Textron Off Road RECOIL iS CREW, Service & Parts Manual

Page 1: ...SERVICE PARTS MANUAL 640774 V REVISED SEP 2017 ISSUED DECEMBER 2014 ...

Page 2: ......

Page 3: ... personal injury or death Textron Specialized Vehicles prohibits and dis claims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle TSV reserves the right to incorporate engineering and design changes to products in this manual without obligation to include these changes on units sold previously The information contained in this ...

Page 4: ...tinue to check the charge on the battery pack This will draw power from the battery pack and eventually drain the batteries if power is not restored in a timely manner As with all electric vehicles the batteries must be checked and recharged as required or at a minimum of 30 day intervals Check and maintain the proper fluid level in all battery cells during the storage period Proper fluid level is...

Page 5: ...MANUAL v ACCELERATOR A 1 BATTERY SYSTEM B 1 BODY C 1 BRAKES D 1 DIFFERENTIAL LOCK E 1 ELECTRICAL SYSTEM F 1 FRONT AXLE REAR AXLE G 1 FRONT SUSPENSION AND STEERING H 1 MOTOR J 1 OPERATOR PROTECTION SYSTEM OPS K 1 REAR SUSPENSION L 1 SEATING M 1 TRUCK BED N 1 WEATHER PROTECTION P 1 WHEELS AND TIRES Q 1 ...

Page 6: ...Page iv 640774 Service Parts Manual NOTES ...

Page 7: ...F THE MANUAL To use this manual consult the GENERAL INDEX to locate the information or illustration required Introduction of some revisions varies due to supply of components therefore it is possible that various combinations of components may be found that are not directly reflected by each illustration Consult the illustration that best suits your situation and then contact the Service Parts Dep...

Page 8: ...s found The part number is the lowest assembly sold by Service Parts and the asterisk indicates that the part depicted is not available for purchase NOTE Descriptions are indented under the assembly that they are used on That assembly is in turn listed under the assembly that it is used on This process is repeated until the highest final assembly is reached To facilitate the maintenance and repair...

Page 9: ...rt number for the body part will denote the color code Locate the part number for the cowl rear body seat pod side panel or seat wrap then locate your color in the list below Replace the last or XX with the two digit color code CODE DESCRIPTION 38 BRIGHT WHITE 39 FLAME RED 72 MATTE BLACK 78 REALTREE XTRA DIPPED 80 REALTREE MAX 5 DIPPED ...

Page 10: ...Service Parts Manual ACCELERATOR Page A 1 640774 Service Parts Manual Front of Vehicle 5 4 14 14 6 1 13 13 7 3 4 12 13 2 2 12 13 3 4 ...

Page 11: ... NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual ACCELERATOR Page A 2 Service Parts Manual 640774 Service Parts Manual 1 626739 ACCELERATOR PEDAL 1 2 14601G11 RIVET 3 16 X 9 16 4 3 00414G6 HEX HEAD BOLT 1 4 20 X 7 8 LG 2 4 00559G7 FLAT WASHER 1 4 4 5 14390G4 HEX LOCK NUT 1 4 20 2 6 635422 ACCELERATOR PEDAL MOUNTING BRACKET 1 7 630045 ACCELERATOR PEDAL COVER 1 8 9 10 11 12 00414G6 HEX HEAD BOLT 1...

Page 12: ...Service Parts Manual Notes ACCELERATOR Page A 3 640774 Service Parts Manual ...

Page 13: ...Service Parts Manual Notes ACCELERATOR Page A 4 Service Parts Manual 640774 Service Parts Manual ...

Page 14: ...Service Parts Manual BATTERY SYSTEM Page B 1 640774 Service Parts Manual 2 17 8 13 14 15 4 5 9 1 Front of Vehicle 10 10 ...

Page 15: ... DESCRIPTION QTY Service Parts Manual BATTERY SYSTEM Page B 2 Service Parts Manual 640774 Service Parts Manual 1 614382 BATTERY 8V 2 2 11027G1 FLANGED LOCK NUT 5 16 18 2 3 4 623299 BATTERY FILL SYSTEM 1 5 634673 BATTERY HOLD DOWN WELDMENT 2 BATTERIES 1 6 7 8 604197 TIE DOWN BOLT 2 9 628624 BATTERY WIRE 12 5 1 10 628632 BATTERY WIRE 92 2 11 12 13 634672 BATTERY TRAY WELDMENT 1 14 548604 FLANGED HEX...

Page 16: ...Service Parts Manual BATTERY SYSTEM Page B 3 640774 Service Parts Manual RECYCLE RE TU RN LE AD 640561 21 16 22 29 30 10 9 3 1 25 24 26 5 11 20 17 10 12 6 14 13 19 2 27 28 Front of Vehicle ...

Page 17: ...TERY WIRE 12 5 5 7 8 9 607297 RUBBER WASHER 47 5MM O D X 12 3MM I D 4 10 11027G1 FLANGED LOCK NUT 5 16 18 6 11 643171 VINYL CAP 6 12 616229 BATTERY HOLD DOWN WELDMENT 1 13 641417 BATTERY FILL SYSTEM 1 14 642123 BATTERY FILL SYSTEM 1 15 16 70386G01 TIE DOWN BOLT 2 17 636142 BATTERY HOLD DOWN WELDMENT 1 18 19 640561 BATTERY WARNING LABEL 1 20 628632 BATTERY WIRE 92 2 21 635683 BATTERY WIRE B TO CONT...

Page 18: ...Service Parts Manual BATTERY SYSTEM Page B 5 640774 Service Parts Manual 4 6 1 2 3 9 CHARGER CORD KIT includes item 9 8 ...

Page 19: ... ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual BATTERY SYSTEM Page B 6 Service Parts Manual 640774 Service Parts Manual 1 626766 BATTERY CHARGER WITH HANDLE 72V 12A 1 2 630758 BATTERY CHARGER INTERNATIONAL WITH HANDLE 72V 12A 1 3 640261 ONBOARD BATTERY CHARGER 72V 1 4 634567 BATTERY CHARGER D PLUG 72V 1 5 6 645743 BATTERY CHARGER D PLUG 72V 1 7 8 652608 CHARGER CORD KIT 5 METER DC CO...

Page 20: ...Service Parts Manual Notes BATTERY SYSTEM Page B 7 640774 Service Parts Manual ...

Page 21: ...Service Parts Manual Notes BATTERY SYSTEM Page B 8 Service Parts Manual 640774 Service Parts Manual ...

Page 22: ...l A 24 B 1 2 3 5 6 20 28 27 21 27 7 10 26 29 13 15 16 18 18 17 A 11 9 4 3 4 INSTRUMENT PANEL ASSEMBLY includes items 10 12 14 DASH ASSEMBLY includes items 15 19 27 27 Front of Vehicle 12 27 12 30 22 23 32 34 31 33 B 665091 MIN 150 cm 59 inches www textronoffroad com 19 ...

Page 23: ...ER FLARE PASSENGER SIDE 1 8 9 633298 INSTRUMENT PANEL ASSEMBLY INCLUDES ITEMS 10 12 1 10 633297 INSTRUMENT PANEL 1 11 71158G01 INSERT 4 CUP 1 12 71364G02 J TYPE SPEED NUT 8 5 13 638059 DASH PANEL BOTTOM 1 14 638066 STEERING COLUMN DASH ASSEMBLY INCLUDES ITEMS 15 19 1 15 638052 COVER 1 16 638052 SWITCH COVER 1 17 71364G03 J TYPE SPEED NUT 8 4 18 608290 PAN HEAD PHILLIPS SCREW 10 16 X 780 LG 4 19 66...

Page 24: ...l information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual BODY FRONT Page C 3 640774 Service Parts Manual 31 655655G01 COWL DECAL 72V DRIVER SIDE FOR VEHICLES MANUFACTURED AFTER 19 SEPTEMBER 2016 1 32 655655G02 COWL DECAL 72V PASSENGER SIDE FOR VEHICLES MANUFACTURED AFTER 19 SEPTEMBER 2016 1 33 626663 COWL DECAL FOR VEHICLES MANUFACTURED BEFORE 19 SEPTEMBER 2016 1 34 655659 COWL DE...

Page 25: ...Service Parts Manual Notes BODY Page C 4 Service Parts Manual 640774 Service Parts Manual ...

Page 26: ...ice Parts Manual BODY MID Page C 5 640774 Service Parts Manual A A Front of Vehicle 10 11 16 19 18 30 33 32 31 24 27 25 26 20 21 34 9 10 11 10 15 11 17 8 9 9 12 37 36 3 2 4 1 2 24 47 41 43 42 44 45 46 39 40 ...

Page 27: ... 3 8 16 6 5 6 7 8 632991G01 FRONT ROCKER PANEL DRIVER SIDE 1 9 16705G1 TRUSS HEAD PHILLIPS SCREW SS 1 4 20 X 1 LG 4 10 23726G4 SPACER 298 4 11 14390G4 LOCK NUT 1 4 20 4 12 632991G02 FRONT ROCKER PANEL PASSENGER SIDE 1 13 14 15 637455G01 FRONT SEAT SIDE PANEL DRIVER SIDE 1 16 71055G01 RIVET 3 16 6 17 10570G12 RIVET 257 X 556 2 18 637455G02 FRONT SEAT SIDE PANEL PASSENGER SIDE 1 19 637453 REAR KICK ...

Page 28: ... HEAD BOLT 5 16 18 X 8 LG 2 35 36 638047G0XX FRONT SIDE PANEL DECAL PASSENGER SIDE 1 37 638049G0XX FRONT SIDE PANEL DECAL DRIVER SIDE 1 38 39 641344G01 FRONT LOCK BRACKET DRIVER SIDE FOR CE VEHICLES ONLY 1 40 641344G02 FRONT LOCK BRACKET PASSENGER SIDE FOR CE VEHICLES ONLY 1 41 00664G7 LOCK WASHER 1 2 FOR CE VEHICLES ONLY 2 42 16705G1 TRUSS HEAD PHILLIPS SCREW SS 1 4 20 X 1 LG FOR CE VEHICLES ONLY...

Page 29: ...Service Parts Manual Notes BODY Page C 8 Service Parts Manual 640774 Service Parts Manual ...

Page 30: ...Service Parts Manual BODY MID Page C 9 640774 Service Parts Manual 1 2 8 3 12 13 9 6 4 5 ...

Page 31: ...ional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual BODY MID Page C 10 Service Parts Manual 640774 Service Parts Manual 1 637458 FLOOR MAT 1 2 640553 UPPER FLOOR PANEL 1 3 14601G11 RIVET 3 16 X 9 16 9 4 302288 HEX HEAD BOLT 1 4 20 X 1 LG 2 5 01110G01 FLAT WASHER 1 4 4 6 14390G4 HEX LOCK NUT 1 4 20 2 7 8 70451G03 LOWER FLOOR PANEL 1 9 14601G11 RIVET 3 16 X 9 16 5 10 11 12 ...

Page 32: ... 11 640774 Service Parts Manual A 1 39 10 9 14 15 5 2 3 8 4 11 16 18 21 20 19 23 24 25 26 27 28 29 31 32 38 34 33 35 36 37 Rear Rocker Panel Passenger Side A Rear Fender Flare Passenger Side 52 53 41 42 40 54 55 43 48 45 46 47 44 50 49 51 ...

Page 33: ...REAR ROCKER PANEL PASSENGER SIDE 1 6 7 8 637456G01 REAR SIDE PANEL DRIVER SIDE 1 9 10570G12 RIVET 257 X 556 2 10 71055G01 RIVET 3 16 5 11 637456G02 REAR SIDE PANEL PASSENGER SIDE 1 12 13 14 637457G01 REAR FENDER FLARE DRIVER SIDE 1 15 16816G2 RATCHET RIVET 25 X 887 3 16 637457G02 REAR FENDER FLARE PASSENGER SIDE 1 17 18 16816G2 RATCHET RIVET 25 X 887 4 19 633165 DRAIN PLUG 8 20 637123 STORAGE COMP...

Page 34: ... REAR SIDE PANEL DECAL WITH LOGO PASSENGER SIDE FOR VEHICLES MANUFACTURED BEFORE 19 SEPTEMBER 2016 1 42 638049G1XX REAR SIDE PANEL DECAL WITH LOGO DRIVER SIDE FOR VEHICLES MANUFACTURED BEFORE 19 SEPTEMBER 2016 1 43 638035 SIDE DECAL 2 44 10570G10 RIVET 155 X 55 FOR CE VEHICLES ONLY 2 45 641492 REAR LOCK BRACKET FOR CE VEHICLES ONLY 1 46 00664G7 LOCK WASHER 1 2 FOR CE VEHICLES ONLY 2 47 16705G1 TRU...

Page 35: ...Service Parts Manual Notes BODY Page C 14 Service Parts Manual 640774 Service Parts Manual ...

Page 36: ...age D 1 640774 Service Parts Manual Front of Vehicle 16 17 Brake Caliper Front of Vehicle Front of Vehicle 21 19 24 23 22 20 25 24 7 4 27 29 6 1 5 9 3 13 7 3 2 2 28 28 BRAKE PEDAL ASSEMBLY includes items 20 21 7 4 15 11 10 9 13 14 ...

Page 37: ...1076G01 COTTER PIN 1 21 X 13 X 43 1 7 10386G2 CLEVIS PIN 375 X 311 X 788 LG 1 8 9 626613 FRONT BRAKE LINE 1 10 613231 HEX HEAD BOLT M6 1 X 20MM LG 1 11 601476 FLANGED LOCK NUT M6 1 1 12 13 616385 REAR BRAKE LINE 1 14 613231 HEX HEAD BOLT M6 1 X 20MM LG 1 15 601476 FLANGED LOCK NUT M6 1 1 16 616459 BANJO BOLT M10 1 X 20MM LG 1 17 613293 CRUSH WASHER M10 2 18 19 641160 BRAKE PEDAL WITH TAPE INCLUDES...

Page 38: ...Service Parts Manual BRAKES Page D 3 640774 Service Parts Manual 4 5 4 6 10 10 8 3 2 1 PARK BRAKE LEVER WITH CABLES includes items 2 4 Front of Vehicle 7 Brake Caliper Front of Vehicle ...

Page 39: ...TEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual BRAKES Page D 4 Service Parts Manual 640774 Service Parts Manual 1 632985 PARK BRAKE LEVER WITH CABLES INCLUDES ITEMS 2 4 1 2 627393 PARK BRAKE 1 3 638154 PARK BRAKE CABLE 2 4 634719 PARK BRAKE SWITCH 1 5 627940 PARK BRAKE BOOT 1 6 302288 HEX HEAD BOLT 1 4 20 X 1 LG 4 7 01111G01 RETAINING RING 8 X 392 2 8 14390G4 FLANGED LOCK NUT 1 4 20 4 ...

Page 40: ...Service Parts Manual Notes BRAKES Page D 5 640774 Service Parts Manual ...

Page 41: ...Service Parts Manual Notes BRAKES Page D 6 Service Parts Manual 640774 Service Parts Manual ...

Page 42: ... Manual DIFFERENTIAL LOCK Page E 1 640774 Service Parts Manual 1 2 2 3 Rear Cable Details 5 5 7 8 4 Differential Lock Cover Differential Lock Pod 633615 9 13 Front Cable Details 6 3 11 18 19 12 27 22 23 24 28 21 26 ...

Page 43: ...RENTIAL LOCK CABLE 1 4 75697G01 DIFFERENTIAL LOCK TRIM PLATE 1 5 71055G01 RIVET 3 16 DIA 3 6 18464G1 PAN HEAD PHILLIPS SCREW 8 18 X 1 LG 2 7 00565G4 LOCK WASHER 8 2 8 635982 SPEED NUT U TYPE 8 4 9 633615 DIFFERENTIAL LOCK DECAL 1 10 11 10386G2 CLEVIS PIN 76 LG 1 12 01110G01 FLAT WASHER 1 4 2 13 635011 EXTENSION SPRING 1 14 31539G1 NYLON CLAMP NOT ILLUSTRATED 5 15 16 17 18 640562 DIFFERENTIAL LOCK ...

Page 44: ...Service Parts Manual Notes DIFFERENTIAL LOCK Page E 3 640774 Service Parts Manual ...

Page 45: ...Service Parts Manual Notes DIFFERENTIAL LOCK Page E 4 Service Parts Manual 640774 Service Parts Manual ...

Page 46: ...Service Parts Manual ELECTRICAL SYSTEM Page F 1 640774 Service Parts Manual 3 4 3 Front of Vehicle A 1 15 16 Front of Vehicle A Front of Vehicle 13 7 7 9 18 8 10 11 10 6 19 24 25 26 652600 ...

Page 47: ...CKET 1 4 00715G2 FLANGED HEX HEAD BOLT 5 16 18 X 80 LG 4 5 6 640361 CONTACTOR AND FUSE BLOCK COVER 1 7 606421 FLANGED HEX HEAD BOLT M6 1 X 30MM LG 3 8 00793G2 FLAT WASHER SS 1 4 2 9 635402 HEX NUT INSERT M6 X 1MM 2 10 601476 FLANGED LOCK NUT M6 1 3 11 636456 WIRE CTLR B TO SOL 1 12 13 602904 TETHER CABLE 1 14 15 629678 WIRE GUIDE BRACKET 1 16 71055G01 RIVET 3 16 LG 3 17 18 635684 WIRE B TO SOL 1 1...

Page 48: ...vice Parts Manual 1 2 5 6 12 22 17 18 20 14 15 21 13 15 23 16 13 19 Front of Vehicle 12V 10Amp MAX 26 10 25 9 28 27 Inside of Cowl Front of Vehicle To Main Harness 3 Pin LED HEADLIGHT ASSEMBLY includes item 27 3 LED HEADLIGHT ASSEMBLY includes item 27 4 5 3 4 ...

Page 49: ... HEADLIGHT ASSEMBLY DRIVER SIDE INCLUDES ITEM 27 1 5 71597G01 SELF THREADING NUT 5MM X 10MM X 15MM 4 6 71781G02 VINYL TAPE 2 7 619100 HEADLIGHT BULB NOT ILLUSTRATED 2 8 31539G1 NYLON CLAMP NOT ILLUSTRATED AR 9 600543 TORX BOLT M4 7 X 12MM LG 2 10 602053 LOCK NUT M4 7 2 11 12 631656 STATE OF CHARGE METER 1 13 627035 PLUG 1 14 627837 WARNING LIGHT 1 15 628931 2 POSITION SWITCH 1 16 609692 KEY SWITCH...

Page 50: ...774 Service Parts Manual 6 8 7 40 5 30 4 CHARGER RECEPTACLE ASSEMBLY includes items 5 7 28 CHARGER RECEPTACLE ASSEMBLY includes items 29 30 VEHICLES MANUFACTURED FROM JUNE 2015 Front of Vehicle 9 10 12 14 13 15 Front of Vehicle 23 24 18 20 19 21 2 1 29 ...

Page 51: ...NESS 1 6 73051G30 CHARGING RECEPTACLE 1 7 25978G25 18 GA WIRE RED 9 1 8 71055G01 RIVET 3 16 4 9 633018 COVER PLATE 1 10 71055G01 RIVET 3 16 4 11 12 633014G03 COVER PLATE ON BOARD CHARGER 1 13 610536 RECEPTACLE ON BOARD CHARGER 1 14 14601G10 RIVET ALUMINIUM 5 32 4 15 71055G01 RIVET 3 16 LG 4 16 17 18 638478 AC RECEPTACLE CE VEHICLES 1 19 00379G4 PAN HEAD PHILLIPS SCREW 10 24 X 1 2 LG 4 20 14390G10 ...

Page 52: ...ual ELECTRICAL SYSTEM Page F 7 640774 Service Parts Manual 5 7 8 6 9 4 1 1 DC DC CONVERTER 72V includes item 2 3 Front of Vehicle 14 15 12 13 18 17 19 20 WHT Wire from control harness BLK ORN Wire from control harness 2 ...

Page 53: ...ice Parts Manual 1 633778 DC DC CONVERTER 72V INCLUDES ITEM 2 1 2 14390G4 LOCK NUT 1 4 20 2 3 23726G11 SPACER 30 LG 2 4 640174 CHARGER BRACKET 1 5 606421 FLANGED HEX HEAD BOLT M6 1 X 30MM LG 3 6 450452 FLANGED HEX NUT M6 X 1 3 7 650845 RELAY 72V 1 8 16816G2 RATCHET RIVET 25 X 887 1 9 641683 JUMPER WIRE 16 AWG 1 10 11 12 629148 TAILLIGHT ASSEMBLY 1 13 71055G01 RIVET 3 16 4 14 01057G01 RIVET 1 4 X 1...

Page 54: ...Service Parts Manual ELECTRICAL SYSTEM Page F 9 640774 Service Parts Manual CONTROLLER ASSEMBLY includes items 2 13 2 13 5 10 9 23 26 27 25 22 12 3 1 4 6 8 16 7 19 18 30 29 Front of Vehicle 20 ...

Page 55: ... 5 635932 TRIM 2 6 6 635402 HEX NUT INSERT M6 X 1MM 4 7 606421 FLANGED HEX HEAD BOLT M6 1 X 30MM 4 8 601476 FLANGED LOCK NUT M6 1 4 9 606262 FLANGED HEX HEAD BOLT M8 1 25 X 16MM LG 12 10 606272 LOCK WASHER 8MM 12 11 12 00415G4 HEX HEAD BOLT 1 4 20 X 1 1 4 LG 4 13 14390G4 FLANGED LOCK NUT 1 4 20 4 14 15 16 71415G01 ELECTRICAL SHOCK WARNING DECAL 1 17 18 632889 FRONT MOTOR WIRE U 134 LG 1 19 632888 ...

Page 56: ...Service Parts Manual Notes ELECTRICAL SYSTEM Page F 11 640774 Service Parts Manual ...

Page 57: ...Service Parts Manual Notes ELECTRICAL SYSTEM Page F 12 Service Parts Manual 640774 Service Parts Manual ...

Page 58: ...e Parts Manual FRONT AND REAR AXLE Page G 1 640774 Service Parts Manual 12 4 4 5 6 Front of Vehicle 3 2 7 5 6 6 7 4 5 REAR POWERTRAIN FRONT POWERTRAIN Front of Vehicle 1 3 2 1 1 6 5 4 9 1 10 10 9 10 9 9 10 12 ...

Page 59: ...5 DESCRIPTION QTY Service Parts Manual FRONT AND REAR AXLE Page G 2 Service Parts Manual 640774 Service Parts Manual 1 653033 CV AXLE ASSEMBLY 1 2 601327 LOCK WASHER 6MM 6 3 605741 HEX HEAD BOLT M6 1 X 25MM LG 6 4 306835 HEX HEAD BOLT 3 8 16 X 1 1 4 LG 8 5 608654 SPLIT LOCK WASHER 10MM 8 6 00571G3 FLAT WASHER 5 16 8 7 616705 BREATHER HOSE 1 8 31539G1 NYLON CLAMP NOT ILLUSTRATED 1 9 10387G1 COTTER ...

Page 60: ... AND REAR AXLE Page G 3 640774 Service Parts Manual 1 INDEPENDENT DIFFERENTIAL includes items 2 22 24 INDEPENDENT DIFFERENTIAL LOCKING includes items 2 22 25 30 7 9 21 8 3 19 4 3 5 12 2 2 15 6 18 14 16 17 11 9 13 21 20 10 6 7 8 ...

Page 61: ...5 16 18 X 1 25 LG 12 6 PIN 5 16 X 1 2 7 RETAINING RING 25MM 1 8 RETAINING RING 1 9 BALL BEARING 25MM X 52MM X 15MM 1 10 GEAR CASE LH INDEPENDENT 1 11 GEAR CASE RH INDEPENDENT 1 12 VENT TUBE 1 4 HOSE 1 13 OUTPUT SHAFT LH 1 14 OUTPUT SHAFT RH 1 15 HELICAL OUTPUT GEAR 1 16 INPUT MOTOR SHAFT SUBASSEMBLY 1 17 INTERMEDIATE SHAFT SUBASSEMBLY 1 18 DIFFERENTIAL SUBASSEMBLY 1 19 BEARING RETAINER 1 20 643972...

Page 62: ...Service Parts Manual Notes FRONT AND REAR AXLE Page G 5 640774 Service Parts Manual ...

Page 63: ...Service Parts Manual Notes FRONT AND REAR AXLE Page G 6 Service Parts Manual 640774 Service Parts Manual ...

Page 64: ...Service Parts Manual FRONT SUSPENSION AND STEERING Page H 1 640774 Service Parts Manual 14 15 19 18 15 17 23 23 16 1 4 2 25 23 23 3 8 7 5 13 27 28 Steering Arm 7 6 9 10 24 22 21 24 ...

Page 65: ...8 4 00571G3 FLAT WASHER 5 16 8 5 637378 POWERTRAIN WELDMENT FRONT 1 6 00463G11 HEX HEAD BOLT 7 16 14 X 1 1 2 LG 3 7 306982 FLAT WASHER 34 6 8 00734G1 LOCK NUT 7 16 14 3 9 641289 FLANGED HEX HEAD BOLT 3 8 16 X 1 LG 3 10 11027G5 FLANGED LOCK NUT 3 8 16 3 11 12 13 638383G01 CONTROL ARM 1 14 00429G4 HEX HEAD BOLT 3 8 16 2 15 00560G1 FLAT WASHER 3 4 4 16 638223 SPLIT SEAM SPACER 3 8 X 2 39 2 17 637745 ...

Page 66: ... 1 FRONT STRUT ASSEMBLY PASSENGER SIDE includes items 3 22 41 2 STRUT BEARING ASSEMBLY DRIVER SIDE includes items 40 43 44 39 STRUT BEARING ASSEMBLY PASSENGER SIDE includes items 42 44 41 Part of Frame 43 44 6 33 17 Front of Vehicle 37 36 35 5 7 8 10 16 22 21 9 20 40 18 3 13 6 11 24 12 14 29 28 25 27 26 15 24 42 19 Control Arm 3 32 POA of strut 4 ...

Page 67: ...31 4 4 632405 GREASE FITTING 1 5 634705 SHOCK STRUT 1 6 633792G02 HUB 1 7 616053 WASHER 1 8 616060 STRUT WASHER 52MM 1 9 645047 STRUT BALL JOINT 1 10 616073 STRUT BUMPER 1 11 638129 BRAKE CALIPER 1 12 616451 BRAKE CALIPER BRACKET 1 13 616596 SOCKET HEAD BOLT 3 8 24 X 3 4 LG 2 14 616672 HEX HEAD BOLT M8 1 25 X 60MM LG 2 15 616673 LOCK NUT M8 2 16 640354 SPRING 1 17 626725 STEERING ARM 1 18 630803 L...

Page 68: ...ONT SUSPENSION AND STEERING Page H 5 640774 Service Parts Manual 31 32 10387G2 COTTER PIN 094 X 1 1 33 19862G2 WHEEL STUD 1 2 20 X 1 718 LG 4 34 35 640847 SUPPORT PLATE 1 36 11027G5 FLANGED LOCK NUT 3 8 16 2 37 641289 FLANGED HEX HEAD BOLT 3 8 16 X 1 LG 2 38 39 642461G01 STRUT BEARING ASSEMBLY INCLUDES ITEM 40 43 44 DRIVER SIDE 1 40 632410G03 STRUT BASE DRIVER SIDE 1 41 642461G02 STRUT BEARING ASS...

Page 69: ...Service Parts Manual Notes FRONT SUSPENSION AND STEERING Page H 6 Service Parts Manual 640774 Service Parts Manual ...

Page 70: ...Service Parts Manual FRONT SUSPENSION AND STEERING Page H 7 640774 Service Parts Manual 12 UNIVERSAL JOINT ASSEMBLY includes items 13 19 3 9 2 1 5 7 8 13 15 19 17 18 16 14 10 11 ...

Page 71: ...EERING COLUMN ASSEMBLY 1 6 7 603799 FLANGED HEX HEAD BOLT M10 25 X 1 5MM LG 4 8 600525 LOCK NUT M10 1 5 4 9 617802 STEERING WHEEL DECAL FOR VEHICLES MANUFACTURED BEFORE 19 SEPTEMBER 2016 1 10 650963 STEERING WHEEL DECAL FOR VEHICLES MANUFACTURED AFTER 19 SEPTEMBER 2016 BEFORE 1 MAY 2017 1 11 663498 STEERING WHEEL DECAL FOR VEHICLES MANUFACTURED AFTER 1 MAY 2017 1 12 642482 UNIVERSAL JOINT ASSEMBLY...

Page 72: ...Service Parts Manual Notes FRONT SUSPENSION AND STEERING Page H 9 640774 Service Parts Manual ...

Page 73: ...Service Parts Manual Notes FRONT SUSPENSION AND STEERING Page H 10 Service Parts Manual 640774 Service Parts Manual ...

Page 74: ...Service Parts Manual MOTOR Page J 1 640774 Service Parts Manual 2 4 5 1 7 8 3 9 6 SPEED SENSOR KIT includes items 7 8 ...

Page 75: ...r additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual MOTOR Page J 2 Service Parts Manual 640774 Service Parts Manual 1 629135 MOTOR 72V 1 2 629596 MOTOR COVER AC 1 3 629597 MOTOR COVER GASKET 1 4 601327 LOCK WASHER 6MM 3 5 616716 HEX HEAD BOLT M6 1 X 16MM LG 3 6 614252 SPEED SENSOR KIT INCLUDES ITEMS 7 8 1 7 612741 SPEED SENSOR 1 8 614253 PAN HEAD PHILLIPS SCREW M6 ...

Page 76: ...Service Parts Manual Notes MOTOR Page J 3 640774 Service Parts Manual ...

Page 77: ...Service Parts Manual Notes MOTOR Page J 4 Service Parts Manual 640774 Service Parts Manual ...

Page 78: ...TION SYSTEM Page K 1 640774 Service Parts Manual 1 11 12 11 11 12 11 12 12 6 5 5 2 9 9 8 8 3 7 7 7 7 7 7 29 8 11 12 10 10 4 14 16 17 18 22 23 21 25 26 27 19 Front of Vehicle Front of Vehicle 15 15 14 FRONT BUMPER WELDMENT includes item 15 ...

Page 79: ...SENGER SIDE 1 5 637663 OPS SEAT SUPPORT 1 6 629023 FRONT CROSSBAR TUBE 1 7 630762 PLUG 1 75 O D 2 8 638599 HEX HEAD BOLT 1 2 13 X 1 LG 2 9 00643G3 FLAT WASHER 0 54 I D X 1 28 O D 2 10 624934 PLASTIC PLUG 1 X 2 LG 2 11 630642 HEX HEAD BOLT 3 8 16 X 2 1 2 LG 2 12 630643 LOCK NUT 3 8 16 2 13 14 641470 FRONT BUMPER WELDMENT INCLUDES ITEM 15 1 15 643635 TUBE PLUG 1 5 O D 2 16 00439G2 HEX HEAD BOLT 5 16...

Page 80: ...Service Parts Manual OPERATOR PROTECTION SYSTEM Page K 3 640774 Service Parts Manual 1 2 3 4 2 5 7 8 19 18 18 1 17 Front of Vehicle Seat Back Assembly 12 13 11 Front of Vehicle 15 ...

Page 81: ...M Page K 4 Service Parts Manual 640774 Service Parts Manual 1 638441 HAND HOLD WELDMENT 1 2 00571G2 FLAT WASHER 5 16 8 3 11098G5 LOCK NUT 3 8 16 4 4 00427G2 HEX HEAD BOLT 3 8 16 X 1 1 4 LG 4 5 641252 PLUG 1 O D X 10 14 GA 2 6 7 00643G3 FLAT WASHER 0 54 I D X 1 28 O D 4 8 308332 HEX NUT 1 2 13 4 9 10 11 16705G1 TRUSS HEAD PHILLIPS SCREW SS 1 4 20 X 1 LG 4 12 01110G01 FLAT WASHER 1 4 4 13 00664G7 LO...

Page 82: ...Service Parts Manual OPERATOR PROTECTION SYSTEM Page K 5 640774 Service Parts Manual 2 3 3 7 5 4 4 11 12 6 13 14 OPS HARDWARE KIT includes items 11 14 OPS UPPER KIT includes items 2 10 1 10 ...

Page 83: ...TEM Page K 6 Service Parts Manual 640774 Service Parts Manual 1 633101 OPS UPPER KIT INCLUDES ITEMS 2 10 1 2 633475 OPS FRONT TOP WELDMENT 1 3 629080 REAR CONNECTOR DRIVER SIDE 2 4 629079 REAR CONNECTOR PASSENGER SIDE 2 5 629082 FRONT CONNECTOR DRIVER SIDE 1 6 629081 FRONT CONNECTOR PASSENGER SIDE 1 7 633554 OPS REAR TOP WELDMENT 1 8 9 10 635127 OPS HARDWARE KIT INCLUDES ITEMS 11 14 1 11 630642 HE...

Page 84: ... Page K 7 640774 Service Parts Manual 15 17 Front Upper OPS Front of Vehicle Rear Upper OPS Front of Vehicle 3 10 18 A 15 15 7 7 19 19 17 17 OPS ACCESSORIES KIT includes items 2 13 1 OPS ACCESSORY HARDWARE KIT includes items 14 19 13 A 4 14 6 2 5 16 ...

Page 85: ...ual 1 632990 OPS ACCESSORIES KIT INCLUDES ITEMS 2 13 1 2 627786 CLAMP 2 3 612254 GRAB HANDLE MOUNT 2 4 629642 CLAMP GUARD 2 5 628577 HEADREST 2 6 629666 HEADREST PLATE 2 7 649134 SEAT BELT RETRACTOR 4 8 629454 SIDE DOOR NET PAIR NOT ILLUSTRATED 1 9 632974 DOOR NET NOT ILLUSTRATED 1 10 611774 GRAB HANDLE 1 11 12 13 639631 OPS ACCESSORY HARWARE KIT INCLUDES ITEMS 14 19 1 14 14390G4 FLANGED LOCK NUT ...

Page 86: ...Service Parts Manual Notes OPERATOR PROTECTION SYSTEM Page K 9 640774 Service Parts Manual ...

Page 87: ...Service Parts Manual Notes OPERATOR PROTECTION SYSTEM Page K 10 Service Parts Manual 640774 Service Parts Manual ...

Page 88: ...1 24 5 23 19 12 25 26 18 7 8 22 40 6 14 15 42 29 30 REAR STRUT ASSEMBLY DRIVER SIDE includes items 3 29 39 1 REAR STRUT ASSEMBLY PASSENGER SIDE includes items 3 26 30 41 2 16 3 STRUT BEARING ASSEMBLY DRIVER SIDE includes items 40 43 44 39 STRUT BEARING ASSEMBLY PASSENGER SIDE includes items 42 44 41 44 43 4 37 ...

Page 89: ...S 3 26 30 41 1 3 103867 FLAT WASHER 31 X 69 X 06 4 4 632405 GREASE FITTING 3 16 1 5 634705 SHOCK STRUT 1 6 633792G02 HUB ASSEMBLY 1 7 616053 WASHER 1 8 616060 STRUT WASHER 52MM 1 9 10 11 645047 STRUT BALL JOINT 1 12 616073 STRUT BUMPER 1 13 14 616451 CALIPER BRACKET 1 15 616596 SOCKET HEAD BOLT 3 8 24 X 3 4 LG 2 16 616672 HEX HEAD BOLT M8 1 25 X 60MM LG 2 17 616673 LOCK NUT M8 2 18 640353 COIL SPR...

Page 90: ...SION Page L 3 640774 Service Parts Manual 31 625748 NYLOCK NUT 1 2 13 2 32 636610 FLAT WASHER 1 2 33 616701 RUBBER WASHER 1 5MM X 76MM 2 34 629592 STRUT BUSHING FEMALE 2 35 629593 STRUT BUSHING MALE 2 36 633875 BRAKE PAD 2 37 19862G2 WHEEL STUD 1 2 20 X 1 718 LG 4 38 39 642461G01 STRUT BEARING ASSEMBLY INCLUDES ITEM 40 43 44 DRIVER SIDE 1 40 632410G03 STRUT BASE DRIVER SIDE 1 41 642461G02 STRUT BE...

Page 91: ...Service Parts Manual Notes REAR SUSPENSION Page L 4 Service Parts Manual 640774 Service Parts Manual ...

Page 92: ...Service Parts Manual REAR SUSPENSION Page L 5 640774 Service Parts Manual 1 5 2 3 10 11 4 4 10 8 14 13 9 26 17 20 22 21 23 23 27 28 28 20 20 20 18 16 19 19 25 ...

Page 93: ...D BOLT 5 16 18 X 1 LG 4 5 634762 TUBE PLUG 2 6 7 8 646647 HITCH RECEIVER 1 9 00463G4 HEX HEAD BOLT 7 16 14 X 1 1 2 LG 4 10 00922G3 FLAT WASHER 7 16 8 11 00734G1 LOCK NUT 7 16 14 4 12 13 638148 REAR BRACKET VEHICLES WITH LOCKING DIFFERENTIAL 1 14 638536 SPRING BRACKET VEHICLES WITH LOCKING DIFFERENTIAL 1 15 16 638383G01 CONTROL ARM WELDMENT 1 17 638223 SPACER 3 8 X 2 390 2 18 637745 FLANGED BUSHING...

Page 94: ...Service Parts Manual Notes REAR SUSPENSION Page L 7 640774 Service Parts Manual ...

Page 95: ...Service Parts Manual Notes REAR SUSPENSION Page L 8 Service Parts Manual 640774 Service Parts Manual ...

Page 96: ...e Parts Manual SEAT BOTTOM BLACK includes items 3 4 Front of Vehicle Front of Vehicle 2 SEAT BOTTOM ASSEMBLY BLACK includes items 2 9 1 SEAT BACK ASSEMBLY BLACK includes items 13 18 12 SEAT BACK BLACK includes items 14 15 13 14 4 6 7 9 8 9 9 3 15 17 18 ...

Page 97: ...89G0006 SEAT BOTTOM ASSEMBLY BLACK INCLUDES ITEMS 2 9 1 2 637823G06 SEAT BOTTOM BLACK INCLUDES ITEMS 3 4 1 3 640234G06 VINYL AND FOAM SEAT BOTTOM 1 4 640198 WOOD SEAT BOTTOM 1 5 6 639904 RETENTION PIN 2 7 638701G01 SEAT LOCATOR TAB DRIVER SIDE 1 8 638701G02 SEAT LOCATOR TAB PASSENGER SIDE 1 9 16705G1 TRUSS HEAD PHILLIPS SCREW SS 1 4 20 X 1 LG 10 10 11 12 640781G06 SEAT BACK ASSEMBLY BLACK INCLUDES...

Page 98: ...Service Parts Manual SEATING Page M 3 640774 Service Parts Manual Front of Vehicle Additional panel is for front seat only 4 1 6 2 3 5 7 ...

Page 99: ...rvice Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual SEATING Page M 4 Service Parts Manual 640774 Service Parts Manual 1 631973 BUCKLE AND BRACKET ASSEMBLY 13 5 LG 1 2 00734G3 LOCK NUT 7 16 20 1 3 00560G3 FLAT WASHER 3 8 1 4 635630 BUTTON HEAD TORX BOLT 7 16 20 X 1 25 LG 1 5 00664G7 LOCK WASHER 1 4 4 6 01110G01 FLAT WASHER 1 4 4 7 00415G6 HEX HEAD...

Page 100: ...Service Parts Manual Notes SEATING Page M 5 640774 Service Parts Manual ...

Page 101: ...Service Parts Manual Notes SEATING Page M 6 Service Parts Manual 640774 Service Parts Manual ...

Page 102: ... BED Page N 1 640774 Service Parts Manual 9 5 6 A A B B 7 Front of Vehicle PLASTIC BED ASSEMBLY includes items 2 11 1 11 2 4 3 MAX 14 o 25 MAX 500 lbs 255 kg MAX 5 in 12 cm P P MAX 100 lbs 15 kg 74821 G01 15 17 10 8 20 21 19 22 ...

Page 103: ...1 3 72649G01 PLASTIC TAILGATE 36 1 4 73450G01 BOWED ANGLE 1 5 73454G01 PIVOT SHAFT 2 6 73455G02 TAILGATE CABLE ASSEMBLY 2 7 00415G2 HEX HEAD BOLT 1 4 20 X 1 1 4 LG 2 8 73460G01 SHOULDER BOLT 1 4 20 X 3 4 LG 2 9 73449G01 CHANNEL EXTRUSION 1 10 16705G2 PAN HEAD SCREW 1 4 20 X 5 8 LG 4 11 16816G5 RACHET RIVET 187 X 550 4 12 13 14 15 74821G01 BED CAPACITY LABEL 500 LB 1 16 17 71055G01 RIVET 3 16 5 18 ...

Page 104: ...Service Parts Manual TRUCK BED Page N 3 640774 Service Parts Manual 1 3 7 6 2 3 4 4 1 3 Front of Vehicle 11 14 12 18 19 19 21 20 13 Front of Vehicle ...

Page 105: ...age N 4 Service Parts Manual 640774 Service Parts Manual 1 71537G02 GAS SPRING 1 2 624030 FLANGED BUSHING 4 3 21683G1 COTTER PIN 15 32 X 2 11 16 3 4 14443G10 CLEVIS PIN 50 X 3 1 5 6 71571G01 CLEVIS PIN 495 X 5 25 2 7 00571G5 FLAT WASHER 5 16 2 8 9 10 11 637508 BED LATCH AND BUMPER STOP BRACKET 1 12 00428G8 HEX HEAD BOLT 3 8 16 X 2 1 4 LG 2 13 00560G1 FLAT WASHER 3 8 4 14 11098G5 LOCK NUT 3 8 16 2 ...

Page 106: ...Service Parts Manual TRUCK BED Page N 5 640774 Service Parts Manual Front of Vehicle 2 12 13 13 14 3 1 6 7 8 9 10 4 ...

Page 107: ...ts Manual TRUCK BED Page N 6 Service Parts Manual 640774 Service Parts Manual 1 637321 BED PIVOT WELDMENT 1 2 00429G2 HEX HEAD BOLT 3 8 16 X 3 25 LG 2 3 00560G1 FLAT WASHER 3 8 4 4 11098G5 LOCK NUT 3 8 16 2 5 6 637500G01 VERTICAL BED WELDMENT DRIVER SIDE 1 7 00414G6 HEX HEAD BOLT 1 4 20 X 7 8 LG 2 8 14390G4 LOCK NUT 1 4 20 2 9 637500G02 VERTICAL BED WELDMENT PASSENGER SIDE 1 10 638165 BED SHOCK SU...

Page 108: ...Service Parts Manual TRUCK BED Page N 7 640774 Service Parts Manual C B A A B C Front of Vehicle 10 12 2 1 9 8 5 4 6 6 11 6 7 ...

Page 109: ...ESCRIPTION QTY Service Parts Manual TRUCK BED Page N 8 Service Parts Manual 640774 Service Parts Manual 1 14443G10 CLEVIS PIN 50 X 3 1 2 638218 BED LATCH WELDMENT 1 3 4 71099G02 LATCH PLATE 2 5 71538G01 TORSION SPRING 1 6 01118G01 HEX HEAD BOLT WITH PATCHLOCK 1 4 20 X 62 LG 10 7 71704G01 HANDLE GRIP 2 8 70113G01 ADJUSTABLE RUBBER BUMPER 2 9 11027G1 FLANGED LOCK NUT 5 16 18 2 10 638189 GAS SPRING M...

Page 110: ...Service Parts Manual Notes TRUCK BED Page N 9 640774 Service Parts Manual ...

Page 111: ...Service Parts Manual Notes TRUCK BED Page N 10 Service Parts Manual 640774 Service Parts Manual ...

Page 112: ...Service Parts Manual WEATHER PROTECTION Page P 1 640774 Service Parts Manual 12 3 2 14 10 11 6 7 5 9 7 13 8 Front of Vehicle WINDSHIELD KIT FULL includes items 2 14 1 4 ...

Page 113: ...ional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual WEATHER PROTECTION Page P 2 Service Parts Manual 640774 Service Parts Manual 1 627079 WINDSHIELD KIT FULL INCLUDES ITEMS 2 14 1 2 WINDSHIELD 1 3 AWNING MOLDING ALUMINUM 1 4 TEXTILE SKIRT PLACEHOLDER 1 5 PLASTIC CLAMP 4 6 HEX NUT 6 7 FLAT WASHER 12 8 HEX HEAD BOLT 4 9 WINDSHIELD GROMMET 6 10 FLAT WASHER 8 11 HEX NUT 4 12 ...

Page 114: ...Service Parts Manual WEATHER PROTECTION Page P 3 640774 Service Parts Manual 11 6 13 13 12 Front of Vehicle WINDSHIELD KIT SPLIT includes items 2 21 1 20 18 19 21 15 14 16 15 17 8 9 7 2 4 5 ...

Page 115: ...4 5 DESCRIPTION QTY Service Parts Manual WEATHER PROTECTION Page P 4 Service Parts Manual 640774 Service Parts Manual 1 627080 WINDSHIELD KIT SPLIT INCLUDES ITEMS 2 21 1 2 WINDSHIELD 1 3 4 AWNING MOLDING ALUMINUM 1 5 TEXTILE SKIN PLACEHOLDER 1 6 PLASTIC CLAMP 2 7 UPPER METAL SEAL 1 8 UNIGRIP 1 9 TEXTILE STRAP 6 10 11 HEX NUT 2 12 HEX HEAD BOLT 2 13 FLAT WASHER 4 14 GROMMET 2 15 FLAT WASHER 10 16 H...

Page 116: ...Service Parts Manual WEATHER PROTECTION Page P 5 640774 Service Parts Manual A TOP CANOPY KIT includes items 2 3 1 HARDWARE KIT includes items 4 7 3 6 4 6 7 6 6 5 5 A 2 ...

Page 117: ...idual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Service Parts Manual WEATHER PROTECTION Page P 6 Service Parts Manual 640774 Service Parts Manual 1 632976 TOP CANOPY KIT INCLUDES ITEMS 2 3 1 2 632977 TOP CANOPY 1 3 632978 HARDWARE KIT INCLUDES ITEMS 4 7 1 4 CLAMP 6 5 BOLT M6 1 X 20 12 6 WASHER M6 18 7 NUT M6 6 ...

Page 118: ...Service Parts Manual Notes WEATHER PROTECTION Page P 7 640774 Service Parts Manual ...

Page 119: ...Service Parts Manual Notes WEATHER PROTECTION Page P 8 Service Parts Manual 640774 Service Parts Manual ...

Page 120: ...items 7 8 5 WHEEL AND TIRE ASSEMBLY REAR DRIVER SIDE includes items 7 8 6 23 24 WHEEL AND TIRE ASSEMBLY FRONT PASSENGER SIDE includes items 15 16 13 WHEEL AND TIRE ASSEMBLY FRONT DRIVER SIDE includes items 15 16 14 WHEEL AND TIRE ASSEMBLY REAR PASSENGER SIDE includes items 19 20 17 WHEEL AND TIRE ASSEMBLY REAR DRIVER SIDE includes items 19 20 18 STYLE OF WHEELS TIRES MAY DIFFER FROM THOSE SHOWN WH...

Page 121: ...0 25 X 8 12 1 5 639549 WHEEL AND TIRE ASSEMBLY REAR PASSENGER SIDE INCLUDES ITEMS 7 8 1 6 639551 WHEEL AND TIRE ASSEMBLY REAR DRIVER SIDE INCLUDES ITEMS 7 8 1 7 631041 WHEEL STEEL 12 X 7 1 8 639541 TIRE KENDA 590 25 X 11 12 1 9 10 630268 CENTER CAP BLACK 4 11 14723G1 LUG NUT 1 2 20 16 12 13 639556 WHEEL AND TIRE ASSEMBLY FRONT PASSENGER SIDE INCLUDES ITEMS 15 16 1 14 639558 WHEEL AND TIRE ASSEMBLY...

Page 122: ...Service Parts Manual Notes WHEELS AND TIRES Page Q 3 640774 Service Parts Manual ...

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Page 124: ...438 3946 FAX 1 800 752 6175 International Phone 001 706 798 4311 FAX 001 706 771 4609 Service Parts Manuals as well as Repair and Service Manuals are available from a local Distributor an authorized Branch Parts Accessories Department or at www textronoffroad com Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of TSV Technical Communication...