Billy Goat BC2403 User Manual

BILLY GOAT ® BC2403 Series Brush Cutter

Owner’s Manual

Patent Number D386768

Accessories

P/N 500102

Part No 500360 1 Form No F062210A

BC2403 Series Brush Cutter Owner’s Manual

ABOUT THIS MANUAL

THANK YOU for purchasing a BILLY GOAT

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.

Brush Cutter. Your new machine has been carefully designed and

CONTENTS

Serial Plate Data ............................................................................................................. .................................. 3

BC2403 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 ........................................................................................................................................................... 10

Operator Controls ....................................................................................................................................... 11

Starting ........................................................................................................................................................ 11

Cutting ......................................................................................................................................................... 13

Shut Down .................................................................................................................................................. 14

Clearing a Clogged Cutting Deck ............................................................................................................... 14

Handling and Transporting ................................................................................................................................ 15

Storage .............................................................................................................................................................. 15

Maintenance ...................................................................................................................................................... 16

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

Illustrated Parts List ........................................................................................................................................... 28

............................. 27

Illustrations

Figure 1 Brush Cutter Assembly Drawing .................................................................................................... 8

Figure 2 Belt Routing Diagram ..................................................................................................................... 21

Figure 3 Starter Switch Wiring ..................................................................................................................... 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 Handleba r Assembly ...................................................................................................................... 30

Figure 8 Transaxle and Blade Deck Assembly ............................................................................................ 32

Figure 9 Blade Drive Spindle Assembly Detail Drawing .............................................................................. 34

Part No 500360 2 F062210A

BC2403 Series Brush Cutter Owner’s Manua

SERIAL PLATE DATA

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

Purchase Date:

Purchased From:

BC 2403 SERIES SPECIFICATIONS

BC2403IC BC2403ICF BC2403HF BC2403H BC2403HEB

Engine Type Briggs and

Model Number 21A902-0149-E1 21A902-0149-E1 GXV390UTIDABG GXV390UTIDABG GXV390K1DE33 Horsepower 13.0 (9.7 kW) 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) 3.0 qt (2.80 L) 2.3 qt (2.18L) 2.3 qt (2.18L) 2.3 qt (2.18L) Oil Capacity 1.5 qt (1.4L) 1.5 qt (1.4L) 1.2 qt (1.13L) 1.2 qt (1.13L) 1.2 qt (1.13L) Engine Weight 58.0 lb (26.3 kg) 58.0 lb (26.3 kg) 70.5 lb (32.0 kg) 70.5 lb (32.0 kg) 72.5 lb (32.9 kg) Unit Weight 266 lb (120.7 kg) 284 lb (128.8 kg) 294 lb (133.4 kg) 278 lb (126.4 kg) 291 lb (132.3 kg) In accordance with

2000/14/EEC standards Sound at Operator’s ear 93 dB(a) 93 dB(a) 93 dB(a) 93 dB(a) 93 dB(a) Shipping Weight 315 lb (143.2 kg) 333 lb (151 kg) 348 lb (157.9 kg) 330 lb (150.0 kg) 340 lb (154.7 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

Stratton INTEK OHV

106 dB(a) 106 dB(a) 106 dB(a) 106 dB(a) 106 dB(a)

15o 15o 20o 20o 20o

Briggs and Stratton INTEK OHV

Honda GXV Honda GXV Honda GXV

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. P/N 500355. Side deck skid.

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

Part No 500360 3 F062210A

BC2403 Series Brush Cutter Owner’s Manual

GENERAL SAFETY INSTRUCTIONS and SYMBOLS

The safety symbols shown below are used throughout this manual. You should be thorou ghly 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 equip ment.

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 a sse mbling, 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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BC2403 Series Brush Cutter Owner’s Manua

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-like material, wire,

rags, cans, metal or other non-organic material. 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.

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BC2403 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: 80 Wind Speed: 2.0 mph (3.2 kph) Wind Direction: South Humidity: 63.5% Barometric Pressure: 29.98” Hg (761mm Hg)

F (25oC)

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: 89 Wind Speed: 6.1 mph (9.9 kph) Wind Direction: West Humidity: 49.7% Barometric Pressure: 29.88” Hg (101.19 kPa)

F (31.7oC)

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 is not 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 area s.

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BC2403 Series Brush Cutter Owner’s Manua

INSTRUCTION LABELS

The labels shown below were installed on your BILLY GOAT 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

(See Figure 6 Item 169)

PN 890254

(See Figure 6 Item 188)

Item No 184 - PN 810736

(See Figure 8 Item 184)

Item No 187 - PN 890301

(See Figure 6 Item 187)

Item No 191 - PN 500176

(See Figure 7 Item 191)

Item No 189 - PN 500168

(See Figure 6 Item 189)

ENGINE LABELS

Honda Briggs and Stratton

Brush Cutter. If any labels are damaged or

PN 500349

(See Figure 7 Item 186)

PN 900327

(See Figure 6 Item 185)

PN 500279

(See Figure 6 Item 190)

Item No 180 - PN 400424

(See Figure 8 Item 180)

Item No 192 - PN 500177

(See Figure 7 Item 192)

PN 100252

Part No 500360 7 F062210A

Attach shifter to linkage here

100

BC2403 Series Brush Cutter Owner’s Manual

202

Brush Cutter Assembly Drawing

Figure 1

Part No 500360 8 F062210A

BC2403 Series Brush Cutter Owner’s Manua

ASSEMBLY INSTRUCTIONS

Your BILLY GOAT ® BC Self-Propelled Brush Cutter was shipped i n one carton, completely assemb led except for th e upper handle assembly and the front guard bar. Mounti ng hardware for the handle and guard bar is temporarily i nstalled on the lower handle and the front of the deck assembly.

READ all safety instructions before assembling unit.

Electric start units are shipped with a battery. A CB18, C50, SC50 or MCB50 series dry or wet battery with a 17.2 Ah rating is required when replacing the battery.

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 500356  Bar Skids, P/N 500355  Owner’s Manual, P/N 500264  Honda or Briggs and Stratton Engine Manual  Warranty Card, P/N 400972  Ty-Wraps (4 ea)

 Tube shifter with grip, P/N 500370

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 t ight on ly.

5. Make sure engine pull starter is properly installed in guid e (145) and then t ighten up per h andle fastener s (Honda e ngin e only).

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

7. Remove mounting hardware (33, 117, 119, and 141) from bar brace (31) and skids (155).

8. Remove the hardware (item 100 and 202) from the transmission linkage. Attach the shifter tube (item 22) with the hardware. Make sure the shifter moves freely.

9. Place a wood block under the deck and attach the skids using har dware removed from them. Use the bottom two holes on the longer end to attach to the front of the deck.

Warning: When attaching the Skids be careful of the blade. Wear thick gloves and

check the position of the blade before putting your hands into the deck to install the bolts though the Skids.

10. Attach guard bar (31) to Skid bar by installing the side bolts into the top two holes on the skids.

11. 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 i nto 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.

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BC2403 Series Brush Cutter Owner’s Manual

12. Reconnect spark plug wire.

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-like material, wire,

rags, cans, metal or other non-organic material. 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 500360 10 F062210A

BC2403 Series Brush Cutter Owner’s Manua

OPERATOR CONTROLS

The operator’s station is at the rear of the machine between the handlebars. The operator should STAND in a position to allow both handlebars to be grasped firmly and which allows sufficient leverage to steer the machine. Operator’s controls are shown below.

Operator Control Locations

1 Blade Clutch Lever 5 ON/OFF Switch 2 Gear Shift Lever 6 Drive Clutch Lever 3 Choke 7 Pull Starter 4 Throttle

STARTING

CHECK engine oil level before operating machine.

1. Place equipment on a level, firm surface that is free of rocks or other debris.

2. Place throttle in START position.

Throttle

Part No 500360 11 F062210A

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