Billy Goat BC2401IC, BC2402IC, BC2402ICE User Manual

Download

Page 1

ACCESSORIES

NUT REPLACEMENT KIT

P/N 500208.

To replace stripped or

damaged insert nuts in

engine base.

BLADE BC2401/2402

P/N 500210.

Original Equipment Blade

for replacement.

BELT TRACTION DRIVE

P/N 500119.

Traction Drive Belt

for BC2401/2402

BELT BLADE DRIVE

P/N 500237.

Blade Drive Belt

for BC2401/2402

BLADE HIGH LIFT

BC2401/2402

P/N 500102.

Optional blade for

replacement

Thank You for Selecting

The Powerful BC SELF-PROPELLED BRUSH CUTTER

Operator Owner's Manual

BC2402IC, BC2402H, BC2402HE, BC2402ICE

Patent Number D386768

BC2402IC BC2402H BC2402HE BC2402ICE

ENGINE: H.P. 13 (9.70 kW) 13 (9.70 kW) 13 (9.70 kW) 13 (9.70 kW) ENGINE: TYPE B&S INTEK OHV HONDA HONDA B&S INTEK OHV ENGINE MODEL NO: MODEL 21 GXV390 V390K1DE33 MODEL 21 ENGINE: FUEL CAP. 3.0 qt. (2.8 L) 2.3 qt. (2.18 L) 2.3 qt. (2.18 L) 3.0 qt. (2.8 L) ENGINE: OIL CAP. 1.5 qt. (1.4 L) 1.20 qt. (1.13 L) 1.20 qt. (1.13 L) 1.5 qt. (1.4 L) WEIGHT: UNIT 266# (120.7 kg) 278# (126.4 kg) 291# (132.3 kg) 273# (124.1 kg) WEIGHT: SHIPPING 315# (143.2 kg) 330# (150.0 kg) 340# (154.7 kg) 325# (147.7 kg) ENGINE WEIGHT: 58.0# (26.3 kg) 70.5# (32.0 kg) 72.5# (32.9 kg) 60.0# (27.3 kg)

MAX. OPERATING SLOPE 15° 20° 20° 15°

UNIT SIZE: OVERALL LENGTH: 82.5"(2.09 m) OVERALL WIDTH 32.0" (0.81m) OVERALL HEIGHT43" (1.09m)

Specifications

Part No. 500264 Form No. F082704A

Page 1 of 12

Page 2

IN THE INTEREST OF SAFETY

BEFORE STARTING ENGINE, READ AND UNDERSTAND THE “ENTIRE OPERATOR'S MANUAL & ENGINE MANUAL.”

THIS SYMBOL MEANS WARNING OR CAUTION. DEATH, PERSONAL INJURY AND/OR PROPERTY DAMAGE MAY OCCUR UNLESS INSTRUCTIONS ARE FOLLOWED CAREFULLY.

WARNING: The Engine Exhaust from this product contains chemicals known

to the State of California to cause cancer, birth defects or other reproductive harm.

WARNING: DO NOT

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

2. DO NOT place hands or feet near moving or rotating parts.

3. DO NOT store, spill or use gasoline near an open flame, or devices such as a stove, furnace, or water heater which use a pilot light or devices which can create a spark.

4. DO NOT refuel indoors where area is not well ventilated. Outdoor refueling is recommended.

5. DO NOT fill fuel tank while engine is running. Allow engine to cool for 2 minutes before refueling. Store fuel in approved safety containers.

& /or damage to unit.

13. DO NOT tamper with governor springs, governor links or other parts which may change the governed engine speed.

14. DO NOT tamper with the engine speed selected by the engine manufacturer.

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

16. DO NOT crank engine with spark plug removed. If engine is flooded, place throttle in “FAST” position and crank until engine starts.

17. DO NOT strike flywheel with a hard object or metal tool as this may cause flywheel to shatter in operation. Use proper tools to service engine.

18. DO NOT operate engine without a muffler. Inspect periodically and replace, if

6. DO NOT remove fuel tank cap while engine is running.

7. DO NOT operate engine when smell of gasoline is present or other explosive conditions exist.

8. DO NOT operate engine if gasoline is

necessary. If engine is equipped with muffler deflector, inspect periodically and replace, if necessary, with correct deflector.

19. DO NOT operate engine with an accumulation of grass, leaves, dirt or other combustible material in the muffler area.

spilled. Move machine away from the spill and avoid creating any ignition until the gasoline has evaporated.

9. DO NOT transport unit with fuel in tank.

20. DO NOT use this engine on any forest covered, brush covered, or grass covered unimproved land unless a spark arrester is installed on the muffler. The arrester must be maintained in effective working order by

10. DO NOT smoke when filling fuel tank.

11. DO NOT choke carburetor to stop engine. Whenever possible, gradually reduce engine speed before stopping.

12. DO NOT run engine at excessive speeds. This may result in injury

TABLE OF CONTENTS

SAFETY INSTRUCTIONS GENERAL SAFETY ASSEMBLY LIT. BAG & CONTROLS LABELS OPERATION MAINTENANCE PARTS DRAWING & LIST TROUBLESHOOTING WARRANTY PROCEDURE

○○○○○○○○

○○○○○○○○○

○○○○○○○

○○○○○

○○

○○○○○

○○○

10 - 12

○○

○○○

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

2 3 3

4 4

5, 9

6 - 8

12 12

Part No. 500264 Form No. F082704A

the operator. In the State of California the above is required by law (Section 4442 of the California Public Resources Code). Other states may have similar laws. Federal

7 8

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

Sound level of 93 dBA at operator position

106 dB

(BC2402HE MODEL)

BAROMETRIC PRESSURE:

SOUND

GENERAL CONDITION:

TEMPERATURE:

WIND SPEED:

WIND DIRECTION:

HUMIDITY:

Page 2 of 12

Sunny

80° F (25° C)

2 MPH (3.2 kmh)

South

63.5 %

29.98" Hg (761mm Hg)

laws apply on federal lands.

21. DO NOT touch hot muffler, cylinder, or fins because contact may cause burns.

22. DO NOT run engine without air cleaner or air cleaner cover.

23. DO NOT operate during excessive vibration!

24. DO NOT leave machine unattended while in operation.

25. DO NOT park machine on a steep grade or slope.

WARNING: DO

1. ALWAYS DO remove the wire from the spark plug when servicing the engine or equipment TO PREVENT ACCIDENTAL STARTING.

2. DO keep cylinder fins and governor parts free of grass and other debris which can affect engine speed.

3. DO pull starter cord slowly until resistance is felt. Then pull cord rapidly to avoid kickback and prevent hand or arm injury.

4. DO examine muffler periodically to be sure it is functioning effectively. A worn or leaking muffler should be repaired or replaced as necessary.

5. DO use fresh gasoline. Stale fuel can gum carburetor and cause leakage.

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

7. Follow engine manufacturer operating and maintenance instructions.

8. Inspect machine and work area before starting unit.

VIBRATION

VIBRATION LEVEL 1.1g

Vibration levels at the operators handles were measured in the vertical, lateral, and longitudinal directions using calibrated vibration test equipment. Tests were performed on 05/19/95 under the conditions listed:

GENERAL CONDITION:

TEMPERATURE:

WIND SPEED:

WIND DIRECTION:

HUMIDITY:

BAROMETRIC PRESSURE:

72° F (22.2° C)

5 MPH (8.0 kmh)

30.06" Hg (763mm Hg)

Sunny

South West

67 %

Page 3

GENERAL SAFETY

For your safety and the safety of others, these directions should be followed:

Do not operate this machine without first reading owner's manual and engine manufacturer's manual.

Use of Ear Protection is recommended while operating this machine.

Use of Eye and Breathing protection is recom mended when using this machine.

·DO NOT place hands or feet beneath cutting deck, near

debris outlet or near any moving parts.

·DO NOT start engine or operate unit with bystanders in or near the work area.

·DO NOT start or operate machine with blade or drive clutch engaged.

ASSEMBLY

Read all safety and operating instructions before assembling or starting this unit.

PUT OIL IN ENGINE BEFORE STARTING.

DISCONNECT SPARK PLUG WIRE BEFORE ASSEMBLING UNIT.

Your Billy Goat Brush Cutter is shipped from the factory in one carton, completely assembled except for the upper handle, and front guard bar.

NOTE: Electric start units are shipped without a battery. The battery bracket is designed to use CB18 series, C50 series, SC50 series, or MCB50 series dry or wet cell batteries with a 17.2 Ah minimum rating.

·DO NOT operate during excessive vibration.

·DO NOT perform any maintenance or inspection until engine has

been turned off and has come to a complete stop, and the spark plug has been removed

·DO NOT operate machine with guards removed.

·DO NOT use this machine for cutting areas containing rock,

glass, string like material, wire, rags, cans, metal, or other nonorganic material.

·DO NOT operate this machine on slopes greater than specified on page 1.

·DO NOT operate machine near any hot or burning debris, or any toxic or explosive material.

·DO NOT allow children to operate this equipment.

1. REMOVE unit from carton and allow upper handle (item 40) to lay on ground behind unit. Set guard bar(Item 31) to the side for now.

2. REMOVE hardware items 115, 117, 141, 143, & 144 from temporary storage positions on lower handle (items 51, & 52).

3. ATTACH upper handle to lower as shown below, and securely tighten all fasteners. For easy alignment of handles during installation, loosen the four screws that secure the lower handles. Line up and hand tighten all handle hardware before final tightening. Note: Be sure the engine starter rope is properly installed in the starter rope guide (item 145) before tightening the corresponding fasteners. NOTE: Be sure to tighten hardware that secures that handle braces (Item 5,6) to the transaxle.

4. REMOVE hardware items 102, 103, 117, 119, 124, 141, & 152 from temporary storage positions on deck and skid assy at front of unit (items 2, 155, & 156)

5. ATTACH guard bar(Item 31) to deck as shown below. Install the center bolts(Item 153) first, and install the bolts that fasten through the sides of the deck last. Securely tighten all fasteners. Note: Hardware items 117, 119, & 141 are used to secure both the front skid attachment and the sides of the guard bar. Be sure both are securely attached.

6. CONNECT spark plug wire to spark plug.

PACKING CHECKLIST

These items should be included in your carton. If any of these parts are missing, contact your dealer.

Check

Literature

Assy

Engine

Manual

Part No. 500264 Form No. F082704A

Page 3 of 12

Check

Per Model

Handle Upper Assembly 500256

Bar Guard WA 500235

Literature Assy 500263

Briggs & Stratton

Honda(English)

Honda W/Electric Start (English)

Page 4

LITERATURE ASSY P/N 500263

CONTROLS

Literature Checklist

BRIGGS & STRATTON

Briggs engines have a choke

type carburetor that is operated by moving the throttle control to the full start position. See STARTING section, see page 5.

Owner's

Manual

Warranty

Card

Check

Owner's

Manual

500264

Warranty

Card

400972

Ty Wrap 900407

Qty: (4)

These labels should be included on your Brush Cutter. If any of these labels are damaged, replace them before putting this equipment into operation. Item and part numbers are given to help in ordering replacement labels..

Label Do Not Fill While Engine Is Hot Item 63 Part No.400268

INSTRUCTION LABELS

WARNING

EXPLOSIVE FUEL

STOP ENGINE AND ALLOW TO COOL BEFORE REFUELING.

400268

Label Ear Eye Breathing Item No. 188 Part No. 890254

WARNING

890254

Label Warning Guards Item 185 Part No.900327

Throttle Control

START

STOP

Briggs & Stratton

900327

HONDA

Honda engines have a separate choke lever that is

operated by pulling back along with moving the throttle control to the full start position if necessary. See STARTING section, see page 5.

Pull to choke

ENGINE LABELS

START

STOP

Label Danger Keep Hands and Feet Away Item 180 PartNo.400424

Label Shift BC2400 Item No. 186 Part No. 500202

Label Chock Wheels Item No. 189 Part No. 500168

1N32

WHEELS MUST BE CHOCKED

OR BLOCKED WHEN UNIT IS

PARKED ON A SLOPE.

DANGER

Label Danger Flying Material Item 184 Part No.810736

Label Clutch Blade Item 192 Part No.500177

500168

500177

810736

Label Read Owner's Manual Item No. 187 Part No. 890301

500176

Label Clutch Drive Item 191 Part No.500176

US DESIGN PATENT

NO: D386768

Label Patent No Item 190 Part No.500279

PART NO. 500279

Read and follow Operating Instructions before running engine.

Gasoline is flammable. Allow engine to cool at least 2 minutes before fueling.

Engines emit carbon monoxide, DO NOT run in enclosed area.

Honda

Part No. 500264 Form No. F082704A

Page 4 of 12

Page 5

OPERATION

INTENDED USE: This is not a lawn mower. The Brush

Cutter is designed for cutting overgrown weeds, brush, and other types of organic growth to a height of 3-1/2". The unit may also be used to clear small saplings 1-1/2" in dia. or less. It does not provide the cut quality of a finish cut lawn mower. The unit is designed for use in rural areas, and should not be used in settings where conditions require that the unit be operated in tight or confined areas. Be sure to inspect work area and machine before operating. Make sure that all operators of this equipment are trained in general machine use and safety.

Like all mechanical tools, reasonable care must be used when operating machine. Do not operate unit in areas where bystanders may be present.

Do not operate if excessive vibration occurs. If excessive vibration occurs, shut engine off immediately and check for damaged or worn blade, loose blade bolt, loose blade adapter key, loose engine or lodged foreign objects. Note: See parts list for proper blade bolt torque specifications. (See trouble shooting section on page 12).

16.1

STARTING

PUT OIL IN ENGINE BEFORE STARTING.

ENGINE: See engine manufacturer’s instructions

for type and amount of oil and gasoline used. Engine must be level when checking and filling oil and gasoline.

ENGINE SPEED: Controlled by throttle lever on the handle.

FUEL VALVE: Move fuel valve to "ON" position (when

provided on engine).

CHOKE:

Briggs engines have a choke type carburetor that is operated by moving the throttle control to the full start position. Honda engines have a separate choke lever that is operated by pulling back when starting. Push it back to its original position after the engine has started.

THROTTLE: Move remote throttle control to fast position. Pull starting rope to start engine.

ELECTRIC START: Choke the engine if necessary. Push and hole down on the rocker switch until engine starts, then release switch to run.

IF YOUR UNIT FAILS TO START:

See Troubleshooting on page 12.

NOTE: Do not engage blade during transport between work sites. The blade should remain disengaged at all times when work is not being performed.

The best performance is achieved when cutting in dry conditions. If the deck becomes choked with grass or debris during operation, back unit off of debris allowing machine to clear itself and continue cutting, or shut the unit off and clear the clog by hand (See below). A drop in engine RPM or a noticeable change in engine sound is usually a good indicator of a clogged discharge or other interference.

Under most conditions cutting should be done in first or second gear. Third gear should be reserved for conditions where weeds and brush are thinned out or not as tall. The quality of the cut produced is directly related to the unit's ground speed during cutting. If the quality of the cut is not satisfactory (i.e. material left standing) you should shift into a lower gear during cutting. For improved control in confined areas, this machine can be pushed forward or backward by releasing the operator's clutch lever, placing the transaxle in neutral, and pushing the machine.

CLEARING A CLOGGED CUTTING DECK:

Turn engine off and wait for blade to stop completely. Disconnect spark plug wire. Wearing durable gloves, remove clog. Danger, the clog may contain sharp materials. Reconnect spark plug wire.

BLADE CLUTCH

The Brush Cutter blade clutch is controlled by an operator presence control. To engage the blade, depress the operator's left hand control lever against operator's handle. The blade is disengaged by releasing this lever.(See Fig. 1.1)

NOTE: The blade clutch must be either fully engaged for cutting or fully disengaged to bring the blade to a stop. Do not operate the unit with the blade clutch partially engaged. Premature belt wear and clutch failure will result from improper operation of the clutch.

CAUTION: Use extreme care when operating the blade. Inspect the work area for foriegn objects that could cause damage to the unit or injure the operator if struck by the blade. Never operate the blade with bystanders in the work area.

Lever Up Disengages

Handle

Clutch

Lever

16.2

CUTTING OPERATION

Lever

GENERAL OPERATION: To engage the blade,

depress the operator's left hand control lever against operator's handle. The blade is disengaged by releasing this lever.(See Fig. 1.1) To engage the wheel drive, lift the operator's right hand control lever against operator's handle. The drive is disengaged by releasing this lever.(See Fig. 1.2) Ground speed can be varied by shifting gears as described on page 9. To begin cutting engage the blade lever, allow the blade to spin up to speed, and engage the wheel drive to begin moving forward into the material to be cut.

Part No. 500264 Form No. F082704A

Page 5 of 12

Fig. 1.1

Down Engages Clutch

Page 6

PARTS DRAWING

BC2402HE, BC2402H, BC2402IC,

BC2402ICE

Part No. 500264 Form No. F082704A

Page 6 of 12

Page 7

PARTS

LIST

Part No. 500264 Form No. F082704A

ITEM BC2402HE BC2402H BC2402ICE BC2402IC

NO. DESCRIPTION Part No QTY Part No QTY Part No QTY Part No QTY

1 Deck Assembly with labels 500239 1 500239 1 500239 1 500239 1 2 Deck WA BC2401 500266 1 500266 1 500266 1 500266 1 3 Deflector Front BC2400 500125 1 500125 1 500125 1 500125 1 4 Base Assembly with labels 500240 1 500240 1 500240 1 500240 1 5 Handle Brace Left 500196 1 500196 1 500196 1 500196 1 6 Handle Brace Right 500200 1 500200 1 500200 1 500200 1 7 Door Base Engine 500233 1 500233 1 500233 1 500233 1 8 Transaxle 3 SPD BC2400 500342 1 500342 1 500342 1 500342 1

9 Pulley 5.0" OD ‘A’ Sec. 830180 1 830180 1 830180 1 830180 1 10 Belt Traction Drive 500119 1 500119 1 500119 1 500119 1 11 Plate Pivot Idler / Shifter 500122 1 500122 1 500122 1 500122 1 12 Shifter Pivot WA 500169 1 500169 1 500169 1 500169 1 13 Pulley Idler 800260 1 800260 1 800260 1 800260 1 14 Wheel & Tire 16" AG SP LH 500343 1 500343 1 500343 1 500343 1 15 Wheel & Tire 16" AG SP RH 500344 1 500344 1 500344 1 500344 1 16 Arm Idler WA 500170 1 500170 1 500170 1 500170 1 17 Cable Clutch Blade BC2400 500259 1 500259 1 500259 1 500259 1 18 Cable Clutch Drive BC2400 500327 1 500327 1 500327 1 500327 1 19 Bar Shift T-axle 500121 1 500121 1 500121 1 500121 1 20 Angle Support T-axle 500127 1 500127 1 500127 1 500127 1 21 Rod Link Shifter 500144 1 500144 1 500144 1 500144 1 22 Tube Shift With Grip 500171 1 500171 1 500171 1 500171 1 23 Clutch Brake 500338 1 500338 1 500338 1 500338 1 24 Grip 3/4 ID - Black 610102 1 610102 1 610102 1 610102 1 25 Tube Pointer 500184 1 500184 1 500184 1 500184 1 26 Plate Mount Idler WA 500228 1 500228 1 500228 1 500228 1 27 Pulley Idler 4.5" OD X 3/8 500270 1 500270 1 500270 1 500270 1 28 Hub Cap 900486 2 900486 2 900486 2 900486 2 29 Belt Blade Drive 500237 1 500237 1 500237 1 500237 1 30 Spacer Spindle BC2401 500232 1 500232 1 500232 1 500232 1 31 Bar Guard WA BC2401 500235 1 500235 1 500235 1 500235 1 32 Bushing Shifter 500130 1 500130 1 500130 1 500130 1 33 Washer Hub Cap 850237 2 850237 2 850237 2 850237 2 34 Spindle WA BC2400 500174 1 500174 1 500174 1 500174 1 35 Bearing 7/8" ID Sealed Press 500101 2 500101 2 500101 2 500101 2 36 Shaft Drive Blade 500107 1 500107 1 500107 1 500107 1 37 Spacer Spindle Bearing 500115 1 500115 1 500115 1 500115 1 38 Pulley 7" OD x 7/8" BORE 500253 1 500253 1 500253 1 500253 1 39 Lever Control Blade 500312 1 500312 1 500312 1 500312 1 40 Handle Upper BC2400 500243-S 1 500243-S 1 500243-S 1 500243-S 1 41 Grip Handle 1 ID x 7.5 500267 2 500267 2 500267 2 500267 2 42 Lever Control Clutch 500142 1 500142 1 500142 1 500142 1 43 Bushing Lever Control 500152 4 500152 4 500152 4 500152 4 44 Fitting Mount Cable 500187 2 500187 2 500187 2 500187 2 45 Engine 13 HP Honda GXV390 Electric Start 500333 1 - - - - - -

Engine 13 HP Honda GXV390 - - 500334 1 - - - Engine 13 HP OHV B & S - - - - - - 520046 1

Engine 13 HP OHV Briggs Electric Start - - - - 520039 1 - 46 Pulley Drive Traction BC 500238 1 500238 1 500238 1 500238 1 47 Spacer Engine WA 2401 500262 1 500262 1 500262 1 500262 1 48 Control Throttle BC2400 500213 1 500213 1 500213 1 500213 1 49 Nut Lock 3/8-16 Thin 8161042 1 8161042 1 8161042 1 8161042 1 50 Blade 24" BC2400 500210 1 500210 1 500210 1 500210 1 51 Handle Lower RH BC2400 500140 1 500140 1 500140 1 500140 1 52 Handle Lower LH BC2400 500141 1 500141 1 500141 1 500141 1 53 Adapter Blade WA 500191 1 500191 1 500191 1 500191 1 54 Washer Friction Blade 500108 1 500108 1 500108 1 500108 1 55 Guard Hand BC2401 500339 2 500339 2 500339 2 500339 2 56 Screwcap 8x3/8 HW H Type B 100121 2 100121 2 100121 2 100121 2

100 101 Bolt Carraige 1/4 - 20 x 3/4 8024021 4 8024021 4 8024021 4 8024021 4 102 Nut Lock 1/4 - 20 *8160001 13 *8160001 13 *8160001 12 *8160001 12 103 Screw Cap 5/16 - 18 x 1 1/4 *8041029 13 *8041029 13 *8041029 13 *8041029 13 104 Washer Lock 5/16 split *8177011 11 *8177011 11 *8177011 11 *8177011 11 105 Plate Impeller W as her 850443 1 850443 1 850443 1 850443 1 106 Screw Cap 7/16-20 X 3" 500269 1 500269 1 500269 1 500269 1 107 SCREWCAP 5/16-18 X 1" *8041028 9 *8041028 9 *8041028 9 *8041028 9 108 Screw Cap 5/16 - 18 x 2 3/4 *8041035 6 *8041035 6 *8041035 6 *8041035 6 109 Bolt Carraige 5/16 - 18 x 3/4 8024039 2 8024039 2 8024039 2 8024039 2 110 Washer Flat 1/2" 900230 1 900230 1 900230 1 900230 1 111 Pin Cotter 3/32 x 3/4" *8197016 1 *8197016 1 *8197016 1 *8197016 1

Page 7 of 12

Page 8

* Denotes standard hardware item, that may be purchased locally.

Item Description BC2402HE Qty. BC2402H Qty. BC2402ICE Qty. BC2402IC Qty.

No. Part No. Part No. Part No. Part No.

112 Bolt Shoulder 1/2 x 1 500114 1 500114 1 500114 1 500114 1 113 Nut Lock 3/8-16 *8160003 3 *8160003 3 *8160003 3 *8160003 3 114 Bolt Idler 800888 1 800888 1 800888 1 800888 1 115 Screw Cap 5/16 x 2" *8041032 2 *8041032 2 *8041032 2 *8041032 2 116 Nut Jam 5/16 - 18 *8142002 2 *8142002 2 *8142002 2 *8142002 2 117 Nut Lock 5/16 - 18 *8160002 28 *8160002 28 *8160002 30 *8160002 30 118 Bolt Carraige 5/16 - 18 x 1 *8024040 6 *8024040 6 *8024040 6 *8024040 6 119 Screw Cap 5/16 x 1 1/2 *8041030 4 *8041030 4 *8041030 4 *8041030 4 120 Washer 3/8 FC *8171004 1 *8171004 1 *8171004 1 *8171004 1 121 Terminal Piggyback 3/16 890010 1 890010 1 - - - 122 Screw Cap 1/4 - 28 x 1/2 GR5 850408 1 850408 1 850408 1 850408 1 123 Washer Lock 5/16 external tooth 8181008 1 8181008 1 8181008 1 8181008 1 124 Washer 1/4 FC *8171002 5 *8171002 5 *8171002 5 *8171002 5 125 Screw Self Tap 5/16 *8123128 1 *8123128 1 *8123128 1 *8123128 1 126 Pin Hair Cotter 900471 2 900471 2 900471 2 900471 2 127 Washer 5/16 SAE *8172008 2 *8172008 2 *8172008 2 *8172008 2 128 Pin Cotter 3/32 x 3/4 8197016 1 8197016 1 8197016 1 8197016 1 129 Washer 3/4 SAE *8172015 2 *8172015 2 *8172015 2 *8172015 2 130 Washer 0.765 x 1.250 x 0.060 850238 2 850238 2 850238 2 850238 2 131 Spacer Engine 830113 1 830113 1 830113 1 830113 1 132 Ring Snap 0.750 850230 2 850230 2 850230 2 850230 2 133 Key 3/16 x 2 1/8 9201087 2 9201087 2 9201087 2 9201087 2 134 Spindle Assembly Complete 500242 1 500242 1 500242 1 500242 1 135 Screw Cap 7/16 - 20 x 1 1/4 GR8 800554 1 800554 1 800554 1 800554 1 136 Washer 1.25 x 0.882 x 0.125 500182 1 500182 1 500182 1 500182 1 137 Ty Wrap 900407 4 900407 4 9004 07 4 900407 4 138 Key Sq 3/16 x 5/8 9201072 2 9201072 2 9201072 2 9201072 2 139 Screw Cap 7/16 - 20 x 2 GR8 500188 1 500188 1 500188 1 500188 1 140 Washer Lock 7/16 Tw. Tooth 850132 3 850132 3 850132 3 850132 3 141 Washer 5/16 FC *8171003 27 *8171003 27 *8171003 23 *8171003 23 142 Bracket Clutch Cable Guard 500321 1 500321 1 500321 1 500321 1 143 Screw Cap 5/16 - 18 x 1 3/4 *8041031 7 *8041031 7 *8041031 9 *8041031 9 144 Screw Cap 5/16 - 18 x 2 1/2 *8041034 1 *8041034 1 *8041034 1 *8041034 1 145 Guide Rope 830533 2 830533 2 146 Grip Lever 500181 2 500181 2 500181 2 500181 2 147 Label Start/Stop Toggle 500329 1 148 Screwcap 5/16-18 X 3/4" 8041026 1 8041026 1 8041026 1 8041026 1 149 Guide Belt LH 5002 30 1 500230 1 5002 30 1 500230 1 150 Guide Belt RH 500231 1 500231 1 500231 1 500231 1 151 Screw Cap 5/16 - 24 x 1 *400164 2 *400164 2 *400164 2 *400164 2 152 Screw Cap 1/4 - 20 x 1 1/4 *8041007 3 *8041007 3 *8041007 3 *8041007 3 153 Screw Cap 1/4 - 20 x 2 3/4 *8041013 1 *8041013 1 *8041013 1 *8041013 1 154 Screwcap 1/4-20 x 2” *8041010 2 *8041010 2 *8041010 2 *8041010 2 155 Skid RH BC v-cup WA 500291 1 500291 1 500291 1 500291 1 156 Skid LH BC v-cup WA 500292 1 500292 1 500292 1 500292 1 157 Switch Box Assy BC 500318 1 500283 1 500283 1 500283 1 158 Switch Toggle 500307 1 500281 1 500307 1 500281 1 159 Harness Assy 500306 1 890442 1 520118 1 890442 1 160 Bushing Strain Relief 500282 1 500282 1 5002 82 1 500282 1 161 Label Throttle 810656 1 810656 1 810656 1 810656 1 162 Cable Battery Red W/Charge 500304 1 - - 520111 - - 163 Cable Battery Black 10" 790133 1 - 790133 1 - 164 Bracket Battery Rear 500347 1 - - 500347 1 - 165 Strap Hold Down 790303 1 - - 790303 1 - 166 167 168 169 Label Hot Engine 400268 1 400268 1 4002 68 1 400268 1 170 Bolt Shoulder 5/16 x 1 1/2 500340 2 500340 2 500340 2 500340 2 180 Label OPEI 400424 2 4004 24 2 400424 2 400424 2 184 Label Flying Debris 810736 1 810736 1 810736 1 810736 1 185 Label Guards 900327 2 900327 2 900327 2 900327 2 186 Label Shift BC2400 500202 1 5002 02 1 500202 1 500202 1 187 Label Read 890301 1 8903 01 1 890301 1 890301 1 188 Label Ear Eye Breathe 890254 1 890254 1 890254 1 890254 1 189 Label Chock Wheels 5001 68 1 500168 1 500168 1 500168 1 190 Label Patent No 500279 1 5002 79 1 500279 1 500279 1 191 Label Clutch Drive 500176 1 500176 1 500176 1 500176 1 192 Label Clutch Blade 500177 1 500177 1 500177 1 500177 1 193 Plate Choke Mount BC 500325 1 500325 1 194 Screw Machine 10-32 X 3/4" 430248 1 430248 1 195 Control Cable Choke BC 500326 1 500326 1 196 Ring Retaining External 3/4 520176 1 520176 1 520176 1 520176 1

Part No. 500264 Form No. F082704A

Page 8 of 12

Page 9

OPERATION continued

16.3

PROPULSION

This Brush Cutter is self-propelled, and is controlled by an operator presence control. To engage the wheel drive, lift the operator's right hand control lever against operator's handle. The drive is disengaged by releasing this lever.(See Fig. 1.2)

GROUND SPEED can be varied by selecting a higher or lower gear using the gear shift lever at the rear of the machine(See Fig. 2), or by changing the engine rpm. To shift the Brush Cutter into reverse, release all controls and rotate the shift lever to the left, when the lever stops lift it up and continue to turn it to the left until it stops again.

Lever Up

Handle

Engages Clutch

16.6

STORAGE

Never store engine indoors or in enclosed poorly ventilated areas with fuel in tank, where fuel fumes may reach an open flame, spark or pilot light, as on a furnace, water heater, clothes dryer or other gas appliance.

If engine is to be unused for 30 days or more, prepare as follows:

Be sure engine is cool. Do not smoke. Remove all gasoline from carburetor and fuel tank to prevent gum deposits from forming on these parts and causing possible malfunction of engine. Drain fuel outdoors, into an approved container, away from open flame. Run engine until fuel tank is empty and engine runs out of gasoline.

NOTE: Fuel stabilizer (such as Sta-Bil) is an acceptable alternative in minimizing the formation of fuel gum deposits during storage. Add stabilizer to gasoline in fuel tank or storage container. Always follow mix ratio found on stabilizer container. Run engine at least 10 min. after adding stabilizer to allow it to reach the carburetor.

CAUTION: Wheels must be chocked or blocked when unit is parked on a slope.

SHIFT LEVER

Lever

Fig. 1.2

16.4

CUTTING HEIGHT ADJUSTMENT

Cutting height can be adjusted to allow a 1” lower cutting height. This is particularly useful for cutting grasses that lay over when over grown. (i.e. Bermuda, Johnson, etc.)

Note: When cutting brush and normal field grasses it is strongly recommended that you operate your brush cutter at the standard (top) cutting height.

16.5

Using three people to lift machine is recommended. Lift holding the handle and front guard for deck. Secure in place during transport.

Never lift the unit with the engine running.

HANDLING & TRANSPORTING:

1N32

890254

Fig. 2

ENGINE

When servicing engine refer to specific manufacturers engine owner's manual. All engine warranty is covered by the specific engine manufacturer. If your engine requires warranty or other repair work contact your local servicing engine dealer. When contacting a dealer for service it is a good idea to have your engine model number available for reference(See table page 11). If you can not locate a servicing dealer in your area you can contact the manufacturers national service organization.

Briggs & Stratton: 800-233-3723

American Honda: 800-426-7701

Part No. 500264 Form No. F082704A

Page 9 of 12

Page 10

MAINTENANCE

Use only a qualified mechanic for any adjustments, disassembly or any kind of repair .

WARNING: TO AVOID PERSONAL INJURY, ALWAYS TURN MACHINE OFF, MAKE SURE ALL MOVING PARTS COME TO A COMPLETE STOP.

DISCONNECT SPARK PLUG WIRE BEFORE SERVICING UNIT.

RECONNECT SPARK PLUG WIRE, AND ALL GUARDS BEFORE STARTING ENGINE.

WHEN POWER WASHING, DO NOT SPRAY DIRECTLY ON THE BLADE CLUTCH.

Note: Blade, and drive belts are normal wear items.

These should be inspected on a regular basis and replaced if worn.

Tip: To prevent wheels from seizing to axles remove

them once per season and coat the axles with anti-seize compund. This should be done more often if using a pressure washer to clean the unit regularly.

TRANSAXLE DRIVE BELT

Tools required: 1/2 inch socket, 1/2 inch universal extension bar, pry bar or long screw driver, adequate support for machine.

1. Disconnect spark plug wire.

2. Support rear of unit to allow access to underside of the machine towards the rear. Note: Unit is heavy. Be sure support is adequate to prevent personal injury.

3. Loosen but do not remove the two nuts (116) holding the plate mount idler (item 26) in place. This will release the tension on the blade drive belt (29). NOTE: It may be necessary to apply some force to the pulley to slide it over from it’s tight position and release the belt.

4. Working from the underside of the machine, loosen but do not remove the four screws (103) holding the two belt guides(Items 149 & 150) in place next to the crankshaft drive pulley (9) at the rear of the machine. This will loosen the belt guides(Items 149 & 150) and allow them to move to the side. NOTE: This step requires the use of a universal joint or universal extension bar to reach the screws(103) holding the belt guide(149). If universal joint is not available you may remove the “neutral stop bolt”(Item 115) and associated nuts (116 &

117) to allow the idler arm to swing back and allow access to the screws(103) holding the belt guide(149).

5. With the guides loose slip the transaxle drive belt(Item 10) out of the groove on the drive pulley and down past the pulley.

6. Slip the old belt(10) up and over the pulley on the transaxle (Item

9) and remove belt from machine.

7. Install new belt in groove on transaxle pulley(Item 9) and slip into groove on transaxle drive pulley(46).

8. Tighten four screws(103) to secure belt guides(149 & 150) in place. Note: With clutch levers engaged, be sure belt guides do not touch belts after installation.

9. Reconnect spark plug wire.

WHEEL DRIVE CLUTCH ADJUSTMENT

17.1

NOTE: When sharpening the blade it is a good idea to check the balance of the blade. A properly balanced blade will increase life of the bearings and other components.

Tools required: 5/8 inch socket, torque wrench, adequate support.

1. Disconnect spark plug wire.

2. Support front of unit to allow access to the blade. Note: Unit is heavy. Be sure support is adequate to prevent personal injury.

3. Block the blade to prevent it from rotating during removal.

4. Remove the blade bolt (Item 139), lockwasher (140), and large friction washer (54).

5. Remove the blade (50) and, replace or sharpen the blade.

NOTE: When replacing the blade use only B.G.I. Part no.

500210.

6.Replace the blade using all fasteners in the exact order they were removed. Torque blade screw to 60 ft-lbs. NOTE: Before installing the fasteners inspect them for wear and replace as necessary.

17.2

When replacing one belt the other should be inspected for wear and replaced if worn. It is good practice to change both belts when either is worn beyond use. Use only original equipment belts for replacement. Billy Goat uses only premium quality, kevlar corded and coated belts in your unit. Substitute

belts do not meet the design and performance requirements for your unit , and will greatly reduce machine performance and belt life.

BLADE REMOVAL / SHARPENING

BELT REPLACEMENT

As the belt wears, adjustments may be required to maintain proper control cable tension, and clutch engagement. If the belt begins slipping or squealing during normal operation it may require an adjustment to increase the clutch cable (item 18) tension. A properly adjusted wheel drive clutch should require a minimum of 3 lbs. of force to completely depress the end of the clutch lever. Clutch cable tension adjustment is located at the back of the engine base. To increase tension adjust the cable so that more of the adjusting barrell is exposed on the outside of the machine. To decrease tension adjust the barrell in the opposite direction. When replacing a belt be sure to check that it is properly tensioned.

BLADE DRIVE BELT

Tools required: 1/2 inch socket, 1/2 inch universal extension bar, pry bar or long screw driver, adequate support for machine.

1. Disconnect spark plug wire.

2. Support rear of unit to allow access to underside of the machine towards the rear. Note: Unit is heavy. Be sure support is adequate to prevent personal injury.

3. Remove the two screws (103) and washers (141) holding the engine base door (7), and remove the door.

4. Loosen but do not remove the two nuts (116) holding the plate mount idler (item 26) in place. This will release the tension on the blade drive belt (29). NOTE: It may be necessary to apply some force to the pulley to slide it over from it’s tight position and release the belt.

5. Working from the underside of the machine, loosen but do not remove the four screws (103) holding the two belt guides(Items 149 & 150) in place next to the crankshaft drive pulley (9) at the rear of the machine.

Part No. 500264 Form No. F082704A

Page 10 of 12

Page 11

MAINTENANCE continued

5.(cont) This will loosen the belt guides(Items 149 & 150) and allow them to move to the side. NOTE: This step requires the use of a universal joint or universal extension bar to reach the screws(103) holding the belt guide(149). If universal joint is not available you may remove the “neutral stop bolt”(Item 115) and associated nuts (116 & 117) to allow the idler arm to swing back and allow access to the screws(103) holding the belt guide(149).

6. With the guides loose slip the blade drive belt(29) out of the groove on the drive pulley and down past the pulley. Note: It is necessary to remove the transaxle drive belt(10) from its groove to allow removal of the blade drive belt.

7. Pull the belt back through the hole in the top of the engine base and remove it from the machine. NOTE: Removal of the belt from the blade drive pulley requires some force to walk the belt past the front portion of the pulley.

8. Install new belt into groove on blade drive pulley. Push remaining length of belt back through engine base toward clutch/brake drive pulley.

9. Reach through from rear of machine and pull new belt through and install it in the groove on the clutch/brake drive pulley. NOTE: Make sure the blade belt is properly seated in the clutch/brake drive pulley(Item 23) and not resting in the gap between the clutch/brake pulley(23) and the transaxle drive pulley(46)

10. Tighten four screws to secure belt guides (item 149 & 150) in place. NOTE: Be sure belt is correctly routed when replacing. (See Fig. 3)

11. Set tension on belt by reaching in through top of engine base with a long screwdriver or other pry bar and pushing the idler pulley over against the belt to increase tension. While holding the belt under tension tighten the two screws (107) that hold the idler arm in place. Note: Proper belt tension can be verified by checking the tight side (non-idler side)belt deflection. The belt should deflect 3/16”-1/4” with force applied perpendicular to the belt after tensioning.

12. Replace engine base door (item 7) and tighten screws to hold it in place

13. Reconnect spark plug.

BLADE DRIVE BELT TENSION ADJUSTMENT

1. Disconnect spark plug wire.

2. Remove the two screws holding the engine base door (item 7), and remove the door.

3. Examine the condition of the belt and note the position of the idler assembly and the amount of tension on the blade belt.

3. Loosen the two nuts (Item 117) on top of the engine base, holding the idler arm assembly (Item 26) in place .

4. Reset tension on belt by reaching in through top of engine base with a long screwdriver or other pry bar and pushing the idler pulley over against the belt to increase tension. While holding the belt under tension tighten the two screws that hold the idler arm in place.

5. Replace engine base door and verify blade belt tension setting by operating the unit in the conditions that caused it to slip originally.NOTE: If belt continues to slip it may be worn out and require replacement before proper operation can resume.

STARTER SWITCH WIRING

Blade Drive Belt

Belt in top groove of engine pulley

Maintenance Schedule

Maintenance Operation

Engine (See Engine Manual)

Check for excessive vibration

Inspect for loose parts

Inspect for worn or damaged parts

Sharpen Blade

Inspect belts for wear

Check blade clutch cable tension

Replace blade and traction belts

Inspect battery for damage or leak

Check battery terminal for corrosion

Lubricate throttle control cable and linkage.

MAINTENANCE HISTORY

Date of Service

Transaxle

Drive Belt Belt in bottom groove of engine pulley

Fig. 3

Follow these hourly maintenance intervals.

Every 5 hrs

Every

or (Daily)

Use

Service Performed

Every 25

hrs

Every 50

hrs

Every

100-150 hrs

Part No. 500264 Form No. F082704A

Page 11 of 12

Page 12

MAINTENANCE continued

17.3

CLUTCH ADJUSTMENT

Clutch/Brake Adjustment:

As the clutch/brake wears, adjustments may be required to maintain proper control cable tension, and clutch engagement.

MINIMUM FORCE = 10 LBS. WHEN FULLY DEPRESSED

If the clutch/brake begins slipping or squealing during normal operation it may require an adjustment to increase the clutch cable tension. A properly adjusted blade clutch should require a minimum of 10 lbs. of force to completely depress the end of the clutch lever.(See Fig. 4) Adjust by tightening or by loosening clutch cable adjusting nut as required, located at the rear of the engine base. When adjusting cable tension on blade control cable be sure to leave slack in cable to allow for engagement of blade brake. Replacement of cable or clutch/brake may be

MOVE ADJUSTER OUT TO INCREASE CABLE TENSION

necessary if adjustment will not allow for proper clutch and brake engagement.

WARNING: If the clutch begins to squeal or slip, do not

MOVE ADJUSTER IN TO DECREASE CABLE TENSION

continue to operate your unit until adequate adjustment or repair has been performed.

Improper adjustment can cause clutch to slip and overheat, greatly reducing machine performance and clutch life.

TROUBLESHOOTING

Problem

The engine will not start

Starter does not turn (Electric start unit only)

The engine will not stop

Will not cut or has poor cutting performance.

Abnormal vibration.

Belt slips or smokes.

Clutch slips or squeals. Clutch cable tension too low . Clutch worn or damaged. Increase clutch cable tension (see above). Replace clutch/brake

Blade brake will not engage. Inadequate slack in clutch cable . Clutch worn or damaged.

No self propelling.

Self propelled drive will not release .

Engine is locked, will not pull over.

Stop switch is off. Throttle is not in ON position. Out of gasoline. Bad or old gasoline. Spark plug wire disconnected. Dirty air cleaner.

Battery is too low or dead. Battery cable is disconnected or battery terminal is corroded. Bad starter switch or wire harness. Bad starter.

Damaged stop switch. Stop switch wire is disconnected. Stop switch wire is worn or damaged.

Dull Blade. Clogged deck. Excessive quantity of debris built up or blocking blade. Engine RPM set too low.

Loose or out of balance blade or loose engine.

Belt tension too low . Belt worn or stretched. Pulleys worn or damaged.

Operator's clutch lever not releasing clutch. Broken or out of adjustment clutch cable. Worn or broken belt.

Clutch cable out of adjustment.

Debris locked against blade. Engine problem.

Before Requesting Service Review These Suggestions

Possible Cause

Check switch, throttle, & gasoline. Check for spark with an approved tester. Clean or replace air cleaner. Contact service dealer.

Charge battery or replace with a new one. Clean battery terminals. Replace starter switch. Replace Wire harness. Contact service dealer.

Replace stop switch. Connect stop switch wire. Replace stop switch wire.

Unclog deck (see page 5). Sharpen blade. Check engine RPM.(see page 11 for settings)

Check blade and replace if required. Check Engine.

Increase tension at idler(see page 11). Replace belt. Replace pulleys

Adjust or replace cable (see above). Replace clutch/brake

Adjust clutch cable. Replace any worn, damaged or malfunctioning parts.

Adjust clutch cable. See page 10 Wheel Drive Clutch Adjustment.

Remove debris (see page 5 ). Contact an engine servicing dealer for engine problems.(see page 10)

Fig. 4

Solution

22.1 Contact your nearest engine manufacturer's authorized

Serial Plate

106 dB

Purchase Date

Part No. 500264 Form No. F082704A

Engine Service and Warranty

servicing dealer.

Record your machine model, serial number and

date-of-purchase and where purchased

1803 S.W. Jefferson Lee's Summit, MO 64082 / USA

Tel (816) 524-9666 Fax (816) 524-6983

Model Serial No.

Unit(Weight) Engine Power

lbs. kg kW rpm

Purchased from

-1

min

Page 12 of 12

Should a Billy Goat Machine fail due to a defect in material and / or workmanship, the owner should make a warranty claim as follows:

-The Machine must be taken to the dealer from whom it was purchased or to an authorized Servicing Billy Goat Dealer.

-The owner must present the remaining half of the Warranty Registration Card, or, if this is not available, the invoice or receipt.

-The Warranty Claim will be completed by the authorized Billy Goat Dealer and submitted to their respective Billy Goat Distributor for their territory. Attention: Service Manager. Any parts replaced under warranty must be tagged and retained for 90 days.

-The distributor service manager will sign off on the claim and submit it to Billy Goat for consideration.

-The Technical Service Department at Billy Goat will study the claim and may request parts to be returned for examination. Billy Goat will notify their conclusions to the distributor service manager from whom the claim was received.

-The decision by the Quality / Service department at Billy Goat to approve or reject a Warranty claim is final and binding.

Note: To process a Warranty Claim, it is necessary to quote the Model & Serial Number which are printed on the Billy Goat Serial Plate (See owner’s manual).

WARRANTY PROCEDURE

BILLY GOAT INDUSTRIES INC.

1803 S.W. JEFFERSON STREET LEE'S SUMMIT, MO 64082 / USA PHONE: 816-524-9666 FAX: 816-524-6983 www.billygoat.com

Billy Goat BC2401IC, BC2402IC, BC2402ICE User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual