Bush Hog TH440, TH4400, TH420, TH4200 User Manual

4 (3)

BUSH HOG

Trail Series ®

OFF ROAD UTILITY VEHICLES

Operator’s Manual

TH420MODELS

TH440

TH4200

TH4400

ASSEMBLY • OPERATION • MAINTENANCE

107

$10.00

50044549

CONGRATULATIONS!

You have invested in the best vehicle of its type on the market today.

The care you give your Bush Hog vehicle will greatly determine your satisfaction with its performance and its service life. We urge a careful study of this manual to provide you with a thorough understanding of your new vehicle before operating, as well as suggestions for operation and maintenance.

If your manual should become lost or destroyed, Bush Hog will be glad to provide you with a new copy. Order from Bush Hog, P. O. Box 1039, Selma, Alabama 36702-1039. Most of our manuals can also be downloaded from our website at www.bushhog.com.

As an authorized Bush Hog dealer, we stock genuine Bush Hog parts which are manufactured with the same precision and skill as our original equipment. Our trained service personnel are well informed on methods required to service Bush Hog equipment, and are ready and able to help you.

Should you require additional information or assistance, please contact us.

YOUR AUTHORIZED BUSH HOG DEALER

BECAUSE BUSH HOG MAINTAINS AN ONGOING PROGRAM OF PRODUCT IMPROVEMENT, WE RESERVE THE RIGHT TO MAKE IMPROVEMENTS IN DESIGN OR CHANGES IN SPECIFICATIONS WITHOUT INCURRING ANY OBLIGATION TO INSTALL THEM ON UNITS PREVIOUSLY SOLD.

BECAUSE OF THE POSSIBILITY THAT SOME PHOTOGRAPHS IN THIS MANUAL WERE TAKEN OF PROTOTYPE MODELS, PRODUCTION MODELS MAY VARY IN SOME DETAIL. IN ADDITION, SOME PHOTOGRAPHS MAY SHOW SHIELDS REMOVED FOR PURPOSES OF CLARITY. NEVER OPERATE THIS IMPLEMENT WITHOUT ALL SHIELDS IN PLACE.

BUSH HOG®

Trail Series Utility Vehicles

TABLE OF CONTENTS

SECTION

PAGE

Retail Customer’s Responsibility

2

Warranty

 

3

Dealer Preparation Check List

 

5

Safety Alert Symbols

 

6

Safety Precautions

 

7

I INTRODUCTION AND DESCRIPTION

20

Introduction

 

20

Description

 

20

Specifications

 

27

II OPERATION

 

29

General Safety

 

29

Pre-Operation Checklist

 

29

Vehicle Break-In Period

 

29

Starting The Engine

 

30

Driving The Vehicle

 

30

Braking

 

31

Stopping The Engine

 

31

Using The Cargo Box

 

32

Load Distribution

 

33

Driving Safely

 

34

Driving On Slippery Surfaces

 

34

Driving Uphill

 

35

Sidehilling

 

36

Driving Downhill

 

36

Driving Through Water

 

36

Driving Over Obstacles

 

38

Driving In Reverse

 

39

Parking On An Incline

 

40

Hauling Cargo

 

41

Emptying The Cargo Box

 

42

Towing Loads

 

43

Parking The Vehicle

 

43

4-Wheel Drive

 

44

Disengaging 4-Wheel Drive

 

44

Noise Emission Control System

45

Spark Arrestor

 

46

SECTION

PAGE

III MAINTENANCE

 

46

Periodic Maintenance Schedule

47

Lubrication Recommendations

 

50

Engine Oil

 

51

Engine Oil Filter Change

 

52

Transaxle

 

52

Front Differential

 

53

Right Angle Drive

 

54

Constantly Variable Transmission

55

Vehicle Immersion

 

56

Engine Air Filter

 

57

CVT Enclosure Air Filter

 

57

Fuel filter

 

58

Spark Plugs

 

58

Spark Arrestor

 

59

Throttle System

 

60

Brake Inspection

 

61

Parking Brake Adjustment

 

62

Steering Wheel Inspection

 

63

Seat Belts

 

63

Tires

 

64

Wheel Lug Nuts

 

64

Wheel Installation

 

65

Lights

 

65

Cleaning Your Vehicle

 

66

Storage

 

67

Removal From Storage

 

67

Battery

 

67

Replenishing Battery Fluid

 

68

Battery Removal

 

68

Battery Installation

 

69

Battery Storage

 

69

IV ASSEMBLY

 

70

Attaching Occupant Protection

 

 

Structure

 

70

Optional Equipment

 

70

Items To Check

 

70

Seat Belt Installation

 

71

Rubber Bumper Pad Adjustment

72

Troubleshooting CheckList

 

73

Safety Decals

 

74

Torque Specifications

 

76

1

RETAIL CUSTOMER’S

RESPONSIBILITY

UNDER THE

BUSH HOG WARRANTY

It is the Retail Customer and/or Operator’s responsibility to read the Operator’s Manual, to operate, lubricate, maintain and store the product in accordance with all instructions and safety procedures. Failure of the operator to read the Operator’s Manual is a misuse of this equipment.

It is the Retail Customer and/or Operator’s responsibility to inspect the product and to have any part(s) repaired or replaced when continued operation would cause damage or excessive wear to other parts or cause a safety hazard.

It is the Retail Customer’s responsibility to deliver the product to the authorized Bush Hog Dealer, from whom he purchased it, for service or replacement of defective parts which are covered by warranty. Repairs to be submitted for warranty consideration must be made within thirty (30) days of failure.

It is the Retail Customer’s responsibility for any cost incurred by the Dealer for traveling to or hauling of the product for the purpose of performing a warranty obligation or inspection.

2

LIMITED WARRANTY

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OOOOOOOOOOO

Bush Hog warrants to the original purchaser of any new Bush Hog equipment, purchased from an authorized Bush Hog dealer, that the equipment be free from defects in material and workmanship for a period of one (1) year for non-commercial, state, and municipalities’ use and ninety (90) days for commercial use from date of retail sale. The obligation of Bush Hog to the purchaser under this warranty is limited to the repair or replacement of defective parts.

Replacement or repair parts installed in the equipment covered by this limited warranty are warranted for ninety (90) days from the date of purchase of such part or to the expiration of the applicable new equipment warranty period, whichever occurs later. Warranted parts shall be provided at no cost to the user at an authorized Bush Hog dealer during regular working hours. Bush Hog reserves the right to inspect any equipment or parts which are claimed to have been defective in material or workmanship.

DISCLAIMER OF IMPLIED WARRANTIES & CON-

SEQUENTIAL DAMAGES

Bush Hog’s obligation under this limited warranty, to the extent allowed by law, is in lieu of all warranties, implied or expressed, INCLUDING IMPLIED WARRANTIES OF MER-

CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE and any liability for incidental and consequential damages with respect to the sale or use of the items warranted. Such incidental and consequential damages shall include but not be limited to: transportation charges other than normal freight charges; cost of installation other than cost approved by Bush Hog; duty; taxes; charges for normal service or adjustment; loss of crops or any other loss of income; rental of substitute equipment, expenses due to loss, damage, detention or delay in the delivery of equipment or parts resulting from acts beyond the control of Bush Hog.

CONTINUED

3

CONTINUED

THIS LIMITED WARRANTY SHALL NOT APPLY:

1.To vendor items which carry their own warranties, such as engines, tires, and tubes.

2.If the vehicle has been subjected to misapplication, abuse, misuse, negligence, fire or other accident.

3.If parts not made or supplied by Bush Hog have been used in connection with the vehicle, if, in the sole judgement of Bush Hog such use affects its performance, stability or reliability.

4.If the vehicle has been altered or repaired outside of an authorized Bush Hog dealership in a manner which, in the sole judgement of Bush Hog, affects its performance, stability or reliability.

5.To normal maintenance service and normal replacement items such as gearbox lubricant, or to normal deterioration of such things as belts and exterior finish due to use or exposure.

6.To expendable or wear items such as teeth, chains, sprockets, belts, springs and any other items that in the company’s sole judgement is a wear item.

NO EMPLOYEE OR REPRESENTATIVE OF BUSH HOG IS AUTHORIZED TO CHANGE THIS LIMITED WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY UNLESS SUCH CHANGE IS MADE IN WRITING AND SIGNED BY BUSH HOG’S SERVICE MANAGER, POST OFFICE BOX 1039, SELMA, ALABAMA 36702-1039.

OOOOOOOOOOOOOOOOOOOO

Record the model number, serial number and date purchased. This information will be helpful to your dealer if parts or service are required.

MODEL NUMBER

SERIAL NUMBER

DATE OF RETAIL SALE

4

DEALER PREPARATION CHECK LIST

UTILITY VEHICLE

BEFORE DELIVERING MACHINE — The following check list should be completed. Use the Operator’s

Manual as a guide.

r1. Engine has been serviced.

r2. Battery fluid level is checked.

r3. All warning lights checked for operation.(Engine oil, park brake, & neutral light)

r4. Assembly completed

r5. All fittings lubricated.

r6. All shields in place and in good condition.

r7. All fasteners torqued to specifications given in Torque Chart.

r8. All decals in place and readable. (See decal page.)

r9. Overall condition good (i.e. paint, welds)

r10.Parking brake checked and adjusted, if necessary.

r11. Steering checked and adjusted, if necessary.

r12.Check tire pressure.

r13.Operators manual has been delivered to owner and he has been instructed on the safe and proper use of the utility vehicle.

Dealer’s Signature

Purchaser’s Signature

THIS CHECKLIST TO REMAIN IN

OWNER’S MANUAL

It is the responsibility of the dealer to complete the procedures listed above before delivery of this vehicle to the customer.

5

Safety Alert Symbol

This Safety Alert Symbol means:

“ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!”

This symbol is used to call attention to safety precautions that should be followed by the operator to avoid accidents. When you see this symbol, carefully read the message that follows and heed its advice. Failure to comply with safety precautions could result in death or serious bodily injury.

Safety Signs Signal Words

The signal words DANGER, WARNING, AND CAUTION are used on the equipment safety signs. These words are intended to alert the viewer to the existence and the degree of hazard seriousness.

This signal word indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury.

This signal word indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury

This signal word indicates a potentially hazardous situation exist which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

6

IMPORTANT SAFETY PRECAUTIONS

This symbol is used to call attention to safety precautions that should be followed by the operator to avoid accidents. When you see this symbol, carefully read the message that follows and heed its advice. Failure to comply with safety precautions could result in serious bodily injury.

In addition to the design and configuration of equipment, hazard control and accident prevention are dependent upon the awareness, concern, prudence and proper training of personnel in the operation, transport, maintenance and storage of equipment. Lack of attention to safety can result in accident, personal injury, reduction of efficiency and worst of all—loss of life. Watch for safety hazards and correct deficiencies promptly. Use the following safety precautions as a general guide to safe operations when using this machine. Additional safety precautions are used throughout this manual for specific operating and maintenance procedures. Read this manual and review the safety precautions often until you know the limitations.

IMPORTANT OPERATOR SAFETY PRACTICES:

BEFORE OFF-ROAD UTILITY VEHICLE USE:

Read, understand and follow all the Operator’s Manual instructions.

Explain all instructions to operators who cannot read or understand the instructions.

Only allow vehicles to be operated by trained persons.

Allow no persons younger than 16 years old to operate.

Do not operate under the influence of alcohol or drugs.

Inspect vehicle for safe operating condition.

DURING OFF-ROAD UTILITY USE:

Fasten seat belt.

Use vehicle only for off-road operations.

Avoid sudden starts, stops, turns, or direction reversals to prevent load shifts, endanger passengers, or losing vehicle control.

Use speeds to allow vehicle to stop safely and be under control in all travel conditions.

Reduce speeds for wet, slippery, loose surfaces, steep grades and unfamiliar terrain.

Never operate vehicle on hills steeper than 15 degree slope.

Use proper loading and securing material for loads in cargo box and trailers.

Use proper towing practices.

7

Do not tow heavy loads on hills steeper than 5 degree slope.

Avoid driving through water exceeding floorboard height.

Before leaving, servicing, or adjusting the vehicle, stop engine, set parking brake, remove key, wait for engine and all moving parts to stop.

AVOID VEHICLE RUNOVER AND RIDER OR OPERATOR FALL OFF:

Only allow persons to ride in seats equipped with seat belts.

All persons fasten seat belts when riding.

Allow no riders in cargo box or on vehicle.

Keep all persons clear of operating vehicle.

Keep alert for stumps, holes, ruts, wet, slippery and uneven terrain.

Before backing up or turning, look behind and around vehicle for persons.

AVOID VEHICLE UPSETS AND ROLLOVER:

Avoid sudden starts, stops, or turns.

Use very slow speed when turning.

Always use brakes when going down slope.

Reduce speed and load on rough or hilly terrain.

Avoid overloading vehicle and shifting loads.

Keep alert for stumps, holes, ruts, wet, slippery and uneven terrain.

AVOID FUEL FIRE AND EXPLOSIONS:

Stop engine and allow to cool before refueling.

Do not smoke while refueling.

Never fill fuel tank indoors.

Clean up spilled fuel before starting engine.

Only use approved Underwriter’s Laboratory (U.L.) or American Society for Testing & Material (ASTM) non-metal portable fuel containers.

Remove fuel containers from vehicle beds or trunks and placing on the ground before filling.

Keep nozzle in contact with fuel container opening while filling.

Remove utility vehicle and equipment from truck beds or trailers and re-fuel on the ground.

CARGO BOX LOAD OPERATIONS:

LOADING:

Do not exceed vehicle’s Gross Vehicle Weight (GVW) rating. This includes vehicle operating weight, material load (cargo box load), personnel weight, options weight, accessories weight, and attachments weight (towing loads).

Do not exceed cargo box load rating.

Confine loads to cargo box physical dimensions.

Spread load evenly and securely anchor all loads in cargo box. Shifting and uneven loads will effect vehicle control and stability.

Avoid sudden starts, stops, and turns which could cause load shifts.

8

Reduce loads and speed when operating over rough or hilly terrain.

Use low vehicle speeds when operating with cargo box loads. Heavy loads will affect steering, braking, stability, and overall handling of the vehicle. Limit loads to those that can be safely controlled.

Allow for increased braking distance.

UNLOADING:

Stop vehicle on level ground, set parking brake before raising cargo box.

Avoid unloading or dumping on slopes, hills or inclines.

MANUALLY RAISED CARGO BOX UNITS:

Unload manual lift cargo box before raising cargo box by hand.

Securely lock manual support lift rod before working beneath raised cargo box.

Fully lower cargo box and securely re-latch lift rod before operating vehicle.

OPTIONAL ELECTRIC POWER LIFT CARGO BOX UNITS:

Operate switch while seated in operator seat.

Keep body parts away from cargo box and all bystanders away from vehicle.

Do not dump or unload vehicle parked on an incline, slopes, hills, or with rear wheels at an edge of a drop-off. The cargo box weight may shift and cause the vehicle to tip or rollover.

Fully lower cargo box before operating vehicle.

TOWING OPERATIONS:

Do not exceed vehicle’s Gross Vehicle Weight (GVW) rating. This includes vehicle operating weight, material load (cargo box load), personnel weight, options weight, accessories weight, and attachment weight (towing loads).

Always use approved rear hitch point.

Do not tow a load weight (trailer weight and cargo weight) that exceeds towing weight rating.

Do not exceed the tongue weight rating.

Never exceed 16 km/h (10 mph)when towing loads. Use slow speeds to maintain control of vehicle and towing load.

Allow for increased braking distance from towed load weight.

Do not tow heavy loads on slopes greater than 5 degree incline.

Heavy towed equipment may jackknife and cause utility vehicle to overturn when going downhill or turning.

9

CONTROLLING PARTY INFORMATION

(Reference: SAE J2258-DEC 2003-Light-Utility Vehicle, APPENDIX B, PART II - For the Controlling Party.) The Controlling Party is the person(s) or organization(s) responsible for the operation and maintenance of a vehicle.

MAINTENANCE AND OPERATIONS:

The Controlling Party should perform the following:

Properly use and maintain utility vehicle to avoid serious injury or death.

Follow additional specific safety practices as may reasonably be required for safe operations.

Perform periodic safety survey of vehicle operating areas.

Identify operating area hazards.

Identify areas where vehicle should not be operated.

SAFETY SURVEY:

The Controlling Party should conduct an operating area safety survey to identify possible hazards:

Steep Grade Hazards:

Restrict vehicle operations to designated pathways in steep grade areas.

Erect steep grade warning signs.

State: “Warning, steep grade, descend slowly” on signs.

Loose Terrain Hazards:

Keep vehicle traction, steering, stability and braking under control by avoiding loose terrain areas.

Wet area Hazards:

Keep vehicle traction, steering, stability and braking under control by avoiding wet areas.

Sharp Turns, Blind Corners, Bridge Approaches Hazards:

Erect warning signs,

State precautions to avoid the hazards on signs.

Pedestrian and Utility Vehicle Traffic Hazards:

Erect warning signs.

State warnings of traffic conditions and use caution on signs.

Reroute vehicle or pedestrian traffic to avoid interference.

10

OPERATOR TRAINING:

The controlling Party should develop, conduct an operator-training program and permit only properly trained persons to operate the utility vehicle.

OPERATOR-TRAINING PROGRAM:

The program should include, as a minimum, the following:

Review:

Vehicle operator’s manual instructions.

Vehicle’s safety decals.

Safe loading practices.

Proper use of vehicle’s controls and consequences of improper use.

Controlling Party’s safety practices developed from operating area safety survey.

Review conditions that affect vehicle’s stability and may cause its instability:

Operator’s failure to follow safety practices.

Operator’s exercise of judgement.

Operating area slopes, grades, and terrain conditions.

Vehicle’s speed, turning, braking, loadings, towing and dynamic forces.

Attachments and improper loading.

The Controlling Party should train and evaluate vehicle operator’s competency to comply with these practices.

MAINTENANCE AND INSPECTION PROCEDURES:

Review and perform vehicle manufacturer’s recommended procedures.

Use a scheduled preventive maintenance, lubrication, and inspection program.

Use trained and authorized personnel to maintain, repair, adjust, and inspect vehicles

Conduct recommended procedures in a properly ventilated work area.

Use original vehicle manufacturer’s replacement parts.

Use recommended procedures for returning vehicle to service.

Use recommended procedures for returning vehicle to service.

Conduct vehicle performance checks in an area free of vehicular and pedestrian traffic.

Use vehicle manufacturer’s engine shut down and vehicle immobilization recommended procedures before undertaking maintenance or repairs.

Chock wheels and block chassis before working underneath vehicle.

Do not use open flames to check level or leakage of fuel, battery electrolyte, or coolant.

Equip work area with fire extinguisher equipment.

Follow vehicle manufacturer’s recommended inspection and maintenance procedures.

11

FUEL SYSTEM:

Check for leaks and condition of parts.

Before disconnection fuel system parts and making repairs:

Allow engine to run until fuel system is depleted.

Allow engine to stop.

Allow engine to cool.

Disconnect battery.

CONDUCT PERIODIC INSPECTION ON THE FOLLOWING SYSTEMS:

Brake system.

Steering system.

Electrical system.

Transmission system.

Exhaust system.

Warning system.

Switches and devices.

Follow vehicle manufacturer’s recommended inspection maintenance procedures.

Keep vehicle clean to reduce fire hazards and allow ease of vehicle inspection.

VEHICLE INSTRUCTION AND SAFETY DECALS:

Keep clean and legible.

Replace illegible decals.

VEHICLE MODIFICATION AND ADDITIONS:

Contact vehicle manufacturer before making modifications that affect vehicle capacity and safe vehicle operations.

12

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards while climbing a hill

WHAT CAN HAPPEN

Vehicle overturn

HOW TO AVOID THE HAZARD

Maintain a steady speed when climbing a hill

If you lose forward speed:

Apply the brakes.

Lock the parking brake after fully stopped.

If you begin rolling backwards:

Never apply engine power.

Apply the brake gradually.

When fully stopped, lock parking brake.

In the event of an accident, have a qualified service dealer check the complete vehicle for possible damage, including (but not limited to) brakes, throttle and steering.

13

WARNING

POTENTIAL HAZARD

Operating this vehicle on paved surfaces

WHAT CAN HAPPEN

Loss of control

HOW TO AVOID THE HAZARD

This vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control.

Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel slowly and do not make sudden turns or stops.

WARNING

POTENTIAL HAZARD

Operating this vehicle without proper instruction

WHAT CAN HAPPEN

Loss of control, accident

HOW TO AVOID THE HAZARD

The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain.

All opertors must read and understand the Operator’s manual and all warning and instruction labels before operating the vehicle.

14

WARNING

POTENTIAL HAZARD

Operating this vehicle on public streets, roads or highways

WHAT CAN HAPPEN

Collision with another vehicle

HOW TO AVOID THE HAZARD

Never operate this vehicle on any public street, road or highway, including dirt or gravel.

In many states it’s illegal to operate vehicles of this type on public streets, roads and highways.

WARNING

POTENTIAL HAZARD

Operating this vehicle after consuming alcohol or drugs

WHAT CAN HAPPEN

Could seriously affect your judgment.

Could cause you to react more slowly.

Could affect your balance and perception.

Could result in an accident.

HOW TO AVOID THE HAZARD

Driving this vehicle requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it’s prohibited by law to drive while intoxicated or under the influence of drugs.

15

WARNING

POTENTIAL HAZARD

Operating this vehicle at excessive speeds

WHAT CAN HAPPEN

Loss of control, accident

HOW TO AVOID THE HAZARD

Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience.

WARNING

POTENTIAL HAZARD

Attempting jumps and other stunts

WHAT CAN HAPPEN

Loss of control, accident and/or vehicle overturn

HOW TO AVOID THE HAZARD

Never attempt jumps and other stunts. Avoid exhibition driving.

WARNING

POTENTIAL HAZARD

Operating on frozen bodies of water.

WHAT CAN HAPPEN

Severe injury or death can result if the vehicle and/or the operator fall through the ice.

HOW TO AVOID THE HAZARD

Never operate the vehicle on a frozen body of water.

16

WARNING

POTENTIAL HAZARD

Failure to inspect the vehicle before operating

Failure to properly maintain the vehicle

WHAT CAN HAPPEN

Accident, equipment damage

HOW TO AVOID THE HAZARD

Always inspect your vehicle before each use to make sure it’s in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in the Operator’s Manual.

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating this vehicle on unfamiliar terrain

WHAT CAN HAPPEN

Loss of control, vehicle overturn

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution when operating on unfamiliar terrain.

always be alert to changing terrain conditions when operating the vehicle. May come upon hidden conditions when operating the vehicle. You may come upon hidden rocks, bumps, or holes suddenly, without enough time to react.

17

WARNING

POTENTIAL HAZARD

Failure to follow the minimum age recommendations for this vehicle.

WHAT CAN HAPPEN

Serious injury or death (the child or others)

HOW TO AVOID THE HAZARD

Only persons with a valid driver’s license should operate this vehicle.

Even though a child may be within the age group for which some vehicles are recommended, he or she may not have the skills, abilities, or judgement needed to operate the vehicle safely and may be involved in a serious accident.

WARNING

POTENTIAL HAZARD

Operating this vehicle with improper tires or with improper or uneven tire pressure

WHAT CAN HAPPEN

Loss of control, accident and/or overturn

HOW TO AVOID THE HAZARD

Always use the size and type of tires specified in the Operator’s Manual for this vehicle.

always maintain proper tire pressure as described on the decal and in the Operator’s Manual.

18

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

WARNING

After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.

WARNING

Always keep combustible materials away from the exhaust system. Exposure to the hot components could result in a fire.

WARNING

Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline.

Always stop the engine when refueling.

Always refuel outdoors or in a well ventilated area.

Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored.

Do not over fill the tank. Do not fill the tank neck.

If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

19

SECTION I

INTRODUCTION AND DESCRIPTION

INTRODUCTION

We are pleased to have you as a Bush Hog customer. Your Bush Hog Trail Series utility vehicle has been carefully designed to give maximum service with minimum down time. This manual is provided to give you the necessary operating and maintenance instructions for keeping your vehicle in top operating condition. Please read this manual thoroughly. Understand what each control is for and how to use it. Observe all safety precautions decaled on the machine and noted throughout the manual for safe operation of the vehicle. If any assistance or additional information is needed, contact your authorized Bush Hog dealer.

DESCRIPTION (Trail Hunter shown on next page)

1.

Occupant Protection

17.Ignition Key

 

Structure (O.P.S.)

18.Fuel Gauge

2.

Hand hold

19.Hour Meter

3.

Gear Selector

20.Choke Knob

4.

Steering wheel

21.Power Bed Lift Switch

5.

Seat

(Optional)

6.

Seat Belt

22.Neutral Light

7.

Fuel Tank Cap

23.4-Wheel Drive Switch

8.

Battery (Under Hood)

and Light

9.

Headlights

24.Winch Switch (Optional)

10.Front Bumper/

25.Driving Light Switch

 

Brush Guard

26.Cargo Bed Light Switch

11.Power Winch (Optional)

27. Parking Brake Light

12.Cargo Light (Optional)

28. Oil Pressure Light

13.Cargo Box

29. DC Power Outlet

14.Hitch Receiver

30. Parking Brake

15.Winch Wiring Pigtail

31. Brake Pedal

16.Cup Holder

32. Throttle Pedal

17.Ignition Key

33. Tailgate Latch

18.Fuel Gauge

34. Cargo Box Release Handle

20

 

 

 

1

 

 

 

NOTICE!

 

 

 

 

 

 

 

 

 

LOCATIONS OF CON-

 

2

6

 

 

TROLS AND FEATURES

 

5

 

 

 

 

MAY VARY SLIGHTLY

 

 

 

 

 

 

 

 

 

ON DIFFERENT MODELS.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

10

7

11

3

4

18

19

17

30

31

32

20

25

26

21

9

27 28 22 23

29

16

24

12

13

33

34

 

14

15

21

 

 

 

 

Bush Hog TH440, TH4400, TH420, TH4200 User Manual

UNDER HOOD AREA (WITH CARGO TRAY REMOVED)

Battery, Brake Fluid Reservoir, Fuses and Relays, Grease Fitting

UNDER SEAT AREA

Engine Air

Engine Oil

Engine Oil

CVT Enclosure

Intake

Filler Cap

Dipstick

Air Cleaner

22

RIGHT FRONT WHEEL REMOVED

Disc Brake Assembly Front Strut Assembly Winch (Optional)

CARGO BED RAISED (SHOWING ENGINE COMPARTMENT)

Transfer Gearbox Trailing Arm Pivot Grease Fitting

Engine Air

Cleaner Housing

with

Grease Fitting Evacuator Valve

For Pillow Block

Hidden From View

23

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