Cushman Truckster XD 2018 User manual

OWNER’S GUIDE
672240 - A
Truckster®XD
ISSUED JANUARY 2018
Distributed by:

WELCOME
Read and comply with all of the instructions and safety precautions in this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease it’s stability or increase the
speed beyond the factory-set speed. Such modifications can cause serious personal injury or death. The manufacturer of this
vehicle, TEXTRON SPECIALIZED VEHICLES (TSV Augusta), prohibits and disclaims responsibility for any such modifications
or any other alteration which would adversely affect the safety of the 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 before attempting to set up, operate, adjust, or service the machine.
CALIFORNIA Proposition 65
Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose
you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which
are known to the State of California to cause cancer and birth defects or other reproductive
harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as
necessary, service your vehicle in a well-ventilated area and wear gloves or wash your
hands frequently when servicing your vehicle. For more information go to
www.P65Warnings.ca.gov/passenger-vehicle.

Never modify the vehicle in any way that will alter the weight distribution of the vehicle, decrease its stability or increase the speed
beyond the factory specifications. Such modifications can cause serious personal injury or death. Textron Specialized Vehicles prohibits
and disclaims responsibility for any such modifications or any other alteration which would adversely affect the safety of the vehicle.
TSV reserves the right to incorporate engineering and design changes to products in this manual, without obligation to include these
changes on units sold previously.
The information contained in this 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 LIABILITY
FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES resulting from the use of the information and materials in this manual.
These are the original instructions as defined by 2006/42/EC.
CONTACT US:
Textron Specialized Vehicles
1451 Marvin Griffin Road
Augusta, Georgia, USA 30906-3852
North America:
Technical Assistance & Warranty PHONE: [phone] FAX: [phone]
Service Parts PHONE: 1-888-GET-EZGO (1-888-438-3946) FAX: [phone]
International: PHONE: [phone] FAX: [phone]
PHONE: [phone] FAX: [phone]
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OWNER’S GUIDE
Truckster XD®Diesel
Truckster XD®Gas
STARTING MODEL YEAR 2018

NOTES
ii Owner’s Guide
This vehicle was designed and assembled in the United States of America (USA). The stan-
dards and specifications listed in the following text originate in the USA unless otherwise
indicated.
Use Original Equipment Manufacturer (OEM) approved parts to keep the warranty effective.
If you do not correctly maintain the batteries, you will cancel the warranty. Refer to the
MAINTENANCE section for instructions on the correct maintenance of the batteries.
BATTERY PROLONGED STORAGE
The batteries will discharge over time. The rate of discharge is dependent on the ambient
temperature, the age and condition of the batteries.
Fully charged batteries will not freeze in winter temperatures unless the temperature is less
than -75°F (- 60°C).
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return discarded batteries to distributor, manufacturer
or lead smelter for recycling. For neutralized spills, put residue in acid-resistant containers
with absorbent material such as sand. Dispose in accordance with local, state and federal
regulations for acid and lead compounds. Contact local or state environmental authorized
people for the disposal information.
The Cushman Truckster XD with a Kubota Gasoline or Diesel engine is a self propelled vehicle. The hydraulic systems
are for the steering, 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 always be done by an approved technician.
IMPORTANT: Do the maintenance included in this manual to make sure that the vehicle operates correctly.
This Owner’s Guide is part of the vehicle and must stay with the vehicle always. Suppliers of both original and used
vehicles must keep the manual with the vehicle.
Compliance with the conditions or operation, service and repair specified by the manufacturer, are understood to be
part of the correct use.
ALL operators MUST read through this manual and understand the Safety Instructions, controls, lubrication and
maintenance procedures.
Make sure that you obey all safety and road traffic regulations.
You must not make any changes to the vehicle that the manufacturer does not approve. This type of change can
release the manufacturer from the liability for any damage or injury.
Only if the vehicle manufacturer is no longer in business and there is no successor to the business can you make
changes to the vehicle, provided that:
• An engineer in the industrial truck industry, who knows the safety requirements, must design, test and install the
changes to the vehicle.
• You must keep a permanent record of the design, tests and installation of the changes.
• You must approve and make applicable changes to the vehicle capacity plate, decals, tags and manuals.

NOTES
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Owner’s Guide
• You must apply a permanent and visible label to the vehicle. The label must provide a description of the changes,
when the changes were made 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
vehicle is used. When the vehicle is at its end of life, there are guidelines in this manual for the removal of the vehicle
from use.
Use only Cushman approved parts.

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TABLE OF CONTENTS
1
Owner’s Guide
INTRODUCTION
LOCATION OF VEHICLE SERIAL NUMBER PLATE....................................................... 3
ENGINE SERIAL NUMBER.............................................................................................. 4
SERIAL NUMBERS .......................................................................................................... 4
GUIDELINES FOR THE DISPOSAL OF SCRAP PRODUCTS........................................ 4
SAFETY
GENERAL......................................................................................................................... 7
NOTICES, CAUTIONS, WARNINGS AND DANGERS .................................................... 7
HOW TO OPERATE SAFELY .......................................................................................... 8
IMPORTANT SAFETY 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 LUBRICANTS ................................................................................... 24
ACCESSORIES.............................................................................................................. 24
SUPPORT LITERATURE ............................................................................................... 27
........................................................................................................................................ 27
OPERATING PROCEDURES
OPERATOR COMPARTMENT....................................................................................... 29
GAUGE PANEL .............................................................................................................. 30
RIGHT-SIDE CONTROL PANEL.................................................................................... 32
LEFT-SIDE CONTROL PANEL ...................................................................................... 34
CENTER CONSOLE....................................................................................................... 37
OPERATION................................................................................................................... 39
INTERLOCK SYSTEM.................................................................................................... 40
OPERATING PROCEDURE........................................................................................... 40
MAINTENANCE
LUBRICATION CHART................................................................................................... 51

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TABLE OF CONTENTS
2
Owner’s Guide
FLUID REQUIREMENTS................................................................................................ 51
GENERAL PRECAUTIONS............................................................................................ 52
TO 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 INSPECTION.......................................................................................... 64
CARE AND CLEANING.................................................................................................. 64
PERIODIC SERVICE SCHEDULE
PERIODIC SERVICE SCHEDULE ................................................................................. 71

Read 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 PLATE
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4Owner’s Guide
INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
ENGINE SERIAL NUMBER
The engine serial number is located on the engine
valve cover. Label shows the engine group and serial
number.
The engine serial number is also located on the engine
block.
SERIAL NUMBERS
Record the vehicle and engine numbers shown below:
Vehicle Number:_________________________
Engine Number:__________________________
GUIDELINES FOR THE DISPOSAL OF SCRAP PRODUCTS
During Service Life
The used oil, oil filters and engine coolant are hazardous materials. Follow the recommended procedures for their safe
disposal.
If a fluid leakage occurs, contain the spill to make sure that the fluid does not flow into the ground or 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
environment is controlled safely.
End of Service Life
Follow these guidelines along with applicable health, safety and environmental laws. Always use approved local waste
disposal and agencies for recycled materials.
• Park the vehicle in a location where all of the necessary lifting equipment can be used.
• Use correct tools and Personal Protective Equipment (PPE) and follow instructions in the technical manuals
applicable to the vehicle.
• Remove and dispose of properly:
1. Batteries
2. Fuel
3. Engine coolant
4. Oils
• Follow instructions and safety information in the technical manual to disassemble the structure of the vehicle. Be
aware of parts that have mechanical pressure or tension applied, including springs.
• Separate items that will not be disposed of and can be returned to storage.
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  
Diesel Engine Gasoline Engine

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INTRODUCTION
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
5
Owner’s Guide
• Separate disposable items into specific material groups and dispose of according to the agencies for recycled
materials that are available. 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
• Place items that can not be easily identified into the “General discarded materials” area.
• Do not burn the discarded materials.
• Change the vehicle records to show that the vehicle is no longer in service and has been discarded. Supply this
serial number to Cushman Warranty Department so records can be closed.

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

Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
7
Owner’s Guide
SAFETY
GENERAL
For any questions about material in this manual, contact an authorized representative.
Read and understand all labels on the vehicle.Always replace any damaged or missing labels.
On steep hills, it is possible for vehicles to coast at speeds higher than the vehicle is designed to travel. To prevent loss
of vehicle control and possible serious injury, speeds should be limited to no more than 25 mph.
Catastrophic damage to the drivetrain components due to excessive speed may result from driving the vehicle above 25
mph. Damage caused by excessive speed may cause a loss of vehicle control, is costly, is considered abuse, and will not
be covered under warranty.
Signs similar to the ones illustrated should be used to warn of situations that could result in an unsafe condition.
.
NOTICES, CAUTIONS, WARNINGS AND DANGERS
Read all NOTICES, CAUTIONS, 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
vehicle or make the vehicle dangerous to operate.
NOTICE:A NOTICE indicates and describes information not related to personal injury.
NOTICE:Some accessories continue to operate with the key in the OFF position. Leaving these accessories acti-
vated after the vehicle is shut down can cause the battery to discharge.
NOTICE:12V accessories must be connected to the DC to DC converter. The converter is rated for 390 Watt out-
put. Exceeding this power rating may result in unintended accessory operation or failure.
A CAUTION indicates a dangerous condition that can cause an injury that is not life
threatening.
A WARNING indicates a dangerous condition that can cause death or serious injury.
A DANGER indicates a dangerous condition that will cause death or serious injury.
This manual contains recommended maintenance procedures from the manufacturer. Follow these procedures and fault
isolation information to get optimum service from the product, and to decrease the risk of personal injury or property dam-
age.

8Owner’s Guide
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
SAFE OPERATION
INCORRECT OPERATION OF THE VEHICLE CAN BE DANGEROUS.
Familiarize yourself with the location and correct operation of controls before operat-
ing. Inexperienced operators must receive instruction from a trained person.
Only use parts, accessories and attachments approved by Cushman.
Read this Owner’s Guide and other training material. If the operator or technician can not read this manual, the owner is
responsible to provide this information to the operators and technicians. Manuals in additional languages may be avail-
able on the Cushman.com website or from your Cushman dealer.
Read all of the instructions for this vehicle carefully. Know the controls and correct operation of all equipment.
Anyone who does not understand these instructions must not operate the vehicle. The local regulations can limit the age
of the operator.
Never operate a vehicle near people or animals.
The operator or owner is responsible for accidents or hazards that occur to other people or property.
Never allow anyone to operate or service the vehicle or its attachments without correct instructions.
Do not operate equipment while tired, sick or after using alcohol or drugs.
Preparation
When you operate the vehicle, wear correct clothing such as: slip resistant work shoes or boots, work gloves, hard hat,
safety glasses and hearing protection. Secure long hair, loose clothing and remove jewelry that can be caught in moving
parts.
Do not operate the equipment with the Interlock System disconnected or if the system does not operate correctly. Do not
disconnect or prevent the operation of any switch.
Never operate equipment without labels, guards, shields, deflectors or other protective devices 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 the vehicle.
Operate the vehicle in adequate light. Use caution when operating the vehicle during bad weather. Never operate the
vehicle with lightning in the area.
Inspect the area to select the accessories and attachments that are needed to correctly and safely do the job. Only use
parts, accessories and attachments approved by Cushman.
Be careful of holes in the terrain and other hazards that are not visible.
Inspect the area where the equipment is operated. Remove all objects you can find before you operate. Be careful of
obstructions above the ground (low tree limbs, electrical wires) and also underground obstacles (sprinklers, pipes, tree
roots). Enter a new area carefully. Look for possible hazards.
Operation
Never operate the engine in an unventilated area. Carbon monoxide in exhaust fumes can increase to dangerous levels
quickly.
Never carry more than one passenger. Keep other people or animals away from the vehicle.
Engage the parking brake, press the clutch pedal and put the transmission in neutral before you start the engine. Only
start the engine with the operator in the seat. Never start the engine with people near the vehicle.
Keep your entire body inside the operator compartment while the vehicle is in operation. Keep your hands and feet away
from moving parts.
Do not use on the slopes greater than the safe slope limit for the equipment.
To guard against over turning or loss of control:
• Operate the vehicle vertically on the face of slopes, not horizontally across the face.
• Do not start or stop suddenly on slopes.
• Decrease the speed when you operate on slopes or when you must turn. Use caution when you change direction. Turf
condition can change the vehicle stability.
• Use caution when you operate the vehicle near drop-offs, ditches or embankments.
• Be careful of holes in the terrain and other hazards that are not visible.

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SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
9
Owner’s Guide
When you drive in the reverse direction, look behind and down to make sure the path is clear. Do not operate the attach-
ments when you drive in the reverse direction.
Use caution when you go near corners, trees or other objects that can prevent a clear view.
Equipment must meet the current regulations to be driven on the public roads.
Check for traffic and operate at reduced speed before you cross paths or roads.
Do not release the load in the direction of or allow people near the vehicle while in operation.
Do not operate the vehicle with damaged guards or without safety devices in position.
Do not change the engine governor setting or over-speed the engine. Never change or tamper with adjusters that are
closed with a seal for the engine speed control.
Before you leave the operator compartment, for any reason:
• Disengage all the drives and lower attachments to the ground.
• Engage the parking brake.
• Press the clutch pedal and put the transmission in 1st Gear
• Stop the engine and remove the key.
When you hit an object or the vehicle has a vibration that is not normal, inspect the vehicle for damage and make repairs.
Decrease the throttle setting before you stop the engine.
Do not use this equipment for uses that the vehicle was not designed for.
ROPS (Roll Over Protective Structure)
The ROPS is a safety device to provide protection in the event of a rollover and when operating under low-hanging
objects. Always use the seat belt when you operate the vehicle. Make sure the seat belt can be released quickly in an
emergency.
Check for clearance before you drivebeneath objects.Do not contact tree branches,electrical wires or other objects with
the ROPS.
Inspect the ROPS for damage. Make sure all ROPS hardware is properly installed and tightened.
Do not weld, drill, change or bend the ROPS. Replace a damaged ROPS. Do not try to repair a damaged ROPS.
Do not remove the ROPS from the vehicle.
Cushman must approve any changes to the ROPS.
Safe Handling of Fuels
Fuel and the fuel vapors are flammable. Use caution when adding fuel to the vehicle. Fuel vapors can cause an explo-
sion.
Never use containers that are not approved to store or transfer fuel.
Never store the vehicle or fuel containers near an open flame or any device that can cause ignition of fuel or fuel vapors.
Never fill fuel containers inside a vehicle or on a truck or trailer with a plastic liner. Always put the fuel container on the
ground away from your vehicle before you fill the container.
Refuel the vehicle before starting the engine. Never remove the fuel cap or add fuel to the vehicle while the engine is in
operation or hot.
Refuel outdoors only. Do not smoke when refueling. Extinguish all types of ignition before refueling.
The fuel nozzle must touch the rim of the fuel tank when you add fuel to the vehicle. Do not use a device to lock the fuel
nozzle in the open position.
Do not over fill the fuel tank.
Always tighten the fuel tank cap and container cap after you add fuel.
If the fuel spills on your clothing, change your clothing immediately.
Maintenance and Storage
Before you clean, adjust or repair this equipment:
1. Engage the parking brake.
2. Press the clutch.
3. Put the transmission in first gear.
4. Stop the engine.
5. Remove the key.

10 Owner’s Guide
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
Make sure the vehicle is parked on a solid and level surface.
Never work on a vehicle that is supported only by the jack.Always use the jack stands.
Never allow anyone without proper training to service the vehicle or attachments.
When the vehicle is parked, put into storage or left unattended, lower the bed unless the positive mechanical lock is
used.
Do not store fuel near flames or drain the fuel inside an enclosed space.
Wear protective clothing and use insulated tools when you service the battery.
Disconnect the battery before you service the vehicle. Always disconnect the negative battery cable before the positive
battery cable. Always connect the positive battery cable before the negative battery cable.
Charge the battery in a well ventilated area. The battery can release hydrogen gas that is explosive. To prevent an explo-
sion, keep any device that can cause sparks or flames away from the battery.
Disconnect the battery charger from the power supply before you connect or disconnect the battery charger to the bat-
tery.
Keep hands and feet away from moving parts. Do not adjust the vehicle with the engine in operation, unless the adjust-
ment needs the engine in operation.
Carefully release the pressure 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 enough force to penetrate skin. If hydraulic fluid has penetrated your skin, a doctor
must remove the hydraulic fluid surgically within a few hours to prevent gangrene from occurring.
When you service the hydraulic system, make sure the hydraulic fittings, tubes and hoses are tightened to the correct
torque. Make sure the hydraulic system is in good condition before you start the engine.
Keep the vehicle and the engine clean.
Allow the engine to cool before storing.Always remove the ignition key.
Keep all nuts, bolts and screws tight to make sure the equipment is in safe condition.
Replace worn or damaged parts for safety. Replace damaged or worn labels. Only use parts, accessories and attach-
ments approved by Cushman.
To decrease fire hazard, remove materials that burn from the engine, muffler, battery tray and fuel tank area.
Disconnect the battery, instrument cluster and controller connectors before you weld on this vehicle.
Loading the Vehicle on a Trailer
Be careful when you load or unload the vehicle on a trailer. The trailer must be wider than the vehicle and capable of car-
rying the weight of the vehicle.
Use a full-width ramp to load or unload the vehicle on a trailer.
Use straps, chains, cables or ropes to secure the vehicle to the trailer. Both front and rear straps must be sent down and
toward sides of trailer.
Make sure all latches are correctly fastened.

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SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
11
Owner’s Guide
IMPORTANT SAFETY NOTES
Some illustrations in this manual show the shields, guards or plates, removed. Do not
operate this equipment without these devices correctly fastened in position.
The Interlock System on this vehicle requires the clutch pedal to be fully pressed for
the engine to start. If the optional high-low hydraulic system is installed, the high-low
switch must be in the OFF 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 pedal and use the brake pedal to stop the vehicle.
•Disengage all drives.
•Engage the parking brake.
•Put the transmission in 1st gear
•Stop the engine and remove the ignition key.
Keep your hands, feet and clothing away from moving parts. Wait for all movement to
stop before you clean, adjust or service the vehicle.
Keep people and animals away from the area of operation.
Never carry more than one passenger.
If additional information or service is needed, contact your authorized Cushman dealer. Your
dealer knows correct methods to service this equipment.

12 Owner’s Guide
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
SAFETY LABELS
Understand the purpose of these labels. The labels are important to the safe operation of the vehicle. REPLACE THE
DAMAGED LABELS IMMEDIATELY.
Battery Explosion Danger
To prevent injury while you work on the battery:
1. Connect the negative (BLACK) wire after the positive (RED)
wire. Remove 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 battery:
1. Connect the positive (+) battery terminal of thecharged battery
to the positive battery terminal of the drained battery.
2. Connect the negative (–) battery terminal of the charged
battery to the frame of the vehicle with the drained battery.
The engine coolant is under pressure. To prevent injury, do not remove the radiator
cap on a hot radiator.
To prevent injury, do not touch the muffler or muffler
shield. The muffler temperatures can be more than
150° F (66° C).
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B
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
13
Owner’s Guide
Always wear your seat belt 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 belt.
Do not carry passengers on your lap.
To prevent injury, do not service the vehicle with the truck bed lifted unless the cylinder support is
installed on the bed cylinder. Read the manual.
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14 Owner’s Guide
SAFETY
Read all of SAFETY and this section before attempting any procedure. Pay particular attention 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 condition and can
cause engine damage.
Use caution when you close the tailgate to
prevent injury to fingers or hands.