Cushman Hauler 4x4 Crew Diesel 2019 Operator'S Manual Download

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! WARNING

Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.

Important Safety Information

Anyone who operates the ROV should read and understand this information before

operating this vehicle.

Summary of Contents for Hauler 4x4 Crew Diesel 2019

Page 1: ......

Page 2: ...FETY TRAINING Free training is available for Recreation Off Highway Vehicles ROV operators and passengers from the Recreational Off Highway Vehicle Association ROHVA Cushman recommends that you comple...

Page 3: ...y product designed and manufactured to give dependable service Be sure as the owner operator of this vehicle to become thor oughly familiar with its basic operation maintenance and storage procedures...

Page 4: ...ishing Brake Pads 37 General Maintenance 38 64 Maintenance Schedule 39 Liquid Cooling System 40 Shock Absorbers 41 General Lubrication 42 Hydraulic Brake 44 Fuel Hoses 45 Protective Rubber Boots 45 Re...

Page 5: ...ll if you feel the vehicle may tip over Always use proper procedures if you stall or roll backward when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or r...

Page 6: ...because you may not be able to avoid colliding with other vehicles Always wear protective gear includ ing a helmet or hard hat where appropriate Never consume alcohol or drugs before or while operati...

Page 7: ...if not avoided could result in death or serious injury 5 Hangtags This Cushman ROV comes with hangtags containing important safety information Anyone who operates the ROV should read and understand th...

Page 8: ...s a hazardous situation which if not avoided could result in death or serious injury 6 Important Safety Information Anyone who operates the ROV should read and understand this information before opera...

Page 9: ...WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury 7 Warning Labels...

Page 10: ...WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury 8 Warning Labels...

Page 11: ...ock Drive Select Switches 9 Ignition Start Switch 10 DC Power Outlets 11 Storage 12 LCD Information Gauge 13 Shift Lever 14 Passenger Seat Belt 15 Passenger Side Cargo Box Tilt Lever 16 Engine Air Fil...

Page 12: ...s accident HOW TO AVOID THE HAZARD Only people 16 years of age or older with a valid driver s license should operate this vehicle WARNING POTENTIAL HAZARD Operating or riding in the vehicle without we...

Page 13: ...s Long sleeved shirt or jacket Long pants Helmet or Hard Hat where appropriate WARNING POTENTIAL HAZARD Operating this vehicle after or while consuming alcohol or drugs WHAT CAN HAPPEN Could seriously...

Page 14: ...inside the passenger compartment during operation WHAT CAN HAPPEN Serious injury or death Body parts could strike objects outside of vehicle or be crushed in the event of a rollover or accident HOW TO...

Page 15: ...on and maintenance procedures and schedules described in this Operator s Manual WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN You...

Page 16: ...lls WHAT CAN HAPPEN This vehicle can overturn more easily on steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the vehicle on hills too steep for the vehicle or f...

Page 17: ...side of the hill WARNING POTENTIAL HAZARD Crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause the vehicle to overturn HOW TO AVOID THE HAZARD Avoid crossing the sid...

Page 18: ...ou When it is safe to proceed go slowly WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN You could lose control of the vehicle You could also regain traction unexpectedly which may cause t...

Page 19: ...t HOW TO AVOID THE HAZARD Always use the size and type tires specified in this Operator s Manual for this vehicle Always maintain proper tire pressure as described in this Operator s Manual WARNING PO...

Page 20: ...OTENTIAL HAZARD Securing a person improperly in the vehicle due to physical size WHAT CAN HAPPEN Serious injury or death Occupant could strike objects in the passenger compart ment fall out of the veh...

Page 21: ...7 kPa 12 psi 82 7 kPa Rear Tire Inflation Pressure No Cargo w Cargo 14 psi 96 5 kPa 16 psi 110 3 kPa MISCELLANEOUS Dry Weight Approx 846 4 kg 1866 lb Curb Weight 884 5 kg 1950 lb ROPS Tested Curb Weig...

Page 22: ...ntings secure Shock spring preload equal on left and right Components free of all debris Lights Switches Check light bar light bar w high beam and light bar w low beam light switch to OFF Check tailli...

Page 23: ...n when the glow plug indicator light goes off turn the ignition key to START When the engine stars release the ignition key to the RUN position Do not increase engine RPM above idle 4 Let the engine w...

Page 24: ...a second then apply them again On surfaces such as ice mud or loose gravel pump the brake pedal rapidly 3 Never ride the brake Even main taining minimal pressure on the brake pedal will cause the brak...

Page 25: ...maintain a slow speed Crossing Obstacles Crossing obstacles can be hazardous There is always the possibility of the vehicle tipping If you cannot go around an obstacle follow these guidelines 1 Stop t...

Page 26: ...wheel drive Crossing Water This vehicle can only operate in water up to its floorboard Stay away from fast moving rivers This vehicle s tires can be buoyant In deep water the vehicle may lose traction...

Page 27: ...llegal to cross public roads in some places Know your local laws Plan Ahead Always bring basic items to make your experience safe and enjoyable Be pre pared for whatever you may encounter First aid ki...

Page 28: ...switch will return to the RUN position The key can not be removed in this position NOTE This vehicle has safety interlock switches which prevent the starter motor from activating when the brake pedal...

Page 29: ...Apply the brake by pressing the brake pedal down Steering Wheel Tilt Latch Pull on the lever located on the steering column and move the steering wheel to the desired position then release the lever...

Page 30: ...eleased Doors and Shoulder Bars In addition to the seat belts there are left and right side bars to restrict arms from extending outside the vehicle Never operate the vehicle with the bars removed or...

Page 31: ...hen raise the cargo box 2 To lower the cargo box push down firmly on the front of the box The box will automatically lock into position Behind Seat Storage A storage compartment is located behind the...

Page 32: ...S system is battery system pow ered therefore the battery must be in good condition and fully charged Power delivery and overload protection is pro vided by an EPS relay and 30 amp fuse located under...

Page 33: ...process to set the clock The option of selecting the 12 hour or 24 hour clock is available press the Left But ton to alternate between the two modes Next press the Middle Button to choose the hour and...

Page 34: ...is turned ON the indicator will illuminate on the speedometer to remind occupants to secure their seat belts 11 Engine Malfunction Indicator A diagnostic trouble code see list and engine icon will be...

Page 35: ...sition P0372 Crankshaft Position Sensor Missing Tooth P0373 Crankshaft Position Sensor Spike Detected P0480 Fan Primary Relay Control Circuit P0500 Vehicle Speed Sensor P0562 System Voltage Low P0563...

Page 36: ...ty Total weight of trailer and all cargo in the trailer Trailering and Towing MOD001B This vehicle is equipped with a rear frame mounted receiver for a standard 5 1 cm 2 in receiver hitch When loading...

Page 37: ...ken not to over fill the tank If overfilled fuel may leak onto the engine creating a fire hazard WARNING Operating this vehicle without extra caution when towing a trailer will be hazardous Trailer to...

Page 38: ...cle operation above the winter fuel s cloud point Operation below the fuel s cloud point could result in complete fuel system gelling Recommended Engine Oil The recommended oil to use is synthetic eng...

Page 39: ...re Do not idle the engine for excessively long periods of time During the first 50 hours of operation always use less than 70 throttle Varying the engine RPM during the break in period allows the comp...

Page 40: ...f any component of this vehicle is detected DO NOT OPERATE THE VEHICLE Take the vehicle to an authorized Cush man dealer for inspection and adjustment or repair If the owner operator does not feel qua...

Page 41: ...Wheel lug nuts torque to 100 ft lb Spark plugs check gap Clutch engagement RPM approx 1500 1600 RPM Shocks springs Alternator belt Spark arrestor replace as necessary Drive and driven clutch replace...

Page 42: ...move the hood by sliding it toward the rear of the vehicle and out of the slots in the grill MOD044A 2 Inspect the coolant level cold The level shouldn t be lower than the cold full line When it s at...

Page 43: ...cle is equipped with adjustable shock absorbers in the front and rear to allow for different driving and loading conditions The front shock absorbers or front and rear shock absorbers have an adjustme...

Page 44: ...OTE Refer to the oil level stick on pages 33 34 in this manual for the location and proper way to check oil Change the engine oil and oil filter at the scheduled intervals The engine should always be...

Page 45: ...r a few minutes 9 Turn the engine off and wait at least one hour Recheck the oil level 10 Inspect the area around the drain plug and oil filter for leaks 11 Install the maintenance cover and middle se...

Page 46: ...efully inspect the hydraulic brake hoses for cracks or other damage If found take the vehicle to an authorized Cushman dealer to have the brake hoses replaced Brake Pads The clearance between the brak...

Page 47: ...for free play by grasping the steering knuckle and turning it from side to side and up and down 5 If boot damage is present or ball joint free play seems excessive con tact an authorized Cushman deal...

Page 48: ...mmends the 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...

Page 49: ...110 volt elec trical outlet 5 By pushing the Mode button A on the left side of the charger select the Nor mal Charge Icon E The Normal Charge Indicator C should illuminate on the upper left portion o...

Page 50: ...ck 7 Attach one clamp of the negative black jumper cable to the negative terminal 3 of the good battery B then attach the other clamp of the neg ative black jumper cable 4 to an unpainted metal surfac...

Page 51: ...tional 3 4 turn 3 Cycle the key switch to run two com plete cycles run off run off to charge the fuel filter and purge any air from the system 4 Check for any fuel leaks then start the engine and chec...

Page 52: ...cargo box raised if desired AIR FILTER REMOVAL AND INSPECTION 1 Remove dirt and debris from around the air filter housing cover then squeeze the clean out valve to clear it of any accumulated dirt or...

Page 53: ...ter housing for the air filter hous ing cover to fit properly MOD091A MOD092 2 Install the air filter housing cover with the clean out valve at the 5 o clock position then turn the air fil ter housing...

Page 54: ...aired using a plug type repair If the damage is from a cut or if the puncture cannot be repaired using a plug the tire must be replaced When operating the vehicle in areas where transportation or serv...

Page 55: ...car bon deposits from the screen taking care not to damage the screen NOTE If the screen or gasket is damaged in any way it must be replaced 3 Install the spark arrester assembly and secure with the...

Page 56: ...wing procedure 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 an...

Page 57: ...e harness MOD112 5 Install screw A first then flex the cargo box fender away from the cargo box to access and install screw B MOD117A MOD113 6 Position the outer cargo box side panel behind the two ta...

Page 58: ...should be an aver age operating load on the vehicle when adjusting the headlight aim 2 Measure the distance from the floor to the mid point of each headlight 3 Using the measurements obtained in step...

Page 59: ...r is ter minated when the ignition switch is turned off One switched power output terminal is located under the dashboard behind the LCD information gauge Orange black is positive and black is negativ...

Page 60: ...orage compart ment lift up on the lock arm and open toward the vehicle occupant MOD044A Seat Belts Inspect the seat belts for damage and frayed or torn edges Check that the belts extend and retract sm...

Page 61: ...ge 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 v...

Page 62: ...6 Apply light oil to the upper steering shaft bushing and plungers of the shock absorbers 7 Tighten all nuts bolts cap screws and screws Make sure rivets holding components together are tight Replace...

Page 63: ...nect the battery cables making sure to connect the positive cable first 7 Check the entire brake systems fluid level pads etc all controls head lights taillight brake light and head light aim adjust...

Page 64: ...clude normal wear abuse or corrosion and the following parts and items Tires CV Boots Torn or Punctured Upholstery Oil Filter Drive Belt Cracks or Gouges in Body Panels Air Filter Brake Pads Drive Dri...

Page 65: ...in the event the selling dealer has ceased to do business you have moved or you are in a location away from your selling dealer warranty may be performed by any autho rized Cushman dealer The authoriz...

Page 66: ...3100 miles whichever comes first COMPONENTS COVERED The emissions warranty covers major emissions control components and emission related components listed as follows Engine Management and Sensors Fu...

Page 67: ...65 Maintenance Record DATE MILEAGE SERVICE PERFORMED NOTES...

Page 68: ...66 NOTES...

Page 69: ...s sold to another party Warranty coverage is only available in the country in which the original retail purchase occurs to the original retail purchaser resident in that country Address Change Ownersh...

Page 70: ...Fold Back CHANGE OF ADDRESS OWNERSHIP Cushman 1451 Marvin Griffin Road Augusta GA 30906 Place Stamp Here...

Page 71: ...o notify Cushman for correct registration information Record the Vehicle Identification Number and Engine Serial Number in the spaces provided to assist you in ordering parts from your authorized Cush...

Page 72: ...USA To locate your nearest dealer visit www textronoffroad com 1 800 774 3946 Technical Assistance Warranty 1 888 438 3946 Service Parts 2262 191 WARNING The Engine Exhaust from this product contains...

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Cushman Hauler 4x4 Crew Diesel 2019, Operator'S Manual

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