Bush Hog TH420 Operator's Manual

107$10.0050044549Trail SeriesOFF ROAD UTILITY VEHICLESOperator’s ManualMODELSTH420TH440TH4200TH4400ASSEMBLY • OPERATION • MAINTENANCEBUSH HOG®

• Do not tow heavy loads on hills steeper than 5 degree slope.• Avoid driving through water exceeding floorboard height.• Before leaving, servicing, o

• 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 aff

CONTROLLING PARTY INFORMATION(Reference: SAE J2258-DEC 2003-Light-Utility Vehicle, APPENDIX B,PART II - For the Controlling Party.) The Controlling Pa

OPERATOR TRAINING:The controlling Party should develop, conduct an operator-trainingprogram and permit only properly trained persons to operate the ut

FUEL SYSTEM:• Check for leaks and condition of parts.• Before disconnection fuel system parts and making repairs:• Allow engine to run until fuel syst

WARNING13POTENTIAL HAZARDStalling, rolling backwards while climbing a hillWHAT CAN HAPPENVehicle overturnHOW TO AVOID THE HAZARDMaintain a steady spee

WARNINGWARNINGPOTENTIAL HAZARDOperating this vehicle on paved surfacesWHAT CAN HAPPENLoss of controlHOW TO AVOID THE HAZARDThis vehicle’s tires are de

WARNINGWARNINGPOTENTIAL HAZARDOperating this vehicle on public streets, roads or highwaysWHAT CAN HAPPENCollision with another vehicleHOW TO AVOID THE

WARNINGWARNINGPOTENTIAL HAZARDOperating this vehicle at excessive speedsWHAT CAN HAPPENLoss of control, accidentHOW TO AVOID THE HAZARDAlways travel a

WARNINGWARNINGPOTENTIAL HAZARDFailure to inspect the vehicle before operatingFailure to properly maintain the vehicleWHAT CAN HAPPENAccident, equipmen

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 y

WARNINGWARNINGPOTENTIAL HAZARDFailure to follow the minimum age recommendations for thisvehicle.WHAT CAN HAPPENSerious injury or death (the child or o

19WARNINGLeaving the keys in the ignition can lead to unauthorized use ofthe vehicle resulting in serious injury or death. Always removethe ignition k

SECTION IINTRODUCTION AND DESCRIPTIONINTRODUCTIONWe are pleased to have you as a Bush Hog customer. Your Bush HogTrail Series utility vehicle has been

1810119265727 282422 2318171929433031321625262120341415331312NOTICE!LOCATIONS OF CON-TROLS AND FEATURESMAY VARY SLIGHTLYON DIFFERENT MODELS.21

UNDER HOOD AREA (WITH CARGO TRAY REMOVED)UNDER SEAT AREABattery, Brake Fluid Reservoir, Fuses and Relays, Grease FittingEngine AirIntakeEngine OilFill

RIGHT FRONT WHEEL REMOVEDDisc Brake Assembly Front Strut Assembly Winch (Optional)CARGO BED RAISED (SHOWING ENGINE COMPARTMENT)Engine AirCleaner Housi

FEATURESDC Power OutletThe 12 volt accessory port is provided to power auxiliary lights orother accessories.Indicator LightsLights on the dash indicat

CONTROLSSwitchesIgnition SwitchThe ignition switch is a three position, key-operated switch. The keycan be removed from the switch when it is in the O

CAUTIONDO NOT ATTEMPT TO SHIFT THE TRANSMISSIONWHILE THE VEHICLE IS MOVING OR DAMAGE TOTHE TRANSMISSION COULD RESULT.ALWAYS PLACE THE TRANSMISSION IN

SPECIFICATIONSTRAIL HUNTER TRAIL HANDENGINE TH420 TH440 TH4200 TH4400Type 4-cycle, OHV V-twin, air-cooled gasMake Briggs & Stratton Honda Honda Ho

BUSH HOG®Trail Series Utility VehiclesTABLE OF CONTENTSSECTION PAGERetail Customer’s Responsibility 2Warranty 3Dealer Preparation Check List 5Safety A

SPECIFICATIONSTRAIL HUNTER TRAIL HANDDRIVE TRAIN TH420 TH440 TH4200 TH4400Transmission Continuously Variable Transmission (CVT)CVT Protection Shielded

SECTION IIOPERATIONGENERAL SAFETYOnly qualified people familiar with this operator’s manual shouldoperate this machine.PRE-OPERATION CHECKLIST1. Fill

Starting The Engine1. Sit in the driver’s seat and fasten the seat belt.2. Lock the parking brake3. Place the transmission in neutral.4. Pull the chok

3. With both hands on the steering wheel, release pressure onbrake pedal and carefully apply pressure to throttle pedal. Vehicle spe

ALWAYS APPLY THE PARKING BRAKE BEFORE LEAVINGTHE VEHICLE. THE ENGINE/TRANSMISSION PROVIDESNO BRAKING EFFORT WHEN THE ENGINE IS NOT RUN-N

Load Distribution1. Always load the cargo box placing the load as far forward as possible.2. Always operate the vehicle with extreme care whe

Driving SafelyDriving Procedures1. Sit in the driver’s seat with the seat belt fastened.2. After starting the engine and allowing it to warm

Driving UphillWhenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (15° maximum).3. Keep both fee

SidehillingDriving DownhillWhenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Slow down.3. Apply the brakes slightly

1. Always determine water depths and current before entering.2. Choose a crossing where both banks have gradual inclines.3. Proceed slowly, avoiding r

RETAIL CUSTOMER’SRESPONSIBILITYUNDER THEBUSH HOG WARRANTYIt is the Retail Customer and/or Operator’s responsibilityto read the Operator’s Manual, to o

Driving Over ObstaclesBe alert! Look ahead and learn to read the terrain you’re traveling on.Watch for hazards such as logs, rocks and low hanging bra

Driving In ReverseFollow these guidelines when operating in reverse:1. Back slowly.2. Apply the brakes lightly for stopping.3. Avoid turning at sharp

Parking On An InclineAvoid parking on an incline if possible. If it is unavoidable, followthese precautions:1. Place the transmission in lo

Hauling CargoBush Hog utility vehicles have been designed to carry or tow specificcapacities. Always read and understand the load distribution warning

Emptying The Cargo Box (Electric Lift Models)1. Select a level site to empty the cargo box. Do not attempt to unload the vehicle while p

Towing LoadsBelt LifeUse low forward gear when hauling or towing heavy cargo to extendbelt life.Parking The Bush Hog Utility Vehicle1. Stop the vehicl

WARNING4-Wheel DriveYour Bush Hog Utility Vehicle is equipped with an exclusive 4-wheeldrive system that can be activated by a switch on the dash

3. Stop completely.4. Shift into forward and drive.If the hubs remain engaged after following these instructions, returnthe vehicle to your dealer for

CAUTONUSFS Approved Spark ArrestorThe muffler on this vehicle was tested and approved in accordancewith the USFS Forest Service Stanedard 5100-1A.SECT

Periodic Maintenance ScheduleWARNINGItem Frequency RemarksBrake System Pre-operation InspectTires Pre-operation InspectWheels Pre-operation InspectFra

LIMITED WARRANTYOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOOBush Hog warrants to the original purchaser of any new BushHog equipment, purchased from an authorized

Item Frequency RemarksEngine Cylinder 25 hrs. Re-torque required at first Head/Cylinderr service onlyBase Fastenerss Engine Oil-Level 25 hrs. Check le

Item Frequency Remarksn Fuel System 100 hrs. Check for leaks at fuel capH lines, fuel valve, filter, pumpand carburetor.Replace lines every two years.

MAINTENANCE AND LUBRICATIONLubrication RecommendationsNOTE: Hours are based on 10 mph average. If service is due at 20hours, the equivalent odometer r

Engine OilMaintain the engine oil at the proper level to ensure a properly func-tioning engine, and change the oil and oil filter every 100 hours ore

Engine Oil and Filter Change1. Run the engine two or three minutes until warm. Stop the engine.2. Clean the area around the drain plug at the

Front DifferentialThe front differential oil should be changed every 100 hours If thevehicle is used in wet conditions, the oil should be c

Right Angle DriveThe right angle drive oil should be changed every 100 hours.1. With the vehicle on a level surface remove the fill plug and drain pl

Constantly Variable Transmission (CVT)Do not modify any component of the CVT system. Doing so mayreduce its strength so that a failure may

Vehicle ImmersionIf it is impossible to take your vehicle to a dealer before starting it, fol-low the steps outlined below.Honda Engines1. Move the ve

Engine Air FilterWe recommend that the air filter be cleaned every 25 hours andreplaced once a year.1. The air filter is accessible from th

CONTINUEDTHIS LIMITED WARRANTY SHALL NOT APPLY:1. To vendor items which carry their own warranties, such asengines, tires, and tubes.2. If the vehicle

Fuel FilterYour Bush Hog utility vehicle is equipped with an in-line fuel filter thatshould be replaced by your dealer after every 100 hours of

Spark ArrestorUse the following procedure to periodically purge accumulated car-bon from the exhaust system.1. Loosen the set screw and remove t

Throttle SystemThrottle FreeplayIf the throttle pedal has excessive play due to cable stretch or cablemisadjustment, it will cause a delay in throttle

Brake InspectionThe front and rear brakes are hydraulic disc type brakes and are acti-vated by the brake pedal.Routine inspections are recommended to

Brake Inspection5. Check the brake system for fluid leaks.6. Check the brake pedal for excessive travel or a spongy feel.7. Check the friction pads fo

Steering Wheel InspectionCheck the steering wheel for freeplay and smooth operation as out-lined in the Maintenance Schedule.1. Park the vehicle on le

TiresTire Tread DepthAlways replace tires when tread depth is worn to 1/8” (.3 cm) or less.Wheel Lug NutsInspect the lug nuts occasionally for t

3. Elevate the side of the vehicle by placing a suitable stand under the frame.4. Remove the wheel lug nuts. Remove the wheel.Wheel Installation1. Wi

Cleaning Your VehicleKeeping your vehicle clean will not only improve its appearance, butit can also extend the life of various components. With a few

8. Tie a plastic bag over the exhaust pipe and air cleaner inlet to prevent moisture or small animals or insects from entering.9. Cover the veh

DEALER PREPARATION CHECK LISTUTILITY VEHICLEBEFORE DELIVERING MACHINE — The followingcheck list should be completed. Use the Operator’sManual as a gui

Batteries produce explosive gases. Keep sparks, flame,cigarettes, etc. away. Ventilate when charging or usingin an enclosed space. Always shield eyes

Tie-Down BracketNegative (Black) Cable Positive (Red) Cable69Battery Installation1. Set the battery in its holder.2. Install the ba

Attaching Occupant Protection Structure To Vehicle(Refer to illustrations on following pages)Remove occupant protection structure from shipping

TH420/TH440 ModelsTH4200/TH4400 ModelsInnerSeat BeltInnerSeat BeltOutsideSeat BeltOutsideSeat Belt1/2” x 2-1/2”Bolt & Locknut1/2” x 1-1/2”Bolt &am

Rubber Bumper Pad AdjustmentThe plastic bed of the Utility Vehicle is equipped with two rubberbumper pads located at the bottom front

TROUBLESHOOTING CHECK LISTSTARTER MOTOR WON’T TURN ENGINE:• Gear shift lever not in neutral• Battery discharged• Battery leads do not make good contac

SAFETY DECALSTo promote safe operation, Bush Hog supplies safety decals on allproducts manufactured. Because damage can occur to safety deca

No. 3No. 4No. 5No. 6No. 775

TORQUE SPECIFICATIONSB O L T D IA M E T E RW R E N C H (IN .) “ B ” A N D S A E S A E S A ES IZ E (IN .) “ A ” T H R E A D S IZ E G R A D E 2

WRENCH BOLTSIZE DIA. ASTM ASTM ASTM ASTM(mm) “A” (mm) “B” 4.6 8.8 9.8 10.98 5 1.8 (2.4) 5.1 (6.9) 6.5 (8.8)10 6 3 (4) 8.7 (12) 11.1 (15)13 8 7.3 (10)

Safety Alert SymbolSafety Signs Signal WordsThe signal words DANGER, WARNING, AND CAUTION are used onthe equipment safety signs. These words are inten

NOTES:

NOTES:

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IMPORTANT SAFETY PRECAUTIONSIn addition to the design and configuration of equipment, hazard con-trol and accident prevention are dependent upon the a