Bush Hog TH440 manual

107 $10.00 50044549 T rail Series O F F R O A D UT I L I T Y V E HI CL E S Operator’s Manual M OD E L S T H 4 2 0 T H 44 0 T H 4 2 0 0 T H 44 0 0 ASSEMBLY • OPERATION • MAINTENANCE BUSH HOG ®[...]

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 sug[...]

B U SH H OG ® Tr ai l Se ri es U ti li ty V eh ic les TA BL E OF CO NTE NT S SECTION PAGE Retail Customer’s Responsibility 2 Warranty 3 Dealer Preparation Check List 5 Safety Alert Symbols 6 Safety Precautions 7 I I N T R O D U C T I O N A N D D E S C R I P T I O N 2 0 Introduction 20 Description 20 Specifications 27 II OPERATION 29 General Safe[...]

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 eq[...]

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 comm[...]

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[...]

D E A L E R P R E P A R A T I O N C H E C K L I S T 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. A[...]

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 the viewer to the existence and the degree of hazard seriousness. This signal word indicates a poten- tially hazardous situation which, if not avoided, will result in death or serious [...]

I M P O R T A N T S A F E T Y P R E C A U T I O N S 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 attention to safety can result in accid[...]

• 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. A VO ID V E HI CL E R UN OV ER A ND R ID ER O R OP ER AT OR F A LL O FF : •[...]

• 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 [...]

CONTROLLING PARTY INFORMATION (R efe ren ce: S AE J2 258 -DE C 200 3-L igh t-U til ity V ehi cle , APP END IX B, PA RT II - F or th e Con tro lli ng P ar ty .) 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[...]

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 loa[...]

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. C ON D U C T P E R I O DI C I NS P EC T I O N O N TH E F O L L O W I N G SY S TE M S: • Brake sys[...]

WARNING 13 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 gradual[...]

WARNING 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 operati[...]

WARNING 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 [...]

WARNING 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. POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident and/or v[...]

WARNING 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 schedule[...]

WARNING 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, [...]

19 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, th[...]

SECTION I INTRODUCTION AND DESCRIPTION INTRODUCTION We are pl eased to h ave you as a Bu sh Hog cus tomer. Yo ur Bush Ho g Trail S eries ut ility ve hicle has b een care fully des igned to g ive maxi - mum ser vice wit h minimu m down time . This man ual is pro vided to gi ve you the n ecessa ry operat ing and mai ntenan ce instru ctions f or keep-[...]

1 8 10 11 9 2 6 5 7 27 28 24 22 23 18 17 19 29 4 3 30 31 32 16 25 26 21 20 34 14 15 33 13 12 NOTICE! LO CA TI ON S OF CO N- TR OL S AN D FE AT URE S MA Y VA RY S LI GH TLY ON D IF FE RE NT MO DEL S. 21[...]

UNDER HOOD AREA (WITH CARGO TRAY REMOVED) UNDER SEAT AREA Battery, Brake Fluid Reservoir, Fuses and Relays, Grease Fitting Engine Air Intake Engine Oil Filler Cap Engine Oil Dipstick CVT Enclosure Air Cleaner 22[...]

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[...]

FEATURES DC Power Outlet The 12 volt accessory port is provided to power auxiliary lights or other 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- wheel drive is engaged. An oil pressure light indicates when oil pressure is lower than normal a[...]

CONTROLS Switches Ignition Switch The ignition switch is a three position, key-operated switch. The key can be removed from the switch when it is in the OFF position. OFF Engine off. All electrical circuits are off except ACC. 12V. ON E le ct ri ca l ci rc u it s ar e on . El ec tr ic al e q ui pm en t can be used START Ele ct ric s tar ter i s en [...]

CAUTION DO NOT ATTEMPT TO SHIFT THE TRANSMISSION WHILE THE VEHICLE IS MOVING OR DAMAGE TO THE TRANSMISSION COULD RESULT. A LW A Y S P L A C E T H E TR A NS M I S S I ON I N G E A R W IT H T H E P AR K I N G B RA K E AP P LI E D A N D T UR N T HE V E HI C L E O F F W HE N E V E R T H E V E H I C L E I S L E F T UN A TT EN DE D. 26 Brake Pedal The br[...]

SPECIFICATIONS TRAIL HUNTER TRAIL HAND ENGINE TH420 TH440 TH4200 TH4400 Type 4-cycle, OHV V-twin, air-cooled gas Make B ri g gs & S t ra t to n Honda Honda Honda HP / (cc) 16 hp (4 80cc ) 20 h p (614 CC) 2 4 hp (67 0cc) Lubrication Full Pressure with automotive style spin-on canister Air Cleaner R e m o t e , 2 - s t a g e c y c l o n e t y p e[...]

SPECIFICATIONS TRAIL HUNTER TRAIL HAND DRIVE TRAIN TH420 TH440 TH4200 TH4400 Transmission Continuously Variable Transmission (CVT) CVT Protection S hi e ld e d (T H 42 0 o nl y) , Fu l ly e n cl o se d pr es su ri ze d wi th f il t er e d ai r i nt a ke ( TH 44 0 , TH 4 20 0 a nd T H4 40 0 ) Final Drive Bu sh Ho g Dua l-Ra nge t ran sax le wi th Hi[...]

SECTION II OPERATION GENERAL SAFETY Only qualified people familiar with this operator’s manual should operate 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. Use a clean funnel and fuel can. 3. Do not mix oil with gasoline. 4. Do not use wh[...]

Starting The Engine 1. Sit in the driver’s seat and fasten the seat belt. 2. Lock the parking brake 3. Place the transmission in neutral. 4. Pull the choke control all the way out. 5. Tu rn th e ign iti on k ey t o ST ART a nd cr ank f or 10 s eco nds m axi mum . 6. If engine does not start, release ignition switch and wait five sec- onds; then t[...]

3. With both hands on the steering wheel, release pressure on brake pedal and carefully apply pressure to throttle pedal. Vehicle speed is controlled by the amount of pressure on the throttle pedal. The CVT shifting is done automatically. 4. D r i v e sl o w l y a t f i r s t , p ra c t i c i n g m an e u v e r i n g an d u s i n g th e t h r o t t[...]

ALWAYS APPLY THE PARKING BRAKE BEFORE LEAVING THE VEHICLE. THE ENGINE/TRANSMISSION PROVIDES NO BRAKING EFFORT WHEN THE ENGINE IS NOT RUN- NING. IF THE VEHICLE MOVES, IT MIGHT BE DAMAGED OR CAUSE INJURY. WARNING CAUTION EXHAUST SYSTEM COMPONENTS ARE VERY HOT DURING AND AFTER USE OF THE VEHICLE AND WILL CAUSE BURNS IF THEY COME IN CONTACT WITH SKIN. [...]

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 hauling or towing loads. 3. Drive slowly with the transmission in low range. 4. Insure that th e cargo box latch (on manual lift models) is secure- ly latched before loading and operating. Unintentiona[...]

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 the steering wheel, slowly depress the throttle w[...]

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 OF CONTROL OR VEHICLE OVERTURN. ALWAYS CHECK THE TERRAIN CAREFULLY BEFO[...]

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 floorboards. Follow these procedures when operat[...]

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. NOTE: After running your vehicle in water, it?[...]

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 YOUR VEHICLE SUDDENLY COMES IN CONTACT WITH A HIDDEN OBSTACLE. NOT ALL OBSTACLES ARE IMMEDIATELY VISIBLE. REDUCE SPEED AND TRAV- EL WITH CAUTION[...]

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 before backing. WARNING 39 FAILURE TO USE CAUTION WHE[...]

Parking On An Incline Avoid parking on an incline if possible. If it is unavoidable, follow these 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 PROPERTY DAMAGE AND SERIOUS INJURY. ALWAYS APPLY THE PARKING BRA[...]

Hauling Cargo Bush Hog utility vehicle s have been designed to carry or tow specific capac ities. Al ways read an d und erstan d t he load distr ibutio n w arning s liste d on the warning decals .Never excee d the follo wing capacit ies. Model Max. Capa city Cargo Box To wing Capaci ty Trail Hunter 1,250 lbs. 750 lbs. 1,500 lbs. Trail Hand 1,500 lb[...]

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 the switch, lower the cargo box completely before mo[...]

Towing Loads Belt Life Use low forward gear when hauling or towing heavy cargo to extend belt 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. WARNING TOWING IMPROPERLY CAN ALTER VEHICLE HANDLING [...]

WARNING 4-Wheel Drive Your Bush Hog Utility Vehicle is equipped with an exclusive 4-wheel drive 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 engage anytime the rear wheels begin to lose tr[...]

3. Stop completely. 4. Shift into forward and drive. If the hubs remain engaged after following these instructions, return the 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 causing thereof: 1. The removal or rendering inopera[...]

CAUTON USFS Approved Spark Arrestor The muffler on this vehicle was tested and approved in accordance with the USFS Forest Service Stanedard 5100-1A. SECTION III MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubric[...]

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 Inspect Steering Pre-operation Inspect Coolant/Level[...]

Item Frequency Remarks Engine Cylinder 25 hrs. Re-torque required at first Head/Cylinderr service only Base Fasteners s Engine Oil-Level 25 hrs. Check level daily; break-in service at 25 hrs. s Engine Oil - 100 hrs. Change oil at 100 hours; H Change more often in cold weather use s Oil Filter 100 hrs. Replace with oil change H H Engine breather 100[...]

Item Frequency Remarks n Fuel System 100 hrs. Check for leaks at fuel cap H li ne s, fue l va lv e, f ilt er, pum p and carburetor.Replace lines every two years. Fuel Filter 100 hrs. Replace annually Spark Arrestor 100 hrs. Clean out s Fr ont Ge arc ase Oil 10 0 h rs . Che ck m ont hly ; ch an ge an nua lly n Cl utc hes (d ri ve 10 0 hr s. In spe c[...]

MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Chart Item Lube Method Frequency Engine Oil SAE 10W-30, Add to proper level Check level daily API [...]

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 or every six months, whichever comes first. Dirt and metal particles col- lect in the oil, and oil loses its lubricative quality if used too long. Suggested break-in oil change is at 25 hours, or one mo[...]

Engine Oil and Filter Change 1. Run the engine two or three minutes until warm. Stop the engine. 2. Clean the area around the drain plug at the bottom of the crankcase. 3. Place a drain pan beneath the engine and remove the drain plug. Allow the oil to drain completely. 4. Clean drain hole and replace the drain plug. Torque to 14 ft. lbs. 5. Remove[...]

Front Differential The front differential oil should be changed every 100 hours If the vehicle is used in wet conditions, the oil should be checked more fre- quently. If the oil has a milky appearance, it should be changed as soon as possible. Failure to properly maintain this area can result in premature wear or possible failure of the front diffe[...]

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 sight window. Oil Change 1. Remove the combination bre[...]

Constantly Variable Transmission (CVT) Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The CVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and addi- tional loads on components. The CVT system rotates a[...]

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 carburetor drain screw by turning the screw counter- [...]

Engine Air Filter We recommend that the air filter be cleaned every 25 hours and replaced once a year. 1. The air filter is accessible from the right side of the vehicle, below the passenger seat. Loosen both fastening clips and remove the housing cover. There is an outer and inner filter that may then be pulled out for service or replacement. 2. I[...]

Fuel Filter Your Bush Hog utility vehicle is equipped with an in-line fuel filter that should be replaced by your dealer after every 100 hours of opera- tion.Do not attempt to clean the fuel filter. Spark Plugs The spar k pl ugs s hou ld be chan ged ever y 10 0 hou rs. T he sp ark plug s are a cce ssib le fro m und er the se at or u nde r the cargo[...]

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 deposits and clean the inside of the tubing. 2. Place the engine in neutral and start the engine. Purge the accu- m[...]

Throttle System Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no freeplay, the throttle may be hard to control, and idle may be erratic. Throttle Freepl[...]

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 in good operating condition. Inspect the level of the brake fluid before each operation. Change the brake fluid at the intervals outlined in the Maintenance Schedule beginning[...]

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), about the thickness of a dime. Parking Brake Adj[...]

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 freeplay or strange noises, or the steering feels ro[...]

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 the lug nuts slightly. WARNING OP ER AT ING YO[...]

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 toward the outside and the rotation arrows on the tire [...]

Cleaning Your Vehicle Keeping your vehicle clean will not only improve its appearance, but it 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 hose and a pail of mild soap and water. Use a professional type wa[...]

8. Tie a plastic bag over the exhaust pipe and air cleaner inlet to prevent moisture or small animals or insects from entering. 9. Cove r the vehi cle with a canv as cover . Do not us e pla stic or coa ted mat eria ls sinc e th ey d o no t al low ven til atio n fo r th e ve hic le. Re mov al Fr om Sto ra ge 1. Chec k th e batte ry elec tro lyte le [...]

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN. R e p l e n i s h i n g B a t t e r y F l u id ( C o n v e n t i o n a l B a t t e r y ) A p o o r l y m a i n t a i n e d b a t t e r y w[...]

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 properly routed. NOTE: When installing a new battery, [...]

Attaching Occupant Protection Structure To Vehicle (Refer to illustrations on following pages) Remove occupant protection structure from shipping bundle and arrange weldments around the vehicle. Loosen all fasteners before beginning assembly. Disconnect the front cross member from one front side frame mem- ber so the front frame weldments can be po[...]

TH420/TH440 Models TH4200/TH4400 Models Inne r Seat Belt Inn er Se at Be lt 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 will be to the outside of the[...]

Rubber Bumper Pad Adjustment The plastic bed of the Utility Vehicle is equipped with two rubber bumper pads located at the bottom front of the bed. These rubber bumpers are factory adjusted to prevent rattling when the bed is in the down position. If adjustment should be needed at a later time proceed as follows: Manual Lift - Screw pads down enoug[...]

TROUBLESHOOTING CHECK LIST STAR TER MOTOR WON’T TURN ENGINE : • Gear shift lever not in neutral • Battery discharged • B at t e r y l e ad s d o n o t m a ke g o od c o n t a c t w it h t he b a tt e ry t e rm i n a l s o r g ro u n d o n f r am e • Fuse failure (check to find and correct the cause of the failure) ENGINE CRANKS, BUT WON?[...]

SAFETY DECALS To pro mote sa fe oper ati on, Bus h Hog supp lie s s afet y decal s on a ll pro duc ts ma nufa ctu red . Bec ause dama ge ca n occ ur to safe ty de cals eit her throu gh sh ipme nt, use or recon dit ioni ng, Bush Ho g wil l, up on req ues t, pr ovid e saf ety de cal s for any of ou r prod uct s in the fiel d at no cha rge . Cont act [...]

No. 3 No. 4 No. 5 No. 6 No. 7 75[...]

TORQUE SPECIFICATIONS B O L T D I A 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 I Z E ( I N . ) “ A ” T H R E A D S I Z 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 - 24 UNF 13 (17) 19 (26) 27 (37) 9[...]

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 (84) 167 (226) 181 (245) 230 (312) 30 20 122[...]

NOTES:[...]

NOTES:[...]

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