Cushman Hauler 4x4 Crew Diesel 2019 Operator's Manual
  1. Manuals
  2. Brands
  3. Cushman Manuals
  4. Offroad Vehicle
  5. Hauler 4x4 Crew Diesel 2019
  6. Operator's manual

Cushman Hauler 4x4 Crew Diesel 2019 Operator's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Hauler 4x4 Crew Diesel 2019 and is the answer not in the manual?

Questions and answers

Related Manuals for Cushman Hauler 4x4 Crew Diesel 2019

Summary of Contents for Cushman Hauler 4x4 Crew Diesel 2019

  • Page 2 Keep this Operator’s Manual with this vehicle at all times. If you lose your manual, contact Cushman for a free replacement. The labels should be considered permanent parts of the vehicle. If a label comes off or becomes hard to read, contact Cushman for a free replacement. Contact Cushman, Service Department, 1451 Marvin Griffin Road, Augusta, GA 30906, or call 1-800-774-3946 for proper registration informa- tion.

  • Page 3: Foreword

    Read and understand the entire Operator’s tron Specialized Vehicles for purchasing Manual before operating this vehicle to a Cushman vehicle. Built with American ensure safe and proper use. Always oper- engineering and manufacturing know- ate the vehicle within your level of skill how, it is designed to provide superior and current terrain conditions.

  • Page 4: Table Of Contents

    Table of Contents Foreword ..........1 Shock Absorbers .......41 General Lubrication ......42 Parts and Accessories ......1 Hydraulic Brake .........44 Division I — Safety Fuel Hoses ........45 Safety Alert..........4 Protective Rubber Boots ....45 Hangtags ..........5 Rear Knuckle Grease Zerks ....45 Important Safety Information....

  • Page 5: Division I - Safety

    Do not turn at excessive speed. • Always have the vehicle checked by an authorized Cushman dealer if it has been involved in an accident. • Never operate on hills too steep for your abilities. Practice on smaller hills before attempting larger hills.

  • Page 6: Safety Alert

    Safety Alert You should be aware that THIS VEHI- * Never operate this vehicle at exces- sive speeds. Go at a speed which is CLE IS NOT A TOY AND CAN BE proper for the terrain, visibility con- HAZARDOUS TO OPERATE. This ditions, and your experience.

  • Page 7: Hangtags

    Hangtags This Cushman ROV comes with hangtags containing important safety information. Anyone who operates the ROV should read and understand this information before riding. HANGTAG TO GO HERE Indicates a hazardous situation which, if not ! WARNING avoided, could result in death or serious injury.

  • Page 8: Important Safety Information

    Important Safety Information Anyone who operates the ROV should read and understand this information before operating this vehicle. Indicates a hazardous situation which, if not ! WARNING avoided, could result in death or serious injury.

  • Page 9: Warning Labels

    Warning Labels Indicates a hazardous situation which, if not ! WARNING avoided, could result in death or serious injury.
  • Page 10 Warning Labels Indicates a hazardous situation which, if not ! WARNING avoided, could result in death or serious injury.

  • Page 11: Location Of Parts And Controls

    Location of Parts and Controls 1. Brake Fluid Reservoir 2. Fuel Cap 3. Operator Side Cargo Box Tilt Lever 4. Operator Seat Belt 5. Operator Shoulder Restraint 6. Tilt Steering Wheel Lever MOD036B 7. Headlight Switch 8. 2WD/4WD/Rear Axle Lock Drive Select Switches 9.

  • Page 12: Warnings

    Warnings ! WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate this vehicle properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD All operators of this vehicle must read and understand this Operator’s Manual and all warning and instruction labels prior to operating this vehicle.

  • Page 13: Warnings

    ! WARNING POTENTIAL HAZARD Operating or riding in this vehicle without wearing protective gear including a helmet (or hard hat where appropriate). WHAT CAN HAPPEN Operating or riding without protective gear increases your chances of serious injury or death in the event of an accident.
  • Page 14 ! WARNING POTENTIAL HAZARD Operating or riding in the vehicle without occupant side restraints properly secured. WHAT CAN HAPPEN Serious injury or death. Occupants or their body parts can strike objects outside the vehicle, be crushed by the vehicle, or fall out of the vehicle during maneuvers or in the event of an accident.
  • Page 15 ! WARNING POTENTIAL HAZARD Attempting abrupt maneuvers, sideways sliding, skidding, fishtailing, or donuts. WHAT CAN HAPPEN Increases the chance of an accident including a rollover. HOW TO AVOID THE HAZARD Never attempt abrupt maneuvers, sideways sliding, skidding, fishtailing, or donuts. Don’t try to show off.
  • Page 16 ! WARNING POTENTIAL HAZARD Failing to use care in turns; turning too sharply or aggressively. WHAT CAN HAPPEN The vehicle could go out of control causing a collision, tip over, or rollover. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in this Operator’s Man- ual.
  • Page 17 ! WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in this Operator’s Manual. Always check the terrain carefully before you start up any hill. Never climb hills with slippery or loose surfaces.
  • Page 18 ! WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the vehicle to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Never attempt to ride over large obstacles, such as large rocks or fallen trees. When you go over obstacles, always follow proper procedures as described in this Operator’s Manual.
  • Page 19 Never modify this vehicle through improper installation or improper use of accessories. All parts and accessories added to this vehicle should be genuine Cushman compo- nents designed for use on this vehicle and should be installed and used according to instructions.
  • Page 20 ! WARNING POTENTIAL HAZARD Operating through or over thick or sharp brush, timber, debris, or rocks. WHAT CAN HAPPEN Serious injury or death. Brush, branches, debris, and rocks can enter or pene- trate the passenger compartment and strike occupants. Running over sharp branches, rocks, or other large objects can also cause loss of control.

  • Page 21: Division Ii - Operation/Maintenance

    Division II — Operation/Maintenance Specifications ENGINE Type Four-Cycle/Liquid-Cooled Bore 75 mm (2.952 in.) Stroke 77.6 mm (3.055 in.) Displacement 1028 cc (62.7 cu in.) Target Idle RPM 1200 +/- 25 Max RPM 3850 CHASSIS Length (Overall) 397.51 cm (156.5 in.) Height (Overall) 187.96 cm (74 in.) Width (Overall)

  • Page 22: Vehicle Operation

    Vehicle Operation Pre-Start/Pre-Operation Checklist Item Remarks Brake System Pedal firm — near top of travel. Fluid at proper level. Check for fluid leaks. Controls Steering free — no binding — no excessive free-play. Shift lever in park. Accelerator free — no binding — returns to idle position. Fluids Coolant level to bottom of radiator neck.

  • Page 23: Vehicle Operation

    Vehicle Operation Starting the Engine 3. If the engine still does not start, turn the ignition key to OFF and then to Always start with the vehicle on a flat, level RUN to recycle the glow plug timer surface. Carbon monoxide poisoning can for a 3rd time;...
  • Page 24 V-belt failure or in damage to related drive system components. ! WARNING 5. To select park, move the shift lever Use only Cushman-approved brake completely up until the letter “P” is fluid. Never substitute or mix differ- displayed on the LCD information ent types or grades of brake fluid.
  • Page 25 Driving Downhill Slow down before entering a turn. The basic turning technique is to drive at low Always drive straight down the hill and speed and gradually adjust the amount of always avoid hills that are very steep. steering to suit the driving surface. Do not make sudden sharp turns on any sur- 1.
  • Page 26 Crossing Water 4. Use only enough power to cross the obstacle but still give yourself plenty This vehicle can only operate in water up of time to react to changes in condi- to its floorboard. Stay away from fast- tions. Crawl over the obstacle. moving rivers.
  • Page 27 6. You have to assume that oncoming • First-aid kit* • Food and water cars don’t see you, and if they do, • Tool kit* they won’t be able to predict your • Cell phone actions. *Storage locations and potential storage 7.

  • Page 28: General Information

    General Information Shift Lever  NOTE: This vehicle is equipped with an audible alarm to warn the This vehicle has a Continuously Variable operator above the speed of 15 mph Transmission (CVT) which transfers if the operator’s seat belt is not fully power to the dual range transmission.
  • Page 29 Steering Wheel Tilt Latch In situations when additional traction is necessary, rear axle lock or four-wheel Pull on the lever located on the steering drive would be the desired choice. Some column and move the steering wheel to situations may require four-wheel drive the desired position;...

  • Page 30: Doors And Shoulder Bars

    2. To lock the seat into position, slide the rear of the seat into the seat retain- ! WARNING ers and push down firmly on the front Only appropriate-sized passengers of seat. The seat must engage the may ride in this vehicle. Passengers retainers and lock into position.
  • Page 31 Cargo Box Latch Handles MOD118A CAUTION MOD062A 1. To raise the cargo box, lift the handle When using ratchet-type straps, do upward; then raise the cargo box. not over tighten or damage to the cargo box could occur. 2. To lower the cargo box, push down firmly on the front of the box.

  • Page 32: Power Steering (If Equipped)

    To access behind-the-seat storage, turn The EPS system is battery system pow- the 1/4-turn fastener clockwise and tilt ered; therefore, the battery must be in the seat backrest forward. good condition and fully charged. Power delivery and overload protection is pro- vided by an EPS relay and 30-amp fuse located under the hood in the Power Dis- tribution Module (PDM).

  • Page 33: Lcd Information Gauge (Digital)

     (4) Speedometer/Tachometer/Clock Dis- NOTE: The code reset procedure is play — Indicates approximate vehicle to turn the key switch to the OFF posi- speed in MPH or KM/H when speed- tion, then back to the ON position. If ometer function is selected, RPM the code continues to be displayed, when tachometer function is selected, take your vehicle to an authorized...
  • Page 34 CAUTION Cushman does not recommend using a pressure washer to clean the radia- tor core. The pressure may bend or flatten the fins causing restricted air flow, and electrical components on the radiator could be damaged.

  • Page 35: Diagnostic Trouble Codes

    Diagnostic Trouble Codes Display Fault Description C0063 Tilt Sensor Circuit High C0064 Tilt Sensor Circuit Low/SG/Open P0119 Engine Coolant Temp Sensor Circuit Intermittent P0217 Engine Coolant Over Temperature Detected P0370 Loss of Crankshaft Position Sensor Synchronization/Gap Position MOD063 P0372 Crankshaft Position Sensor Missing 3.

  • Page 36: Load Capacity Ratings Chart

    Rear Tongue, Cargo, and Storage Compartments Weight — Total weight on trailer tongue, cargo box, and storage compartments. Towing Capacity — Total weight of trailer and all cargo in the trailer. Trailering and Towing MOD063A 6. Check the oil level after additional oil is added to the engine and confirm the oil is within the operating range.

  • Page 37: Transporting

    Always maintain a slow speed when trailering and towing and avoid sudden acceleration, quick maneuvers, and sud- den stops. Braking distance will be affected when towing a trailer. When towing a trailer, always maintain slow speed and allow more stopping distance than when not towing a trailer.
  • Page 38 Although Fuel for 32° F (0° C) Cushman synthetic engine oil is the only and Above oil recommended for use in this engine, use of any API-certified SM 5W-50 oil is Acceptable fuels for temperatures above acceptable.

  • Page 39: Engine Break-In

    At the discretion and expense of the owner/ operator, the vehicle may be taken to an authorized Cushman dealer for this initial service. New vehicles and engines require a “break- in” period. The first month is most critical to the life of this vehicle.

  • Page 40: General Maintenance

    Follow the Main- an authorized Cushman dealer for profes- tenance Schedule and all ensuing sional service. maintenance instructions/informa- tion.

  • Page 41: Maintenance Schedule

    Maintenance Schedule Period Check/Inspect Replace Clean See Pre-Start/Pre-Operation Checklist Daily Break-In -Wheel lug nuts First (torque to 100 ft-lb) 10 hours/100 miles -Wheel lug nuts -Transaxle fluid First (torque to 100 ft-lb) -Front differential fluid 50 hours/500 miles -Fluid levels -Engine oil and filter Recurring -Fluid levels...

  • Page 42: Liquid Cooling System

    If leakage or damage is perature, the coolant level may be detected, take the vehicle to an authorized above the cold full line. Cushman dealer for service. Also, the cool- ant level should be checked periodically. CAUTION Continued operation of the vehicle...

  • Page 43: Shock Absorbers

    2. When pure coolant (no air) flows The front shock absorbers or front and from the bleed hole, install the bleed rear shock absorbers have an adjustment plug and tighten securely. sleeve with five preload adjustment posi- tions that can be turned with a special 3.

  • Page 44: General Lubrication

    Cargo Box Latches Periodically apply a light coat of grease to the latches and pins. Do not over grease. Engine Oil and Filter  NOTE: Refer to the recommended oil viscosity chart on page 36 in this manual for the proper engine oil. ...
  • Page 45 1. Place the vehicle on level ground; then remove the fill plugs: (A) front differential and (C) transaxle. MOD016A 5. Using the oil filter wrench and a ratchet handle (or a socket or box-end MOD073A wrench), remove the old oil filter and dispose of properly.

  • Page 46: Hydraulic Brake

    Carefully inspect the hydraulic brake hoses of oil into each fill hole: for cracks or other damage. If found, take the vehicle to an authorized Cushman • (A) Front differential fill plug: Add dealer to have the brake hoses replaced.

  • Page 47: Fuel Hoses

    Lower/Right and Left) attempting to move it up and down. 5. If boot damage is present or tie rod end free-play seems excessive, con- tact an authorized Cushman dealer for service. Drive Axle Boots MOD094A 1. Secure the vehicle on a support stand to elevate the front wheels.
  • Page 48 Maintenance Charging  NOTE: recommends the Cushman use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery main- tenance charging. Maintenance charging is required on all batteries not used for more than two weeks or as required by battery drain.
  • Page 49  NOTE: If, after charging, the bat- tery does not perform to operator expectations, bring the battery to an authorized dealer for Cushman 3300D further troubleshooting.  NOTE: Not using a battery char- Jump-Starting ger with the proper float mainte- nance will damage the battery if ...
  • Page 50 1. On the vehicle to be jump-started, 5. Disconnect all external accessories remove the battery cover and any ter- such as cell phones, GPS units, and minal boots. radios on both vehicles. CAUTION ! WARNING Failure to disconnect electronic acces- Any time service is performed on a bat- sories during jump-starting may cause tery, the following must be observed:...
  • Page 51 Idle RPM 9. Start the vehicle with the dead bat- tery and allow it to run for several Do not attempt to make engine idle RPM minutes before disconnecting the adjustments on the diesel engine. If jumper cables. engine adjustments are necessary, take the vehicle to an authorized dealer.

  • Page 52: Primary Air Filter/Safety Filter/Clean-Out Valve

    Primary Air Filter/Safety Filter/Clean-out Valve The engine air filter inside the air filter housing must be kept clean to provide good engine power and fuel mileage. If the vehicle is used under normal condi- tions, service the filter at the intervals specified.
  • Page 53 Leaks should be inspected by an  NOTE: The flower shape of the authorized Cushman dealer. primary filter element must line up CAUTION with the same-shaped void in the air filter housing for the air filter hous- Do not attempt to clean the primary ing cover to fit properly.

  • Page 54: Wheels

    If proper tools and related items are not available, have this maintenance per- MOD002 formed by an authorized Cushman dealer or a qualified tire repair station. CAUTION CAUTION A torn air filter can cause damage to When breaking the tire bead loose the engine.

  • Page 55: Muffler/Spark Arrester

    3. Elevate the vehicle. 3. Install the spark arrester assembly and secure with the cap screw. 4. Remove the lug nuts. Tighten to 60 in.-lb. 5. Remove the wheel. Light Bulb Replacement 6. Install the wheel and install the lug CAUTION nuts.
  • Page 56 1. Remove the four screws from the inner cargo box side panel, two rear tie-down screws and one tailgate latch bail screw; then remove the six screws from the underside of the cargo box and remove the outer cargo box side panel. MOD097A 3.
  • Page 57 MOD113 MOD117A 3. Remove the taillight/brake light assembly and disconnect it from the harness by pushing on the connector lock. MOD113 6. Position the outer cargo box side panel behind the two tabs on the cargo box fender; then fit all tabs into their adjoining slots in the side panel MOD110 MOD112A...

  • Page 58: Checking/Adjusting Headlight Aim

    8. Start at the rear of the cargo box and tuck the outer side panel under the cargo box and work it into place from back to front. MOD626  NOTE: There should be an aver- age operating load on the vehicle when adjusting the headlight aim.

  • Page 59: Fuses

    If MOD100A the new fuse blows after a short period of use, consult an authorized Cushman dealer immediately. Electrical Output Terminals Three output terminals for electrical accessories are located on the front and rear wiring harnesses.

  • Page 60: Storage Compartments/Tools

    To open the dashboard storage compart- ment, lift up on the lock arm and open toward the vehicle occupant. REAR MOD101A CAUTION Always use electrical accessories MOD044A less than 30 amps (Accessory Fuse). Seat Belts Storage Compartments/ Inspect the seat belts for damage, and frayed Tools or torn edges.

  • Page 61: Occupant Shoulder Restraints

    (ROPS) for any deformation, damage, improper installation, loose or missing fasteners, modifications, drilling, repair, welding and/or a missing label. If any of these circumstances are discovered, do not operate and immediately bring the MOD033D vehicle to an authorized Cushman dealer for service.

  • Page 62: Preparation For Storage

    Preparation for Storage Cushman recommends the following pro- 4. Clean the interior of the air filter cedure to prepare the vehicle for storage. housing. An authorized Cushman dealer should 5. Plug the hole in the exhaust system perform this service; however, the owner/ with a clean cloth.

  • Page 63: Preparation After Storage

    Cushman recommends the following pro- light aim; adjust or replace if cedure. necessary. 1. Clean the vehicle thoroughly.

  • Page 64: Limited Warranty

    Limited Warranty Textron Specialized Vehicles, a division of Textron, Inc. (the Company), extends a limited warranty as described below on each new vehicle it assembles and on each genuine part and accessory assembled and sold by an authorized dealer. The limited warranty on the vehicle is extended to the original retail purchaser for the time periods described below;...

  • Page 65: Warranty Procedure/Owner Responsibility

    At the time of sale, an ROV Rider Training Certificate and Owner Registration form is to be completed by the selling dealer and consumer. The receipt of the form by Cushman is a condi- tion precedent to warranty coverage. It is the selling dealer’s responsibility to retain and/or sub- mit appropriate copies of the form to the appropriate place(s) to initiate warranty coverage.

  • Page 66: Epa Emission Control Statement/Warranty Coverage - Rov

    STATEMENT/WARRANTY Cushman warrants to the original retail purchaser, and each subsequent purchaser, that all U.S. EPA-cer- tified Cushman ROVs are designed, built, and equipped to conform to all U.S. EPA Emission Control Reg- ulations. Please read the following information completely.

  • Page 67: Maintenance Record

    Maintenance Record DATE MILEAGE SERVICE PERFORMED/NOTES...
  • Page 68 NOTES...

  • Page 69: Change Of Address Or Ownership

    Change of Address or Ownership Textron Specialized Vehicles, a division of Textron, Inc., keeps on file the current name and address of the owner of this vehicle. This allows us to reach the current owner with any important safety information which may be necessary to protect customers from personal injury or property damage.
  • Page 70 Fold Back Place Stamp Here CHANGE OF ADDRESS/OWNERSHIP Cushman 1451 Marvin Griffin Road Augusta, GA 30906...

  • Page 71: Identification Numbers Record

    This vehicle has two identification numbers: Vehicle Identification Number (VIN) and Engine Serial Number (ESN). These numbers are required by the dealer to com- plete warranty claims properly. No warranty will be allowed by Cushman if the VIN or ESN is removed or mutilated in any way.
  • Page 72 California Proposition 65 ! WARNING The Engine Exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. TEXTRON SPECIALIZED VEHICLES 1451 Marvin Griffin Road Augusta, GA 30906-3852, USA To locate your nearest dealer, visit www.textronoffroad.com 1-800-774-3946 - Technical Assistance &...

This manual is also suitable for:

Hauler 4x4 diesel 2019Hauler 4x4 gas 2019

Table of Contents

Save PDF