DFK CUSHMAN TITAN HD Installation Instructions Manual Download

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DFK America Inc.

2215 W. Curtiss Street
Downers Grove, IL

Phone: 630-324-6793

Email:

[email protected]

www.dfkcabs.com

CUSHMAN

TITAN XD/HD

If your vehicle has headlights, remove them from the front of the vehicle and set aside.

Drill a 1” diameter hole to the left 6” and up 6” from the existing RH headlght hole.

Summary of Contents for CUSHMAN TITAN HD

Page 1: ...INSTALLATION INSTRUCTIONS CUSHMAN TITAN XD HD ...

Page 2: ...e types of tools have product dealer do the install for you Some parts contain sharp edges wear protective gloves if necessary Always keep your assembly area clean uncluttered and well lit Keep visitors and children a safe distance away from the assembly area Visitors should wear the same safety equipment described under Dress for safety DO NOT wear loose clothing gloves neckties or jewelry if usi...

Page 3: ...brics brushes etc DO NOT use solvents or alkaline detergents or cleaners with ammonia ammonium hydroxide DO NOT remove any impurities from the surface with razor blades or other sharp items DO NOT clean cab when the polycarbonate plates are heated by the sun DO NOT use a squeegee as it could scratch the polycarbonate doors and back windshield DO NOT clean pressure wash with a water current strengt...

Page 4: ... Inc 2215 W Curtiss Street Downers Grove IL 4 PREPARATION FOR INSTALLATION CUSHMAN TITAN XD HD Uninstall headlights from the front of the vehicle and set aside for re installation later in instructions Be sure to mark the wires with tape for easier re install CAB PREVIEW ...

Page 5: ...Phone 630 324 6793 Email info dfkcabs com www dfkcabs com DFK America Inc 2215 W Curtiss Street Downers Grove IL 5 Uninstall the Cushman badge from the vehicle s front panel CUSHMAN TITAN XD HD ...

Page 6: ...ne 630 324 6793 Email info dfkcabs com www dfkcabs com DFK America Inc 2215 W Curtiss Street Downers Grove IL 6 Mount the badge onto the front plastic panel using the original hardware CUSHMAN TITAN XD HD ...

Page 7: ...e 630 324 6793 Email info dfkcabs com www dfkcabs com DFK America Inc 2215 W Curtiss Street Downers Grove IL 7 LEFT DOOR FRAME RIGHT DOOR FRAME Place the template onto the vehicles side CUSHMAN TITAN XD HD ...

Page 8: ...Phone 630 324 6793 Email info dfkcabs com www dfkcabs com DFK America Inc 2215 W Curtiss Street Downers Grove IL 8 Align the template into position and fix with one handed clamps CUSHMAN TITAN XD HD ...

Page 9: ...324 6793 Email info dfkcabs com www dfkcabs com DFK America Inc 2215 W Curtiss Street Downers Grove IL 9 CUSHMAN TITAN XD HD Make marks on the sides of the vehicle in accordance with the picture below red arrows ...

Page 10: ...0 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD MAKE SURE THAT ALL DISTANCES ARE CORRECT SEE NEXT PAGES mm STANDARD ...

Page 11: ...1 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com Drill Ø 14mm holes centered into the marks red circles CUSHMAN TITAN XD HD SEE NEXT PAGE ...

Page 12: ...12 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com DETAILED VIEWS CUSHMAN TITAN XD HD ...

Page 13: ...ners Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com Remove the Left Door from the frame by lifting it off the hingepins CUSHMAN TITAN XD HD Place the left door frame onto the vehicle side in accordance with the prepared holes ...

Page 14: ...rtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the left door frame to the vehicle using the included bolts washers and nuts and tighten slightly 1 Nm SEE NEXT PAGE ...

Page 15: ...ica Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com DETAILED VIEWS CUSHMAN TITAN XD HD For the rear frame mounting assembly use included thick washer red circle ...

Page 16: ...16 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com DETAILED VIEWS CUSHMAN TITAN XD HD ...

Page 17: ...17 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com Repeat previous steps to install the right door frame CUSHMAN TITAN XD HD ...

Page 18: ...America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com REAR PANEL 1 Place the rear support X cross onto the door frames CUSHMAN TITAN XD HD 60E01U01 20W001 ...

Page 19: ...t Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the rear support H frame to the door frame using the included bolts washers and covers and tighten slightly on both sides 9 in lbs or 1 Nm ...

Page 20: ... Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com ROOF Place the roof onto the door frames and align into position with the original rivet nuts CUSHMAN TITAN XD HD ...

Page 21: ...ove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the roof to the door frame with the included bolts washers and covers on both sides NOW TIGHTEN THE DOOR FRAMES BOLTS AND THE REAR SUPPORT X CROSS BOLTS CORRECTLY ...

Page 22: ... DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com REAR PANEL 2 Place the rear bottom panel onto the rear support X cross CUSHMAN TITAN XD HD ...

Page 23: ...a Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the rear bottom panel to the rear support X cross with the included bolts and washers ...

Page 24: ...5 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com Align the rear polycarbonate assembly into position CUSHMAN TITAN XD HD 60E01U01 20M008 ...

Page 25: ...ica Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the rear polycarbonate to the roof with the included bolts washers nuts and covers ...

Page 26: ...27 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com DETAILED VIEW CUSHMAN TITAN XD HD ...

Page 27: ... 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the rear polycarbonate to the rear bottom panel with the included bolts washers nuts and covers ...

Page 28: ...merica Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com FRONT PANEL 1 Install the front panel ledge onto the prepared pins CUSHMAN TITAN XD HD 60E01U01 10M012 ...

Page 29: ...c 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the front panel ledge to the door frame with the included bolt washers and cover on both sides ...

Page 30: ...31 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Tighten original nuts red circle on both sides DETAILED VIEW ...

Page 31: ... America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com Place the right front sealing ledge onto the right door frame CUSHMAN TITAN XD HD 60E01U01 10M016 ...

Page 32: ...wners Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the right front sealing ledge to the right door frame using the included bolts and washers REPEAT PREVIOUS STEPS WITH THE LEFT FRONT SEALING LEDGE ...

Page 33: ...America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com FRONT PANEL 1 Place the front plastic cover onto the door frames CUSHMAN TITAN XD HD 60E01U01 10M013 ...

Page 34: ...nc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the front plastic cover to the door frames with th included bolts and washers on both sides ...

Page 35: ...a Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com Place the front glass assembly onto the door frames and align into position CUSHMAN TITAN XD HD 60E01U01 10M006 ...

Page 36: ...erica Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the front upper ledge to the roof using the included bolts washers and covers ...

Page 37: ...Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Loosen the glass stop holder bolts and adjust the glass stop into the best position on both side ...

Page 38: ...il info dfkcabs com www dfkcabs com TITAN HD XD WIPER INSTALLATION INSTRUCTIONS CUSHMAN TITAN XD HD Connect the wiper harness with the wiper motor DETAILED VIEW Route the washer tube through the front glass using original grommet red circle Connect the washer tube to the washer jet ...

Page 39: ...24 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Uninstall the harness cover Route the wiper harness branch to the wiper motor blue line Then install the harness cover and mount using the included M6x14 bolts washers and covers red circle DETAILED VIEW ...

Page 40: ...a Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD FOR TITAN XD INSTRUCTIONS CONTINUE TO NEXT PAGE FOR TITAN HD INSTRUCTIONS PROCEED TO PAGE 66 ...

Page 41: ...215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Route the bottom of the pre installed Wiper Harness through the right front support ledge hole red circle ...

Page 42: ... Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Continue routing the Wiper Harness under the dashboard using front LEFT light opening red line ...

Page 43: ...s Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Uninstall original left dashboard cover red circle and route the Wiper Harness through the hole Save the screws for the later use ...

Page 44: ...DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com Install the washer tank to the washer tank bracket using included bolts CUSHMAN TITAN XD HD ...

Page 45: ...owners Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the washer pump and washer tank brackets together using the included bolts Connect the washer tube from the washer pump to the tank green arrow ...

Page 46: ...4 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Connect the Wiper Harness from the wiper washer and the washer tube to the washer pump Use red wire to top terminal and yellow green wires to bottom terminal DETAILED VIEW of the harness connection to pump ...

Page 47: ...ca Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Align the washer assembly into position and mount with the original dashboard cover screws ...

Page 48: ...nc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Route the rest of the Wiper Harness under the dashboard to the left side of the vehicle blue line ...

Page 49: ...dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Uninstall the original left dashboard cover and replace it with the included cover red rectangle Route the branch of the Wire Harness for the wiper washer switch under the dashboard and through the prepared hole blue rectangle 60E01U01 00 001 ...

Page 50: ... Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Connect the switch branch of the Wiper Harness to the switch and press the switch into the hole DETAILED VIEW of the connection on back of switch ...

Page 51: ...ss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com Connect the wiper washer harnesses to the vehicle s main harness CUSHMAN TITAN XD HD BEFORE FIRST USAGE FILL THE WASHER TANK WITH THE WASHER LIQUID ...

Page 52: ...53 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD ...

Page 53: ...rtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Following the red line in the picture below route the harness through the steering column area to the wiper washer switch ...

Page 54: ...55 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Connect the washer tank harness to the washer motor ...

Page 55: ...FK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com Place the plastic dashboard cover onto the front dashboard CUSHMAN TITAN XD HD 60E01U01 10M014 ...

Page 56: ...57 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com Connect front lights to Vehicle wiring harness CUSHMAN TITAN XD HD ...

Page 57: ... 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Place the front lights onto the front plastic panel and mount to the original holder using the included bolts washers and covers Mount the front lights to the front plastic panel using original bolts ...

Page 58: ...FK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com Place the plastic dashboard cover onto the front dashboard CUSHMAN TITAN XD HD 60E01U01 10M014 ...

Page 59: ...30 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the plastic dashboard cover to the front panel ledge using the included screws washer and covers If needed drill ᴓ6mm holes into the center marks can be seen on the reverse side of the cover ...

Page 60: ...Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD RIGHT DOOR LEFT DOOR Place the right door onto hinges after lubricating the hinge pins and installing the 10mm washers 60E01U01 50M005 ...

Page 61: ...America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the safety string snap hook to the door frame using pre installed eyebolt ...

Page 62: ...Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD IF MIRRORS ARE NOT PRE INSTALLED FOLLOW INSTRUCTIONS BELOW Uninstall original bolts and washers from the polycarbonate fixing assembly ...

Page 63: ...erica Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Place the right door mirror onto the left door panel and mount using included bolts ...

Page 64: ...65 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Repeat previous steps with the left door CAB INSTALL COMPLETE ...

Page 65: ...IONS FOR TITAN HD CONTENTS OF THE TITAN HD CONVERSION KIT A E H G C F B D A WASHER BOTTLE MOUNT BOX 1 B HEADLIGHT WIRE EXTENSIONS 4 C WIRE CONNECTORS 4 BUTT CONNECTORS 4 SPADECONNECTORS D SELF DRILLING TAPPING SCREWS AND CAPS 3EACH E LEFT RIGHT HEADLIGHT BRACKETS 1 EACH F POWER WIRE HARNESS 1 G HEADLIGHT BLACKOUT COVERS 2 H 8 200mm CABLE TIES 8 ...

Page 66: ...ove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD If your vehicle has headlights remove them from the front of the vehicle and set aside Drill a 1 diameter hole to the left 6 and up 6 from the existing RH headlght hole ...

Page 67: ... Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Run Wiper Harness from right side ROPS through newly drilled hole DETAILED VIEW FROM OVERHEAD ...

Page 68: ...t Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Remove the 2 Phillips screws from the far back of the rear deck and lift and set aside the wooden bed to begin installation of the Power Harness ...

Page 69: ...ED WITH PAGE 79 Route the single red wire forward toward the cab area through the opening on the right side of the center compartment across to the left Ground the black wire on closest battery terminal in the LEFT battery compartment Continue routing the red and black wire harness forward along the ORIGINAL wire harness white line below Use zip ties as needed to hold wiring in place Fuse box Grou...

Page 70: ...erica Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Remove the 3 access panels in order to gain access to pull the wire harness through ...

Page 71: ...tiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Route Power Harness through the steel holders and then upward through rubber boot access area alongside the steering column ...

Page 72: ...ute the Power Harness under the parking brake between the seats down under the floor and up through the steering column area using rigid wire snake Once ample wire has been pulled through the steering column route it through the steel wire channel across to the left and down to connect into the wiper washer harness Red to Double Red Black to Double Yellow REPLACE THE 3 ACCESS COVERS ...

Page 73: ...DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Install the washer tank to the washer tank bracket using included bolts ...

Page 74: ...owners Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Mount the washer pump and washer tank brackets together using the included bolts Connect the washer tube from the washer pump to the tank green arrow ...

Page 75: ...nc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Align the washer assembly onto the dasboard cover and mount with included screws washers and nuts ...

Page 76: ...4 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Connect the Wiper Harness from the wiper washer and the washer tube to the washer pump Use red wire to top terminal and yellow green wires to bottom terminal DETAILED VIEW of the harness connection to pump ...

Page 77: ...iss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Connect the switch branch of the Wiper Harness plug to the back of the wiper washer switch and press the switch into the hole ...

Page 78: ...reet Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD DETAILED VIEW OF PLUG IN TO BACK OF SWITCH INSERT FUSE INTO BLOCK SHOWN ON PAGE 70 REINSTALL BACK WOODEN PANEL AND SECURE WITH THE 2SCREWS ...

Page 79: ...80 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Align the washer assembly into best position ...

Page 80: ...Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com Fix the washer assembly to the dashboard with the original bolts If necessary use included self drilling tapping bolts CUSHMAN TITAN XD HD ...

Page 81: ...82 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD DETAILED VIEW ...

Page 82: ...Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com HD MODELS WITH NO HEADLIGHTS CUSHMAN TITAN XD HD Pre determine the proper position for the Blackout plate to cover the headlight openings ...

Page 83: ...merica Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Remove the cover layer from the 2 sided tape along the back of the Blackout cover ...

Page 84: ...ers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Position and push the Blackout cover into place being sure to push down around the entire edge If the cover is not firmly held use the supplied ABS adhesive ...

Page 85: ...using the headlight Blackout coverl standoff bracket and additional wire as shown below 1 Remove hole plug from plastic cover panel 2 Pull light wires through the hold and Insert mounting stem 3 Put short side of mounting bracket over mounting stem and mounting nut Tighten 4 Insert wire extensions through the back mounting stem and connect to the light wires with butt connector s ...

Page 86: ...es through the existing light mounting hole on the front of thevehicle 7 Push the back bracket stem into the hole and apply pressure around the perimeter of the plastic cover to allow the tape to adhere 8 Put supplied bolt on the back bracket stem from behind to secure the entire lightassembly 9 Crimp spade connectors onto extension wires 10 Reconnect the power wires to the extension wires to the ...

Page 87: ...88 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD DETAILED VIEW ...

Page 88: ...89 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com DETAILED VIEW CUSHMAN TITAN XD HD ...

Page 89: ...90 DFK America Inc 2215 W Curtiss Street Downers Grove IL Phone 630 324 6793 Email info dfkcabs com www dfkcabs com CUSHMAN TITAN XD HD Return to pgs 59 65 to complete HD installation ...

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