 100202 129907 01960 C C 9 gt 8 5 2 9 729907 51320 QA027 REVO7 12 23 11 89 FUEL SYSTEM FUEL INJECTION LINES AND NOZZLE YANMAR TIER II DIESEL go ang Ss gt Ss UNS bw S PIPE ASSEMBLY FUEL INJECTION PIPE ASSEMBLY FUEL INJECTION Part Number 129907 59810 129907 59820 NE EE PIPE ASSEMBLY FUEL INJECTION PIPE ASSEMBLY FUEL INJECTION 122907 59830 129907 59840 PIPESEAL FUEL INJECTOR 123907 11601 129937 53000 26106 080182 26106 060162 122780 59100 129907 59710 129550 59120 119305 59120 QA027 REVO7 12 23 11 90 FUEL SYSTEM ENGINE FUEL LINE YANM
11. n Z PULLEY W ATER PUMP PIPE A COOLING WITH CLAMPS HOSE B ASSEMBLY W ATER REMOTEFAN BELT NOT SHOWN 6 7 5 do _ 1 __2 13 2242 5 5 8 _ a 2 23 _25 26 2 28 2 QA027 REVO7 12 23 11 48 COOLING SYSTEM ENGINE COOLING SYSTEM COOLING SYSTEM WITH COPPER RADIATOR TRANMISSION FLUID R POWER STEERING FLUID QA027 REVO7 12 23 11 49 COOLING SYSTEM ENGINE COOLING SYSTEM I FAN NPN TORS NPN NPN QA027 REVO7 12 23 11 50 DRIVELINE DRIVE SHAFT ASSEMBLY FRONT ALL TT 4 8 MODELS QA027 REVO7 12 23 11 51 DRIVELINE DRIVESHAFT ASSEMBLY REAR ALL 4 8 MODELS 00130 1 DRIVE SHAFT A TT4 00130 END YOKE STRAP KIT 6 A TT4 00137 CROSS BEARING REAR D S NEW STYLE QA027 REVO7 12 23 11 TRANSMISSION TRANSAXLE MOUNTING amp MISC PARTS ALL TT 4 8 MODELS QA027 REVO7 12 23 11 53 TRANSMISSION TRANSAXLE MOUNTING amp MISC PARTS ALL TT 4 8 MODELS 2 ROUND STRAP 3 O SWITCFENEOTRAL STARTER amp BACKUP LIGHT 4 1 DPSTCKTRANMESIONFLUD 5 2 DOWELPIN TRANSTOENGINEALIGNMENT 5 TORQUECONVERTR o SCREW HEXCAP WITHWASHERMI2 175 X30 As 1 GASKET amp FITERMAINTE ANCEPACKAGE Torque convertors
12. x a O RING 1A G85 0 GASKET LIQUID pom 8 E 10 11 13 5 16 17 18 19 2 22 23 _ 24 25 26 27 28 29 30 3 QA027 7 12 23 11 POWER TRAIN ENGINE GASKETS YANMAR TIER DIESEL 10 24 28 11 171388 OPTIONAL PARTS QA027 REVO7 12 23 11 45 POWER TRAIN ENGINE GASKETS YANMAR TIER DIESEL lim 24321 000850 SEAL W ASHER 225 rrr NOZZLE A NOZZLE GASKET LIQUID __ __ O7 5 9 10 o no _ 12 _ 1 _ ss p 15 E Em NN NETO 19 _ 20 A 2 23 _ _ 24 25 _ 2 O7 28 29 3 a 1 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 4 3 QA027 REV07 12 23 11 46 COOLING SYSTEM ENGINE COOLING SYSTEM QA027 REVO7 12 23 11 47 COOLING SYSTEM ENGINE COOLING SYSTEM 1 THERMOSTATHOUSNG s 26065622 4 GASKET THERMOSTAT HOUSING THERMOSTAT THERMOSTAT GASKET PLUG MiS GASKET GASKET n BOLT PIPEJOINT 2 JOINT 16 TEMPERATURE SENDING UNIT TIER ONLY 17 TEMPERATURE SENDING UNIT TIER II ONLY 18 DRAIN PLUG 19 GASKET WATER PUMP 20 WATER PUMP 24 FAN SPACER 25 26 27 28 25 WIN gt
13. TABLE OF CONTENTS INTRODUCTION ia 3 PURPOSE amp USEOF THIS MANUAL A 3 TECHNICAL ASSISTANCE aa 3 ORDERING SPARE SERVICE PARTS art 3 CONTACT INFORMATION 3 WARRANTY a aa Meu Ede 8 THREEGLE WARRANTY INFORMATION a Z aaa aan aa 8 STANDARD WARRANTY INFORMATION cccccccccssssssssscssccecssssssscsscseceesessscssesececsesssesssscceceeseesssssesesessasesesceseessaueesees 9 SAFETY INFORMATION e es eg 10 VEHICLE TID INFORMATION eite oce teet aree eoe teet petente eunte e a eene eee e bl E 11 12 YANMAR C CC 12 AUTHORIZED YANMAR DISTRIBUTOR INFORMATION 12 EAGLE TUGS SERVICE BULLETIN ESB 02F08 13 SERVICE PARTS ILLUSTRATIONS amp DETAILIA 15 IDENTIFICATION KEY r T E E E EEES 15 POWER TRAIN u l sen M 16 Engine Dress Yanmar Tier II amp Tier Engines en nn enne 16 Alternator Yanmar Tier 19 Alternator Yanmar Tier ILEngibe I
14. 58 AXLES AXLE ASSEMBLY REAR ALL 4 8 MODELS SO ri WAS s s 1 RIGHTHANDBACKNGPLATE INCLUDED IN U BOLT KIT CALL EAGLE TUGS FOR INFORMATION IF YOUR TUG IS EQUIPPED WITH LIMITED SLIP QA027 REVO7 12 23 11 AXLES RECOMMENDED TORQUE SPECIFICATIONS FOR DANA 44 AXLE FRONT WRENCH TORQUE POSITION THREAD LBS FT Siceting Bolt Stop Screw amp jam Nut RECOMMENDED TORQUE SPECIFICATIONS FOR DANA 60 AXLE REAR WRENCH TORQUE POSITION THREAD LBS FT ET 1 Kingpin EEE 64 Axle Shaft Flange Nuts 64 Spindle Mounting Nuts 60 80 Upper Kingpin 500 600 tering Bolt Stop Screw amp Jam Nut A For Grade 9 fastener with locking serrations on underside of cap screw head or nut If cotter pin cannot be installed after minimum torque is attained the nut must be advanced until cotter pin can be installed QA027 REVO7 12 23 11 59 AXLES AXLE ASSEMBLY BREAKDOWN FRONT NON DRIVE 2WD QA027 REVO7 12 23 11 61 AXLES AXLE ASSEMBLY BREAKDOWN FRONT NON DRIVE 2WD 25 nr store co 4 2 USTING s amm E 0 7 O ASSEMBLY LOWER s 3s RNG SNP x 9 we 19 2 NUMAM 706652X STEERING KNUCKLE R H 1 WE 11 706653X KIT STEERING KNUCKLE
15. INC 15 21 23 29 DIFF PARTS LTD SLIP INC 15 21 23 24 26 28 29 43 48 cum ES 1 AA aa 41 gt ES m QA027 REVO7 12 23 11 70 BRAKES PARKING BRAKE ACTUATOR ASSEMBLY QA027 REVO7 12 23 11 71 BRAKES PARKING BRAKE ACTUATOR ASSEMBLY EQUALIZER s 2 2 2 HAND BRAKE ON WARNING OPTIONAL 81008429 82050000 82066700 AE OPT 0069 2 2 212 2 2121 2 9 2 21212 2 5 QA027 REV07 12 23 11 BRAKES DRUM BRAKE ASSEMBLY REAR QA027 REVO7 12 23 11 73 BRAKES DRUM BRAKE ASSEMBLY REAR tem E SEE BELOW SEE KIT BELOW BRAKE ADJUSTING SOCKET W ASHER FLAT SEE KIT BELOW W ASHER 3492670 3492656 SPRING SPACER H2588 LEFT BRAKE ADJUSTING KIT INCLUDES H2589 RIG BRAKE ADJUSTING KIT INCLUDES _ 7 H7146 LEFT OR BRAKE SPRING INCLUDES KIT PARTS NOT SOLD SEPERATELY 1 1 1 1 7 10 11 12 13 14 15 19 19 20 20 21 24 25 26 27 28 29 30 6 Hem ma 1 S _ 2 5 Em 8 10 1 1 da 5 19 9 20 2 2 25 26 2 2 2 30 QA027 REVO7 12 23 11 BRAKES BRAKE ACTUATOR ASSEMBLY QA027 REVO7 12 23 11 75 BRAKES BRAKE ACTUATOR ASSEMBLY
16. White exhaust smoke See authorized Yanmar Faulty spray pattern of fuel injection industrial engine dealer Fuel injection timing delay or distributor Engine burning oil QA027 REVO7 12 23 11 139 140 MAINTENANCE Recommended TT 4 12 Tool List 1 Screwdrivers a Philips 1 2 4 long b Slotted 1 8 X 4 3 16 X 4 1 4 X 6 5 16 X 8 2 Torx 125 127 T30 T40 3 Nut Drivers a 1 4 5 16 3 8 4 Allen Wrench a 7 64 1 8 5 32 3 16 7 32 1 4 5 16 3 8 5 Adjustable Wrench 8 amp 10 6 Metric Combination Wrenches 8MM 10MM 12MM 13MM 14MM 15MM 16MM 17MM 18MM 19MM 20MM 21MM 7 Standard Combination Wrenches a 1 4 5 16 11 32 3 8 7 16 1 2 9 16 5 8 11 16 3 4 13 16 7 8 15 16 11 8 8 3 8 Drive Deep Standard Sockets a 3 8 7 16 1 2 9 16 9 1 2 Drive Deep Standard Sockets 9 16 3 4 15 16 1 1 8 10 3 8 Drive Standard Sockets 5 16 3 8 7 16 1 2 9 16 5 8 11 16 3 4 11 3 8 Drive Metric Sockets 7 8 9 10 11 12 13 14 15 16 12 1 2 Drive Metric Sockets 16 17 18 19 20 21 22 23 24 13 1 2 Drive Standard Sockets 9 16 5 8 11 16 3 4 13 16 7 8 15 16 1 1 1 8 QA027 REVO7 12 23 11 MAINTENANCE 14 Swivel Universal 1 2 3 8 Drives 15 Extension 3 8 Drive 3 6 10 inch 16 Extension Drive 3 6 10 inch 17 OTC 7157 18 OTC 7080 19 OTC 1902 20 12 volt test light 21 Torque Wrench 25 250 Foot Pounds 22 7 inch diagonal pliers 23 8 inch long nose
17. 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 The following list contains some general WARNINGS that you should follow when you work on equipment eAlways wear safety glasses for eye protection safety stands whenever a procedure requires you to be under the equipment eBe sure that the ignitions switch is always in the OFF position unless otherwise required by the procedure eSet 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 eOperate the engine only in a well ventilated area to avoid the danger of carbon monoxide eKeep yourself and your clothing away fr
18. AVAILABLE WHEN ORDERING PARTS NOTE THIS MANUAL COVERS PARTS amp SERVICE FOR EAGLE TT4 TT8 2WD AND ALL WHEEL DRIVE MODELS WITH BOTH THE YANMAR TIER AND TIER 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 IT OR TIER III ENGINE YOU CAN CHECK THE DISPLAY LOCATED ON THE DASHBOARD BY THE FOLLOWING 1 TURN DISPLAY 2 PRESS ENTER 3 SCROLL TO EAGLE SET UP 4 PRESS ENTER 5 YOU WILL SEE SELECT ENGINE YANMAR TIER II OR YANMAR TIER ON YOUR SCREEN TO DETERMINE IF YOUR TUG IS POWERED BY A TIER OR TIER III ENGINE WITHOUT TURNING ON DISPLAY ALL TIER II TUGS ARE EQUIPPED WITH A MANUAL ALUMINUM FOOT PEDAL AND ALL TIER TUGS ARE EQUIPEED WITH A BLACK PLASTIC ELECTRONIC FOOT PEDAL QA027 REVO7 12 23 11 16 POWER TRAIN ENGINE DRESS See page 18 to determine proper spacer needed Note Torque values shown in this manual are for clean non lubricated fasteners unless otherwise specified CAUTION The tightening torque in the above Standard Torque Chart should be applied only to the bolts with a 7 head JIS strength classification 71 Apply 60 torque to bolts that are not listed QA027 REV
19. ITEMS 33 3942 53 a 00MX 2 SEE 5 ums 3 _ a 777 amp 2 AE JONAS _ Y A o 2 TE 39 _ m 509 2 s 2 2 0 x 28 5 CL 5 a NuremNmE __ amp 35 crea 2 n n T 2 2 T T 2 2 1 2 1 2 2 2 2 12 12 rN N sN 76 706570 SPINDLE ASSEMBLY INCLUDES ITEMS 706527X KIT SPINDLE SEAL amp BEARING INCLUDES 5468226 1SET ANCHOR BOLTS 81 5 297 1X 2 GREASABLE U JOINT FOR ITEM 46 QA027 REVO7 12 23 11 66 AXLES AXLE ASSEMBLY BREAKDOWN REAR DRIVE QA027 REVO7 12 23 11 67 AXLES AXLE ASSEMBLY BREAKDOWN REAR DRIVE 36 36847 8 STUD HUB Hem m 5 EA ars HE __12 da _ 5 5 E 18 09 om _ 2 23 5 2 _ 2 32 30 32 3 3 QA027 REVO7 12 23 11 68 AXLES AXLE ASSEMBLY BREAKDOWN REAR DRIVE QA027 REVO7 12 23 11 69 AXLES AXLE ASSEMBLY BREAKDOWN REAR DRIVE CONT 36805 16979 706671X 707084X NUT LOCK DIFF PARTS STD
20. JOON 0 E 6 V5IIM 4 54 4 4 4 LI QA027 REVO7 12 23 11 120 LIGHTS amp ELECTRICAL HEADLIGHT TAILLIGHT amp SPOTLIGHT ASSEMBLY QA027 REVO7 12 23 11 121 LIGHTS amp ELECTRICAL HEADLIGHT TAILLIGHT SPOT LIGHT ASSEMBLY A TT4 00291 6 HEADLIGHT W OPTIONAL TURN SIGNAL A TT4 00291 5 REAR FACING SPOT LIGHT OPTION 3 A TT4 00292 TAILLIGHT TAILLIGHT ASSEMBLY Part Number HEADLIGHT amp SPOTLIGHT Part Number OPTIONS NOT SHOWN 10 AE OPT 0076 ROOF MOUNTED TURN SIGNAL LAMP 1 1 AE OPT 0099A 1 MASTER BATTERY DISCONNECT SWITCHPLOCKOUT LEVER KIT OPTION BATTERY DISCONNECT amp FUSES AE OPT 0099 MASTER BATTERY DISCONNECT SWITCH 25 AMP ACG GLASS ROUND FUSE QA027 REVO7 12 23 11 122 OTHER ASSEMBLY BODY ASSEMBLY 62 10 603 20 QA027 REVO7 12 23 11 123 OTHER ASSEMBLY SEAT AND SEAT OPTIONS rom 3 PY Part Number 1 A TT4 0048 1 7 QA027 REVO7 12 23 11 124 WHEELS amp TIRES WHEEL amp TIRE ASSEMBLY Part Number 1 VIII STUDFRONTDANA44 STUDREAR DANA QA027 REVO7 12 23 11 125 WHEELS amp TIRES WHEEL amp TIRE ASSEMBLY DUAL REAR WHEEL M
21. RING GEAR 129953 21570 FLYWHEEL WITH RING GEAR QA027 REVO7 12 23 11 POWER TRAIN CRANKSHAFT amp PISTON YANMAR TIER III DIESEL QA027 REVO7 12 23 11 31 POWER TRAIN CRANKSHAFT amp PISTON YANMAR TIER III DIESEL 1 65 05 025____ 3 a PBIONWIHRNGSTANDARD 2 PSTONWITHRINGSTANDARDOS 25 sO NTN 4 4 4 mum MS NE 5 9 10 3 ao _ m da 5 1 7 10 11 12 13 14 15 16 17 18 QA027 REV07 12 23 11 POWER TRAIN CAMSHAFT DRIVING GEAR YANMAR TIER II DIESEL QA027 REVO7 12 23 11 33 POWER TRAIN CAMSHAFT amp DRIVING GEAR YANMAR TIER IT DIESEL Oy 12990 26950 1 10 11 12 13 14 15 6 7 8 1 O7 8 EN 10 3 ao ERU 1 1 1 QA027 REVO7 12 23 11 POWER TRAIN CAMSHAFT amp DRIVING GEAR YANMAR TIER III DIESEL QA027 REVO7 12 23 11 35 POWER TRAIN CAMSHAFT amp DRIVING GEAR YANMAR TIER III DIESEL liem m 2 I CAMSHAFT ASSEMBLY INCLUDES ITEMS 5 7 10 11 12 13 14 15 6 7 8 1 E 5 9 lo ao 12 IE 15 1 1 1 1 QA027 REVO7 12 23 11 36 POWER TRAIN GOVERNOR ASSEMBLY YANMAR TIER III DIESEL ONLY
22. chains but are much easier to mount and are very kind in terms of abrasion to all surfaces 7 Keep fuel tank full as much as possible 8 Consult with Eagle Tugs factory for additional assistance QA027 REVO7 12 23 11 143 MAINTENANCE FRONT END ALIGNMENT PROCEDURE Find center line of tire front and back Check with tape measure to see difference The front should be 1 16 inch more that the rear 1 16 inch toe out if less or greater loosen the two bolts on the tie rod clamp Turn clamp in or out to achieve desired setting 1 16 in toe out Retighten two bolts on the tie rod clamp 1 16 TOE OUT TIE ROD CLAMP amp BOLT QA027 REVO7 12 23 11 144 MAINTENANCE FRONT AXLE MAINTENANCE Dana 44 Front Axle Disassembly Procedure Please refer to the steps below for proper adjustment procedure Note Please refer to the attached picture of the Dana 44 axle for number reference Disassembly Procedure Step 1 Lift the tug so that both of the front tires are off the ground and make sure the unit is secured properly Step 2 Remove both front wheels Step 3 Remove both front calipers leaving the brake hose intact Step 4 Remove both of the hub center caps Step 5 Use lock ring pliers to remove both lock rings on the left and right side of the tug 62 Step 6 Remove the Gear 69 spindle 70 and spring retainer 71 on both sides Step 7 Use socket 7157 to remove the locking nut 59 Step 8 Rem
23. pliers 24 6 3 4 inch slip joint pliers 25 9 1 2 inch arc joint pliers 27 Pickle Fork 28 Snap wring pliers 29 30 26 Multimeter Ball Pien Hammer 32 oz Oil Filter wrench 2 3 4 inch to 3 3 4 inch in diameter 31 Grease gun with 20 flex hose 32 Oil pan drain 33 Funnel QA027 REVO7 12 23 11 141 142 MAINTENANCE TIPS FOR INCREASED ALL WEATHER TRACTION DURING AIRCRAFT PUSHBACK 1 Reduce air pressure in pneumatic tires from 60 PSI to as low as 25 PSI restore air pressure to 60 psi as soon as weather emergency ends 2 When pushing with All Wheel Drive tractors make sure the tow bar is level or slightly downhill toward tractor 3 When towing with Rear Wheel Drive raise hitch height 4 When pushing with Rear Wheel Drive lower hitch height Note These strategies 2 3 and 4 maximize all weather traction 5 When pushing aircraft on ice or icy snow with All Wheel Drive a wheel may loose traction wheel spin To stop front wheel spin apply some service brake gradually with left foot until wheel spin stops and hold while con tinuing the pushback Coordinate the left foot service brake pressure and the right foot accelerator to maintain a smooth pushback To stop rear wheel spin apply parking brake with lever until it stops while continuing the pushback 6 On ice or snow use chains or cables If the use of chains is prohibited there are traction cables that serve the same function as
24. returned by the customer to Eagle or an Au thorized Service Representative via prepaid transportation and which is found to be defective will be repaired or replaced and returned to the 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 Electrical Component Warranty Electrical components including but not limited to display starters alternators and electric fans shall be covered under the respective original manufacturers warranty for each individual component Copies of the respective warranties are available upon request This warranty does not extend to the tires batteries and battery chargers as these are warranted directly to the user by their re spective manufacturer and not by Eagle or an Authorized Service Representative This warranty does not apply to any Eagle tow tractor or component part s that have been subjected to misuse accident vandal ism environmental conditions improper handling or application maintenance neglect including lack of lubricants or fluids nor does it extend to the Eagle tow tractor and or parts which have been repaired or altered outside of Eagle s plant or the facility of an Authorized Service Representative without the permission of Eagle This warranty does not apply to routine maintenance or wearable parts of the Eagle tow tractor such as filters seals plugs hose
25. 027 REV07 12 23 11 99 EXHAUST amp INTAKE SYSTEM INTAKE MANIFOLD YANMAR TIER II DIESEL a EATERY 1 4 a TR EATERY 5 4 6 380092 a BOLLMSXSOPLATED BOLLMSX4SPLATED s S INTAKEMANIFOLD QA027 REVO7 12 23 11 100 EXHAUST amp INTAKE SYSTEM EXHAUST MANIFOLD YANMAR TIER DIESEL LOOSE PART QA027 REVO7 12 23 11 101 EXHAUST amp INTAKE SYSTEM EXHAUST MANIFOLD YANMAR TIER III DIESEL MI 3 a N wo Ri E OT X 9 975 2 1 e 15 16 7 10 11 12 13 14 15 16 17 18 QA027 REVO7 12 23 11 102 EXHAUST amp INTAKE SYSTEM INTAKE MANIFOLD YANMAR TIER DIESEL QA027 REVO7 12 23 11 103 EXHAUST amp INTAKE SYSTEM INTAKE MANIFOLD YANMAR TIER DIESEL 2 O MOLA O a 1 a4 20 3 s AIR HEATER 2 PLATED s POULMBXSOPLATID 9 _ 1 MANIFOLD wr INTAKE u 6 BOULMBXiPLATD _ QA027 REVO7 12 23 11 104 OP
26. 0954 or 1 877 255 2287 Outside the Continental U S and Canada please contact Eagle directly 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 QA027 REVO7 12 23 11 13 WARRANTY Eagle Tugs Service Bulletin ESB 02 08 one on ane wer Date October 14 2008 Affected Models Diesel powered TT series tow tractors Subject Tier 3 Stage diesel engine fuel requirements Background The EPA mandated change to Tier 3 diesel engines and EC directives for Stage IIIA diesel engines with higher emission requirements has caused some changes to recommended and acceptable fuels This document will clarify those requirements as they pertain to Eagle Tugs products Tier 2 Eagle Tugs is currently phasing out Tier 2 engines as part of EPA and EC mandated controls These engines will no longer be available for sale unless part of a military exemption or being exported to non conforming countries Tier 2 engines will run on standard diesel fuels 1 D and 2 D with sulfur content up to 5000ppm without modification Tier 2 engines will run on jet fuels Jet A and JP8 with either lubricity filter additives or OEM fuel system modifications to accomodate the lower lubricity jet fuels Tier 3 Stage IIIA Eagle Tugs is curre
27. 14 5 Note The fuel system needs to be primed under certain conditions Before starting the engine for the first time After running out of fuel and fuel has been added to the fuel tank After fuel system maintenance such as changing the fuel filter and draining the fuel water separator or replacing a fuel system component To prime the fuel system 1 Turn the key to the ON position for 10 to 15 seconds This will allow the electric fuel pump to prime the fuel system 2 NEVER use the starter motor to crank the engine in order to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or ring gear QA027 REVO7 12 23 11 96 AIR CLEANER AIR CLEANER ASSEMBLY EM Part Number Description _ 8 00093 INTAKE TUBE NPN 36 HOSE CLAMP 9 P601437 1 AIR CLEANER ELEMENT QA027 7 12 23 11 97 EXHAUST amp INTAKE SYSTEM EXHAUST SYSTEM A TT4D 00253 3 2PC EXHAUST TAIL PIPE 129930 13200 EXHAUST GASKET A TT4 00254 EXHAUST CLAMP 2 HD3 8 THREAD A TT4 00258 2 MUFFLER EXHAUST BRACKET YANMAR THES NATTA QA027 REVO7 12 23 11 98 EXHAUST amp INTAKE SYSTEM EXHAUST MANIFOLD YANMAR TIER II DIESEL LOOSE PART NUT uemusm 4 eme 4 1 ASK STEEN 6 QA
28. 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 QA027 REVO7 12 23 11 POWER TRAIN 55 AND 80 AMP ALTERNATOR ASSEMBLY YANMAR TIER DIESEL Part Number 129795 01900 26116 101202 26306 100002 26366 100002 26106 080222 26014 080252 an Description 55 AMP ALTERNATORS 10 07 THRU 1 08 80 ALTERNATORS THERE AFTER TRANSIT PRO MODELS MAY BE EQUIPPED WITH AN OPTIONAL 105 AMP ALTERNATOR QA027 REVO7 12 23 11 20 POWER TRAIN 40 AMP ALTERNATOR ASSEMBLY YANMAR TIER II DIESEL Part Number 1 129795 01900 26306 100002 7920 11 25132 004150 ALTERNATOR BELT NOT SHOWN QA027 REV07 12 23 11 21 POWER TRAIN 105 AMP HIGH OUTPUT ALTERNATOR ASSEMBLY TUGS WITH TRANSIT PRO AND CAB OPTIONS Oy AEOPT 0021 90720 3 SPAGR 360102 1 8 9440 ALTERNATOR BELT NOT SHOW N QA027 REVO7 12 23 11 POWER TRAIN HEAD COVER ASS 23 POWER TRAIN HEAD COVER ASSEMBLY 6 PLATE BREATHER ora 1 DAPHRAMBREATHER mo SPRING BIANRAM 1 COVER u 1 SPLAT 6 SCREW5XIO
29. 85 86 87 Brake Pressure Horn Relay Ignition Relay Parking Brake Switch QA027 REVO7 12 23 11 Power A Power B Acc Power Trans Temp Spotlight Horn Relay GND Empty Lights Power Lights GND Heater Low Heater High Dash Connector Dark Brown 41L Red LFT 00 I Dark Brown 411 00 T m 11 Front Lett Headlight Front Lett Running Light Front Left Turn Signal Front Right Headlight Front Right Running Light Front Right Radi RE Turn Signal 116 ELECTRICAL SCHEMATICS VEHICLE WIRING HARNESS YANMAR TIER DIESEL Heater Spotlight Alt Excite Bulb Beacon Accelerator Pedal I 5 7 9 10 Ground ECU Power 2 A2 D2 Red Alt Excite Start Relay 4 ovi ECU Power 5 Beas SR 6 P RUUEEEUUUUUUUURUUURUNRUURUUOM CAN Low 7 A wisted Parr CAN High As gt AY treuow 2 Empty A9 2 Empty 10 Z Empty A11 2 H30 Power A12 _____ Z H30 Cennector A Idle Val Switch B1 Parking Brake Switch 82 Gear Selector Switch Empty 84 Foot Pedal Signal 85 NS N Empty B Fuel Level Sender B7 Empty 88 Empty 89 Empty 810 Empty 811 Empty 812 Connector 8 Empty Empty c2 Empty Empty C4 Empty cs Empty bo resid GND Ca
30. A RN 124 Wheel Tire Assembly Dual Rear Wheel Model 125 RHET eee dix RM MEE 126 Hitch De itte aa en e e ed bind 126 Strobe Beacon amp Floor n nl d tei ide rt iet ds 127 arie do 8 128 Cab Eater tina pa ate d a E 130 Other Options NOt eterne ihm rn 131 132 Daily Operator Responsibilities amp Filter Reference 132 L brication Chart iii data 133 Preventative Maintenance Schedule aa 134 TI4 TT8 Specifications amp Capacities 79 136 Yanmar Engine Trouble 138 Recommended Tool List 140 Tip For All Weather Traction inttr rtt ae er ana ER Ed e Fee Eee Rea 86 142 Front End Alignment Procedure trei teet reati et d oe 88 143 Eront Axle Maintenance eter e i n Er Oe Emi eles 144 ADDENDUM seen Q 146 QA027 REV07 12 23 11 WARRANTY 3 Year Limited Warranty Information The Eagle Tugs Eagle 3 Year Warranty covers all TT series eTT series XL series eXL series and USATS tow tractors used in aviation applic
31. AR TIER II 2 8 QA027 REVO7 12 23 11 91 FUEL SYSTEM ENGINE FUEL LINE YANMAR TIER II 1 5 SSCS BOLT 3 18875956 RETURN s 12607596 O 1 PPEASSEMBLYFOREFURN a 1 a WASHER s am vsme 1 1 PIPEASSYFUELRETUEN WITHCLAMES 7 PIPEASYFUELWIHCLAMS s 1 s 1 1 n 12900 55610 1 i 2 PBOLLMSXSOPLATED 15 1 WATER SEPERATOR COMPLETE ASSY 1 1 1 1980550 1 FUE WATER SEPERATOR ELEMENT Note The fuel system needs to be primed under certain conditions Before starting the engine for the first time After running out of fuel and fuel has been added to the fuel tank After fuel system maintenance such as changing the fuel filter and draining the fuel water separator or replacing a fuel system component To prime the fuel system 1 Turn the key to the ON position for 10 to 15 seconds This will allow the electric fuel pump to prime the fuel system 2 NEVER use the starter motor to crank the engine in order to prime the fuel system This may cause the starter motor to overheat and damage the coils pinion and or rin
32. EAGLE TUGS THE POWER MOVE YOU Parts and Service Manual Vehicle Types TT 4 TT 5 TT 6 amp TT 8 Engine Type Yanmar Diesel 4TNV98 Tier II amp Tier III Engine Models With H30 Display QA027 REVO7 12 23 11 This page was intentionally left blank QA027 REVO7 12 23 11 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 amp 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 Eag
33. ENANCE TT4 8 DIESEL SPECIFICATIONS amp CAPACITIES MODEL 4TNV98 DESCRIPTION Vertical In line diesel 3 3 Liter four cylinder direct injection engine OF CYLINDERS 4 IN LINE BORE amp STROKE INCHES mm 3 858 X 4 331 in 98 X 112 mm BATTERY Group 65 860 Cold Cranking Amps automotive battery ENGINE CRANKCASE CAPACITIES ENGINE U S QUARTS IMPERIAL QUARTS LITRES 331 DIESEL OIL SAE 15W40CD ONLY USE OIL THAT IS RATED FOR A DIESEL ENGINE FUEL TANK REFILL CAPACITIES U S GALLONS IMPERIAL GALLONS LITERS 104225 47375 USA SAE SOCIETY OF AUTOMOTIVE ENGINEERS NO 2 D NO 1 D ASTM D975 94 JAPAN JIS K2204 GRADE NO 2 EUROPEAN UINION 590 96 INTERNATIONAL ISO 8217 DMX UNITED KINGDOM BS 2869 AL OR 2 KSM 2610 CHINA GB252 Please refer to Yanmar Engine Instruction Manual for further information QA027 REVO7 12 23 11 137 MAINTENANCE TT4 8 DIESEL SPECIFICATIONS amp CAPACITIES TRANSMISSION REFILL CAPACITIES ENGINE U S PINTS IMPERIAL PINTS LITRES 23 L DIESEL USE DEXTRON III TYPE TRANSMISSION FLUID OR EQUIVALENT ADD 9 PINTS 7 5 IMPERIAL PINTS OR 4 25 LITERS IF TORQUE CONVERTOR HAS BEEN DRAINED ENGINE COOLING SYSTEM REFILL CAPACITIES ENGINE U S QUARTS IMPERIAL QUARTS LITRES 3 3 L DIESEL 16 00 13 30 15 10 50 50 MIXTURE OF GLYCOL AND CLEAN WATER BRAKE SYSTEM The brake system is power assisted hydr
34. ERATOR COMPARTMENT Item 1 ACCELERATOR PEDAL ASSEMBLY TIER III DIESEL Part Number A TT4 00289 A MTT5 0457 QA027 REVO7 12 23 11 105 OPERATOR COMPARTMENT ACCELERATOR PEDAL ASSEMBLY YANMAR TIER II DIESEL 1 BALJONTKT NUTINDLUDD ____ 1 ACCHERATORUBOLTKT psf ACCELERATOR CLEVIS PINKIT TUG MODEL AND SERIAL NUMBER REQUIRED TO ORDER THIS PART QA027 REV07 12 23 11 106 OPERATOR COMPARTMENT INSTRUMENT PANEL QA027 REVO7 12 23 11 107 OPERATOR COMPARTMENT INSTRUMENT PANEL A TT4 00609 HEATER FAN SWITCH OPTIONAL mes 1 EATER CONTROL AMMETERGUAGEQPTONAD TRANSTEMPGAUGE OPTONAD Eagle Tugs TT series Quick Start Guide Powering up the H30 Display Panel Pressing the POWER button will turn on the H30 control panel On key ignition equipped units turn the key to the on position And then press the POWER button Starting the Engine Once the H30 panel has booted up it will prompt you to hold the ENTER key to crank the engine Hold the ENTER key until the unit starts For cold weather operation the display will prompt you to wait for the engine warm up before prompting you to crank the engine POWER button ENTER button Turning off the Engine To turn off the engine press the POWER button On key ignition equipped u
35. G 1 25TB 12 12 3 4 MSAE 3 4 SUCTION BARB 90 DEG FITTING PN PN 10 11 12 13 14 5 6 1 Hem i 7 5 poa __ on _ 9 da 5 5 O7 om _ 2 o 25 26 _ 2 32 so 31 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 3 8 HYDRAULIC HOSE WK PSI350 33 QA027 REVO7 12 23 11 82 This page was intentionally left blank QA027 REVO7 12 23 11 83 HYDRAULIC ASSIST HYDRAULIC ASSIST SYSTEM SCHEMATIC MASTER CYLINDER STEERING BOX Y AA b c 2 5 A Y QA027 REV07 12 23 11 STEERING SYSTEM STEERING SYSTEM BREAKDOWN QA027 REVO7 12 23 11 85 STEERING SYSTEM STEERING SYSTEM BREAKDOWN A TT4 00381 A TT4 00382 STEERING BOX NPN NPN N A A TT4 00386 A TT4 00393 E m B 1 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 ITEMS 7 amp 8 NOT SOLD SEPERATELY THESE PARTS ARE INCLUDED IN ITEMS 22 amp 23 ITEM 17 amp 18 ARE INCLUDED IN ITEM 16 QA027 REVO7 12 23 11 86 FUEL SYSTEM FUEL SYSTEM OPTION FOR TIER ONLY QA027 REVO7 12 23 11 87 FUEL SYSTEM FUEL SYSTEM AO rr NON 3 ra car ser A s i e 7
36. L H 1 RO WE _ 3 2 CB ROTOR ASSEMBLY Ca OR we _ m o SMNXENU 68 2 1XWASHERWHELBRGNUT 2 TN oO 3 3662 6 STODSTHRNGKNUCKE x 6 s Recommended tools 7157 remove Front Axle Spindle Nut Dana 44 7080 To remove Front Axle Top Ball Joint Dana 44 1902 remove Front amp Rear Axle Spindle Nut Dana 70 QA027 REVO7 12 23 11 62 AXLES AXLE ASSEMBLY BREAKDOWN FRONT DRIVE ALL WHEEL DRIVE COMPLETE ASSY 46 U JOINT ONLY 81 19 20 18 QA027 REVO7 12 23 11 63 AXLES AXLE ASSEMBLY BREAKDOWN FRONT DRIVE ALL WHEEL DRIVE Pari Number 3 30768 SiS ER PINTON OIL INNER 5 706617X KIT SHIM PINION ADJ CUM AA ameno o s 70 Kr OUTERPINIONDEARINGERACE 9 C Gr PINON ON OUTER m a CAP DIFFERENTIAL BEARING QA027 REVO7 12 23 11 64 AXLES AXLE ASSEMBLY BREAKDOWN FRONT DRIVE ALL WHEEL DRIVE COMPLETE ASSY 46 U JOINT ONLY 81 19 20 18 QA027 REVO7 12 23 11 65 AXLES AXLE ASSEMBLY BREAKDOWN FRONT DRIVE ALL WHEEL DRIVE fem 40 310026 2 BOLT STOP 41 500381 3 NUT LOCK 42 706653X STEERING KNUCKLE L H INCLUDES ITEMS 33 39 42 amp 53 42 706652X 2 STEERING KNUCKLE R H Rd INCLUDES
37. O7 12 23 11 132 MAINTENANCE DAILY OPERATOR RESPONSIBILITIES Proper Fluid Checks Engine Oil Check engine oil with the unit on a level surface the key in the OFF position the shifter position in PARK and parking brake applied Open side access door Remove dipstick from crankcase wipe it with a cloth Insert it fully and take out it gently again Check the oil level by the marks on the dipstick The oil level must be be tween the Max level and the Min level DO NOT OVERFILL Coolant DO NOT remove recovery tank cap or check coolant level while engine is hot With engine cool the key in the OFF position the shifter position in PARK and the parking brake applied open hood set hood prop and look at left side of recovery tank The reservoir tank is translucent so the fluid is readily visible without remov ing the cap Fluid level should be at the Cold fill level Transmission Fluid With unit in park and parking brake set in the ON position start engine Open side access door Remove dipstick from transmission case wipe it with a cloth Insert it fully and take it out gently again Check the fluid level by the marks on the dipstick The transmission fluid level must be between the Max level and the Min level on the dipstick DO NOT OVERFILL Brake Fluid Check brake fluid with the unit on a level surface the key in the OFF position the shifter position in PARK an
38. O7 12 23 11 POWER TRAIN ENGINE DRESS 1 4 3 4 10 35 GR8 HCSBOLT NEN NENNEN ware 7 A TT8 00360 SP20PB11L145H9L PRINCE PUMP FRONT ENGINE MOUNT B TT5D 00006 1 10 TM27C00305 ID FLEX PLATE WASHER FLEX PLATE n _ __ 1 REXPLATEADAPTR RXYWHELWIHRNGGEM 4 _ ____ i5 TRANSPLATESPACR i16 6 1 ow 3 AJPLATEDOWH PNSSBX2S 777 E m 2 SC XO PLATE m 2 NGNEMOUNTTRANSPLATE m 1 m sw O 2 TEANSMSSONDOWE PN a FANBRACKETSPACER a FANBRACKETSPACER REMOTEFANBRACKET REVOTEFANSNAPRNG m REMOTEFANSHAFTHOUSNG 2 REMOTEFANBEARING 1 REVOTEFANSHAFT imas rightening Torque 6 mm powo 94108 QA027 REVO7 12 23 11 gt 18 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
39. ODELS Description 1 STANDARDTIRETS 3 SCOR REARS 4 3 s WHELADAPTRLUGNUT s QA027 REVO7 12 23 11 126 OPTIONS HITCH OPTIONS Part Number 1 AE OPT 0033 The above are standard hitch options Please call for special hitch options information QA027 REVO7 12 23 11 127 OPTIONS STROBE BEACON amp FLOOR MAT OPTIONS Cm J Oy 1 1 AMBERROTATINGBEACON 1 E 18 E o alo q 34 OPERATOR SWITCHMAT QWITHSENSOR _ A TT10 00451 1 SWITCHMAT DELAY TIMER QA027 7 12 23 11 128 OPTIONS CAB OPTION QA027 REVO7 12 23 11 129 OPTIONS CAB OPTION I AE OPT 0003 1 CAB ASSEMBLY COMPLETE m 9 1 SLIDING WINDOW 1 RON QUARTER WN m Thoms LTE LIGHT BULB NOT SHOWN lo QA027 REVO7 12 23 11 130 OPTIONS PY ENGINE RETURN Part Number 3 CONTROL VALVE E 2 4 memes TER FAN ST s rumes TEMPERATURE CONTROL P QA027 REVO7 12 23 11 131 OPTIONS OTHER OPTIONS LISTED NOT SHOWN Part Number AE OPT 0001 BACK UP ALARM AE OPT 0086 INTERCOM JACK AE OPT 0094 12V ACCESSORY OUTLET QA027 REV
40. TAPHNG 15 AFE 7777777777 OS 15 aro 1 muews 129907 11320 HEAD COVER ASSY INCLUDES ITEMS 1 13 1111 6 _ 7 QA027 REV07 12 23 11 24 POWER TRAIN CYLINDER BLOCK ASSEMBLY YANMAR TIER II DIESEL LO QA027 REVO7 12 23 11 25 POWER TRAIN CYLINDER BLOCK ASSEMBLY YANMAR TIER II fem Qy _________ 1 000002 2 NGN 1 7290000 7 1299000202 i QA027 REVO7 12 23 11 26 POWER TRAIN CYLINDER BLOCK ASSEMBLY YANMAR TIER III DIESEL QA027 REVO7 12 23 11 27 POWER TRAIN CYLINDER BLOCK ASSEMBLY YANMAR TIER DIESEL CYLINDER HEAD GASKET 129900 02341 MAIN BEARING SET O S 025 11 729927 01560 1 CYLINDER BLOCK ASSY INC ITEMS 1 10 QA027 REVO7 12 23 11 POWER TRAIN CRANKSHAFT amp PISTON YANMAR TIER II DIESEL QA027 REVO7 12 23 11 29 POWER TRAIN CRANKSHAFT amp PISTON YANMAR TIER II DIESEL Sy 6 1259090 5 7 BXLRD s CONNECTING RODASSY WASHER 129907 21660 V PULLEY CRANKCASE 1 i n GEAR CRANKSHAFT 1 129902 21000 CRANKSHAFT ASSY INCLUDES ITEMS 12 15 129900 21600
41. as quickly as possible EXCEPT AS SET FORTH ABOVE ALL WARRANTIES CONDITIONS REPRESENTATIONS INDEMNITIES AND GUARAN TEES 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 CUSTOMER DISTRIBUTOR DEALER OR ANY REPRESENTATIVE ARE HEREBY OVERWRITTEN AND EXCLUDED AND NO LIABILITY SHALL ATTACH TO EAGLE THER IN CONTRACT OR IN TORT OR STRICT LIABILITY IN TORT FOR ANY DAMAGE TO PROPERTY LOSS OF PROF ITS 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 MACHINE OR THE SUPPLY OF SERVICES SUBJECT TO CHANGE WITHOUT NOTICE Please check our website www eagletugs com periodically for service bulletins and manual updates Note The Eagle Tugs 3 Year Warranty covers TT series eTT series XL series eXL series and USATS tow tractors which are used in aviation applications All MTT and RTT series and Transit Pro models as well as all Eagle tow tractor models which are used in industrial applications are covered under the Eagle Standard Warranty of 1 Year or 2 000 hours Eagle Bob Tails are covered under Ford Motor Company s Standard Warranty for each respective Ford truck model QA027 REVO7 12 23 11 10 WARRANTY IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe
42. ations Eagle Tugs warrants that these tractors will be free from defects in material and workmanship for a period of 3 years or 3 000 operating hours with the exception of the electrical system see electrical component warranty below from date of delivery to the first customer or first use 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 Eagle s election any part or parts deemed defective after examination by Eagle or an Authorized Service Representative Any Eagle tractor or any of its parts returned by the customer to Eagle or an Authorized Service Repre sentative via prepaid transportation and which is found to be defective will be repaired or replaced and returned to the customer prepaid On the other hand should a part be found not defective inspection and handling charges may be charged to the cus tomer or Authorized Service Representative by Eagle Electrical Component Warranty Electrical components including but not limited to display starters alternators and electric fans shall be covered under the respective original manufacturers warranty for each individual component Copies of the respective warranties are available upon request This warranty does not extend to the tires batteries and battery chargers as these are warranted dir
43. aulic front disc type and rear drum type USE DOT 3 BRAKE FLUID STEERING SYSTEM The steering system is power assisted hydrostatic type Use Either Power Steering Fluid Equivalent Soec For GM 9985010 CHRYSLER 5 5931 OR FORD ESW M2C128 C 10W Mineral AXLE REFILL CAPACITIES AXLE U S PINTS IMPERIAL PINTS LITRES FRONT STEER NON DRIVE FRONT DRIVE AXLE REAR DRIVE AXLE SERVICE REFILL CAPACITIES ARE DETERMINED BY FILLING TO THE BOTTOM OF THE FILLER HOLE USE 80W90 GEAR LUBRICANT QA027 REVO7 12 23 11 138 MAINTENANCE YANMAR ENGINE TROUBLE SHOOTING Low engine Coolant Add engine coolant Dirty radiator fins Clean the radiator fins See authorized Yanmar Engine coolant leaking industrial engine dealer or distributor Indicator V belt loose or damaged Adjust V belt or replace See authorized Yanmar Contaminated engine coolant industrial engine dealer or distributor Faulty engine coolant pump V belt loose or damaged Adjust V belt or replace Battery failure Check battery condition Battery Indicator See authorized Yanmar Faulty alternator industrial engine dealer or distributor Faulty electrical wiring or See authorized Yanmar faulty indicator industrial engine dealer or distributor See authorized Yanmar Battery Indicator stays ON Faulty alternator industrial engine dealer or distributor Fault i il itch industrial engine deal aulty e
44. d parking brake applied Open hood set hood prop and locate master cylinder reservoir Remove spring clips and take off lid Brake fluid level should be at the top of reservoir Power Steering Fluid Check power steering fluid with key in OFF position the shifter position in PARK and the parking brake applied Open hood set hood prop remove cap from power steering reservoir Fluid level should be between the arrows on the indicator stick DO NOT OVERFILL Recommended Filters Engine oil 129150 35153 Fuel Filter 119802 55801 Air Cleaner Donaldson P601437 Fuel Water Seperator Filter 129242 55730 Transmission Filter Wix 58705 Lubricity Filter Tier only Fleetgard 520000 QA027 REVO7 12 23 11 133 MAINTENANCE LUBRICATION CHART EP MULTIPURPOSEGREASE ENGINE COOLANT CHECK ETHYLENE GLYCOL WATER 50 50 MIX ACCELERATOR CABLE LUBE SUMMER MONTHS WD40 PENETRATING OIL mamma ASAS WHEN ENGINE IS AT OPERATING TEMPERATURE IT IS RECOMMENDED BY MANUFACTURER TO PROLONG THE LIFE OF YOUR ACCELERATOR CABLE THAT THE ABOVE LUBRICATION BE FOLLOWED QA027 REVO7 12 23 11 134 MAINTENANCE PREVENTATIVE MAINTENANCE SCHEDULE Description of Check Service Operational Hours Syste T m X check Requires Service Daily 50 250 500 750 1000 1250 1500 2000 Contact your local Yanmar distributor or dealer Engine Oil Engine Oil and filter
45. ectly to the user by their re spective manufacturer and not by Eagle or an Authorized Service Representative This warranty does not apply to any Eagle tow tractor or component part s that have been subjected to misuse accident vandal ism environmental conditions improper handling or application maintenance neglect including lack of lubricants or fluids nor does it extend to the Eagle tow tractor and or parts which have been repaired or altered outside of Eagle s plant or the facility of an Authorized Service Representative without the permission of Eagle This warranty does not apply to routine maintenance or wearable parts of the Eagle tow tractor such as filters seals plugs hoses belts brake pads or shoes 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 This warranty does not cover or provide credit for the following tractor rental or other substitute equipment lodging loss of time income sales or profits loss of the use of tractor telephone calls or communication expense lift truck storage fees injury or death to persons or damage or destruction of property or consequential incidental or punitive damages Labor Allowance A labor allowance may be issued upon request at Eagle s discretion Allowable labor hours and a per hour labor rate will be determined by Eagle according to reasonable automotive s
46. first 50 and every 250 hours thereafter Fuel ir Cleaner Element Lubricity Filter every 250 hours C Ai r nt every 500 hours Engine Engine Rubber Mounts x x x Compartment Lap Intake Exhaust Valve Seats Adjust Intake Exhaust Valve Clearance Check amp Adjust Governor Lever amp Engine Speed Control every 250 hours Inspect Crankcase Breather System Valve Cleaning Inspect Clean amp Check Injection Nozzles Electrical Electrical Wires and Connections IX x Battery Cables Throttle Throttle Controls Brake Pads Front Drum Brake Lining Rear Brake Lines and Hoses 04027 REV07 12 23 11 135 MAINTENANCE PREVENTATIVE MAINTENANCE SCHEDULE Description Check Service Operational Hours X Check Requires Service 50 250 500 750 1000 1250 1500 2000 Contact your local Yanmar distributor or dealer Suspension Suspension U Bolts 110 120 FT LBS IC I PI XX ewe EC gt O encon 15 XIX XI XI CI x x Lug Nut Torg 150 FT LBS The above chart provides recommended preventative maintenance intervals Your actual maintenance program May vary depending on vehicle usage This section below has been added to for your record keeping convenience Tug serial umber 00002 __ Regn QA027 7 12 23 11 136 MAINT
47. g amp Parts ici hanan q 52 Transaxle Case Extension amp Retainer 54 AXE A a sees 56 Axle Assembly Front Non Drive 56 Axle Assembly Front Drive All Wheel Drive 57 QA027 REV07 12 23 11 TABLE OF CONTENTS Axle Assembly Reais 2 ont ete ataq ii Oe rne 58 Recommended Axle Torque Specs ni nete 59 Axle Assembly Breakdown Front Non Drive 2WD 2 60 Axle Assembly Breakdown Front Drive All Wheel 62 Axle Assembly Breakdown Rear n nennen nnn 66 BRAKES PEE 70 Parking Brake Actuator Assembly nennen 70 Dr m Brake Assembly Rear eee eter mese rer er 3 ka 86 89 72 Brake Assembly V 74 Brake System Hydraulics M 7 VV 76 Hydraulic Assist With Prince 78 Hydraulic Assist With Metaris Pump nennen nennen 80 Hydraulic Assist Schematic 83
48. g gear QA027 REVO7 12 23 11 92 FUEL SYSTEM FUEL INJECTION PUMP YANMAR TIER DIESEL Description FUEL INJECTION PUMP 3 10x 3 BOLT MS X 30 PLATED 3 3 BOLT MS X20 PLATED RETAINER 5 1 BOLLM XISPLATED UNE QA027 REVO7 12 23 11 93 FUEL SYSTEM FUEL INJECTION LINES AND NOZZLE YANMAR TIER III DIESEL TUOS aD 1 PIP ASSEMBLY FUEL INJECTION x 2 Tr PIPEASSEMBLYFUELINICTION 3 12575980 1 ASSEMBLY FUEL INJECTION 29927 59840 PIPBASSEMBLYFUELINIECHON 7 322592 s 2636606002 2 9 1 10 2 __ N N QA027 REVO7 12 23 11 94 FUEL SYSTEM ENGINE FUEL LINE YANMAR TIER DIESEL QUE seda gt CES 2 220 5 42 7 22 27 e LISTAR QA027 REVO7 12 23 11 95 FUEL SYSTEM ENGINE FUEL LINE YANMAR TIER DIESEL 1 3 3 4 s 7 s 5 19 _ 1I980255801 n 1000 m 2509 m 1 2 3 4 5 7 10 11 12 13
49. le Warranty and procedure as well as information pertaining to the safe operation of your Eagle product please see the Eagle Operations Manual that was also included with your vehicle TECHNICAL ASSISTANCE When addressing a repair procedure or operational problem please remember that Eagle technical support is only a phone call away Eagle technicians are available to assist you in vehicle diagnostics and recommended repair proce dures We encourage you to use this service to reduce machine down time and to gain a better understanding of proper repair procedures ORDERING SPARE SERVICE PARTS Eagle inventories most of the component parts found in its TT series tow tractors and most spare service parts can be shipped the same day the order is received Parts orders need to be received at Eagle by 12 00 pm Noon EST in order for the parts to be shipped that same day Parts ordered after 12 00 pm EST will most likely be shipped the following day NOTE PLEASE CHECK OUR WEBSITE PERIODICALLY FOR MANUAL UPDATES AS WELL AS SERVICE BULLETINS Eagle Corporate Office 26111 Northline Rd Taylor MI 48180 800 671 0431 www eagletugs com Customer Service Parts amp Service Technical Support customerservice eagletugs com parts eagletugs com support eagletugs com 734 442 1000 800 671 0431 734 442 1000 800 671 0431 734 442 1000 800 671 0431 QA027 REV07 12 23 11 This page was intentionally left blank QA027 REVO7 12 23 11
50. may vary Please contact Eagle for further information QA027 REV07 12 23 11 TRANSMISSION TRANSAXLE CASE EXTENTION amp RETAINER ALL TT 4 8 MODELS QA027 REVO7 12 23 11 55 TRANSMISSION TRANSAXLE CASE EXTENTION amp RETAINER ALL TT 4 8 MODELS NPN 6 SCREW HEXCAP M8X125X23 SCREW HEX CAP W ASH HEAD M8 1 25 X 2 3878447 4471573 6501474 4504568 4269787 4329829 6500368 NPN NPN 4659342 82180 6501474 6101285 SCREW HEX CAP W ASH 6 1 X 16 RETAINER 4567494 NPN a 2 2 2 N N A TT4 00657 16 p NE TNT 9 5 EE S 09 20 2 22 N PLEASE HAVE TUG MODEL AND SERIAL NUMBER AVAILABLE WHEN ORDERING THIS PART QA027 REVO7 12 23 11 56 AXLES AXLE ASSEMBLY FRONT NON DRIVE TT4 TT6 2WD ONLY NPN 1 A TT4 00362 1 TT4 00363 A TT4 00366 A A A TT4 00119 A A INCLUDED IN U BOLT KIT QA027 REVO7 12 23 11 10 AXLE ASSY FRONT NON DRIVE 3 8 16 LOCK NUT U BOLT KIT AXLE CLAMP PLATE W ASHER U BOLT 57 AXLES AXLE ASSEMBLY FRONT DRIVE ALL WHEEL DRIVE STEERING ARM AWD 4 memi Kr s mew s NN 5 5 1 8 INCLUDED IN U BOLT KIT QA027 REVO7 12 23 11
51. ngine oil pressure switc industria a 2 er Check and adjust oil level indicator stays ON No or low level of engine oil as necessary Clogged engine oil filler Replace engine oil filter QA027 REVO7 12 23 11 MAINTENANCE YANMAR ENGINE TROUBLE SHOOTING Engine Does Not Start No diesel fuel Refuel and prime fuel system Air in fuel system Prime fuel system Replace with recommended Improper diesel fuel diesel fuel Starter motor operates Clogged fuel filter Replace fuel filter but engine does not start See authorized Yanmar Poor fuel injection industrial engine dealer Compressed air leakage from or distributor intake exhaust valves Faulty engine stop solenoid Starter motor does not operate or rotates too Battery needs chargin Check electrolyte recharge L V 8108 8 slowly engine canbe Faulty starter switch Clean terminals retighten turned manually See authorized Yanmar Faulty starter motor industrial engine dealer Engine cannot be or distributor manually turned Inner parts seized or damaged White or Black Exhaust Smoke Engine overload Reduce load Clogged air cleaner element Clean element or replace Replace with recommended Improper diesel fuel diesel fuel See authorized Yanmar Black exhaust smoke Faulty spraying of fuel injection industrial engine dealer Exessive intake exhaust valve or distributor clearance Replace with recommended Improper diesel fuel diesel fuel
52. nits turn the key to the off position after the display panel has turned off QA027 REVO7 12 23 11 108 OPERATOR COMPARTMENT TRANSMISSION CONTROL A TT4 00419 302008 302348 QA027 REVO7 12 23 11 109 ELECTRICAL SCHEMATICS DASH WIRING HARNESS Yous 1 6 86 0 17 WV3NOVIO yB yoog jyBipjoog 6 1uBn C uong WOH OL DST ZUOSH LL MOJ 4 1 1 01 8696 C oe 010 umon 61LL 8692 50000 9vy9 SHUM SIOGS 09879 ySUDJ Xu ecv uodo 6 9 C 9461 5VCIL JOMOd QA027 REVO7 12 23 11 110 ELECTRICAL SCHEMATICS Ground Al Inj Pump Hold Supply A2 Alt Excite Start Relay A3 A4 Ignition Relay A5 Empty Empty Empty Empty A7 9 Empty 10 Output Power Supply All H30 Power Supply 12 H30 Empty Park Brake Switch Gear Selector Switch Empty Empty Empty Fuel Level Sender Empty Mag Pickup A B9 Mag Pickup B10 Empty B11 Cold Start Aid B12 H30 B Empty Empty Empty Empty Inj Pump Pull Emp
53. ntly phasing in Tier 3 Stage conforming engines per EPA and EC mandates Tier 3 engines will run on fuels with sulfur content of less than 500 ppm or 0596 without modification This includes fuels commonly referred to Low Sulfur Diesel LSD and Ultra Low Sulfur Diesel ULDS Tier 3 engines will NOT run properly on Jet A or JP8 fuel due to the high sulfur content The EGR system on tier 3 engines allows sulfur in the fuel to recirculate from the exhaust back into the intake where it is converted to sulfuric acid which corrodes internal engine components In the future as jet fuel standards are directed towards lower sulfur content this may change Tabulated Data 995 mtm Tier 2 No modificabon necessary No modification necessary enhancement or engine modification If you have any questions please contact Eagle technical support at 734 442 1000 Revision 1 10 15 08 QA027 REVO7 12 23 11 14 This page was intentionally left blank QA027 REVO7 12 23 11 SERVICE PARTS ILLUSTRATIONS amp DETAIL IDENTIFICATION KEY The following abbreviations are used throughout the parts lists in this section Abbreviation rM Not Listed Part required but not shown on diagram No Part Number Parts shown and numbered but not stocked and sold by Eagle Cj SCY used for bolts clamps etc AR as Asrequired HELP US SERVICE YOU BETTER HAVE MODEL AND SERIAL NUMBER
54. om moving parts when the engine is running especially the fan and belts eTo prevent serious burns avoid contact with hot metal parts such as the radiator exhaust manifold tail pipe catalytic converter and muffler eDo not smoke while working on the equipment eTo 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 eKeep hands and other objects clear of the radiator and blades 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 QA027 REVO7 12 23 11 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 H VEHICLE S N ENGINE POWER MFG DATE TRACTOR MASS MODEL DRAW BAR PULL ENGINE TOW CAPACITY ENGINE S N VERTICAL HITCH CAP N MANUFACTURED BY 2 ORTHLIME RD TA 48180 USA PHONE 800 471 0431 salerfeaglelugs com www eoglelugs com Data Plate Location QA027 REV07 12 23 11 12 WARRANTY WARRANTY REGISTRATION INFORMATION Please complete and return the Eagle Tugs Warranty Registration Card provided
55. our website www eagletugs com periodically for service bulletins and manual updates The Eagle Tugs 3 Year Warranty covers TT series eT T series XL series eXL series and USATS tow tractors used in aviation applications All MTT and RTT series and Transit Pro tow tractors and all Eagle models which are used in industrial applications are covered under the Eagle Standard Warranty of 1 Year or 2 000 hours Eagle Bob Tails are covered under Ford Motor Company s Standard Warranty for each respective Ford truck model QA027 REVO7 12 23 11 WARRANTY Standard Limited Warranty Information The Eagle Tugs EAGLE Standard Warranty covers all MTT RTT series and Transit Pro tow tractors as well as all Eagle tow tractor models used in industrial applications Eagle Tugs warrants that these tractors will be free from defects in material and workmanship for a period of 1 year or 2 000 operating hours with the exception of the electrical system see electrical component warranty below from date of delivery to the first customer or first use whichever comes first Written notice of any claimed de fect 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 Eagle s election any part or parts deemed defective after examination by Eagle or an Authorized Service Representative Any Eagle tractor or any of its parts
56. ove the locking ring 58 Step 9 Remove the spindle nut Step 10 Slide the rotor amp hub assembly off the spindle leaving the bearings inside the hub QA027 REVO7 12 23 11 145 MAINTENANCE FRONT AXLE MAINTENANCE Reassembly Procedure If the Backing Plate amp Spindle Were Removed Step 1 Install the backing plate with the chamfer facing the spindle Note Be sure the backing plate is aligned in the correct position as it was before it was removed Step 2 Tighten the 6 new 3 8 24 stover lock nuts to 33ft Ibs Step 3 Install the rotor amp hub assembly making sure the bearing does not fall out Step 4 Install the spindle nut with the dowel facing toward you Tighten to 35ft lbs to seat the bearings while spinning the rotor Step 5 Loosen the spindle nut and re snug Step 6 Install the lock ring making sure the hole in the ring lines up with the dowel on the nut If it does not rotate the nut so the dowel is aligned Step 7 Install the lock nut and torque to 50ft lbs Step 8 Install the spring seat with the flat part facing toward you Step 9 Install the spring the gear and the clip Step 10 Apply small amount of RTV sealant to the cap and install Step 11 Install the caliper Step 12 Install the tires and lug nuts and torque the nuts to 90ft Ibs QA027 REVO7 12 23 11 146 QA027 REVO7 12 23 11
57. s belts brake pads or shoes 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 This warranty does not cover or provide credit for the following tractor rental or other substitute equipment lodging loss of time income sales or profits loss of the use of tractor telephone calls or communication expense lift truck storage fees injury or death to persons or damage or destruction of property or consequential incidental or punitive damages Labor Allowance A labor allowance may be issued upon request at Eagle s discretion Allowable labor hours and a per hour labor rate will be determined by Eagle according to reasonable automotive standards Warranty Claim Procedure When a warranty situation arises it is essential that the customer contact Eagle s Warranty Depart ment at 1 734 442 1000 The customer will need to provide Eagle with the tow tractor serial number and engine hours A cus tomer service representative will analyze the problem and determine the next steps In many cases Eagle s technical support per sonnel will be able to analyze the problem and recommend adjustments that will solve the problem and reduce down time If fur ther service is required an Eagle customer service representative will work with customer personnel to arrange a service provider and or parts be sent to your facility for the repair
58. tandards Warranty Claim Procedure When a warranty situation arises it is essential that the customer contact Eagle s Warranty Depart ment at 1 734 442 1000 The customer will need to provide Eagle with the tow tractor serial number and engine hours A cus tomer service representative will analyze the problem and determine the next steps In many cases Eagle s technical support per sonnel will be able to analyze the problem and recommend adjustments that will solve the problem and reduce down time If fur ther service is required an Eagle customer service representative will work with customer personnel to arrange a service provider and or parts be sent to your facility for the repair as quickly as possible EXCEPT AS SET FORTH ABOVE ALL WARRANTIES CONDITIONS REPRESENTATIONS INDEMNITIES AND GUARAN TEES 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 CUSTOMER DISTRIBUTOR DEALER OR ANY REPRESENTATIVE ARE HEREBY OVERWRITTEN AND EXCLUDED AND NO LIABILITY SHALL ATTACH TO EAGLE EI THER 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 OTH ERWISE WHICH ARISE OUT OF OR IN CONNECTION WITH THE SALE OR USE OF ANY EAGLE MACHINE OR THE SUP PLY OF SERVICES SUBJECT TO CHANGE WITHOUT NOTICE Please check
59. ty Temp Sender Empty Oil Pressure Sender 2 C4 5 C7 C8 C9 Empty C10 Empty C11 Empty C12 H30 Empty Parking Brake Switch Gear Selector Switch Empty Ignition Relay Empty Fuel Level Sender Empty Empty Fuel Pump 1 Empty H30 Power C 1 2 3 4 5 6 y 8 9 0 11 12 YANMAR ENGINE WIRING HARNESS YANMAR TIER II DIESEL Red Brown elow Red Purple Red Red Black Lt Brown Vehicle Connector QA027 REVO7 12 23 11 1 2 t 2 Fuel Pump oil Pressure Ter Sender Engine Wiring Harness Tier 2 4INV98 ELECTRICAL SCHEMATICS YANMAR ENGINE WIRING HARNESS YANMAR TIER II DIESEL tLe Battery T lt Excite lt Mag Eat GND Alternator 86 Inj Pump Pull Relay 30 87 86 85 Air Heater Relay Hold Pull Inj Pump 1 2 1 552 1 2 1 2 1 2 Fuel Pump Oil Pressure Temp Sender Starter Air Heater Sender Engine Wiring Harness Tier 2 41NV98 QA027 REVO7 12 23 11 112 ELECTRICAL SCHEMATICS YANMAR ENGINE WIRING HARNESS YANMAR TIER III DIESEL 5 Starter SAWGRea B59 8598 316 RingL gt 10 AWG Rea 860 2 B60A 516 Ring B608 53 SP4 0 Batiery 10 AWG Black B45 Rig
60. your tug or fill out and submit on line at www eagletugs com 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 TIRES For tire warranty please contact Eagle directly by phone at 800 671 0431 by email at support eagletugs com or through our website at www eagletugs com BATTERY In the U S and Canada call 1 888 823

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