Textron Inc 898353, 898353EE, 898354, 898354EE, 898356 MAINTENANCE MANUAL

PARTS AND

MAINTENANCE MANUAL

TITAN VEHICLE

MODELS: 898353, 898353EE, 898354, 898354EE, 898356, 898356EE, 898355, 898355EE, 898357, 898357EE

Part No. 4113731

1 GENERAL INFORMATION

1.1		GENERAL INFORMATION

IMPORTANT!

THIS MANUAL WILL AID YOU IN THE SAFE OPERATION AND PROPER MAINTENANCE OF YOUR EQUIPMENT. READ MANUAL THOROUGHLY BEFORE ATTEMPTING OPERATION. IF ANY PORTION IS NOT CLEARLY UNDERSTOOD, CONTACT AN AUTHORIZED DEALER FOR CLARIFICATION.

To make sure you are fully aware of safety and service information, the following two symbols are used throughout this manual.

! This symbol is used throughout the manual to alert you to information about unsafe actions or situations, and will be followed by the word DANGER, WARNING, or CAUTION. DANGER indicates immediate hazards that may result in severe injury or death. WARNING indicates unsafe actions or situations that may cause severe injury, death and/or major equipment or property damage. CAUTION indicates unsafe actions or situations that may cause injury, and/or minor equipment or property damage.

NOTE: This appears next to information or instructions which will help you operate and maintain your equipment the right way.

!WARNING

The information and instructions included in this manual alert you to certain things you should do very carefully. If you do not, you could:

•hurt yourself or others

•hurt the next person who operates the equipment

•damage the equipment.

This manual contains essential operation and safety information and must remain with the unit at all times, within easy access of any operator.

Additional manuals are available through your dealer.

IMPORTANT!

THIS EQUIPMENT SHOULD NOT BE MODIFIED OR ADDED TO WITHOUT THE MANUFACTURER'S AUTHORIZATION.

!WARNING

Altering this equipment in any manner which adversely affects the equipments operation, performance, durability or use, may cause hazardous conditions.

Direct any inquiries to:

Textron Golf, Turf and Specialty Products Attn: Director of Engineering Services P.O. Box 82409

Lincoln, NE 68501±2409 USA

SPECIFICATION INFORMATION

All information contained in this manual is the latest available at the time of printing. Textron Golf, Turf and Specialty Products reserves the right to make changes at any time without notice.

Whenever a name brand product is specified, an equivalent product may be used unless stated otherwise.

CHANGE OF OWNERSHIP OR ADDRESS

Textron Golf, Turf and Specialty Products makes every effort to keep owners informed of all safety related information. Therefore, changes in ownership and/or address should be reported to the manufacturer.

Your dealer has REGISTRATION CHANGE FORMS which will be filled out and filed by the dealer for his records, and a copy will be sent to the manufacturer.

DEALER INFORMATION

For your nearest dealer location write to:

Textron Golf, Turf and Specialty Products Attn: Sales Coordinator

P.O. Box 82409

Lincoln, NE 68501±2409 USA

In the USA and Canada call 1±888±922±8873 (dealer information only).

MODELS

898353 & 898353EE ± 36 Volt Swing Out Batteries

3000 Pound ± 13 M.P.H.

898354 & 898354EE ± 48 Volt Swing Out Batteries

4000 Pound ± 9 M.P.H.

898356 & 898356EE ± 48 Volt Swing Out Batteries

5000 Pound ± 7 M.P.H.

898355 & 898355EE ± 36 Volt Four Passenger

3000 Pound ± 13 M.P.H.

898357 & 898357EE ± 36 Volt

3000 Pound ± 13 M.P.H.

		2002 Textron Inc.
	250±1±02±CU	Lincoln, Nebraska •All Rights Reserved.
		Printed in U.S.A.

TABLE OF CONTENTS

SECTION				PAGE
1	General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		Inside Front Cover
	1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		Inside Front Cover
2	Identification
	2.1	Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .	. . . . . . . . . 3
	2.2	Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 3
	2.3	Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 3
3	Service
	3.1	Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 4
	3.2	Maintenance Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 4
	3.3	Chassis Lubrication Guide . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 5
	3.4	Chassis Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 5
	3.5	Bulbs, Fuses And Flashers . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 6
4	Specifications
	4.1	Vehicle Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 7
	4.2	Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 7
5	Maintenance
	5.1	Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 8
	5.2	Battery Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 8
	5.3	Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 8
	5.4	Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 9
	5.5	Jacks And Jacking Locations . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 9
	5.6	Solid Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . .	. . . . . . . . . 9
	5.7	Pneumatic Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .	. . . . . . . 10
	5.8	Tire Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .	. . . . . . . 10
	5.9	Touch-up Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .	. . . . . . . 10
6	Controller Parameters
	6.1	36 Volt Controller Parameters . . . . . . . . . . . . . . . . . . . . .	. . . . . .	. . . . . . . 11
	6.2	36 Volt Max Speed Adjustment . . . . . . . . . . . . . . . . . . . .	. . . . . .	. . . . . . . 13
	6.3	48 Volt Controller Parameters . . . . . . . . . . . . . . . . . . . . .	. . . . . .	. . . . . . . 14
7	Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . .	. . . . . . . 17
8	Parts
	8.1	Frame, Deck, Front Panel, Tie Downs . . . . . . . . . . . . . .	. . . . . .	. . . . 18±19
	8.2	Frame, Deck, Front Panel, Tie Downs . . . . . . . . . . . . . .	. . . . . .	. . . . 20±21
	8.3	Frame, Deck, Front Panel, Tie Downs . . . . . . . . . . . . . .	. . . . . .	. . . . 22±23
	8.4	Front Axle, King Pin Pivots, Spring Perch, Spring, Brackets		. . . . . 24±25
	8.5	Front Spring, Front Frame Brace, Arm And Bushing . .	. . . . . .	. . . . . . . 26
	8.6	Front Hub Without Front Brake . . . . . . . . . . . . . . . . . . . .	. . . . . .	. . . . . . . 27
	8.7	Seat, Backrest [Stopwall] Frame, Backrest, Seat Switch . . . .		. . . . 28±29
	8.8	Rear Seat, Folding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .	. . . . 30±31
	8.9	Brakes (Rear Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . .	. . . . 32±33
	8.10 Brakes (Rear Hydraulic) . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . .	. . . . 34±35
	8.11 Brakes (Four Wheel Hydraulic) . . . . . . . . . . . . . . . . . . . .		. . . . . .	. . . . 33±37
	8.12 Master Cylinder (Rear Brakes) . . . . . . . . . . . . . . . . . . . .		. . . . . .	. . . . 38±39
	8.13 Master Cylinder (Four Wheel Brakes) . . . . . . . . . . . . . .		. . . . . .	. . . . 40±41
	8.14 Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . .	. . . . . . . 42
	8.15 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . .	. . . . . . . 43
	8.16 Front Brake And Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . .	. . . . 44±45
	8.17 Brake (Rear Wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . .	. . . . 46±47

1

	TABLE OF CONTENTS
SECTION		PAGE
8 Parts
8.18	Brake, Hub (Rear Wheel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 48±49
8.19	Parking Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 50±51
8.20	Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 52±53
8.21	Rear Springs, Spacer, Shackles, U±bolts . . . . . . . . . . . . . . . . . . .	. . 54±55
8.22	Shock Absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 56±57
8.23	Differential (13.00:1 ratio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 58±61
8.24	Differential (Full Floating, 13.00:1 ratio) . . . . . . . . . . . . . . . . . . . . .	. . 62±63
8.25	Differential (Full Floating, 15.67:1 ratio) . . . . . . . . . . . . . . . . . . . . .	. . 64±67
8.26	Differential (15.67:1 ratio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 68±71
8.27	Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 72±73
8.28	Steering Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 74±75
8.29	Speed Control Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 76±77
8.30	Motor (36 Volt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 78±79
8.31	Motor (48 Volt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 80±81
8.32	Belts & Pulleys (48 Volt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 82±83
8.33	Belts & Pulleys (3000 Lb. Capacity) . . . . . . . . . . . . . . . . . . . . . . . .	. . 84±85
8.34	Belts & Pulleys (6 MPH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . 86
8.35	Battery Hold Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . 87
8.36	Battery Hold Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 88±89
8.37	Swing Out Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 90±91
8.38	Battery Hold Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . 92
8.39	Tire And Wheel And Spare Tire Accessory . . . . . . . . . . . . . . . . . .	. . . . . 93
8.40	Tire And Wheel Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . 94
8.41	Solid Tire And Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . 95
8.42	Clamps, Clips, Grommets, Plugs And Tie . . . . . . . . . . . . . . . . . . .	. . 96±97
8.43	Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 98±99
8.44	Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	100±103
8.45	Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	104±109
8.46	Charger Box Motor Splash Guard . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . 110
8.47	Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	111±116
8.48	Accessory Tool Box & Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . 117
8.49	Accessory Bumper & Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	118±119
8.50	Accessory Turn Signal Set Part No. 886465 . . . . . . . . . . . . . . . .	. . . . 120
8.51	Accessory Turn Signal Set Part No. 886465, wiring . . . . . . . . . .	. . . . 121
8.52	Accessory Headlight Set Part No. 886466 . . . . . . . . . . . . . . . . . .	. . . . 122
8.53	Accessory Box Sides And Tailgate Set Part No. 886467 . . . . . .	. . . . 123
8.54	Accessory Cab Set Part No. 886468 . . . . . . . . . . . . . . . . . . . . . .	124±125
8.55	Accessory Fiberglass Door Set Part No. 886469 . . . . . . . . . . .	126±127
8.56	Accessory Cloth Door Set Part No. 886940 . . . . . . . . . . . . . . . .	128±129
8.57	Accessory Hour Meter & Spare Tire Mount . . . . . . . . . . . . . . . . .	. . . . 130
8.58	Accessory Lift Out Battery Rack Set . . . . . . . . . . . . . . . . . . . . . .	131±134
8.59	Charger Relay Set Part No. 887496 . . . . . . . . . . . . . . . . . . . . . . .	. . . . 135
8.60	Modification 328, 346 Less Charger . . . . . . . . . . . . . . . . . . . . . . . .	. . . . 136
8.61	Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . 137
8.62	Seat Brake Modification 411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	138±139
8.63	Accessory Tilt Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	140±141
8.64	Accessory Controller Programmer . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . 142
8.65	EE Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . 143

9 Wiring Diagram

9.1 Wiring Diagram 36v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144±145

9.2 Wiring Diagram 48v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146±147

2

IDENTIFICATION 2

2.1 VEHICLE IDENTIFICATION

THESE IDENTIFICATION NUMBERS MUST APPEAR ON ALL CORRESPONDENCE CONCERNING THIS VEHICLE.

2.2 MODEL NUMBER

The vehicle model number and serial number are stamped on the vehicle nameplate attached to the left kick panel in front of the steering column.

3936

2.3		SERIAL NUMBER

The serial number and model number are stamped on the center crossmember under the rear deck.

3937

IMPORTANT!

INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN THE PRECEDING ASSEMBLY.

AFTER YOU IDENTIFY A PART BY THE REFERENCE NUMBER AND THE CUSHMAN PART NUMBER,

ALWAYS READ THE DESCRIPTION OF THE PART TO BE SURE IT IS WHAT YOU WANT.

3

3 SERVICE

3.1		SERVICE

!WARNING

When replacement parts are required, use genuine CUSHMAN parts or parts with equivalent characteristics including type, strength and material. Failure to do so may result in product malfunction and possible injury to the operator and/or bystanders.

NEVER attempt to perform service or maintenance functions on this vehicle if you are UNTRAINED or UNAUTHORIZED. Improper maintenance can cause hazardous conditions. See your authorized CUSHMAN dealer for necessary maintenance and service.

When it is necessary to raise the vehicle for any repair or service, use jackstands to provide adequate support. Do not rely on hydraulic or mechanical jacks.

The average miles traveled per hours of operation for CUSHMAN vehicles is usually very low. A vehicle used inside a manufacturing facility or on a security system patrol may be used for 8 hours while traveling only 20 or 25 miles. It is advisable that your vehicle be equipped with an hour meter (set #884737) to record hours of operation. A good maintenance schedule can then be established.

The following maintenance guide provides a check list for servicing your vehicle. The guide is set up for average use on clean, paved surfaces. Vehicles used in dusty areas, for winter driving or operated in mud, snow or water require more frequent service.

3.2		MAINTENANCE GUIDE

WEEKLY

Check tire pressure(exclude solid tires).

Fill batteries to proper level and check specific gravity.

AS REQUIRED

Remove and clean wire terminals, battery terminals and batteries, reinstall wire terminals.

EVERY 200 HOURS

Perform previous services

Check brake fluid level (BF)

Check differential oil level

Lubricate chassis*

EVERY 600 HOURS OR YEARLY

Perform previous services

Repack front wheel bearings (PG)

Repack rear wheel bearings (PG)

Change differential oil (EP)

Check brake linings

Adjust brakes as required

Check motor brushes

*Use lithium base pressure gun grease on all grease fittings and lubrication points.

LUBRICATION CODE

PG ± Pressure gun grease (lithium base)

EP ± Extreme pressure lube SAE 80±90 Multigrade

BF ± Brake fluid DOT (3)

4

SERVICE 3

3.3CHASSIS LUBRICATION GUIDE

Perform every 200 hours

	LUBRICATION AREA		NUMBER OF
			LUBRICATION POINTS
			OR FITTINGS*
	1.	Steering linkage	4
	2.	Brake pivots	2
	3.	King pin bushings	2
	4.	Selector switch contacts, pivot
		and shaft spacer	11
	5.	Wheel arm pivots	2

*Use a lithium base pressure gun grease on all grease fittings and lubrication points.

Use 30 wt. oil on selector switch pivot shaft.

3.4CHASSIS LUBRICATION CHART

♦

♦

IMPORTANT

XTOW LINE ATTACHING POINTS

♦JACKING LOCATIONS

NOTE

•Illustration shows eight batteries and direct drive motor. Some models use six batteries and/or belt drive motor.

♦

♦

5

3 SERVICE

3.5BULBS, FUSES AND FLASHERS

Description	Specification or	Trade No.	Cushman No.
BULBS
Headlight (accessory)	35 Watt	No. 4411	820594
	(3000 CP)
Light, Rear Left,
Stop, Tail and Turn Signal (accessory)	32±4 CP	No. 1157	822049
Light, Rear Right,
Stop, Tail and Turn Signal (accessory)	32±4 CP	No. 1157	822049
Turn Signal, Front (accessory)	32±4 CP	No. 1157	822049
Turn Signal, Pilot (accessory)	1 CP	No. 53	811953
Power On Light	2 CP	No. 1893	828473
FLASHERS
Hazard and Turn Signal (accessory)			822867
FUSES (Located under instrument panel)
Five Required	20 AMP		826000

6

						SPECIFICATIONS 4
4.1		VEHICLE SPECIFICATIONS
	Model Number		Traction Type	Differential	Speed
			Motor	Ratio	Range
	898353		36 Volt DC	13.00:1	13	MPH (21Km/h)
	898353EE		Direct Drive		UP TO
			to Differential		35	MILES(56 Km)
	898354		48 Volt DC	13.00:1	9 MPH (14.5 Km/h)
	898354EE		Belt Drive		UP TO
			to Differential		35	MILES(56 Km)
	898356		48 Volt DC	15.67:1	7 MPH (11Km/h)
	898356EE		Belt Drive		UP TO
			to Differential		30	MILES (48 Km)
	898355		36 Volt DC	13.00:1	13	MPH (21Km/h)
	898355EE		Direct Drive		UP TO
			to Differential		35	MILES(56 Km)
	898357		36 Volt DC	13.00:1	13	MPH (21Km/h)
	898357EE		Direct Drive		UP TO
			to Differential		35	MILES(56 Km)
	Determining factors affecting the range are: battery condition and size, payload, the number of stops,
	speed and operating terrain.

4.2		BATTERY SPECIFICATIONS

SPECIFICATIONS

These vehicles require ªgolf cart typeº 6 volt batteries each with a MINIMUM capacity of 180 A.H. (ampere± hours at the SAE 20±hour rate) and 5/16º (8 mm) stud posts.

The MAXIMUM case dimensions are:

•	Length	10 3/8º (264 mm)
•	Width	7 3/16º (183 mm)
•	Height	11 5/8º (295 mm)
		(including posts)
		OR

FOR THE 36 VOLT VEHICLE

Two ªindustrial typeº 18 volt batteries each with a MINIMUM capacity of 450 A.H. (ampere hours at the SAE 20±hour rate) or 294 A.H. (ampere hours at the 3±hour rate) with 5/16 (8 mm) stud type posts.

The MAXIMUM case dimensions are:

•	Length	29	13/16º (776 mm)
•	Width	12	15/16º (329 mm)
•	Height	13	1/2º (343 mm)

OR

FOR THE 48 VOLT VEHICLE

Two ªindustrial typeº 24 volt batteries each with a MINIMUM capacity of 375 A.H. (ampere hours at the SAE 20±hour rate) or 245 A.H. (ampere hours at the 3±hour rate) with 5/16 (8 mm) stud type posts.

The MAXIMUM case dimensions are:

•	Length	30	9/16º (776 mm)
•	Width	12	15/16º (329 mm)
•	Height	13	1/2º (343 mm)

7

5 MAINTENANCE

5.1		BATTERY CHARGING

NOTICE

•DO NOT attempt to recharge the batteries with a charger not designed for this vehicle.

•Industrial batteries may require special chargers. Obtain charger recommendations from the battery supplier.

See your authorized CUSHMAN dealer for information about lifting devices.

!WARNING

UNTRAINED/UNAUTHORIZED persons should NEVER attempt to service or recharge the batteries of this vehicle.

To avoid injury, use an adequate lifting device to lift the batteries and/or rack.

NEVER use metal chains, etc., to lift the batteries and/or rack. They can cause electrical arcing resulting in battery explosion.

Stay clear when lifting, lowering or moving the batteries and/or rack. Do NOT place hands on the batteries and/or rack or the vehicle.

See your authorized CUSHMAN dealer for information about lifting devices.

5.2		BATTERY LOCATION

The batteries are located under the rear deck.

Model 898355, 898355EE, 898357 and 898357EE are equipped with fixed battery racks.

Models 898353, 898353EE, 898354, 898354EE, 898356, and 898356EE are equipped with swing out battery racks accessible from each side of the vehicle, both secured in position with a latch handle (shown). Make sure racks are securely latched before operating the vehicle.

3111

Latch Handle

!WARNING

Fully engage battery tray latch pin in innermost slot. If tray is not properly latched and swings open when vehicle is in motion

•Bystanders may be struck

•Vehicle and surroundings may be damaged.

5.3		BATTERY CHARGER

The standard vehicle is equipped with a built in fully automatic AC charger located under the deck at the rear of the vehicle.

Accessory chargers of various types are also available.

•Follow the instructions on the charger or the vehicle.

•ALWAYS place the charger cord in the pocket designed for it on the standard vehicle.

NOTICE

•New HIGH CAPACITY batteries will have a finish charge rate of 2 to 4 amps after charging for 16 hours. LOWER CAPACITY batteries may require a shorter charging time. This MAXIMUM charging time is required ONLY after operating (driving) the vehicle for 2 hours or more, i.e.: Shorter operating (driving) time requires shorter charging time.

8

MAINTENANCE 5

5.4		DIFFERENTIAL

The filler plug and the drain plug are illustrated. Check oil level every 200 hours. It should always be up to the level of the filler hole.

IMPORTANT!

DRAIN DIFFERENTIAL AFTER FIRST 100 HOURS OF SERVICE AND REFILL WITH EP80±90 MULTIGRADE EXTREME PRESSURE LUBRICANT. THEREAFTER LUBRICANT SHOULD BE CHANGED PER MAINTENANCE GUIDE.

REPAIRING THIS REAR AXLE IS A MAJOR SERVICE OPERATION AND SHOULD BE PERFORMED BY YOUR AUTHORIZED CUSHMAN DEALER WHO HAS THE NECESSARY EQUIPMENT AND INFORMATION.

1

2

3112

1.Filler Plug

2.Drain Plug

5.5JACKS AND JACKING LOCATIONS

A scissors type jack with a 1 1/2 ton (1361 Kg) (minimum) capacity is required.

The jacking locations are shown on the chassis lubrication chart illustration (page 10). Raise the vehicle ONLY enough to perform maintenance required.

5.6		SOLID TIRES

FRONT AND REAR TIRE REMOVAL

2

1

3569

1.Valve Stem Hole

2.Wheel Retaining Nuts

Remove and reinstall as follows:

•Remove the wheel retaining nuts and remove wheel assembly from hub.

•Remove wheel hardware.

•Remove and discard tire.

•Press new tire in place.

•Reinstall and tighten wheel hardware.

•Reinstall tire and wheel and tighten wheel retaining nuts to 70 to 100 ft.±lbs. (95 to 140 N´m) torque.

•Make sure the valve stem hole is located toward the outside.

NOTICE

•The valve stem hole in the wheel half MUST be towards the outside so the wheel retaining nuts will tighten properly.

NOTICE

•Use replacement tires equivalent to or exceeding original equipment specifications.

9

5 MAINTENANCE

5.7		PNEUMATIC TIRES

FRONT AND REAR TIRE REMOVAL

2

1

3110

1.Wheel Retaining Nuts

2.Valve Stem

Remove and reinstall as follows:

•Remove the wheel retaining nuts and remove wheel assembly from hub.

•Reinstall tire and wheel by reversing above sequence and tighten wheel retaining nuts to 70 to 100 ft.±lbs. (95 to 140 N´m) torque.

•Make sure the valve stem is located toward the outside.

5.8		TIRE AIR PRESSURE

Keep tires inflated according to the specifications corresponding to the particular tire size.

Tire Size	Cold Inflation Pressure
5.70 x 8	45 PSI (310 kPa)

Inflat tires with care. Use a pressure gauge before connecting an air hose to a partly inflated tire. Due to the low air volume needed, over±inflation may be reached in a matter of two or three seconds.

NOTICE

•Air pressure needed is determined by the payload carried. Adjust pressure as required.

Lower pressure will help avoid leaving tire marks in soft turf. Higher pressures may be required for heavy loads. NEVER exceed maximum pressure indicated on tire.

•Improper inflation will shorten the life of your tires considerably.

•If the vehicle is operated on any surface other than smooth and level, the use of foam filled or solid tires could cause premature failure of tires, axles and suspension components.

•The 5.70 x 8 load range C (steel guard) and D tires are only to be used on the welded one piece wheel only.

•Use replacement tires equivalent to or exceeding original equipment specifications.

5.9		TOUCH-UP PAINT

Safety Yellow

•16 oz. (0.5L) spray can LEAD FREE. Order part number 833252.

•1 quart (0.9L) can LEAD FREE. Order part number

833251.

10

CONTROLLER PARAMETERS 6

6.1

36 VOLT PROGRAMMING

CURTIS 1244-5406 (2703504) CONTROLLER PARAMETERS

FOR MOTOR (2703945) GE MODEL NO. 5BC49JB2056

CUSHMAN FACTORY SET CONTROLLER PARAMETERS

PARAMETER

RANGE

DESIRE

UNITS

DESCRIPTION

ACCESS

VOLT

3

OEM

M1 DRIVE C/L

350

max. current controller will supply

OEM

100±400

AMP

M2 DRIVE C/L

350

to the motor during drive operation

M3 DRIVE C/L

350

N/A

OEM

M4 DRIVE C/L

350

max. current controller will supply

M1 BRAKE C/L

170

OEM

100±400

AMP

M2 BRAKE C/L

170

to the motor during braking

M3 BRAKE C/L

170

N/A

OEM

M4 BRAKE C/L

170

M1 THRT BRK %

establishes the braking force

0±100

34

%

U

M2 THRT BRK %

34

(% of regen braking current limit)

M3 THRT BRK %

34

N/A

OEM

M4 THRT BRK %

34

M1 ACCEL RATE

0.1±5.0

0.7

SEC

sets time it takes to accelerate from

U

M2 ACCEL RATE

0.7

0% to 100% output

M3 ACCEL RATE

0.7

N/A

OEM

M4 ACCEL RATE

0.7

DECEL RATE

0±10

1.5

SEC

sets time it takes controller to

U

respond to throttle decrease

M1 BRAKE RATE

4

set time it takes controller to go from

U

0.1±5.0

SEC

0% to 100% braking when

M2 BRAKE RATE

4

changing directions

M3 BRAKE RATE

4

N/A

OEM

M4 BRAKE RATE

4

0±10

6

provides faster than normal accel-

U

QUICK START

eration upon sudden throttle demand

controls feel of vehicle as it slows

TAPER RATE

0±64

64

1/32 of a SEC

OEM

down & approaches zero speed

M1 MAX SPEED

0±100

100

%

max. controller output at full throttle

U

M2 MAX SPEED

60

(see max speed adjustment section)

M3 MAX SPEED

100

N/A

OEM

0±100

M4 MAX SPEED

100

M1 CREEP SPEED

0

defines initial controller output when

OEM

0±25

%

M2 CREEP SPEED

0

controller initiates regenerative braking

M3 CREEP SPEED

0

N/A

OEM

M4 CREEP SPEED

0

REGEN SPEED

0±100

10

%

defines vehicle speed above which

OEM

controller initiates regenerative braking

CTRL MODE

1

OEM

THROTTLE TYPE

2

OEM

M1 = FORWARD DIRECTION

Shaded area indicates where

parameters have been changed.

M2 = REVERSE DIRECTION

FACTORY SETTINGS

Shaded area should not be changed

from factory settings.

11

6 CONTROLLER PARAMETERS

6.1

36 VOLT PROGRAMMING

CURTIS 1244-5406 (2703504) CONTROLLER PARAMETERS

FOR MOTOR (2703945) GE MODEL NO. 5BC49JB2056

CUSHMAN FACTORY SET CONTROLLER PARAMETERS

PARAMETER

RANGE

DESIRE

UNITS

DESCRIPTION

ACCESS

OEM

THRTL DEADBAND

0±30

10

%

sets the throttle neutral range

THROTTLE MAX

OEM

60±100

sets the throttle full output point

90

%

M1 THRTL MAP

40

modifies the vehicle's response to

20±80

%

OEM

M2 THRTL MAP

40

throttle input

M3 THRTL MAP

40

N/A

OEM

M4 THRTL MAP

40

defines minimum allowed current in

4.5

FIELD MIN

2±20

AMP

U

( DO NOT

motor's field winding (see max speed

adjust <4.5

adjustment section) must keep within

or >10)

4.5±10 for safe operation

defines maximum allowed current in

OEM

FIELD MAX

7.5±30

30

AMP

motor's field winding

FLD MAP START

defines armature current at which the field

OEM

60

AMP

0±240

map starts to increase from field min. valve

FIELD MAP

controls how much field current is applied

0±100

50

%

OEM

for a given armature current

CURRENT RATIO

determine the maximum torque the motor

1, 2, 4 or 8

2

OEM

can provide at partial throttle

determine how strongly the controller

RESTRAINT

1±10

3

OEM

attempts to limit vehicle speed

adjust applied motor voltage as a function

LOAD COMP.

0±25

0.0

OEM

of motor load current

high pedal disable (prevents vehicle from

0, 1 or 2

1

OEM

HPD

driving if greater than 25% throttle is applied

when controller turned on

static return to off prevents vehicle from

SRO

0, 1, 2 or 3

U

0 or 1

being started when ªin gearº

Type 0: no SRO

Type 1: SRO on (interlock input plus a

direction input)

Type 2: Not used

Type 3: Not used

sets time to allow interlock switch to be

SEQUENCING DLY

0±3

2

cycled to prevent inadverted activation

OEM

of HPD or SRO

MAIN CONT INTR

request for interlock input before

OEM

ON

vehicle operation

MAIN OPEN DLY

0±40

1

main contactor dropout delay

OEM

enables main contactor checks for

OEM

WELD CHECK

ON

welded circuit

M1 = FORWARD DIRECTION

M2 = REVERSE DIRECTION

FACTORY SETTINGS

Shaded area indicates where parameters have been changed.

Shaded area should not be changed from factory settings.

12

CONTROLLER PARAMETERS 6

6.1

36 VOLT PROGRAMMING

CURTIS 1244-5406 (2703504) CONTROLLER PARAMETERS

FOR MOTOR (2703945) GE MODEL NO. 5BC49JB2056

CUSHMAN FACTORY SET CONTROLLER PARAMETERS

PARAMETER

RANGE

DESIRE

UNITS

DESCRIPTION

ACCESS

MAIN CHECK

enables main contactor checks for

ON

OEM

open circuit

AUX ENABLE

N/A

OEM

OFF

EM BRAKE

OFF

N/A

OEM

AUX DELAY

0.0

N/A

OEM

AUX CHECK

OFF

N/A

OEM

N/A

EM BRAKE DELAY

0.0

OEM

EM BRAKE CHECK

N/A

OEM

OFF

REV DRVR CHECK

OFF

N/A

OEM

defines contactor pull±in voltage as %

CONT PULL IN

20±100

34

%

OEM

of nominal battery voltage

defines contactor holding voltage ± in

CONT HOLDING

26

%

OEM

20±100

voltage 95% of nominal battery voltage

EMR REV ENABLE

OFF

N/A

OEM

EMR REV C/L

350

N/A

OEM

EMR REV. CHECK

OFF

N/A

OEM

ANTI±TIEDOWN

OEM

OFF

N/A

FAULT CODE

ON

allows faults to be displayed

OEM

PEDAL INTRLCK

OFF

N/A

OEM

enables or disables pre±charge function

PRE CHARGE

ON

OEM

M1 = FORWARD DIRECTION

M2 = REVERSE DIRECTION

FACTORY SETTINGS

Shaded area indicates where parameters have been changed.

Shaded area should not be changed from factory settings.

6.2			MAX SPEED ADJUSTMENT
			36 VOLT PROGRAMMING
		CURTIS 1244±5406 (2703504) CONTROLLER
	FOR MOTOR (2703945) G.E. MODEL NO. 5BC49JB2056
			MAX SPEED CHART
		MAX SPEED (MPH)		FIELD MIN	MI/MAX SPEED
		13		4.5	100
		12		5.5	100
		11		6.5	100
		10		7.5	100
		9		8.5	100
		8		10	100
		7		10	90
		6		10	75

Max speed in the forward mode may be limited by adjusting the field MIN and M1 max speed parameters as shown in the chart above. Max speed in the reverse direction may be increased from factory setting by adjusting the M2 max speed parameter only. Never adjust M2 to be larger than M1 (don't adjust reverse speed to be faster than forward speed)

13

6 CONTROLLER PARAMETERS

6.3

48 VOLT PROGRAMMING

CURTIS 1244-5407 (2703505) CONTROLLER PARAMETERS

FOR MOTOR (2703946) GE MODEL NO. 5BC49JB2061

CUSHMAN FACTORY SET CONTROLLER PARAMETERS

PARAMETER

RANGE

DESIRE

UNITS

DESCRIPTION

ACCESS

VOLT

4

OEM

M1

DRIVE C/L

350

max. current controller will supply

OEM

100±400

AMP

350

M2

DRIVE C/L

to the motor during drive operation

M3 DRIVE C/L

350

N/A

OEM

M4 DRIVE C/L

350

M1

BRAKE C/L

165

max. current controller will supply

OEM

100±400

AMP

M2

BRAKE C/L

165

to the motor during braking

M3 BRAKE C/L

165

N/A

OEM

M4 BRAKE C/L

165

M1

THRT BRK %

0±100

14

%

establishes the braking force

U

M2

THRT BRK %

14

(% of regen braking current limit)

M3 THRT BRK %

14

N/A

OEM

14

M4 THRT BRK %

M1

ACCEL RATE

0.1±5.0

0.7

SEC

sets time it takes to accelerate from

U

M2 ACCEL RATE

0.7

0% to 100% output

M3 ACCEL RATE

0.7

N/A

OEM

M4 ACCEL RATE

0.7

DECEL RATE

0±10

1.5

SEC

sets time it takes controller to

U

respond to throttle decrease

M1

BRAKE RATE

0.1±5.0

4

SEC

set time it takes controller to go

U

M2 BRAKE RATE

4

from 0% to 100% braking when

changing directions

M3 BRAKE RATE

4

N/A

OEM

M4 BRAKE RATE

4

0±10

6

provides faster than normal accel-

U

QUICK START

eration upon sudden throttle demand

controls feel of vehicle as it slows

TAPER RATE

0±64

64

OEM

1/32 of a SEC

down & approaches zero speed

M1

MAX SPEED

0±100

100

%

max. controller output at full throttle

U

M2

MAX SPEED

60

(see max speed adjustment section)

M3 MAX SPEED

100

N/A

OEM

0±100

M4 MAX SPEED

100

M1

CREEP SPEED

0

defines initial controller output when

OEM

0±25

%

M2

CREEP SPEED

0

controller initiates regenerative braking

M3 CREEP SPEED

0

N/A

OEM

M4 CREEP SPEED

0

defines vehicle speed above which

OEM

REGEN SPEED

0±100

0

%

controller initiates regenerative braking

CTRL MODE

1

OEM

THROTTLE TYPE

2

OEM

M1

= FORWARD DIRECTION

Shaded area indicates where

parameters have been changed.

M2

= REVERSE DIRECTION

FACTORY SETTINGS

Shaded area should not be changed

from factory settings.

14

6 CONTROLLER PARAMETERS

6.3

48 VOLT PROGRAMMING

CURTIS 1244-5407 (2703505) CONTROLLER PARAMETERS

FOR MOTOR (2703946) GE MODEL NO. 5BC49JB2061

CUSHMAN FACTORY SET CONTROLLER PARAMETERS

PARAMETER

RANGE

DESIRE

UNITS

DESCRIPTION

ACCESS

OEM

THRTL DEADBAND

0±30

10

%

sets the throttle neutral range

THROTTLE MAX

OEM

60±100

sets the throttle full output point

90

%

M1 THRTL MAP

40

modifies the vehicle's response to

20±80

%

OEM

M2 THRTL MAP

40

throttle input

M3 THRTL MAP

40

N/A

OEM

40

M4 THRTL MAP

defines minimum allowed current in

3.5

FIELD MIN

2±20

AMP

U

( DO NOT

motor's field winding (see max speed

adjust <3.5

adjustment section) must keep within

or >10)

3.5±10 for safe operation

defines maximum allowed current in

OEM

FIELD MAX

7.5±30

30

AMP

motor's field winding

FLD MAP START

defines armature current at which the field

OEM

60

AMP

0±240

map starts to increase from field min. valve

FIELD MAP

controls how much field current is applied

0±100

50

%

OEM

for a given armature current

determine the maximum torque the motor

CURRENT RATIO

1, 2, 4 or 8

2

OEM

can provide at partial throttle

determine how strongly the controller

RESTRAINT

1±10

3

OEM

attempts to limit vehicle speed

adjust applied motor voltage as a function

LOAD COMP.

0±25

0.0

OEM

of motor load current

high pedal disable (prevents vehicle from

0, 1 or 2

1

OEM

HPD

driving if greater than 25% throttle is applied

when controller turned on

static return to off prevents vehicle from

SRO

0, 1, 2 or 3

U

0 or 1

being started when ªin gearº

Type 0: no SRO

Type 1: SRO on (interlock input plus a

direction input)

Type 2: Not used

Type 3: Not used

sets time to allow interlock switch to be

SEQUENCING DLY

0±3

2

cycled to prevent inadverted activation

OEM

of HPD or SRO

MAIN CONT INTR

request for interlock input before

OEM

ON

vehicle operation

MAIN OPEN DLY

0±40

1

main contactor dropout delay

OEM

enables main contactor checks for

OEM

WELD CHECK

ON

welded circuit

M1 = FORWARD DIRECTION

M2 = REVERSE DIRECTION

FACTORY SETTINGS

Shaded area indicates where parameters have been changed.

Shaded area should not be changed from factory settings.

15

6 CONTROLLER PARAMETERS

6.3

48 VOLT PROGRAMMING

CURTIS 1244-5407 (2703505) CONTROLLER PARAMETERS

FOR MOTOR (2703946) GE MODEL NO. 5BC49JB2061

CUSHMAN FACTORY SET CONTROLLER PARAMETERS

PARAMETER

RANGE

DESIRE

UNITS

DESCRIPTION

ACCESS

MAIN CHECK

enables main contactor checks for

ON

OEM

open circuit

AUX ENABLE

N/A

OEM

OFF

EM BRAKE

OFF

N/A

OEM

AUX DELAY

0.0

N/A

OEM

AUX CHECK

OFF

N/A

OEM

N/A

EM BRAKE DELAY

0.0

OEM

EM BRAKE CHECK

N/A

OEM

OFF

REV DRVR CHECK

OFF

N/A

OEM

defines contactor pull±in voltage as %

CONT PULL IN

20±100

24

%

OEM

of nominal battery voltage

defines contactor holding voltage ± in

CONT HOLDING

20

%

OEM

20±100

voltage 95% of nominal battery voltage

EMR REV ENABLE

OFF

N/A

OEM

EMR REV C/L

350

N/A

OEM

EMR REV. CHECK

OFF

N/A

OEM

ANTI±TIEDOWN

OEM

OFF

N/A

FAULT CODE

ON

allows faults to be displayed

OEM

PEDAL INTRLCK

OFF

N/A

OEM

enables or disables pre±charge function

PRE CHARGE

ON

OEM

M1 = FORWARD DIRECTION

M2 = REVERSE DIRECTION

FACTORY SETTINGS

MAX SPEED ADJUSTMENT 48 VOLT PROGRAMMING

Shaded area indicates where parameters have been changed.

Shaded area should not be changed from factory settings.

CURTIS 1244±5407 (2703505) CONTROLLER

FOR MOTOR (2703946) G.E. MODEL NO. 5BC49JB2061

MAX SPEED CHART

FOR

MODEL 898354 ± 4000 LBS.

MAX SPEED (MPH)	FIELD MIN	MI/MAX SPEED
9	3.5	100
8	4.5	100
7	6	100
6	8	100

MAX SPEED CHART

FOR

MODEL 898356 ± 5000 LBS.

MAX SPEED (MPH)	FIELD MIN	MI/MAX SPEED
7	3.5	100
6	5.0	100

Max speed in the forward mode may be limited by adjusting the field MIN and M1 max speed parameters as shown in the chart above. Max speed in the reverse direction may be increased from factory setting by adjusting the M2 max speed parameter only. Never adjust M2 to be larger than M1 (don't adjust reverse speed to be faster than forward speed)

16

TORQUE CHART 7

TORQUE SPECIFICATIONS

HEX HEAD CAP SCREWS

The torque values shown should be used as a general guideline when specific torque values are not given.

U.S. Standard Hardware

Grade			Shank Size (Diameter in inches, fine or coarse thread)
			1/4	5/16	3/8	7/16	1/2	9/16	5/8	3/4	7/8	1	1 1/8
SAE	ft.-lbs.		9	18	31	50	75	110	150	250	378	583	782
grade
	N´m		12	24	42	68	102	150	203	339	513	790	1060
5 *
SAE	ft.-lbs.		13	28	46	75	115	165	225	370	591	893	1410
grade
8 **	N´m		18	38	62	108	156	224	305	502	801	1211	1912
Flangelock	ft.-lbs.			24	40
Screw w/
Flangelock	N´m			33	54
Nut
* Grade 5 marking ±				Minimum commercial quality (Lower quality not recommended).
** Grade 8 marking ±

Metric Standard Hardware

Grade		Shank Size (Diameter in millimeters, fine or coarse thread)
		M4	M5	M6	M7	M8	M10	M12	M14	M16	M18		M20	M22	M24	M27
Grade	ft.-lbs.	1.5	3	5.2	8.2	13.5	24	43.5	70.5	108	142		195	276	353	530
8.8*
	N´m	2	4	7	11	18	32	58	94	144	190		260	368	470	707
Grade	ft.-lbs.	2.2	4.5	7.5	12	18.8	35.2	62.2	100	147	202		275	390	498	747
10.9**
	N´m	3	6	10	16	25	47	83	133	196	269		366	520	664	996
Grade	ft.-lbs.	2.7	5.2	8.2	15	21.8	43.5	75	119	176	242		330	471	596	904
12.9 ***
	N´m	3.6	7	11	20	29	58	100	159	235	323		440	628	794	1205

* Grade 8.8 marking ± 8.8

** Grade 10.9 marking ± 10.9

*** Grade 12.9 marking ± 12.9

17

8.1 FRAME

MODELS 898353, 898353EE, 898354, 898354EE, 898356, 898356EE

AND

ACCESSORY FLOOR PLATE DECK

PART NO. 886659

MODELS 898353, 898353EE, 898354, 898354EE, 898356, 898356EE

23	24

25

12

5

8

			4
		9	2
			1
		15
		4	13
	1	2
16
17		11	6
			19
		10	22
			4
			2
3			1
		8	7
		18	20
14

3	21

18

FRAME 8.1

MODELS 898353, 898353EE, 898354, 898354EE, 898356, 898356EE

Ref.	Part	Description	No.	Notes
No.	No.		Req'd
1	103867	Washer, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 17
2	306325	Lockwasher, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . .	. 17
3	306416	Screw, 5/16±18 x 1 . . . . . . . . . . . . . . . . . . . . . . . . .	. . 7
4	306932	Nut, 5/16±18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 17
5	800017	Screw, 1/4±20 x 1, P.T.H. . . . . . . . . . . . . . . . . . . . . . 2
6	800085	Bolt, carriage, 5/16±18 x 1 . . . . . . . . . . . . . . . . . .	. . 8
7	800177	Screw, 5/16±18 x 3/4, P.T.H. . . . . . . . . . . . . . . . . .	. . 2
8	800279	Nut, speed, 1/4±20 . . . . . . . . . . . . . . . . . . . . . . . . .	. . 5
9	800331	Screw, tapping, #14 x 3/4 . . . . . . . . . . . . . . . . . . .	. . 1
10	825922	Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2
11	828889	Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
12	829337	Floor, wood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
13	829865	Bracket, tie down . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 4
14	830790	Plate, Cushman . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
15	837613	Cover, master cylinder . . . . . . . . . . . . . . . . . . . . . .	. . 1
16	886855	Panel, front w/decals . . . . . . . . . . . . . . . . . . . . . . .	. . 1
17	827664	•Decal, warning/operation . . . . . . . . . . . . . . . . . . .	. . 1
18	830926	•Decal, charger . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
19	889888	Frame, (A Models) . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
20	841193	Cover, foot pedal (B models) . . . . . . . . . . . . . . . .	. . 1
21	306419	Screw, 1/4±20 x 1/2 . . . . . . . . . . . . . . . . . . . . . . . .	. . 3
22	893237	Frame, (B Models) . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1

•INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY.

ACCESSORY FLOOR PLATE DECK

PART NO. 886659

MODELS 898353, 898353EE, 898354, 898354EE, 898356, 898356EE

Ref.	Part	Description	No.	Notes
No.	No.		Req'd
23	886659	Deck, floor plate . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
24	829863	•Deck, REAR half . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
25	829993	•Deck, FRONT half . . . . . . . . . . . . . . . . . . . . . . . .	. . 1

19

8

MODELS 898355, 898355EE

15

5

8

				4
	9		20	2
		24		1
	14			23
	4	25		12
1	2
16
17			11	6
	10			19
				22
				4
				2
3		8		1
				7

18

13		21
	3	20

20

FRAME 8.2

		MODELS 898355, 898355EE
Ref.	Part	Description	No.	Notes
No.	No.		Req'd
1	103867	Washer, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . 13
2	306325	Lockwasher, 5/16 . . . . . . . . . . . . . . . . . . . . .	. . . . . . 13
3	306416	Screw, 5/16±18 x 1 . . . . . . . . . . . . . . . . . . . .	. . . . . . . 7
4	306932	Nut, 5/16±18 . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . 13
5	800017	Screw, 1/4±20 x 1, P.T.H. . . . . . . . . . . . . . . . . . . . . . 2
6	800085	Bolt, carriage, 5/16±18 x 1 . . . . . . . . . . . . .	. . . . . . . 4
7	800177	Screw, 5/16±18 x 3/4, P.T.H. . . . . . . . . . . . .	. . . . . . . 8
8	800279	Nut, speed, 1/4±20 . . . . . . . . . . . . . . . . . . . .	. . . . . . . 2
9	800331	Screw, tapping, #14 x 3/4 . . . . . . . . . . . . . .	. . . . . . . 5
10	825922	Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 2
11	828889	Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 1
12	829865	Bracket, tie down . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 4
13	830790	Plate, Cushman . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 1
14	837613	Cover, master cylinder . . . . . . . . . . . . . . . . .	. . . . . . . 1
15	837630	Floor, wood . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 1
16	886855	Panel, front w/decals . . . . . . . . . . . . . . . . . .	. . . . . . . 1
17	827664	•Decal, warning/operation . . . . . . . . . . . . . .	. . . . . . . 1
18	830926	•Decal, charger . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 1
19	891994	Frame (A model) . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 1
20	306419	Screw, 1/4±20 x 1/2 . . . . . . . . . . . . . . . . . . .	. . . . . . . 3
21	841193	Cover, foot pedal (B model) . . . . . . . . . . . .	. . . . . . . 1
22	893238	Frame (B model) . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 1
23	841739	Cover, access . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 1
24	830355	Seal, weather, 35' (10.7M) . . . . . . . . . . . .	As Req'd.
25	800279	Nut, speed, 1/4±20 . . . . . . . . . . . . . . . . . . . .	. . . . . . . 7

•INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY.

21

8.3 FRAME

MODEL 898357, 898357EE

AND

ACCESSORY FLOOR PLATE DECK

PART NO. 886659

22

23

24

12

5

8

			4
	9		2
			1
	15
	4		13
1	2
16
17		11	6
	10		19
			4
			2
3		8	1
			7
	18
14			21
3		20

22

FRAME 8.3

		MODEL 898357, 898357EE
		AND
		ACCESSORY FLOOR PLATE DECK
		PART NO. 886659
Ref.	Part	Description	No.	Notes
No.	No.		Req'd
1	103867	Washer, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 17
2	306325	Lockwasher, 5/16 . . . . . . . . . . . . . . . . . . . . . . . . . .	. 17
3	306416	Screw, 5/16±18 x 1 . . . . . . . . . . . . . . . . . . . . . . . . .	. . 7
4	306932	Nut, 5/16±18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 17
5	800017	Screw, 1/4±20 x 1, P.T.H. . . . . . . . . . . . . . . . . . . . . . 2
6	800085	Bolt, carriage, 5/16±18 x 1 . . . . . . . . . . . . . . . . . .	. . 8
7	800177	Screw, 5/16±18 x 3/4, P.T.H. . . . . . . . . . . . . . . . . .	. . 2
8	800279	Nut, speed, 1/4±20 . . . . . . . . . . . . . . . . . . . . . . . . .	. . 5
9	800331	Screw, tapping, #14 x 3/4 . . . . . . . . . . . . . . . . . . .	. . 1
10	825922	Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2
11	828889	Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
12	829337	Floor, wood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
13	829865	Braket, tie down . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 4
14	830790	Plate, Cushman . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
15	837613	Cover, master cylinder . . . . . . . . . . . . . . . . . . . . . .	. . 1
16	886855	Panel, front w/decals . . . . . . . . . . . . . . . . . . . . . . .	. . 1
17	827664	•Decal, warning/operation . . . . . . . . . . . . . . . . . . .	. . 1
18	830926	•Decal, charger . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
19	893149	Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
20	306419	Screw, 1/4±20 x 1/2 . . . . . . . . . . . . . . . . . . . . . . . .	. . 3
21	841193	Cover, foot pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1

•INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY.

		ACCESSORY FLOOR PLATE DECK
			PART NO. 886659
			MODELS 898336A, 898341A
Ref.	Part	Description	No.	Notes
No.	No.		Req'd
22	886659	Deck, floor plate . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . 1
23	829863	•Deck, REAR half . . .	. . . . . . . . . . . . . . . . . . . . . . . . . 1
24	829993	•Deck, FRONT half .	. . . . . . . . . . . . . . . . . . . . . . . . . 1

•INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY.

23

8.4 FRONT AXLE

(MODELS: 898353, 898353EE

898355 , 898355EE 29 898357, 898357EE)

(MODELS 31 898354, 898354EE 898356, 898356EE 5 LEAF)

9

21

1

16

9

1

12

						6
						33 RIGHT
						34 LEFT
35						6
					7
					2
					4	REPRESENTATIVE
						HARDWARE
					9	10
						1
16						11
						13
			20
			8			19
			14			17
	30					28
	32
		(MODELS:
		898354,		5	27
		898354EE
				23
		898356
		898356EE)				15
						28
		36 MODELS: 898353, 898353EE				18◊
		898353, 898354EE			FRONT
		898355, 898355EE
		898357, 898357EE			OF
24			39		VEHICLE
41						25
			40
			41			26

22

24

37

38

3

24

FRONT AXLE 8.4

Ref.	Part	Description	No.	Notes
No.	No.		Req'd
1	120166	Lockwasher, 1/2 . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 7
2	120177	Lockwasher, 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
3	306414	Screw, 3/8±16 x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 4
4	306562	Nut, 3/8±16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
5	306834	Screw, 3/8±16 x 3/4 . . . . . . . . . . . . . . . . . . . . . . . . .	. 4
6	306835	Screw, 3/8±16 x 1 1/4 . . . . . . . . . . . . . . . . . . . . . . .	14
7	306981	Washer, 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
8	306982	Washer, 7/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 4
9	308332	Nut, 1/2±13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 8
10	311745	Nut, 3/4±16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2
11	312272	Lockwasher, 3/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2
12	316913	Screw, 1/2±13 x 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2
13	548941	Screw, 1/2±13 x 4 1/2 . . . . . . . . . . . . . . . . . . . . . . .	. 4
14	800294	Nut, lock, 7/16±14 . . . . . . . . . . . . . . . . . . . . . . . . . .	. 4
15	807439	Fitting, lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2
16	813850	Bumper, travel limiting . . . . . . . . . . . . . . . . . . . . . . .	. 4
17	817891	Bearing, thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2	◊ See Note.
18	827648	Shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 4
19	829251	Retainer, spring & king pin . . . . . . . . . . . . . . . . . . .	. 2
20	889589	Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2
21	830477	Washer, camber adjuster . . . . . . . . . . . . . . . . . . . .	. 2
22	832998	Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2
23	833099	Bracket, reinforcement . . . . . . . . . . . . . . . . . . . . . . .	. 2
24	833105	Washer, special . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 4
25	886225	Pin, king . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2
26	829229	•Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 1
27	886227	Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2
28	818238	•Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2
29	886234	Spring and bushing, 898353, 898353EE
		898355, 898355EE, 898357, 898357EE . . . . . .	. 1
30	829229	•Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2
31	888753	Spring and bushing (5 leaf)
		898354, 898354EE, 898356, 898356EE . . . . . .	. 1
32	829229	•Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2
33	888200	Bracket, spring perch (RIGHT) . . . . . . . . . . . . . . . .	. 1
34	888201	Bracket, spring perch (LEFT) . . . . . . . . . . . . . . . . .	. 1
35	888203	Perch, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 1
36	888310	Bracket, lower arm (REAR) . . . . . . . . . . . . . . . . . . .	. 1
37	888321	Bracket, lower arm (FRONT) . . . . . . . . . . . . . . . . .	. 1
38	888322	Bolt, lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 1
39	888325	Arm and bushing (LOWER) . . . . . . . . . . . . . . . . . .	. 2
40	807439	•Fitting, lubrication . . . . . . . . . . . . . . . . . . . . . . . . . .	. 1
41	818238	•Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2

•INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY.

◊ Use shims as required to obtain .001 to .011 clearance on opposite end.

25

8.5 FRONT SPRING

FRONT FRAME BRACE, FRONT SPRING, ARM AND BUSHING

MODELS 898356, 898356EE

9

7

2	8

9

4

3

1

5

6

Ref.	Part	Description	No.	Notes
No.	No.		Req'd
1	120177	Lockwasher, 3/8 . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2
2	306414	Screw, 3/8±16 x 1 . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2
3	306562	Nut, 3/8±16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2
4	834200	Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
5	888753	Spring, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
6	829229	•Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2
7	888892	Arm and bushing . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2
8	807439	•Fitting, lubrication . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1
9	818238	•Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2

•INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY.

26

FRONT HUB 8.6

FRONT HUB WITHOUT FRONT BRAKE

MODELS 898353, 898353EE, 898355, 898355EE, 898357, 898357EE

10

7

		5
	4	9
	2
		11
6	3	8
	1

Ref.	Part	Description	No.	Notes
No.	No.		Req'd
1	103960	Washer, 13/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2	Quantity indicated for both	sides.
2	304636	Pin, cotter, 1/8 x 1 1/8 . . . . . . . . . . . . . . . . . . . . . .	. . 2	Quantity indicated for both	sides.
3	385174	Bearing, cone & roller (outer) . . . . . . . . . . . . . . . .	. . 2	Quantity indicated for both	sides.
4	311537	Nut, 3/4±16, castle . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2	Quantity indicated for both	sides.
5	548136	Bearing, cone & roller (inner) . . . . . . . . . . . . . . . .	. . 2	Quantity indicated for both	sides.
6	817250	Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2	Quantity indicated for both	sides.
7	829256	Seal, grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2	Quantity indicated for both	sides.
8	886223	Hub, complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2	Quantity indicated for both	sides.
9	548135	•Cup, bearing (inner) . . . . . . . . . . . . . . . . . . . . . . .	. . 1	Quantity indicated for both	sides.
10	806274	•Screw, wheel mounting . . . . . . . . . . . . . . . . . . . .	. . 5	Quantity indicated for both	sides.
11	808088	•Cup, bearing (outer) . . . . . . . . . . . . . . . . . . . . . . .	. . 1	Quantity indicated for both	sides.

•INDENTED PART NAMES INDICATE THESE PARTS ARE INCLUDED IN PRECEDING ASSEMBLY.

27

8.7 SEAT

21

	22
6	5

7

20

3

5

3

2

5
3				19
1	7
11		23	15
				18
3
7		9	13	14
	20			17
	5
10	3			3
	2
		12		16
8
				4

28