Billy Goat BC2402 User Manual

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BILLY GOAT ® BC2402 Series Brush Cutter

Owner’s Manual

Patent Number D386768

Part No 500264

1

Form No F091506B

BC2402 Series Brush Cutter Owner’s Manual

ABOUT THIS MANUAL

THANK YOU for purchasing a BILLY GOAT® Brush Cutter. Your new machine has been carefully designed and manufactured to provide years of reliable and productive service. This manual provides complete operating and maintenance instructions that will help to maintain your Brush Cutter in top running order. Read this manual carefully before assembling, operating or servicing your equipment.

CONTENTS

Serial Plate Data .............................................................................................................

 

.................................. 3

BC2402 Series Specifications ..................................................................................................

.........................

3

Common Replacement Parts ......................................................................................................

......................

3

General Safety Instructions and Symbols .......................................................................................

..................

4

Sound Data

....................................................................................................................

...................................

6

Vibration Data ................................................................................................................

....................................

6

Intended Use ..................................................................................................................

...................................

6

Instruction Labels ............................................................................................................

..................................

7

Engine Labels .................................................................................................................

...................................

7

Assembly Instructions .........................................................................................................

..............................

9

Operation .....................................................................................................................

 

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10

Operator Controls ............................................................................................................

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11

Starting

.....................................................................................................................

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11

Cutting ......................................................................................................................

 

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13

Shut Down ....................................................................................................................

..............................

14

Cutting Height Adjustment ....................................................................................................

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14

Clearing a Clogged Cutting Deck ..............................................................................................

.................

14

Handling and Transporting .....................................................................................................

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15

Storage .......................................................................................................................

 

.......................................

15

Maintenance ...................................................................................................................

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16

Periodic Maintenance .........................................................................................................

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16

Cleaning .....................................................................................................................

.................................

16

Blade Removal and Sharpening .................................................................................................

................

17

Blade Drive Belt Tension Adjustment ..........................................................................................

...............

18

Blade Clutch Adjustment ......................................................................................................

......................

19

Blade Drive Belt Removal and Replacement .....................................................................................

........

20

Transaxle Drive Clutch Adjustment ............................................................................................

................

22

Transaxle Drive Belt Removal and Replacement .................................................................................

......

23

Wiring Diagrams ...............................................................................................................

...........................

21

Troubleshooting ...............................................................................................................

..................................

25

Engine Maintenance and Repair .................................................................................................

......................

26

Warranty Claim Procedure ......................................................................................................

..........................

26

Maintenance Record ............................................................................................................

.............................

27

Illustrated Parts List ........................................................................................................

...................................

28

 

Illustrations

 

Figure 1

Brush Cutter Assembly Drawing ........................................................................................

............

8

Figure 2

Belt Routing Diagram .................................................................................................

....................

21

Figure 3

Starter Switch Wiring ................................................................................................

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24

Figure 4

Starter Circuit Schematic Diagram ....................................................................................

............

24

Figure 5

ON/OFF Switch Circuit Schematic Diagram

..................................................................................

24

Figure 6

Engine and Engine Base Assembly ......................................................................................

........

28

Figure 7

Handlebar Assembly ...................................................................................................

...................

30

Figure 8

Transaxle and Blade Deck Assembly ....................................................................................

........

32

Figure 9

Blade Drive Spindle Assembly Detail Drawing ..............................................................................

34

Part No 500264

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BC2402 Series Brush Cutter Owner’s Manual

SERIAL PLATE DATA

Record the model number, serial number, date of purchase, and where purchased.

Purchase Date:

Purchased From:

BC 2402 SERIES SPECIFICATIONS

 

BC2402IC

BC2402H

BC2402HE

BC2402ICE

 

 

 

 

 

Engine Type

Briggs and Stratton

Honda GXV

Honda GXV

Briggs and Stratton

 

INTEK OHV

 

 

INTEK OHV

 

 

 

 

 

Model Number

21A902-0149-E1

GXV390UTIDABG

GXV390K1DE33

21A907-0147-E1

 

 

 

 

 

Horsepower

13.0 (9.7 kW)

13.0 (9.7 kW)

13.0 (9.7 kW)

13.0 (9.7 kW)

 

 

 

 

 

Fuel Capacity

3.0 qt (2.80 L)

2.3 qt (2.18L)

2.3 qt (2.18L)

3.0 qt (2.8L)

 

 

 

 

 

Oil Capacity

1.5 qt (1.4L)

1.2 qt (1.13L)

1.2 qt (1.13L)

1.5 qt (1.4L)

 

 

 

 

 

Engine Weight

58.0 lb (26.3 kg)

70.5 lb (32.0 kg)

72.5 lb (32.9 kg)

60.0 lb (27.3 kg)

 

 

 

 

 

Unit Weight

266 lb (120.7 kg)

278 lb (126.4 kg)

291 lb (132.3 kg)

273 lb (124.1 kg)

 

 

 

 

 

In accordance with 2000/14/EEC

106 dB(a)

106 dB(a)

106 dB(a)

106 dB(a)

standards

 

 

 

 

 

 

 

 

 

Sound at Operator’s ear

93 dB(a)

93 dB(a)

93 dB(a)

93 dB(a)

 

 

 

 

 

Shipping Weight

315 lb (143.2 kg)

330 lb (150.0 kg)

340 lb (154.7 kg)

325 lb (147.7 kg)

 

 

 

 

 

Overall Length

 

82.5 in (2.09 m)

 

 

 

 

 

 

Overall Width

 

32.0 in (0.81 m)

 

 

 

 

 

 

Overall Height

 

43 in (1.09 m)

 

 

 

 

 

 

Maximum Operating Slope

15o

20o

20o

15o

COMMON REPLACEMENT PARTS

-Blade. P/N 500210. Original equipment replacement blade.

-High Lift Blade. P/N 500102. Optional replacement blade.

-Traction Drive Belt. P/N 500119. Original equipment replacement drive belt.

-Blade Drive Belt. P/N 500237. Original equipment replacement drive belt.

-Skid, Right Hand. P/N 500291. Right side deck skid.

-Skid, Left Hand, P/N 500292. Left side deck skid.

-Throttle Control Assembly. P/N 500213. Throttle control assembly, including cable.

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BC2402 Series Brush Cutter Owner’s Manual

GENERAL SAFETY INSTRUCTIONS and SYMBOLS

The safety symbols shown below are used throughout this manual. You should be thoroughly familiar with them before assembling, operating or servicing this equipment.

This symbol indicates important information that will prevent injury to yourself or others.

This symbol indicates ear protection is recommended when operating this equipment.

This symbol indicates eye protection is recommended when operating this equipment.

This symbol indicates gloves should be worn when servicing this equipment.

This symbol indicates that this manual and the engine manufacturer’s manual should be read carefully before assembling, operation or servicing this equipment.

This symbol indicates important information that will prevent damage to your BILLY GOAT ® Brush Cutter.

This symbol indicates the engine oil level should be checked before operating this equipment.

Read and make sure you thoroughly understand the following safety precautions before assembling, operating or servicing this equipment:

READ this manual and the engine manufacturer’s manual carefully before assembling, operating or servicing this equipment.

EAR PROTECTION is recommended when operating this equipment.

EYE PROTECTION is recommended when operating this equipment.

EXHAUST from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

DO NOT operate this equipment on any unimproved forested, brushy, or grass covered land unless a spark arrester is installed on the muffler as required by Section 4442 of the California Public Resources Code. The arrester must be maintained in good working order. Other states may have similar laws. Federal laws apply on federal lands.

DO NOT run engine in an enclosed area. Exhaust gases contain carbon monoxide, an odorless and possibly fatal poison.

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BC2402 Series Brush Cutter Owner’s Manual

DO NOT run this equipment indoors or in any poorly ventilated area. Refueling outdoors is recommended.

DO NOT refuel this equipment while the engine is running. Allow engine to cool for at least two minutes before refueling.

DO NOT store gasoline near an open flame.

DO NOT remove gas cap while engine is running.

DO NOT start or operate engine if strong odor of gasoline is present.

DO NOT start or operate engine if gasoline is spilled. Move equipment away from spill until gasoline has completely evaporated.

DO NOT smoke while filling the fuel tank.

DO NOT check for spark with spark plug or spark plug wire removed. Use an approved spark tester.

DO NOT operate engine without a muffler. Inspect muffler periodically and replace if necessary. If equipped with muffler deflector, inspect deflector periodically and replace if necessary.

DO NOT operate engine with grass, leaves or other combustible material near the muffler.

DO NOT touch muffler, cylinder or cooling fins when hot. Contact with hot surfaces may cause severe burns.

DO NOT leave equipment unattended while in operation.

DO NOT park equipment on a steep grade or slope.

DO NOT operate equipment with bystanders in or near the work area.

DO NOT start equipment with drive or blade clutch engaged.

DO NOT operate equipment with guards removed.

DO NOT operate equipment in areas containing rock, glass,string-likematerial, wire, rags, cans, metal or othernon-organicmaterial.

DO NOT operate equipment on slopes greater than specified in Specifications section of this manual.

DO NOT operate equipment near hot or burning debris or any toxic or explosive materials.

DO NOT allow children to operate this equipment.

ALWAYS remove spark plug wire when servicing equipment to prevent accidental starting.

ALWAYS check fuel lines and fittings frequently for cracks or leaks. Replace if necessary.

ALWAYS keep hands and feet away from moving or rotating parts.ALWAYS store fuel in approved safety containers.

Part No 500264

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BC2402 Series Brush Cutter Owner’s Manual

SOUND DATA

SOUND LEVEL 93 Dba at Operator’s position

Sound tests were conducted in accordance with 2000/14/EEC and were performed on 2/21/2002 under the conditions listed below.

Sound power level listed is the highest value for any model covered in this manual. Please refer to serial plate on the unit for the sound power level for your model.

General Conditions:

Sunny

Temperature:

80oF (25oC)

Wind Speed:

2.0 mph (3.2 kph)

Wind Direction:

South

Humidity:

63.5%

Barometric Pressure:

29.98” Hg (761mm Hg)

VIBRATION DATA

VIBRATION LEVEL .5g (4.87 m/s2)

Vibration levels at the operator’s handles were measured in the vertical, lateral and longitudinal directions using calibrated vibration test equipment. Tests were performed on 5/19/1995 under the conditions listed below.

General Conditions:

Sunny

Temperature:

89oF (31.7oC)

Wind Speed:

6.1 mph (9.9 kph)

Wind Direction:

West

Humidity:

49.7%

Barometric Pressure:

29.88” Hg (101.19 kPa)

INTENDED USE

Your BILLY GOAT ® BC Self-Propelled Brush Cutter is designed for cutting overgrown weeds, brush and other growth down to 3½” (8.9 cm) in height. It isnot a lawn mower and does not provide the quality cut of a finish cut mower. It is designed for use in rural areas and should not be operated in tight or confined areas.

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BC2402 Series Brush Cutter Owner’s Manual

INSTRUCTION LABELS

The labels shown below were installed on your BILLY GOAT ® Brush Cutter. If any labels are damaged or missing, replace them before operating this equipment. Item numbers from the Illustrated Parts List and part numbers are provided for convenience in ordering replacement labels. The correct position for each label may be determined by referring to the Figure and Item numbers shown.

PN 400268

PN 890254

PN 500349

(See Figure 6 Item 169)

(See Figure 6 Item 188)

(See Figure 6 Item 186)

 

 

 

Item No 180 - PN 400424

Item No 184 - PN 810736

Item No 187 - PN 890301

(See Figure 8 Item 180)

(See Figure 8 Item 184)

(See Figure 6 Item 187)

 

 

 

PN 900327

Item No 192 - PN 500177

Item No 191 - PN 500176

(See Figure 6 Item 185)

(See Figure 7 Item 192)

(See Figure 7 Item 191)

 

 

 

Item No 189 - PN 500168

PN 500279

(See Figure 6 Item 189)

(See Figure 6 Item 190)

 

 

ENGINE LABELS

HONDA

BRIGGS and STRATTON

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BC2402 Series Brush Cutter Owner’s Manual

Brush Cutter Assembly Drawing

Figure 1

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BC2402 Series Brush Cutter Owner’s Manual

ASSEMBLY INSTRUCTIONS

Your BILLY GOAT ® BC Self-Propelled Brush Cutter was shipped in one carton, completely assembled except for the upper handle assembly and the front guard bar. Mounting hardware for the handle and guard bar is temporarily installed on the lower handle and the front of the deck assembly.

READ all safety instructions before assembling unit.

Electric start units are shipped without a battery. A CB18, C50, SC50 or MCB50 series dry or wet battery with a 17.2 Ah rating is required.

Numbers in parenthesis ( ) refer to item numbers on Figure 1 on the facing page.

1.Remove unit from carton. Make sure the following items that have been packed with unit:

Upper Handle Assembly, P/N 500256

Guard Bar, P/N 500235

Owner’s Manual, P/N 500264

Honda or Briggs and Stratton Engine Manual

Warranty Card, P/N 400972

Ty-Wraps(4 ea)

DISCONNECT spark plug wire before assembling unit.

2.Remove mounting hardware (144, 143, 115, 117, 141) from lower handles (51 and 52).

3.Loosen (but do not remove) four screws (115) securing the lower handles (51 and 52).

4.Attach upper handle (40) to lower handles (51 and 52) with hardware removed in step 2. Tighten finger tight only.

5.Make sure engine pull starter is properly installed in guide (145) and then tighten upper handle fasteners (Honda engine only).

6.Tighten mounting hardware on handle braces (5 and 6).

7.Remove mounting hardware (102, 103, 117, 119, 124 and 141) from deck and skid assembly.

8.Attach guard bar (31) to deck. Install center bolts (152) first and then side bolts.

9.For electric start models secure the battery (not included) in the battery plate (164), hook one side of the strap into the hole then stretch the strap across the top of the battery and hook the opposite side into the opposing hole on the plate. Make sure the battery will not move then connect terminals.

Items 117, 119 and 141 secure both front skid attachment and sides of front guard bar. Make sure both are securely attached.

9.Reconnect spark plug wire.

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BC2402 Series Brush Cutter Owner’s Manual

OPERATION

DO NOT run engine in an enclosed area. Exhaust gases contain carbon monoxide, an odorless and possibly fatal poison.

DO NOT start or operate engine if strong odor of gasoline is present.

DO NOT start or operate engine if gasoline is spilled. Move equipment away from spill until gasoline has completely evaporated.

DO NOT operate engine without a muffler. Inspect muffler periodically and replace if necessary. If equipped with muffler deflector, inspect deflector periodically and replace if necessary.

DO NOT operate engine with grass, leaves or other combustible material near the muffler.

DO NOT touch muffler, cylinder or cooling fins while engine is running. Contact with hot surfaces may cause severe burns.

DO NOT operate equipment with bystanders in or near the work area.

DO NOT operate equipment with guards removed.

DO NOT operate equipment in areas containing rock, glass,string-likematerial, wire, rags, cans, metal or othernon-organicmaterial.

DO NOT operate equipment on slopes greater than specified in Specifications section of this manual.

DO NOT operate equipment near hot or burning debris or any toxic or explosive materials.

DO NOT allow children to operate this equipment.

ALWAYS keep hands and feet away from moving or rotating parts.

ALWAYS check before use, transportation, or storage to make sure the battery is secured and straps holding battery are in good condition. If the strap breaks it will allow the battery to shift and could cause a short damaging the equipment. (Electric start)

ALWAYS connect battery terminals to proper connection cables. (Electric Start)

EAR PROTECTION is recommended when operating this equipment.

EYE PROTECTION is recommended when operating this equipment.

Part No 500264

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