Page 2 - YOUR AUTHORIZED BUSH HOG DEALER; NEVER; THIS IMPLEMENT WITHOUT ALL SHIELDS IN
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 yoursatisfaction with its performance and its service life. We urge a care-ful study of this manual to provide you with a thorough understandingof yo...
Page 3 - BUSH HOG; Trail Series Utility Vehicles; TABLE OF CONTENTS; SECTION
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...
Page 5 - LIMITED WARRANTY; OOOOOOOOOOOOOOOOOOOO; SEQUENTIAL DAMAGES; INCLUDING IMPLIED WARRANTIES OF MER-
LIMITED WARRANTY OOOOOOOOOOOOOOOOOOOO OOOOOOOOOOO Bush Hog warrants to the original purchaser of any new Bush Hog equipment, purchased from an authorized Bush Hog dealer, thatthe equipment be free from defects in material and workmanship fora period of one (1) year for non-commercial, state, and mun...
Page 6 - CONTINUED; THIS LIMITED WARRANTY SHALL NOT APPLY:; NO EMPLOYEE OR REPRESENTATIVE OF BUSH HOG IS; MODEL NUMBER
CONTINUED THIS LIMITED WARRANTY SHALL NOT APPLY: 1. To vendor items which carry their own warranties, such asengines, 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 u...
Page 7 - DEALER PREPARATION CHECK LIST; UTILITY VEHICLE; Dealer’s Signature
DEALER PREPARATION CHECK LIST UTILITY VEHICLE BEFORE DELIVERING MACHINE — The followingcheck list should be completed. Use the Operator’sManual 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, &...
Page 8 - Signal Words; The signal words
Safety Alert Symbol Safety Signs Signal Words The signal words DANGER, WARNING, AND CAUTION are used on the equipment safety signs. These words are intended to alert theviewer to the existence and the degree of hazard seriousness. This signal word indicates a poten-tially hazardous situation which, ...
Page 9 - IMPORTANT SAFETY PRECAUTIONS; IMPORTANT OPERATOR SAFETY PRACTICES:
IMPORTANT SAFETY PRECAUTIONS 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 personnel in the operation,transport, maintenance and storage of equipment. Lack of attentionto saf...
Page 12 - Perform periodic safety survey of vehicle operating areas.
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 Par...
Page 13 - MAINTENANCE AND INSPECTION PROCEDURES:
OPERATOR TRAINING: The controlling Party should develop, conduct an operator-trainingprogram 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....
Page 14 - Check for leaks and condition of parts.; CONDUCT PERIODIC INSPECTION ON THE FOLLOWING SYSTEMS:; • Keep vehicle clean to reduce fire hazards and allow ease of; VEHICLE INSTRUCTION AND SAFETY DECALS:; • Contact vehicle manufacturer before making modifications
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 sys...
Page 15 - WARNING
WARNING 13 POTENTIAL HAZARDStalling, rolling backwards while climbing a hill WHAT CAN HAPPENVehicle overturn HOW TO AVOID THE HAZARDMaintain 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...
Page 22 - INTRODUCTION; Occupant Protection
SECTION I INTRODUCTION AND DESCRIPTION INTRODUCTION We are pleased to have you as a Bush Hog customer. Your Bush HogTrail Series utility vehicle has been carefully designed to give maxi-mum service with minimum down time. This manual is provided to giveyou the necessary operating and maintenance ins...
Page 25 - RIGHT FRONT WHEEL REMOVED
RIGHT FRONT WHEEL REMOVED Disc Brake Assembly Front Strut Assembly Winch (Optional) CARGO BED RAISED ( SHOWING ENGINE COMPARTMENT) Engine Air Cleaner Housing with Evacuator Valve Transfer Gearbox Trailing Arm Pivot Grease Fitting Grease Fitting For Pillow Block Hidden From View 23
Page 26 - FEATURES; DC Power Outlet; To unfasten, press the red button on the side of the buckle.
FEATURES DC Power Outlet The 12 volt accessory port is provided to power auxiliary lights orother accessories. Indicator Lights Lights on the dash indicate when the transmission is in neutral.Four wheel drive models have a light that indicates when 4- wheeldrive is engaged. An oil pressure light ind...
Page 27 - Flip the rocker switch up to turn on and down to turn off.
CONTROLSSwitches Ignition Switch The ignition switch is a three position, key-operated switch. The keycan be removed from the switch when it is in the OFF position. OFF Engine off. All electrical circuits are offexcept ACC. 12V. ON Electrical circuits are on. Electrical equipmentcan be used START El...
Page 28 - CAUTION; Brake Pedal; Low gear is the primary driving range on this vehicle. High is
CAUTION DO NOT ATTEMPT TO SHIFT THE TRANSMISSIONWHILE THE VEHICLE IS MOVING OR DAMAGE TOTHE TRANSMISSION COULD RESULT. ALWAYS PLACE THE TRANSMISSION IN GEAR WITH THEPARKING BRAKE APPLIED AND TURN THE VEHICLE OFFWHENEVER THE VEHICLE IS LEFT UNATTENDED. 26 Brake Pedal The brake pedal is the left pedal...
Page 29 - SPECIFICATIONS; TRAIL HUNTER
SPECIFICATIONS TRAIL HUNTER TRAIL HAND ENGINE TH420 TH440 TH4200 TH4400 Type 4-cycle, OHV V-twin, air-cooled gas Make Briggs & Stratton Honda Honda Honda HP / (cc) 16 hp (480cc) 20 hp (614CC) 24 hp (670cc) Lubrication Full Pressure with automotive style spin-on canister Air Cleaner Remote, 2-sta...
Page 30 - DIMENSIONS
SPECIFICATIONS TRAIL HUNTER TRAIL HAND DRIVE TRAIN TH420 TH440 TH4200 TH4400 Transmission Continuously Variable Transmission (CVT) CVT Protection Shielded (TH420 only), Fully enclosed pressurized with filtered air intake (TH440, TH4200 and TH4400) Final Drive Bush Hog Dual-Range transaxle with High,...
Page 31 - GENERAL SAFETY; Fill the fuel tank with unleaded regular gasolIne.; Do not mix oil with gasoline.; Check battery fluid level.; Trail Hunter models require 18 psi in all four; Clean the air intake screen on the engine if necessary.; VEHICLE BREAK-IN PERIOD
SECTION II OPERATION GENERAL SAFETY Only qualified people familiar with this operator’s manual shouldoperate this machine. PRE-OPERATION CHECKLIST 1. Fill the fuel tank with unleaded regular gasolIne. 2. Make sure dirt and foreign matter are kept out of fuel tank. Usea clean funnel and fuel can. 3. ...
Page 35 - Load Distribution; Drive slowly with the transmission in low range.
Load Distribution 1. Always load the cargo box placing the load as far forward as possible. 2. Always operate the vehicle with extreme care whenever haulingor towing loads. 3. Drive slowly with the transmission in low range. 4. Insure that the cargo box latch (on manual lift models) is secure-ly lat...
Page 36 - Driving Safely; Driving Procedures; Sit in the driver’s seat with the seat belt fastened.; Driving on Slippery Surfaces; Slow down when entering slippery areas.
Driving Safely Driving Procedures 1. Sit in the driver’s seat with the seat belt fastened. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Keeping both hands on t...
Page 37 - Driving Uphill; Whenever traveling uphill, follow these precautions:
Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the floor. 4. Proceed at a steady rate of speed and throttle opening. WARNING CLIMBING HILLS IMPROPERLY CAN CAUSE LOSS OFCONTROL OR VEHICLE O...
Page 38 - Whenever descending a hill, follow these precautions:; Driving Through Water
Sidehilling Driving Downhill Whenever descending a hill, follow these precautions: 1. Proceed directly downhill. 2. Slow down. 3. Apply the brakes slightly to aid in slowing. Driving Through Water Your Bush Hog utility vehicle can operate through water up to a max-imum recommended depth equal to the...
Page 39 - DO NOT
1. Always determine water depths and current before entering. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles. 4. After leaving water, always dry the brakes by applying light pres-sure to the lever repeatedly until braking action is normal...
Page 40 - Driving Over Obstacles
Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on.Watch for hazards such as logs, rocks and low hanging branches. WARNING SEVERE INJURY OR DEATH CAN RESULT IF YOURVEHICLE SUDDENLY COMES IN CONTACT WITH AHIDDEN OBSTACLE. NOT ALL OBSTACLES AREIMMEDIATELY VIS...
Page 41 - Driving In Reverse
Driving In Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6. Always inspect left and right fields of vision bef...
Page 42 - Parking On An Incline; Place the transmission in low gear to help prevent rolling.
Parking On An Incline Avoid parking on an incline if possible. If it is unavoidable, followthese precautions: 1. Place the transmission in low gear to help prevent rolling. 2. Set the parking brake. 3. Block the rear wheels on the downhill side. WARNING 40 A ROLLING VEHICLE CAN CAUSE PROPERTYDAMAGE ...
Page 43 - Hauling Cargo; Trail Hunter
Hauling Cargo Bush Hog utility vehicles have been designed to carry or tow specificcapacities. Always read and understand the load distribution warningslisted on the warning decals.Never exceed the following capacities. Model Max. Capacity Cargo Box Towing Capacity Trail Hunter 1,250 lbs. 750 lbs. 1...
Page 44 - Emptying The Cargo Box; Set the parking brake.
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 parked on an incline. 2. Set the parking brake. 3. Dismount the vehicle. 4. Release the tailgate latch. 5. Operate the bed lift switch to raise the box. 6. Using th...
Page 45 - Stop the vehicle on a level surface.
Towing Loads Belt Life Use low forward gear when hauling or towing heavy cargo to extendbelt life. Parking The Bush Hog Utility Vehicle 1. Stop the vehicle on a level surface. 2. When the engine has stopped, apply the parking brake. 3. Remove the ignition switch key to prevent unauthorized use. WARN...
Page 46 - Disengaging 4-Wheel Drive; Take the following steps to disengage the 4-wheel drive system:
WARNING 4-Wheel Drive Your Bush Hog Utility Vehicle is equipped with an exclusive 4-wheeldrive system that can be activated by a switch on the dash board.When the switch is off, the vehicle is in two-wheel drive at all times.When the switch is in 4-wheel drive, the front wheels will automati-cally e...
Page 47 - Shift into forward and drive.; NOISE EMISSION CONTROL SYSTEM; Lack of proper maintenance.
3. Stop completely. 4. Shift into forward and drive. If the hubs remain engaged after following these instructions, returnthe vehicle to your dealer for service. NOISE EMISSION CONTROL SYSTEM TAMPERING WITH NOISE CONTROL SYSTEEM IS PROHIBITED!U.S. Federal law prohibits the following acts or the caus...
Page 48 - CAUTON; USFS Approved Spark Arrestor; SECTION III; Periodic Maintenance Schedule; Perform these operations more often under severe use, such as; DO NOT TOUCH HOT EXHAUST SYSTEM COMPONENTS.
CAUTON USFS Approved Spark Arrestor The muffler on this vehicle was tested and approved in accordancewith the USFS Forest Service Stanedard 5100-1A. SECTION III MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in thesafest, most relia...
Page 49 - Item; COULD RESULT IN A COMPONENT
Periodic Maintenance Schedule WARNING Item Frequency Remarks Brake System Pre-operation Inspect Tires Pre-operation Inspect Wheels Pre-operation Inspect Frame nuts, bolts, Pre-operation Inspect fasteners Parking Brake Pre-operation Check lever adjustment daily; adjust Throttle Cable Pre-operation In...
Page 52 - MAINTENANCE AND LUBRICATION
MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours are based on 10 mph average. If service is due at 20hours, the equivalent odometer reading would be 200 miles. Performall services at whichever reading is reached first. Lubrication Chart Item Lube Method Frequency Engine Oil SAE 10...
Page 53 - Engine Oil; Oil Check
Engine Oil Maintain the engine oil at the proper level to ensure a properly func-tioning engine, and change the oil and oil filter every 100 hours orevery six months, whichever comes first. Dirt and metal particles col-lect in the oil, and oil loses its lubricative quality if used too long. Suggeste...
Page 55 - Front Differential
Front Differential The front differential oil should be changed every 100 hours If thevehicle is used in wet conditions, the oil should be checked more fre-quently. If the oil has a milky appearance, it should be changed assoon as possible. Failure to properly maintain this area can result inprematu...
Page 56 - Right Angle Drive; The right angle drive oil should be changed every 100 hours.; Oil Change; Remove the combination breather/fill plug from the top
Right Angle Drive The right angle drive oil should be changed every 100 hours. 1. With the vehicle on a level surface remove the fill plug and drain plug and drain oil into a drain pan. Discard the used oil properly. 2. Refill the drive box with SAE 80W-90 w/LSD additive, to the mid- dle of the sigh...
Page 57 - CVT Drying; Test for belt slippage. If the belt slips, repeat the process.
Constantly Variable Transmission (CVT) Do not modify any component of the CVT system. Doing so mayreduce its strength so that a failure may occur at a high speed. TheCVT system has been precision balanced. Any modification willcause the system to be out of balance, creating vibration and addi-tional...
Page 58 - Vehicle Immersion; Honda Engines
Vehicle Immersion If it is impossible to take your vehicle to a dealer before starting it, fol-low the steps outlined below. Honda Engines 1. Move the vehicle to dry ground, or at least to a water level below the floor. 2. Disconnect the fuel pump wires. 3. Remove the spark plugs. 4. Loosen the carb...
Page 59 - Engine Air Filter; Inspect the filter housing and clean out any debris or moisture.; CVT Enclosure Air Filter; Remover the two wing nuts and remove the housing cover.; Engine Air Filter Housing
Engine Air Filter We recommend that the air filter be cleaned every 25 hours andreplaced once a year. 1. The air filter is accessible from the right side of the vehicle, belowthe passenger seat. Loosen both fastening clips and remove the housing cover. There is an outer and inner filter that may the...
Page 60 - Spark Plug Removal and Replacement
Fuel Filter Your Bush Hog utility vehicle is equipped with an in-line fuel filter thatshould be replaced by your dealer after every 100 hours of opera-tion.Do not attempt to clean the fuel filter. Spark Plugs The spark plugs should be changed every 100 hours. The spark plugsare accessible from under...
Page 61 - Spark Arrestor; Loosen the set screw and remove the spark arrestor from the
Spark Arrestor Use the following procedure to periodically purge accumulated car-bon from the exhaust system. 1. Loosen the set screw and remove the spark arrestor from the muffler. Tap the arrestor on a hard surface to loosen carbon depositsand clean the inside of the tubing. 2. Place the engine in...
Page 62 - Throttle System; Throttle Freeplay; Shift the gear lever into neutral.
Throttle System Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or cablemisadjustment, it will cause a delay in throttle response, especially atlow engine speed. The throttle may also not open fully. If the throttlepedal has no freeplay, the throttle may be hard to co...
Page 63 - Brake Inspection; Inspection Procedure; Position the vehicle on level ground.; Brake Fluid
Brake Inspection The front and rear brakes are hydraulic disc type brakes and are acti-vated by the brake pedal. Routine inspections are recommended to keep the brake system ingood operating condition. Inspect the level of the brake fluid beforeeach operation. Change the brake fluid at the intervals...
Page 64 - Check the brake system for fluid leaks.; Parking Brake Adjustment; Trail Hand Parking Brake
Brake Inspection 5. Check the brake system for fluid leaks. 6. Check the brake pedal for excessive travel or a spongy feel. 7. Check the friction pads for wear, damage and looseness. 8. Inspect the brake disc spline and pad wear surface for excessive wear. 9. Change pads when worn to 3/64” (.1 cm), ...
Page 65 - Steering Wheel Inspection; Park the vehicle on level ground.; Seat Belts; Push the red button to make sure it releases freely.
Steering Wheel Inspection Check the steering wheel for freeplay and smooth operation as out-lined in the Maintenance Schedule. 1. Park the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8 - 1.0 in. (20 25 mm) of freeplay. 4. If there is excessive fre...
Page 66 - Tires; Tire Tread Depth; Wheel Lug Nuts; Loosen the lug nuts slightly.
Tires Tire Tread Depth Always replace tires when tread depth is worn to 1/8” (.3 cm) or less. Wheel Lug Nuts Inspect the lug nuts occasionally for tightness or missing nuts.Tighten to 35 ft. lbs. Wheel Removal 1. Stop the engine, place the transmission in gear and engage the parking brake. 2. Loosen...
Page 67 - Remove the wheel lug nuts. Remove the wheel.; Wheel Installation; Attach the lug nuts and finger tighten.; Lights
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 Installation 1. With the transmission in gear and the parking brake engaged, place the wheel in the correct position on the wheel hub. Be sure the valve stem is towar...
Page 68 - Perform all necessary repairs and thoroughly clean the vehicle.
Cleaning Your Vehicle Keeping your vehicle clean will not only improve its appearance, butit can also extend the life of various components. With a few precau-tions, your vehicle can be cleaned much like an automobile. The best and safest way to clean your vehicle is with a garden hoseand a pail of ...
Page 70 - Open the hood to access the battery.
Batteries produce explosive gases. Keep sparks, flame,cigarettes, etc. away. Ventilate when charging or usingin an enclosed space. Always shield eyes when workingnear batteries. KEEP OUT OF REACH OF CHILDREN. Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deterior...
Page 71 - Battery Installation; Set the battery in its holder.; Battery Storage
Tie-Down Bracket Negative (Black) Cable Positive (Red) Cable 69 Battery Installation 1. Set the battery in its holder. 2. Install the battery tie-down bracket and tighten the nuts. 3. First connect the positive (red) cable. 4. Second connect the negative (black) cable. 5. Verify that cables are prop...
Page 72 - Attaching Occupant Protection Structure To Vehicle; OPTIONAL EQUIPMENT; Check oil level in the engine (see engine manual); SECTION IV
Attaching Occupant Protection Structure To Vehicle (Refer to illustrations on following pages) Remove occupant protection structure from shipping bundle andarrange weldments around the vehicle. Loosen all fasteners beforebeginning assembly. Disconnect the front cross member from one front side frame...
Page 73 - Seat Belt Installation
TH420/TH440 Models TH4200/TH4400 Models Inner Seat Belt Inner Seat Belt Outside Seat Belt Outside Seat Belt 1/2” x 2-1/2” Bolt & Locknut 1/2” x 1-1/2” Bolt & Locknut 1/2” x 1” Bolt & Locknut 1/2” x 1” Bolt 7 Locknut Seat Belt Installation Install all seat belts so that the release button...
Page 74 - Rubber Bumper Pad Adjustment; OCCUPANT PROTECTION
Rubber Bumper Pad Adjustment The plastic bed of the Utility Vehicle is equipped with two rubberbumper pads located at the bottom front of the bed. These rubberbumpers are factory adjusted to prevent rattling when the bed is in thedown position. If adjustment should be needed at a later time proceeda...
Page 75 - TROUBLESHOOTING CHECK LIST; STARTER MOTOR WON’T TURN ENGINE:
TROUBLESHOOTING CHECK LIST STARTER MOTOR WON’T TURN ENGINE: • Gear shift lever not in neutral • Battery discharged • Battery leads do not make good contact with the battery terminals orground on frame • Fuse failure (check to find and correct the cause of the failure) ENGINE CRANKS, BUT WON’T START:...
Page 76 - SAFETY DECALS
SAFETY DECALS To promote safe operation, Bush Hog supplies safety decals on allproducts manufactured. Because damage can occur to safety decalseither through shipment, use or reconditioning, Bush Hog will, uponrequest, provide safety decals for any of our products in the field at nocharge. Contact y...
Page 78 - AMERICAN
TORQUE SPECIFICATIONS B O L T D IA M E T E R W R E N C H (I N .) “ B ” A N D S A E S A E S A E S IZ E ( IN .) “ A ” T H R E A D S IZ E G R A D E 2 G R A D E 5 G R A D E 8 7/16 1/4 - 2O UNC 6 (7) 8 (11) 12 (16) 7/16 1/4 - 28 UNF 6 (8) 10 (13) 14 (18) 1/2 5/16 - 18 UNC 11 (15) 17 (23) 25 (33) 1/2 5/16...
Page 79 - METRIC; TORQUE
WRENCH BOLT SIZE DIA. ASTM ASTM ASTM ASTM (mm) “A” (mm) “B” 4.6 8.8 9.8 10.9 8 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) 21.1 (29) 27 (37) 16 10 14.5 (20) 42 (57) 53 (72) 18 12 25 (34) 74 (100) 73 (99) 93 (126) 21 14 40 (54) 118 (160) 116 (157) 148 (201) 24 16 62 (8...
Page 82 - SSeellm
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