Cushman Hauler 4x4 Crew Diesel 2019 Operator's Manual

Operator's Manual for Cushman Hauler 4x4 Crew Diesel 2019 Offroad Vehicle (72 pages)

Specifications:

1518/1518617-hauler_4x4_crew_diesel_2019.pdf file (13 Dec 2023)
  • Manufacturer: Cushman
  • Category of Device: Offroad Vehicle
  • Document: Hauler 4x4 Crew Diesel 2019, File Type: PDF Operator's Manual
  • Updated: 13-12-2023
  • Count of Pages: 72
Download Hauler 4x4 Crew Diesel 2019 Manual (72 pages)

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Data: UPD 13th December 2023

Cushman Hauler 4x4 Crew Diesel 2019 Offroad Vehicle PDF Operator's Manual (Updated: Wednesday 13th of December 2023 04:35:14 PM)

Rating: 4.9 (rated by 25 users)

Compatible devices: Turf Truckster 84043, Turf Truckster 84044, TRX420FA 2009, Trackster 898000, HAULER PRO 2014, Trackster, 1600XD4, YEAR 2012.

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Text Version of Cushman Hauler 4x4 Crew Diesel 2019 Operator's Manual (Summary of Contents)

(Ocr-Read of the Cushman Hauler 4x4 Crew Diesel 2019 Document (Main Content), UPD: 13 December 2023)
  • 2, This vehicle can be hazardous to operate. A collision or rollover can occur quickly, even during what you think are routine maneuvers such as driving or turning on flat terrain, driving on hills, or crossing obstacles, if you fail to take proper precautions. For your safety, understand …

  • 3, Cushman Hauler 4x4 Crew Diesel 2019 1 Foreword Congratulations and thank you from Tex- tron Specialized Vehicles for purchasing a Cushman vehicle. Built with American engineering and manufacturing know- how, it is designed to provide superior ride, comfort, utility, and dependable ser- vice. This Operator’s Manual is furni…

  • 4, Cushman Hauler 4x4 Crew Diesel 2019 2 Table of Contents Foreword ................................................1 Parts and Accessories..........................1 Division I — Safety Safety Alert.............................................4 Hangtags ................................................5 Important Safety Information.........…

  • 5, Cushman Hauler 4x4 Crew Diesel 2019 ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 3 Division I — Safety This vehicle is not a toy and can be hazardous to operate. •Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions wh…

  • 6, ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 4 Safety Alert You should be aware that THIS VEHI- CLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. This vehicle handles differently from other vehicles, including motorcycles and cars. A…

  • 7, ! WARNING Indicates a hazardous situation which, 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 this information before riding. HANGTAG TO GO HERE …

  • 8, ! WARNING Indicates 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 operating this vehicle. …

  • 9, ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 7 Warning Labels …

  • 10, ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 8 Warning Labels …

  • 11, Cushman Hauler 4x4 Crew Diesel 2019 ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 9 Location of Parts and Controls MOD036B MODC049C MOD034B MOD030B MOD641A 1. Brake Fluid Reservoir 2. Fuel Cap 3. Operator Side Cargo Box Tilt Lever 4. Operator Seat Belt 5. Operator Shoulder Restrai…

  • 12, ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 10 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 thi…

  • 13, ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 11 ! 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 …

  • 14, Cushman Hauler 4x4 Crew Diesel 2019 ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 12 ! 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 st…

  • 15, ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 13 ! 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…

  • 16, Cushman Hauler 4x4 Crew Diesel 2019 ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 14 ! 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…

  • 17, ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 15 ! 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 clim…

  • 18, ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 16 ! 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 op…

  • 19, ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 17 ! WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVO…

  • 20, ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 18 ! 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…

  • 21, 19 Division II — Operation/Maintenance Specifications Specifications subject to change without notice. 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 c…

  • 22, Cushman Hauler 4x4 Crew Diesel 2019 20 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 positi…

  • 23, Cushman Hauler 4x4 Crew Diesel 2019 21 Vehicle Operation Starting the Engine Always start with the vehicle on a flat, level surface. Carbon monoxide poisoning can kill you, so keep your vehicle outside while it’s running. Follow these steps to start it up: 1. Step into the vehicle and sit down; then fasten the operator seat belt and …

  • 24, 22 4. To select low range from high range, move the shift lever downward one position until the letter “L” is dis- played on the LCD information gauge.  NOTE: The high range is for nor- mal driving with light loads. The low range is for carrying heavy loads or trailer towing. Compared to HIG…

  • 25, Cushman Hauler 4x4 Crew Diesel 2019 23 Slow down before entering a turn. The basic turning technique is to drive at low speed and gradually adjust the amount of steering to suit the driving surface. Do not make sudden sharp turns on any sur- face. Refer to the sub-sections Driving Uphill, Driving Downhill, Crossing Obst…

  • 26, 24 4. Use only enough power to cross the obstacle but still give yourself plenty of time to react to changes in condi- tions. Crawl over the obstacle.  NOTE: If there is any question about your ability to cross the obstacle safely, you should turn around if the ground is flat and you have room or ba…

  • 27, Cushman Hauler 4x4 Crew Diesel 2019 25 6. You have to assume that oncoming cars don’t see you, and if they do, they won’t be able to predict your actions. 7. It’s illegal to cross public roads in some places. Know your local laws. Plan Ahead Always bring basic items to make your experience safe and…

  • 28, Cushman Hauler 4x4 Crew Diesel 2019 26 General Information  NOTE: This vehicle is equipped with an audible alarm to warn the operator above the speed of 15 mph if the operator’s seat belt is not fully engaged. The seat belt indicator light will remain illuminated until the operator’s seat belt is fully engaged. Control Locations and …

  • 29, 27 In situations when additional traction is necessary, rear axle lock or four-wheel drive would be the desired choice. Some situations may require four-wheel drive and rear axle lock. Drive Selection MOD184 To select 2WD, depress the bottom of the 2WD/4WD switch. To select 4WD, move the switch to the…

  • 30, Cushman Hauler 4x4 Crew Diesel 2019 28 2. To lock the seat into position, slide the rear of the seat into the seat retain- ers and push down firmly on the front of seat. The seat must engage the retainers and lock into position. Passenger Seats 1. To remove a seat, lift up on the front of the seat; then raise the front of the …

  • 31, Cushman Hauler 4x4 Crew Diesel 2019 29 MOD118A  NOTE: Always refer to the Load Capacity Ratings chart in this man- ual when loading and hauling cargo. Tailgate Latches MOD061A 1. To open the tailgate, pull the latch handles (1) (located on the end of the tailgate). 2. To close the tailgate, lift up and push forward firmly. …

  • 32, 30 To access behind-the-seat storage, turn the 1/4-turn fastener clockwise and tilt the seat backrest forward. MOD121A The storage compartment is designed to be a perfect fit for the passenger seat bot- tom(s). 1. Fold the passenger seat backrest(s) down and place the seat bottom(s) int…

  • 33, 31  NOTE: The code reset procedure is to turn the key switch to the OFF posi- tion, then back to the ON position. If the code continues to be displayed, take your vehicle to an authorized dealer for EPS system servicing before resuming operation. In the event of electrical power failure, the EPS system become…

  • 34, 32 (6) Coolant Temperature/Battery Volt- age/Fuel Level Display — Displays coolant temperature, battery voltage, and fuel quantity. Press the Right But- ton to change which parameter is being displayed. Press and hold the Right Button to see the actual values associated with the mode selec…

  • 35, Cushman Hauler 4x4 Crew Diesel 2019 33 Diagnostic Trouble Codes Oil Level Stick There is an oil level stick for checking the engine oil level. To check the oil level, use the following procedure:  NOTE: The vehicle should be on level ground when checking the engine oil level. Preference is to check before operating or…

  • 36, 34 MOD063A 6. Check the oil level after additional oil is added to the engine and confirm the oil is within the operating range. Load Capacity Ratings Chart This vehicle must always be loaded in accordance with the Load Capacity Ratings chart. Under no circumstances should the Vehicle Load Capacity…

  • 37, Cushman Hauler 4x4 Crew Diesel 2019 35 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 towi…

  • 38, 36 MOD080A Tighten the fuel tank cap securely after filling the tank. Recommended Fuel Fuel for 32° F (0° C) and Above Acceptable fuels for temperatures above freezing are diesel #2 (DF2) and #1 (DF1); winter diesel or winterized diesel; EN590; biodiesel containing up to 10% biofuel; and JP-8.…

  • 39, 37 Recommended Front Differential Lubricant  NOTE: Cushman recommends the use of genuine Cushman lubricants. The recommended front differential lubricant is SAE-approved 80W-90 hyp- oid. This lubricant meets all of the lubri- cation requirements of this vehicle. Engine Break-In After the completion of…

  • 40, Cushman Hauler 4x4 Crew Diesel 2019 38 General Maintenance  NOTE: Proper maintenance of this vehicle is important for opti- mum performance. Follow the Main- tenance Schedule and all ensuing maintenance instructions/informa- tion. If, at any time, abnormal noises, vibra- tions, or improper functioning of any component of this …

  • 41, 39 * Dealer maintenance Maintenance Schedule Period Check/Inspect Replace Clean Daily See Pre-Start/Pre-Operation Checklist Break-In First 10 hours/100 miles -Wheel lug nuts (torque to 100 ft-lb) First 50 hours/500 miles -Wheel lug nuts (torque to 100 ft-lb) -Fluid levels -Transaxle fluid -Front d…

  • 42, 40 Liquid Cooling System  NOTE: Debris in the engine com- partment or packed between the cool- ing fins of the radiator can reduce cooling capability. Using a garden hose, wash the radiator to remove any debris preventing air flow. The cooling system capacity can be found in the specification chart. T…

  • 43, 41 2. When pure coolant (no air) flows from the bleed hole, install the bleed plug and tighten securely. 3. Fill the cooling system to the cold fill line of the reservoir. Run the engine for five minutes after the initial fill; then shut off the engine and recheck coolant level once cool. MOD185  N…

  • 44, Cushman Hauler 4x4 Crew Diesel 2019 42 MOD178 MOD179 MOD180 MOD181 General Lubrication Cables None of the cables require lubrication; however, it is advisable to lubricate the ends of the cables periodically with a good cable lubricant. Cargo Box Latches Periodically apply a light coat of grease to the latches and pins.…

  • 45, Cushman Hauler 4x4 Crew Diesel 2019 43 MOD016A 5. Using the oil filter wrench and a ratchet handle (or a socket or box-end wrench), remove the old oil filter and dispose of properly. Capture oil in a suitable pan or absorbent material. Do not reuse oil filter.  NOTE: Clean up any excess oil after removing the filter. 6. A…

  • 46, 44 MOD058A 3. After the oil has been drained, install the drain plugs and tighten to 45 in.-lb (front differential) and 16 ft-lb (tran- saxle). 4. Pour recommended quantity and type of oil into each fill hole: • (A) Front differential fill plug: Add lube until it is level with (B) fill level plug. • (C) …

  • 47, Cushman Hauler 4x4 Crew Diesel 2019 45 4. Install the wheel and tighten the wheel nuts in 25 ft-lb increments to a final torque of 100 ft-lb.  NOTE: Whenever the wheels are removed and installed onto the hub and the lug nuts are tightened, refer to the Maintenance Schedule found on page 39 to identify the appropri- ate service inte…

  • 48, Cushman Hauler 4x4 Crew Diesel 2019 46 MOD176 Inspect and add grease in each Zerk according to the Maintenance Schedule. 1. Clean any dirt or debris from the Zerk before adding grease. 2. Add grease to the Zerk until any trapped air or moisture is pushed out.  NOTE: Under normal use 2-3 pumps of the grease gun is all that will be needed. …

  • 49, 47 800D  NOTE: The maintainer/charger will charge the battery to 95% capacity at which time the Maintenance Charge Indicator (D) will illuminate and the maintainer/charger will change to pulse/float maintenance. If the battery falls below 12.9 DC volts, the charger will automatically start again …

  • 50, 48 1. On the vehicle to be jump-started, remove the battery cover and any ter- minal boots. 2. Inspect the battery for any signs of electrolyte leaks, loose terminals, or bulging sides. Leaking or bulging bat- tery cases may indicate a frozen or shorted battery. 3. Inspect the vehicle to …

  • 51, 49 9. Start the vehicle with the dead bat- tery and allow it to run for several minutes before disconnecting the jumper cables. 10. Remove the jumper cables in oppo- site order of hook-up (4, 3, 2, 1). Be careful not to short cables against bare metal.  NOTE: Have the battery and …

  • 52, 50 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. If operated in …

  • 53, Cushman Hauler 4x4 Crew Diesel 2019 51 6. A dust trail anywhere inside of the air filter housing, inlet tube or on the safety filter is a telltale sign of a leak. Leaks should be inspected by an authorized Cushman dealer. MOD088 MOD089 7. Remove and inspect the safety filter. MOD090 AIR FILTER INSTALLATION 1. Install safet…

  • 54, 52 MOD084A 4. Install the right access panel and secure with two 1/4-turn fasteners. MOD002 Tires Tire Tread Condition 0732-649 The use of worn-out tires on this vehicle is very dangerous. A tire is considered to be worn out when the depth of the tread is less than 3 mm (1/8 in.). Be sure to repla…

  • 55, Cushman Hauler 4x4 Crew Diesel 2019 53 3. Elevate the vehicle. 4. Remove the lug nuts. 5. Remove the wheel. 6. Install the wheel and install the lug nuts. 7. Install the wheel and tighten the wheel nuts in 25 ft-lb increments to a final torque of 100 ft-lb. 8. Remove the jack.  NOTE: Whenever the wheels are removed and installed onto t…

  • 56, 54 MOD097A 3. Install the rubber boot making sure it is sealed around the bulb and connect the wire harness. MOD098A 4. Adjust the headlight (see Checking/ Adjusting Headlight Aim in this sub- section). Taillight/Brake Light Assembly If one or more individual LED bulbs are not working, the tailligh…

  • 57, 55 MOD113 3. Remove the taillight/brake light assembly and disconnect it from the harness by pushing on the connector lock. MOD110 MOD112A 4. Install the new assembly making sure to connect the harness. MOD112 5. Install screw (A) first; then flex the cargo box fender away from the c…

  • 58, Cushman Hauler 4x4 Crew Diesel 2019 56 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. MOD111 9. Once the outer side panel is in place, install the screws securing the cargo box fender and outer side panel. MOD114A MOD115A Checking/Adjusting Headlight Aim The h…

  • 59, Cushman Hauler 4x4 Crew Diesel 2019 57 Fuses The fuses are located in two Power Dis- tribution Modules (PDM) under the hood. If there is any type of electrical system failure, always check the fuses first. MOD044B  NOTE: To remove the fuse, com- press the locking tabs on either side of the fuse cover and lift out. 6411-49…

  • 60, 58 MOD101A Storage Compartments/ Tools This vehicle has a storage compartment within the dashboard and a tool storage compartment beneath the hood. To access the compartment located under the hood, turn the two 1/4-turn fasteners at the rear of the hood and tilt the hood forward; then slide the hood toward…

  • 61, 59 Occupant Shoulder Restraints Inspect the occupant shoulder restraints for damage or loose hardware. MOD033D ROPS Inspect the Rollover Protection Structure (ROPS) for any deformation, damage, improper installation, loose or missing fasteners, modifications, drilling, repair, welding and/or a mi…

  • 62, Cushman Hauler 4x4 Crew Diesel 2019 60 Preparation for Storage Cushman recommends the following pro- cedure to prepare the vehicle for storage. An authorized Cushman dealer should perform this service; however, the owner/ operator may perform this service if desired. 1. Clean the seat cushions with a damp cloth and allow to dry. 2. Cle…

  • 63, 61 Preparation after Storage Taking this vehicle out of storage and correctly preparing it will ensure many miles and hours of trouble-free riding. Cushman recommends the following pro- cedure. 1. Clean the vehicle thoroughly. 2. Clean the engine. Remove the cloth from the exha…

  • 64, 62 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 th…

  • 65, 63 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 …

  • 66, Cushman Hauler 4x4 Crew Diesel 2019 64 U.S. EPA Emission Control Statement/Warranty Coverage — ROV (U.S. Only) 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- ul…

  • 69, 67 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 p…

  • 70, Cushman Hauler 4x4 Crew Diesel 2019 Fold Back CHANGE OF ADDRESS/OWNERSHIP Cushman 1451 Marvin Griffin Road Augusta, GA 30906 Place Stamp Here …

  • 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 mutilate…

  • 72, California Proposition 65 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 & Warranty 1-888-438-3946 - Service Parts 2262-191 ! WARNING The Engine Exhaust from this product contains c…

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