Cushman Truckster XD 2018 Owner'S Manual Download

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OWNER’S GUIDE

672240 - A

Truckster

ISSUED JANUARY 2018

Distributed by:

Summary of Contents for Truckster XD 2018

Page 1: ...OWNER S GUIDE 672240 A Truckster XD ISSUED JANUARY 2018 Distributed by...

Page 2: ...e vehicle If incorrectly used this machine can cause severe injury Those who use and maintain this machine should be trained in its proper use warned of its dangers and must read the entire manual bef...

Page 3: ...manual may be revised periodically by TSV and therefore is subject to change without notice TEXTRON SPECIALIZED VEHICLES DISCLAIMS LIABILITY FOR ERRORS IN THIS MANUAL and SPECIFICALLY DISCLAIMS LIABIL...

Page 4: ...teering bed lift and optional remote hydraulics If you follow all instructions in this manual you increase the life of your vehicle and keep its maximum performance Adjustments and maintenance must al...

Page 5: ...de and the name and address of the company that designed tested and made the changes When you discard worn parts know the environmental result and use the systems available in the country where the ve...

Page 6: ......

Page 7: ...TY NOTES 11 SAFETY LABELS 12 INSTRUCTION LABELS 15 GENERAL SPECIFICATIONS VEHICLE DIMENSIONS 21 VEHICLE SPECIFICATION 22 HYDRAULIC SPECIFICATION 22 VIBRATION LEVEL 23 NOISE 23 SLOPES 24 RECOMMENDED LU...

Page 8: ...O DO SERVICE ON THE VEHICLE 52 ENGINE 53 FUEL SYSTEM 55 BATTERY 56 ENGINE EXHAUST 57 ROPS 58 HYDRAULIC HOSES 58 RADIATOR 60 TIRES 61 TRANSMISSION FLUID LEVEL 62 ELECTRICAL SYSTEM 62 SUSPENSION INSPECT...

Page 9: ...ead all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 3 Owner s Guide INTRODUCTION LOCATION OF VEHICLE SERIAL NUMBER PLAT...

Page 10: ...drainage system Follow the local laws to make sure that leaks are controlled safely The maintenance procedures in this manual make sure that the damage that the vehicle can cause in the local environm...

Page 11: ...le Some common groups are Steel Non ferrous metals Aluminum Brass Copper Plastic Materials Identified Can be recycled Can not be recycled Not Identified Rubber Electrical and Electronic Components Pla...

Page 12: ...6 Owner s Guide INTRODUCTION Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 13: ...S WARNINGS and DANGERS The person who services a vehicle needs the mechanical skill and experience to recognize possible hazardous conditions Incorrect service or repairs can cause damage to the vehic...

Page 14: ...vices fastened Inspect the vehicle before operating Check tire pressure engine oil level radiator coolant level and the air cleaner indi cator Fuel is flammable Use caution when you add the fuel to th...

Page 15: ...t belt when you operate the vehicle Make sure the seat belt can be released quickly in an emergency Check for clearance before you drive beneath objects Do not contact tree branches electrical wires o...

Page 16: ...sure from components with stored energy To prevent injury from hot high pressure oil never use your hands to check for oil leaks Use paper or cardboard to find leaks Hydraulic fluid pressure can have...

Page 17: ...position for the engine to start NEVER operate the vehicle unless the Interlock System operates correctly Before you leaving the vehicle for any reason Release the accelerator pedal Press the clutch p...

Page 18: ...the negative BLACK wire before the positive RED wire 2 Keep sparks and flames away from the battery Prevent contact with the battery acid To prevent injury while you attach jumper cables to the batter...

Page 19: ...when operating the vehicle Do not operate the vehicle with passengers in the truck bed Do not operate vehicle with more than one passenger The passenger must be in the seat supplied and use the seat b...

Page 20: ...ention to Notices Cautions Warnings and Dangers DO NOT USE START ASSIST FLUIDS Start assist fluids in the air intake system can be explosive Start assist fluids can cause an uncontrolled engine condit...

Page 21: ...d Dangers 15 Owner s Guide INSTRUCTION LABELS Center Console Labels Right Side Control Panel Low Speed Range High Speed Range 4WD Bed Float Parking Brake Bed lift Extend Read the manual 2WD Bed lower...

Page 22: ...rticular attention to Notices Cautions Warnings and Dangers Standard Left Side Control Panel Label Diesel Speed Control Option Label Gasoline Speed Control Option Label Headlight Horn Headlight Horn H...

Page 23: ...B SAFETY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 17 Owner s Guide Fuse Panel Labels...

Page 24: ...18 Owner s Guide SAFETY Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 25: ...Torque 52 7 ft lb 71 45 Nm 2200 rpm 51 6 ft lb 69 96 Nm 2600 rpm Maximum Speed 3220 50 rpm No Load 3600 50 rpm No Load Low Idle 1000 50 rpm No Load 1000 50 rpm No Load Rotation Counter clockwise view...

Page 26: ...hydraulics 2529 lb 1147 kg Weight of 4WD Diesel unit with fuel tank filled High Low hydraulics 2717 lb 1232 kg Weight of 2WD Gasoline unit with fuel tank filled High Low hydraulics 2487 lb 1128 kg Wei...

Page 27: ...B GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 21 Owner s Guide VEHICLE DIMENSIONS...

Page 28: ...c Oil Cooler High low hydraulic system option only Steering Hydrostatic power steering 2WD Traction Drive Five speed transmission and two speed rear axle 4WD Traction Drive Five speed transmission two...

Page 29: ...1 1 1997 NOISE The machine was tested for sound pressure Operator Ear The Machinery Safety Directive 2006 42 EC and Exposure of Workers to the Risks Arising From Physical Agents Noise Directive 2003 1...

Page 30: ...on slopes greater than 17 5 RECOMMENDED LUBRICANTS Engine Oil Must meet MIL L 46152 or API Classification grades SN CJ 4 Rear Axle Standard Hydraulic Reservoir 2 1 U S Gallon 7 9 liter 10W30 High low...

Page 31: ...harpshooter System 4322364 Envisio Pro II Sharpshooter System 4322546 15 Foot HD Boom 4323390 15 Foot Sharpshooter Boom 4323391 18 Foot HD Boom 4320589 18 Foot Sharpshooter Boom 4322360 20 Foot HD Boo...

Page 32: ...this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Core Harvester Kit Number 4347127 Quick Aerator Kit Number 4331778 Retrofit Kit Number 4...

Page 33: ...wner s Guide Cab Factory Installed 4341477 Dealer Installed 4316688 Cab Doors 4341480 SUPPORT LITERATURE Contact your Cushman dealer for a complete listing of literature available for your vehicle Veh...

Page 34: ...28 Owner s Guide GENERAL SPECIFICATIONS Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Notes...

Page 35: ...Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 29 Owner s Guide OPERATING PROCEDURES OPERATOR COMPARTMENT...

Page 36: ...LCD Screen The LCD screen shows the vehicle speed the system voltage and the hour meter The speed of the vehicle is shown at the top of the LCD screen The speed is shown in mph or kph The system volta...

Page 37: ...e oil pressure light indicates engine oil pressure is less than 7 psi 0 48 BAR Immediately stop the engine and inspect oil level in the engine If the oil pressure light remains illuminated with the oi...

Page 38: ...hicle moving When the differential lock is engaged both rear wheels rotate at the same speed When the vehicle is driven in the forward or reverse direction the differential lock improves traction When...

Page 39: ...ition to deactivate the turn signals Ignition Switch The ignition switch has three positions OFF RUN and START High Low Hydraulics Switch The high low hydraulic system switch is part of the high low h...

Page 40: ...headlights and the taillights Press the bottom of the switch to deactivate the headlights and the taillights Hand Throttle The hand throttle is part of the optional diesel speed control accessory The...

Page 41: ...n the cruise control position the cruise control speed is set increased or decreased with the set resume switch When the stationary cruise switch is in the stationary position the engine speed is set...

Page 42: ...ottle is moved the accelerator pedal position moves The gasoline engine option pedal controls the engine speed electronically Brake Pedal Press the brake pedal to decrease the vehicle speed or stop th...

Page 43: ...brake is engaged the parking brake light on the instrument panel will illuminate Do not drive the vehicle with the parking brake engaged To disengage the parking brake lower the parking brake lever t...

Page 44: ...to engage the 4WD output to the front axle Move the lever to the 2WD position to disengage the 4WD output to the front axle If the lever does not move easily the selector gears are not aligned in the...

Page 45: ...eat position lever to move the seat backward or forward Release the lever to set the adjustment Make sure the seat is locked in position before operating the vehicle OPERATION Daily Inspection The ins...

Page 46: ...he OFF position and the clutch pedal is completely pressed The engine will start TEST 2 The engine must not start if the clutch pedal is not pressed TEST 3 The engine must not start if the optional hi...

Page 47: ...n slopes or near steep ledges 12 When you drive in the reverse direction look behind and down to make sure the path is clear Use caution when you go near corners trees or other objects that can preven...

Page 48: ...or Reverse gear slowly release the clutch pedal while you press the accelerator pedal When you drive in the forward direction always start in 1st gear and shift into the higher gears as the vehicle s...

Page 49: ...2 56 3 65 4 59 3 20 6 00 8 21 11 68 14 70 1 6 3 0 4 1 5 9 7 4 5 15 9 66 13 21 18 80 23 65 2400 1 04 1 96 2 68 3 81 4 79 3 34 6 26 8 57 12 19 15 34 1 7 3 1 4 3 6 1 7 7 5 37 10 08 13 79 19 62 24 68 2500...

Page 50: ...for the stationary mode to operate Do not drive the vehicle with the switch in the stationary position Press the accelerator pedal until the needed RPM is shown on the tachometer Hold the left side o...

Page 51: ...hicle does not turn over the safest method is to drive up and down on the face of slopes vertically Do not drive across the face horizontally Travel at a slow speed and do not make turns that are not...

Page 52: ...with a high angle lower the accessories to the ground This procedure makes sure the vehicle does not turn upside down 4 Correct tire pressure is necessary for maximum traction How to calculate a slop...

Page 53: ...te To operate the vehicle mounted hydraulic accessories 1 Park the vehicle engage the parking brake stop the engine and remove the key 2 Remove the red connector cover and connect the pressure hose fo...

Page 54: ...hicle 3 An operator is needed to steer the vehicle and operate the vehicle brakes 4 Press the brake pedal put the transmission in neutral and dis engage the parking brake 5 Slowly drive the tow vehicl...

Page 55: ...ng the vehicle on a trailer Be careful when you load or unload the vehicle on the trailer Fasten the vehicle to the trailer to prevent movement on the trailer If the trailer is moved on the highway in...

Page 56: ...B 50 OPERATING PROCEDURES Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers Owner s Guide...

Page 57: ...mission 1 34 Quart 1 27 liter SAE EP 80W 90 Gear Lube 4WD Differential 2 0 Quart 1 89 liter SAE EP 80W 90 Gear Lube Rear Axle Standard hydraulic reservoir 2 7 U S Gallon 10 2 liter 10W 30 API Classifi...

Page 58: ...inflated When you make adjustments or repairs do not wear jewelry or loose fitting clothing that can be caught on moving parts Refer to the repair and service manual for the removal and assembly proc...

Page 59: ...ature of at least 140 F 60 C before operation at full load Check the engine oil level two times each day Oil usage during the first 50 hours of operation can be higher than normal Change the engine oi...

Page 60: ...y If the red band becomes visible in the window replace the filter element Do not remove the element to inspect or clean Unnecessary removal of the filter increases the risk of dust and other particle...

Page 61: ...a blend with more than 10 ethanol Under no circumstances should you use a blend with methanol Refer to the engine s operator manual for fuel recommendations when using blended fuel Check fuel hoses a...

Page 62: ...ccordance with local regulations BATTERY Before servicing the battery make sure the ignition switch is in the OFF position and the key is removed When servicing the battery use insulated tools wear pr...

Page 63: ...charger is activated stay away from the battery A battery that is damaged can cause an explosion Read the battery charger manual for specific instructions on charger operation When possible remove th...

Page 64: ...s and tubes each day Look for wet hoses or oil marks Replace worn or damaged hoses and tubes before operating the vehicle Replacement tubes or hoses must be routed along the same path as the original...

Page 65: ...the hydraulic system 2 Put a container that can hold more than 6 gallons 22 7 liter under the high low hydraulic system tank Remove the drain plug from the bottom of the tank and allow the hydraulic...

Page 66: ...cold mark Drain and fill the cooling system each year Empty and clean the recovery bottle Mix clean water with ethylene glycol anti freeze for the coldest ambient temperature Read and follow the inst...

Page 67: ...h Wheel Mounting Park the vehicle on a solid and level surface Never work on a vehicle that is supported only by the jack Always support the vehicle with jack stands If only the front or rear of the v...

Page 68: ...the drain plug to 9 14 ft lb 12 19 Nm 4 Remove the fluid level plug and fill the transmission with SAE EP 80 90 Gear Lube to the bottom of the level plug 5 Install the level plug Torque the level plu...

Page 69: ...t Fuse F15 30 Amp Radiator Fan Fuse F16 30 Amp Starter Power Fuse F18 30 Amp Main Power Fuse F19 35 Amp Glow Plug Fuse Gasoline Engine Option Fuses l F1 5 Amp Right Brake Jumper Fuse l F2 5 Amp Left B...

Page 70: ...d can cause damage or failure This damage is not covered by the factory warranty Do not spray water at the control panel ignition switch controller or other electrical components Clean all plastic or...

Page 71: ...ean the accessories thoroughly Repair and paint any damaged or bare metal surfaces Lubricate all grease fittings and friction points After Storage Check and install the battery If necessary charge the...

Page 72: ...bottom of the hill Engage the parking brake put the transmission in Neutral and stop the engine Do not disengage the parking brake with the engine stopped The vehicle must not move with the parking br...

Page 73: ...STEERING TOE IN ADJUSTMENT Steering Toe In Adjustment 1 Turn the front wheels to the straight position 2 Loosen the jam nuts on both ends of the axial rods 3 Rotate the axial rods to get the correct...

Page 74: ...Nm 75 8 4 100 11 3 107 12 1 143 16 1 9 16 18 ft lb Nm 92 124 122 165 129 174 172 233 1 4 28 in lb Nm 85 9 6 115 13 0 120 13 5 163 18 4 5 8 11 ft lb Nm 113 153 151 204 159 215 211 286 5 16 18 in lb Nm...

Page 75: ...Action Engine will not start 1 Clutch pedal not pressed 1 Check Interlock System and start up procedure 2 Glow plug has not timed out Diesel Engine Option 2 Reset ignition switch and allow glow plug t...

Page 76: ...70 Owner s Guide MAINTENANCE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 77: ...eering system Check electrical wiring Check fan belt tension Lubricate spindles and casters page 53 page 58 page 67 page 62 Each week 50 Hours Check fuel lines and fittings Inspect parking brake cable...

Page 78: ...72 Owner s Guide PERIODIC SERVICE SCHEDULE Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 79: ...APPENDIX A Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers 73 Owner s Guide...

Page 80: ...74 Owner s Guide APPENDIX A Read all of SAFETY and this section before attempting any procedure Pay particular attention to Notices Cautions Warnings and Dangers...

Page 81: ...vehicle to fail The manufacturer can not know all possible com ponent failures or the methods that failures can occur A vehicle in need of repair does not operate correctly and can be dangerous Be car...

Page 82: ...3946 FAX 1 800 752 6175 International Phone 001 706 798 4311 FAX 001 706 771 4609 Service Parts Manuals and Repair and Service Manuals are available from a local Distributor an authorized Branch TSV P...

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