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Textron Off Road PROWLER EV, Service & Parts Manual

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Textron Off Road PROWLER EV Service & Parts Manual Download Page 9

Page vii

HOW TO USE THE SERVICE PARTS MANUAL

666430 Service Parts Manual

3. COLOR CODE FOR BODY COMPONENTS

The last two digits of the part 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

11

BLACK

89

TRUE TIMBER KANATI

Summary of Contents for PROWLER EV

Page 1: ...REVISED APRIL 2019 666430 H...

Page 2: ...nd lead which are known to the State of California to cause can cer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary...

Page 3: ...oducts in this manual without obligation to include these changes on units sold previously The information contained in this manual may be revised periodically by TSV and therefore is subject to chang...

Page 4: ...ry charger may remain connected to the vehicle to maintain a full charge on the batteries provided the charger is plugged into an active electrical source If power to the electrical source is disconne...

Page 5: ...E SERVICE PARTS MANUAL v ACCELERATOR A 1 BATTERY CHARGER B 1 BODY C 1 BRAKES D 1 ELECTRICAL E 1 ELECTRONIC SPEED CONTROL F 1 FRONT SUSPENSION AND STEERING G 1 MOTOR H 1 ROPS J 1 FRONT AXLE K 1 REAR AX...

Page 6: ...NOTES Page iv 666430 Service Parts Manual...

Page 7: ...for all systems of your vehicle USE OF THE MANUAL To use this manual consult the TABLE OF CONTENT to locate the information or illustration required Introduction of some revisions varies due to supply...

Page 8: ...owest assembly sold by Service Parts and the asterisk indicates the part depicted is not available for purchase NOTE Descriptions are indented under the assembly that they are used on That assembly is...

Page 9: ...The last two digits of the part 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 b...

Page 10: ...666430 Service Parts Manual Page A 1 ACCELERATOR 2 2 3 3 1 12 7 8 11 3 12 4 Front of Vehicle...

Page 11: ...partment for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page A 2 ACCELERATOR 666430 Service Parts Manual 1 656066 ACCELERATOR PEDAL COVER BRACKET 1 2 00414G6 HEX HEAD BOLT 1 4 20 X...

Page 12: ...Page A 3 Notes ACCELERATOR 666430 Service Parts Manual...

Page 13: ...Page A 4 Notes ACCELERATOR 666430 Service Parts Manual...

Page 14: ...666430 Service Parts Manual Page B 1 BATTERY SYSTEM 14 15 4 6 6 6 6 6 6 1 4 8 2 3 11 13 16 7 7 2 8 4 Front of Vehicle 5 10 12...

Page 15: ...TEM 666430 Service Parts Manual 1 629435 BATTERY HOLD DOWN BRACKET 4 12V 1 2 631988 HOLD DOWN BRACKET 1 12V 2 3 647050 BATTERY 12V 6 4 70386G01 TIE DOWN BOLT 5 16 18 X 11 3 4 LG 6 5 01101G01 TIE DOWN...

Page 16: ...666430 Service Parts Manual Page B 3 BATTERY SYSTEM 1...

Page 17: ...erial number of the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTIO...

Page 18: ...Page B 5 Notes BATTERY SYSTEM 666430 Service Parts Manual...

Page 19: ...Page B 6 Notes BATTERY SYSTEM 666430 Service Parts Manual...

Page 20: ...666430 Service Parts Manual Page C 1 BODY B A B 21 GLOVE BOX DOOR ASSY PASSENGER SIDE includes items 22 25 22 25 26 28 27 24 23 A 1 5 13 16 18 6 14 17 2 19 19 15 7 10 9 9 11 2 Front of Vehicle 8...

Page 21: ...73 PAN HEAD TAPPING SCREW M4 8 1 6 X 22MM LG 4 10 71055G01 BLACK ALUMINUM RIVET 3 16 X 38 GRIP 2 11 648561 COMPARTMENT TRAY PANEL 1 12 13 655917G01 UPPER ROCKER PANEL DRIVER SIDE 1 14 655917G02 UPPER...

Page 22: ...666430 Service Parts Manual Page C 3 BODY 1 8 9 10 13 16 16 14 12 10 9 4 2 3 5 5 5 6 7 4 17 15 Front of Vehicle Front of Vehicle...

Page 23: ...ALOBULAR SCREW M6 1 X 23 4MM LG 2 3 602409 BARREL CLIP M6 1 2 4 71597G01 SELF THREADING NUT 5MM X 10MM X 15MM 3 5 01038G01 FLANGED HEX HEAD THREAD FORMING SCREW 1 4 20 X 7 LG 4 6 666244 INSTRUMENT PAN...

Page 24: ...666430 Service Parts Manual Page C 5 BODY 4 7 5 5 Front of Vehicle 8 8 10 5 5 5 1 2 3...

Page 25: ...additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page C 6 BODY 666430 Service Parts Manual 1 652443G103 BATTERY TRAY BRACKET DRIVER SIDE 1 2 652443G203 BATTERY TRAY BRACKET PASSENGER SID...

Page 26: ...666430 Service Parts Manual Page C 7 BODY 22 23 24 23 21 Battery Rack Weldment 6 17 11 1 21 3 12 16 16 3 15 15 7 7 18 6 10 3 3 3 2 Front of Vehicle 17...

Page 27: ...LT M6 1 X 30MM LG 6 3 10570G10 LARGE DOME HEAD SS RIVET 5 32 X 25 GRIP 10 4 5 6 71609G01 SEAT HINGE PLATE 2 7 10570G11 LARGE DOME HEAD SS RIVET 3 16 X 5 GRIP 4 8 9 10 652716G04 SIDE PANEL DRIVER SIDE...

Page 28: ...Service Parts Manual Page C 9 BODY Frame shown for reference only 27 28 29 29 30 30 31 Front of Vehicle Frame shown for reference only Front of Vehicle 1 15 12 4 6 7 8 9 10 11 9 6 14 2 18 22 19 23 24...

Page 29: ...14390G4 LOCK NUT 1 4 20 4 8 00427G2 HEX HEAD BOLT 3 8 16 X 1 25 LG 4 9 00643G1 FLAT WASHER 3 8 4 10 120177 LOCK WASHER 3 8 4 11 641848 HEX NUT 3 8 16 4 12 16816G2 RATCHET RIVET 25 X 887 4 13 14 303459...

Page 30: ...Page C 11 Notes BODY 666430 Service Parts Manual...

Page 31: ...Page C 12 Notes BODY 666430 Service Parts Manual...

Page 32: ...6430 Service Parts Manual Page D 1 BRAKES Front of Vehicle Front of Vehicle 13 12 11 10 14 9 19 5 21 1 23 6 2 16 16 3 2 3 15 16 20 20 7 3 4 Front of Vehicle 6 18 18 17 16 Calliper Front of Vehicle 7 4...

Page 33: ...18 4 6 00439G8 HEX HEAD BOLT 5 18 18 X 1 12 LG 2 7 613231 HEX HEAD BOLT M6 1 X 20MM LG 1 8 12416G2 NYLON CLAMP 10 TO SECURE BRAKE LINES TO FRAME NOT ILLUSTRATED 26 9 635177 SHOULDER BOLT 1 2 X 2 3 8...

Page 34: ...Page D 3 Notes BRAKES 666430 Service Parts Manual...

Page 35: ...Page D 4 Notes BRAKES 666430 Service Parts Manual...

Page 36: ...vice Parts Manual Page E 1 ELECTRICAL 7 FRONT GRILLE WITH LIGHT ASSEMBLY includes items 3 4 6 CHARGER RECEPTACLE ASSEMBLY includes items 10 11 16 16 22 19 21 25 23 20 24 18 27 15 8 11 10 12 17 6 13 7...

Page 37: ...1G01 HEADLIGHT 1 7 71597G01 SELF THREADING NUT 226 9 8 660162 COVER RECEPTACLE 1 9 658089 CHARGER RECEPTACLE ASSEMB LY INCLUDES ITEMS 10 11 1 10 658956 CHARGER HARNESS 1 11 663285 CHARGING RECEPTACLE...

Page 38: ...rts Manual Page E 3 ELECTRICAL Front of Vehicle Part of Control Harness 22 23 Front of Vehicle Floor Panel 16 Front of Vehicle 18 17 16 DC DC CONVERTER 72V includes item 17 19 20 Front of Vehicle 3 11...

Page 39: ...AD CONTROL HARNESS 1 2 3 00789G2 TRUSS HEAD PHILLIPS SCREW 10 24 X 1 25 LG 1 4 00660G5 FLAT WASHER 10 1 5 14390G10 LOCK NUT 10 24 1 6 7 8 16816G2 RATCHET RIVET 25 X 887 1 9 10 629147G01 CONTACTOR 72V...

Page 40: ...Page E 5 Notes ELECTRICAL 666430 Service Parts Manual...

Page 41: ...Page E 6 Notes ELECTRICAL 666430 Service Parts Manual...

Page 42: ...Page F 1 ELECTRONIC SPEED CONTROL 6 8 22 16 15 17 7 26 1 10 24 24 11 3 13 4 19 20 21 23 27 Front of Vehicle 28 29 Part of Frame For Vehicles Manufactured After February 25 2019 For Vehicles Manufactur...

Page 43: ...1027G2 FLANGED LOCK NUT 1 4 20 4 5 6 628665 MOTOR WIRE REAR V 1 7 628667 MOTOR WIRE REAR W 1 8 628668 MOTOR WIRE REAR U 1 9 10 672599G007 CONTROLLER 72V 4WD OFF ROAD FOR VEHICLES MANUFACTURED AFTER FE...

Page 44: ...Page F 3 Notes ELECTRONIC SPEED CONTROL 666430 Service Parts Manual...

Page 45: ...Page F 4 Notes ELECTRONIC SPEED CONTROL 666430 Service Parts Manual...

Page 46: ...666430 Service Parts Manual Page G 1 FRONT SUSPENSION AND STEERING 1 4 5 12 12 19 5 10 3 6 6 8 8 20 18 21 6 Front of Vehicle 24 23 16 13 13 28 30 30 31 31 9 7 7 31 11 27...

Page 47: ...7G2 COTTER PIN 094 X 1 1 7 306982 FLAT WASHER 34 X 92 X 06 6 8 608005 CASTLE NUT M12 1 25 1 9 00463G11 HEX HEAD BOLT 7 16 14 X 1 5 LG GRADE 5 3 10 11098G5 LOCK NUT 3 8 16 2 11 00429G4 HEX HEAD BOLT 3...

Page 48: ...666430 Service Parts Manual Page G 3 FRONT SUSPENSION AND STEERING Front of Vehicle 1 3...

Page 49: ...duct Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page G 4 FRONT SU...

Page 50: ...NGER SIDE includes items 3 22 25 37 2 BRAKE CALIPER includes item 30 11 Part of Frame STRUT BEARING ASSEMBLY DRIVER SIDE includes items 26 27 29 STRUT BEARING ASSEMBLY PASSENGER SIDE includes items 26...

Page 51: ...T WASHER COIL SPRING 52MM 1 9 645047 STRUT BALL JOINT 1 10 616073 STRUT BUMP STOP 1 11 638129 BRAKE CALIPER INCLUDES ITEM 30 1 12 616451 CALIPER MOUNTING BRACKET 1 13 616596 SOCKET HEAD BOLT 3 8 24 X...

Page 52: ...nformation ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY FRONT SUSPENSION AND STEERING 666430 Service Parts Manual 31 625748 NYLOCK NUT M12 1 25 1 32 636610 FLAT WASHER 3 8 1 33 616701 RUBBER WASHER 1 5MM X...

Page 53: ...Page G 8 Notes FRONT SUSPENSION AND STEERING 666430 Service Parts Manual...

Page 54: ...666430 Service Parts Manual Page G 9 FRONT SUSPENSION AND STEERING STEERING COLUMN ASSEMBLY includes items 5 9 4 Front of Vehicle 6 9 11 5 3 2 1 10 8 8 7...

Page 55: ...NO 1 2 3 4 5 DESCRIPTION QTY Page G 10 FRONT SUSPENSION AND STEERING 666430 Service Parts Manual 1 639439 STEERING WHEEL COVER 1 2 601709 LOCK NUT M16 2 1 3 639437 STEERING WHEEL 1 4 600333 STEERING C...

Page 56: ...Page G 11 Notes FRONT SUSPENSION AND STEERING 666430 Service Parts Manual...

Page 57: ...Page G 12 Notes FRONT SUSPENSION AND STEERING 666430 Service Parts Manual...

Page 58: ...e Parts Manual Page H 1 MOTOR 4 5 1 Differential 13 11 Differential Front Motor Rear Motor 6 16 3 15 14 7 8 9 5 For Vehicles Manufactured Before February 24 2019 For Vehicles Manufactured After Februa...

Page 59: ...4 5 DESCRIPTION QTY Page H 2 MOTOR 666430 Service Parts Manual 1 666987 MOTOR 72V 1 2 3 668275 END CAP 1 4 00915G1 BONDED SEAL WASHER 3 5 616716 HEX HEAD BOLT M6 1 X 16MM LG 3 6 658445 DIFFERENTIAL G...

Page 60: ...Page H 3 Notes MOTOR 666430 Service Parts Manual...

Page 61: ...Page H 4 Notes MOTOR 666430 Service Parts Manual...

Page 62: ...666430 Service Parts Manual Page J 1 OPS A A B B 1 2 3 4 5 6 6 25 11 7 8 9 10 12 13 14 15 16 16 17 19 25 20 21 22 23 1 24 Front of Vehicle Part of Frame Part of Frame Part of Frame 18...

Page 63: ...ASSENGER SIDE 1 6 667928 LOWER NET BRACKET 1 7 602415 FLANGED HEX HEAD BOLT M10 1 5 X 80MM LG 1 8 600525 FLANGED LOCK NUT M10 1 5 1 9 612635 BUTTON HEAD TORX BOLT M6 1 X 20MM LG 1 10 601476 LOCK NUT M...

Page 64: ...666430 Service Parts Manual Page J 3 OPS Front of Vehicle 3 1 2 6 6 4 3 5 5 6 6 5 UPPER HARDWARE KIT includes items 5 6...

Page 65: ...rt Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page J 4 OPS 666430 Service Parts Manual 1 666355 REAR UPPER WELDMENT 1 2 666354 FRON...

Page 66: ...666430 Service Parts Manual Page J 5 OPS 11 4 5 7 Front of Vehicle 7 12 6 8 1 10 1 9 1 6 8 9 8 9 1 9 9 6 6 5 HARDWARE KIT includes items 6 12...

Page 67: ...TION QTY Page J 6 OPS 666430 Service Parts Manual 1 649134 SEAT BELT RETRACTOR 4 2 651519 FRONT DOOR NET NOT ILLUSTRATED 1 3 660063G01 SIDE BRACKET WELDMENT DRIVER SIDE 1 4 660063G02 SIDE BRACKET WELD...

Page 68: ...Page J 7 Notes OPS 666430 Service Parts Manual...

Page 69: ...Page J 8 Notes OPS 666430 Service Parts Manual...

Page 70: ...666430 Service Parts Manual Page K 1 FRONT AXLE 6 5 5 6 3 4 4 Front of Vehicle 2 7 8 1 11...

Page 71: ...ormation ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page K 2 FRONT AXLE 666430 Service Parts Manual 1 653033 CV AXLE ASSEMBLY 2 2 601327 LOCK WASHER 6MM 6 3 605741 HEX HEAD BOLT M6 1 X 25MM LG 6 4 306835...

Page 72: ...Page K 3 Notes FRONT AXLE 666430 Service Parts Manual...

Page 73: ...Page K 4 Notes FRONT AXLE 666430 Service Parts Manual...

Page 74: ...Manual Page L 1 REAR AXLE 9 25 2 3 12 15 9 19 13 7 6 21 14 22 18 8 4 9 HYDRAULIC BRAKE CALIPER includes item 10 Front of Vehicle 23 24 1 REAR AXLE DIFFERENTIAL ASSEMBLY includes items 2 14 14 HUB ASSE...

Page 75: ...X 1 50 O D NOT ILLUSTRATED 2 4 10387G1 COTTOR PIN 125 X 1 50 2 5 6 15126G1 LOCK NUT 5 16 24 4 7 17083G2 HEX HEAD BOLT 5 16 24 X 1 LG 4 8 613172 CASTLE NUT 3 4 16 1 9 638129 HYDRAULIC BRAKE CALIPER IN...

Page 76: ...666430 Service Parts Manual Page L 3 REAR AXLE 53 7 17 9 21 5 22 11 2 18 19 4 12 10 22 11 3 3 16 14 15 13 7 8 7 8 1 DIFFERENTIAL SOLID AXLE includes items 2 22 6...

Page 77: ...ERENTIAL SOLID AXLE INCLUDES ITEMS 2 22 1 2 HEX HOLLOW PLUG 2 3 HEX HEAD BOLT 12 4 HEX HEAD BOLT 8 5 TAPPING SCREW 12 6 PIN 2 7 RETAINING RING 2 8 BALL BEARING 4 9 GEAR CASE DRIVER SIDE 1 10 GEAR CASE...

Page 78: ...Page L 5 Notes REAR AXLE 666430 Service Parts Manual...

Page 79: ...Page L 6 Notes REAR AXLE 666430 Service Parts Manual...

Page 80: ...666430 Service Parts Manual Page M 1 REAR SUSPENSION Front of Vehicle Rear Axle 13 13 3 12 13 14 16 8 6 10 9 1 15 3 2 2 3 4 2 19 18 4 2 3...

Page 81: ...633674 SHOCK ABSORBER 2 2 634006 SHOCK ABSORBER WASHER 416 I D X 1 57 O D 4 3 634005 RUBBER BUSHING 4 I D X 1 19 O D X 59 4 4 606255 HEX JAM NUT M10 X 1 25 2 5 6 616098 LEAF SPRING 2 7 8 616321 U BOLT...

Page 82: ...Page M 3 Notes REAR SUSPENSION 666430 Service Parts Manual...

Page 83: ...Page M 4 Notes REAR SUSPENSION 666430 Service Parts Manual...

Page 84: ...666430 Service Parts Manual Page N 1 SEATING 1 SEAT BOTTOM ASSEMBLY includes items 2 12 14 SEAT BACK ASSEMBLY includes items 15 17 15 16 17 2 7 7 8 5 12 11 8 3 4 Front of Vehicle 20 19 20 19...

Page 85: ...1 629269G2406 BLACK 2 VINYL AND FOAM SEAT BOTTOM 1 644819G06 BLACK 3 644351 WOODEN BASE ASSEMBLY 1 4 602551 COVER PLATE 1 5 16816G2 RATCHET RIVET 25 X 887 4 6 7 71610G01 SEAT HINGE 1 8 00720G08 FLAT...

Page 86: ...666430 Service Parts Manual Page N 3 SEATING FLIP SEAT BOTTOM ASSEMBLY includes items 4 7 3 FLIP SEAT BOTTOM ASSEMBLY includes items 2 10 1 4 5 7 2 11 12 13 13 8 10 8 8 9...

Page 87: ...RIPTION QTY Page N 4 SEATING 666430 Service Parts Manual 1 615822 FLIP SEAT BOTTOM ASSEMBLY INCLUDES ITEMS 2 10 1 2 617137 DECK BOARD ASSEMBLY 1 3 621036 FLIP SEAT BOTTOM INCLUDES ITEMS 4 7 1 4 645820...

Page 88: ...666430 Service Parts Manual Page N 5 SEATING Front of Vehicle Front of Vehicle 20 Front of Vehicle 18 19 4 2 3 12 11 18 14 22 21 17 24 23 23 23...

Page 89: ...SEATING 666430 Service Parts Manual 1 2 609854 SEAT BELT LATCH BUCKLE 6 1 3 00734G3 LOCK NUT 7 16 20 1 4 610753 HEX HEAD BOLT 7 16 20 X 1 LG 1 5 6 7 8 9 10 11 609787 REAR SEAT BELT BRACKET 1 12 00427...

Page 90: ...666430 Service Parts Manual Page N 7 SEATING 10 10 11 10 11 10 13 16 10 2 10 11 19 18 17 Front of Vehicle 9 2 15 4 3 5 1 6 6 15 12 8...

Page 91: ...HEAD BOLT 3 8 16 X 1 25 LG 10 3 629050G01 SEAT BACK BRACKET DRIVER SIDE 1 4 629050G02 SEAT BACK BRACKET PASSENGER SIDE 1 5 629112 FLIP SEAT EDGE REINFORCEMENT 1 6 629275 DECK BOARD FILLER 2 7 8 16705G...

Page 92: ...Page N 9 Notes SEATING 666430 Service Parts Manual...

Page 93: ...Page N 10 Notes SEATING 666430 Service Parts Manual...

Page 94: ...666430 Service Parts Manual Page P 1 WEATHER PROTECTION B A A B CANOPY TOP KIT includes items 2 3 1 HARDWARE KIT includes items 4 9 3 Vehicle shown for reference only 7 8 7 9 4 2 5 6 6...

Page 95: ...information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page P 2 WEATHER PROTECTION 666430 Service Parts Manual 1 628584 CANOPY TOP KIT INCLUDES ITEMS 2 3 1 2 627077 CANOPY TOP 1 3 628585 HARDWARE KIT INCL...

Page 96: ...Page P 3 Notes WEATHER PROTECTION 666430 Service Parts Manual...

Page 97: ...Page P 4 Notes WEATHER PROTECTION 666430 Service Parts Manual...

Page 98: ...rvice Parts Manual Page R 1 WHEELS AND TIRES WHEEL AND TIRE ASSEMBLY FRONT includes items 2 3 1 WHEEL AND TIRE ASSEMBLY REAR includes items 6 7 5 6 10 2 9 STYLE OF WHEELS TIRES MAY DIFFER FROM THOSE S...

Page 99: ...omer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page R 2 WHEELS AND TIRES 666430 Service Parts Manual 1 667330 WHEEL AND TIRE ASSEMBLY FRONT INCLUDES ITEMS 2...

Page 100: ...Page R 3 Notes WHEELS AND TIRES 666430 Service Parts Manual...

Page 101: ...Page R 4 Notes WHEELS AND TIRES 666430 Service Parts Manual...

Page 102: ...THE VEHICLE TO MOVE IMMEDIATELY IF NOT ON LEVEL GROUND Move vehicle to desired location and park it properly on level ground chock tires IMMEDIATELY DISCONNECT AUXILIARY POWER AND RECONNECT PRIMARY P...

Page 103: ...DASH PANEL LABEL 1 2 637067 12V OUTLET CE LABEL 1 3 667079 TOW SWITCH DECAL 1 4 5 650238 FRONT GRILLE DECAL 1 6 649875G03 LOGO ATTACHMENT 1 7 663498 STEERING WHEEL DECAL 1 8 666372 FUSE BLOCK LABEL 1...

Page 104: ...Page S 3 Notes DECALS AND LABELS 666430 Service Parts Manual...

Page 105: ...Page S 4 Notes DECALS AND LABELS 666430 Service Parts Manual...

Page 106: ...ce Warranty Phone 1 800 774 3946 FAX 1 800 448 8124 Service Parts Phone 1 888 438 3946 FAX 1 800 752 6175 International Phone 001 706 798 4311 FAX 001 706 771 4609 Owners Guide as well as Repair and S...

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