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®
BUSH HOG
Trail Series
OFF ROAD UTILITY VEHICLES
Operator’s Manual
MODELS
TH420
TH440
TH4200
TH4400
ASSEMBLY • OPERATION • MAINTENANCE
107 $10.00 50044549
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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 care- ful study of this manual to provide you with a thorough understanding of your new vehicle before operating, as well as suggestions for oper- ation and maintenance. If your manual should become lost or destroyed, Bush Hog will be glad to provide you with a new copy. Order
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® BUSH HOG Trail Series Utility Vehicles TABLE OF CONTENTS SECTION PAGE SECTION PAGE Retail Customer’s Responsibility 2 III MAINTENANCE 46 Periodic Maintenance Schedule 47 Warranty 3 Lubrication Recommendations 50 Dealer Preparation Check List 5 Engine Oil 51 Safety Alert Symbols 6 Engine Oil Filter Change 52 Safety Precautions 7 Transaxle 52 Front Differential 53 I INTRODUCTION AND DESCRIPTION 20 Right Angle Drive 54 Introduction 20 Constantly Variable Transmission 55 Description 20 Vehicle Imm
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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 opera- tor 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 operati
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LIMITED WARRANTY OOOOOOOOOOOOOOOOOOOO 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 defectiv
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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, mis- use, negligence, fire or other accident. 3. If parts not made or supplied by Bush Hog have been used in con- nection 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 a
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DEALER PREPARATION CHECK LIST UTILITY VEHICLE BEFORE DELIVERING MACHINE — The following check list should be completed. Use the Operator’s Manual as a guide. r 1. Engine has been serviced. r 2. Battery fluid level is checked. r 3. All warning lights checked for operation.(Engine oil, park brake, & neutral light) r 4. Assembly completed r 5. All fittings lubricated. r 6. All shields in place and in good condition. r 7. All fasteners torqued to specifications given in Torque Chart. r 8. All decals
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Safety Alert Symbol This Safety Alert Symbol means: “ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!” This symbol is used to call attention to safety pre- cautions 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 precau- tions could result in death or serious bodily injury. Safety Signs Signal Words The signal words DANGER, WARNING, AND CAUTION are used on the equipme
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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 sym- bol, 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 con- trol and accident prevention are dependent upon the awareness, concern, prudence and proper training of personn
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• 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
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• Reduce loads and speed when operating over rough or hilly ter- rain. • 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: • Unl
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CONTROLLING PARTY INFORMATION (Reference: SAE J2258-DEC 2003-Light-Utility Vehicle, APPENDIX B, PART II - For the Controlling Party.) The Controlling Party is the per- son(s) or organization(s) responsible for the operation and mainte- nance 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 o
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OPERATOR TRAINING: The controlling Party should develop, conduct an operator-training program and permit only properly trained persons to operate the util- ity 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
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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 main- tenance
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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,
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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 han- dling 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
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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 high- way, 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
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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 b
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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 Lo
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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 HAZ
