Billy Goat BC2402IC, BC2402H, BC2402HE, BC2402ICE Brush Cutter User Manual
Contents
1. o BILLY 23 GOAT Wl 2 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 BC24021C BC2402H BC2402HE BC2402ICE 3 Patent Number D386768 Specifications BC24021C BC2402H BC2402HE BC2402ICE ENGINE H P ENGINE TYPE ENGINE MODEL NO ENGINE FUEL CAP ENGINE OIL CAP WEIGHT UNIT WEIGHT SHIPPING ENGINE WEIGHT MAX OPERATING SLOPE UNIT SIZE Part No 500264 13 9 70 kW B amp S INTEK OHV MODEL 21 3 0 qt 2 8 L 1 5 qt 1 4 L 2664 120 7 kg 3154 143 2 kg 58 04 26 3 kg 15 OVERALL LENGTH 82 5 2 09 m 13 9 70 kW HONDA GXV390 2 3 qt 2 18 L 1 20 qt 1 13 L 278 126 4 kg 330 150 0 kg 70 5 32 0 kg 20 OVERALL WIDTH 32 0 0 81m Page 1 of 12 13 9 70 kW HONDA V390K1DE33 2 3 qt 2 18 L 1 20 qt 1 13 L 291 132 3 kg 340 154 7 kg 72 5 32 9 kg 20 13 9 70 kW B amp S INTEK OHV MODEL 21 3 0 qt 2 8 L 1 5 qt 1 4 L 273 124 1 kg 325 147 7 kg 60 0 27 32. 103 holding the two belt guides Items 149 amp 150 in place next to the crankshaft drive pulley 9 at the rear of the machine Part No 500264 Page 10 of 12 Form No F082704A MAINTENANCE continued 5 cont This will loosen the belt guides Items 149 amp 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 amp 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 brak
3. 900327 FOE MAINTENANCE GCOS A WARNING Read and follow Operating Ly Instructions before running engine KEEP HANDS and FEET AWAY Gasoline is flammable Allow engine Label Danger Flyin ea to cool at least 2 minutes before fueling Material Item 184 Part No 810736 Label Read Owner s Manual Item No 187 Part No 890301 Engines emit carbon monoxide DO NOT run in enclosed area Label Danger Keep Hands and Feet Away Item 180 PartNo 400424 J iH N p Label Shift BC2400 Item No 186 Part No 500202 WAIR CLEANER MAINTENANCE EVERY 50 HOURS UNDER DUSTY CONDITION EVERY 10 HOURS BENTRETIENT DU FILTRE A AIR TOUTES LES 50 HEURES TOUTES LES 10 HEURES EN MILIEU POUSSIEREUX LUFTFILTER PFLEGE ALLE 50 STUNDEN UNTER BESONDERS STAUBIGEN BEDINGUNGEN ALLE 10 STUNDEN Label Clutch Blade Item 192 Part No 500177 A CAUTION WHEELS MUST BE CHOCKED OR BLOCKED WHEN UNIT IS PARKED ON A SLOPE Label Clutch Drive Item 191 Part No 500176 US DESIGN PATENT NO D386768 PART NO 500279 WARNING GASOLINE IS FLAMMABLE SHUT OFF ENGINE AVOID HEAT SPARKS AND OPEN FLAME WHEN REFUELING Z p gt Label Chock Wheels Item No 189 Part No 500168 Label Patent No Item 190 Part No 500279 500168 Part No 500264 Page 4 of 12 Form No F082704A OPERATION INTENDED USE This is not a lawn mower The Brush Cutter is designed for cutting over
4. WIRE handle hardware before final tightening Note Be sure the engine starter BEFORE ASSEMBLING UNIT 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 Oy Read all safety and operating instructions before assembling or starting this unit Your Billy Goat Brush Cutter is shipped from the 4 REMOVE hardware items 102 103 117 119 124 141 amp 152 from factory in one carton completely assembled except temporary storage positions on deck and skid assy at front of unit for the upper handle and front guard bar items 2 155 amp 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 battery The battery bracket is designed to use the deck last Securely tighten all fasteners Note Hardware items 117 CB18 series C50 series SC50 series or MCB50 119 amp 141 are used to secure both the front skid attachment and the series dry or wet cell batteries with a 17 2 Ah sides of the guard bar Be sure both are securely attached minimum rating 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 NOTE Electric start units are shipped without a Per Model Handle Up
5. kg 15 OVERALL HEIGHT43 1 09m Form No F082704A s IN THE INTEREST OF SAFETY BEFORE STARTING ENGINE READ AND UNDERSTAND THE ENTIRE OPERATOR S MANUAL amp ENGINE MANUAL THIS SYMBOL MEANS WARNING OR CAUTION DEATH PERSONAL INJURY AND OR PROPERTY DAMAGE MAY OCCUR UNLESS INSTRUCTIONS ARE FOLLOWED CAREFULLY AWARN NG 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 4 amp or damage to unit 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 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 spilled Move machine away from the spill and avoid creating any ignition until the gasoline has evapor
6. 4 8041035 6 78041035 6 8041035 6 8041035 6 Part No 500264 Page 7 of 12 Form No F082704A Description BC2402HE Qty BC2402H Qty BC2402ICE Qty BC2402IC Qty Dis Patio Patio Patto Pane 112 Bor Shouider V2 x 3 118 Bol Carraige 516 18x1 8024040 6 78024040 6 78024040 6 78024040 6 121 Terminal Pigoyoack sre esoo 1 sooro il T Denotes standard hardware Want i aee purchased locally 143 Screw Cap 5m6 18x134 6041031 7 8041031 7 8041031 o 8041031 9 145 Guide Bope sss 2 sos 2 T T 147 LabelStanvStopTogge sos I 162 Cable Battery Red WCharge soos M sao pp 169 Cable Battery Biak 10 reos i vens 3164 Bracket Battery Rear 50887 1 soq pj 165 Strap Hold Down voa i zoos A nm A one A E AA E 193 Plate Choke MountBC 50025 1 500325 194 Screw Machine 10 32 X 3 4 430248 1 430248 1 J 195 Control Cable ChokeBC_________ 50026 500326 ifl CT Part No 500264 Page 8 of 12 Form No F082704A OPERATION continued 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 dis
7. ated 9 DO NOT transport unit with fuel in tank 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 exces sive speeds This may result in injury 6 TABLE OF CONTENTS SAFETYINSTRUCTIONS 2 GENERAL SAFETY 3 ASSEMBLY 3 LIT BAG amp CONTROLS 4 LABELS 4 OPERATION 5 9 MAINTENANCE 10 12 PARTS DRAWING amp LIST 6 8 TROUBLESHOOTING 12 WARRANTY PROCEDURE 12 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 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
8. ded Lift holding the handle and front guard for deck Secure in place during transport A Never lift the unit with the engine running Part No 500264 Page 9 of 12 STORAGE A 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 P Fig 2 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 wo
9. e Check for spark with an approved tester Clean or replace air cleaner Contact service dealer Starter does not turn Electric start unit only Battery is too low or dead Battery cable is disconnected or battery terminal is corroded Bad starter switch or wire harness Bad starter Charge battery or replace with a new one Clean battery terminals Replace starter switch Replace Wire harness Contact service dealer The engine will not stop Damaged stop switch Stop switch wire is disconnected Stop switch wire is worn or damaged Replace stop switch Connect stop switch wire Replace stop switch wire Will not cut or has poor cutting performance Dull Blade Clogged deck Excessive quantity of debris built up or blocking blade Engine RPM set too low Unclog deck see page 5 Sharpen blade Check engine RPM see page 11 for settings Abnormal vibration Loose or out of balance blade or loose engine Check blade and replace if required Check Engine Belt slips or smokes Belt tension too low Belt worn or stretched Pulleys worn or damaged Increase tension at idler see page 11 Replace belt Replace pulleys 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 Adjust or replace cable see above Re
10. e 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 BELT REPLACEMENT 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 require ments for your unit and will greatly reduce machine performance and belt life 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 relea
11. e 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 amp 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 tigh
12. ear the clog by hand See below A drop in engine RPM or a notice able 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
13. engaged 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 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 Lever Up Engages Clutch Handle Fig 1 2 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 HANDLING amp TRANSPORTING Using three people to lift machine is recommen
14. facturer operating and maintenance instructions 8 Inspect machine and work area before starting unit 7 SOUND 8 XC VIBRATION Sound tests conducted were in accordance with 2000 14 EEC and were performed on 2 21 2002 under the conditions listed 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 GENERAL CONDITION Sunny L TEMPERATURE 80 F 25 C WIND SPEED 2 MPH 3 2 kmh 1 06 d B WIND DIRECTION South BC2402HE MODEL HUMIDITY 63 5 BAROMETRIC PRESSURE 29 98 Hg 761mm Hg Sound level of 93 dBA at operator position 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 Sunny TEMPERATURE 72 F 22 2 C WIND SPEED 5 MPH 8 0 kmh WIND DIRECTION South West HUMIDITY 67 BAROMETRIC PRESSURE 30 06 Hg 763mm Hg MX Part No 500264 Page 2 of 12 Form No F082704A 9 GENERAL SAFETY For your safety and the safety of others these directions should be followed are not operate this machine without first reading DO NOT operate during excessive vibration owner s manual and engine manufacturer s manual DO NOT
15. 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 t Handle Lever c Down Engages Clutch AN NN Fig 1 1 Form No F082704A oe Qon A PO Lek O z a Q lt z x BC2402HE BC2402H BC2402IC BC2402ICE Form No F082704A Page 6 of 12 Part No 500264 BC2402ICE BC24021C Part No QTY Part No QTY BC2402HE BC2402H ped Part No QTY Part No QTY 6 j HandeBraceRight 500200 1 500200 1 8 Transaxle 3 SPDBC2400 500342 1 500342 1 500342 1 500342 1 9 Pulley 5 0 OD A Sec 830180 1 830180 1 830160 1 830180 15 Wheel 8 Tire 16 AG SP RH Bearing 7 8 ID Sealed Press Pulley 7 OD x 7 8 BORE 45 Engine 13 HP Honda GXV390 Electric Stat 500888 1 J Engnei3HPHondaGXV390 5034 A OMR Oc o usen A AA Peas evene ATA iaa Engine 13 HP OHV Briggs Electric Stat O J 52039 1 Blade 24 BC2400 AAA PP a t 107 SCREWCAP 5 16 18X1 ___________ 8041028 9 8041028 9 8041028 9 8041028 9 108 ScrewCap5 16 18x23
16. grown 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 STARTING ut PUT OIL IN ENGINE BEFORE STARTING 94 ENGINE See engine manufacturer s instructions v 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 ful
17. l start position Honda engines have a separate choke lever that is oper ated 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 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 Ze l Page 5 of 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 cl
18. muffler area 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 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 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 resis tance 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 manu
19. per Assembly 500256 Bar Guard WA 500235 Literature Literature Assy Assy 500263 Briggs amp Stratton Honda English Check Honda WIElectric Start English Part No 500264 Page 3 of 12 Form No F082704A Throttle Control 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 Literature Checklist 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 Check Owner s Manual 500264 Owner s Manual START START Warranty den ty Card 400972 Pull to choke Ty Wrap 900407 STOP Qty 4 STOP INSTRUCTION LABELS ENGINE LABELS 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 replace ment labels 009 PE m 15 Briggs amp Stratton 4h WARNING EXPLOSIVE FUEL 8 STOP ENGINE AND ALLOW TO COOL BEFORE REFUELING Label Do Not Fill While Engine Is Hot Item 63 Part No 400268 Label Ear Eye Breathing Item No 188 Part No 890254 O Label Warning Guards d EIE Er i POA EMALI A ADA Item 185 Part No
20. perform any maintenance or inspection until engine has A O Use of Ear Protection is recommended while bso noi d cometo a complete stop and the Spark operating this machine DO NOT operate machine with guards removed T Use of Eye and Breathing protection is recom DO NOT use this machine for cutting areas containing rock mended when using this machine glass string like material wire rags cans metal or other non organic 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 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 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 amp 144 from temporary storage positions on lower handle items 51 amp 52 HT PUT OIL IN ENGINE BEFORE STARTING 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 Y DISCONNECT SPARK PLUG
21. place clutch brake No self propelling Operator s clutch lever not releasing clutch Broken or out of adjustment clutch cable Worn or broken belt Adjust clutch cable Replace any worn damaged or malfunctioning parts Self propelled drive will not Clutch cable out of adjustment Adjust clutch cable See page 10 Wheel Drive Clutch Adjustment release Engine is locked will not pull over Debris locked against blade Engine problem Engine Service and Warranty Contact your nearest engine manufacturer s authorized servicing dealer 21 Serial Plate BiLLY GOAT INDUSTRIES INC 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 Serial No Unit Weight lbs kw Purchased from Purchase Date Part No 500264 Page 12 of 12 Remove debris see page 5 Contact an engine servicing dealer for engine problems see page 10 WARRANTY PROCEDURE 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 o
22. 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 Ibs 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
23. r 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 amp Serial Number which are printed on the Billy Goat Serial Plate See owner s manual BILLY 3 GOAT 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 Form No F082704A
24. rk 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 amp Stratton 800 233 3723 American Honda 800 426 7701 Form No F082704A MAINTENANCE Use only a qualified mechanic for any adjustments disassembly or any kind of repair TURN MACHINE OFF MAKE SURE ALL MOVING WARNING TO AVOID PERSONAL INJURY ALWAYS PARTS COME TO A COMPLETE STOP Y DISCONNECT SPARK PLUG WIRE BEFORE SERVICING UNIT A RECONNECT SPARK PLUG WIRE AND ALL GUARDS BEFORE STARTING ENGINE WHEN POWER WASHING DO NOT SPRAY 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 BLADE REMOVAL SHARPENING 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 4h 1 Disconnect spark plug wire 2 Support front of unit to allow access to the blad
25. se 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 amp 150 in place next to the crankshaft drive pulley 9 at the rear of the machine This will loosen the belt guides Items 149 amp 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 amp 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 amp 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 As the belt wears adjustments may be required to maintain
26. ten 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 O BATTERY BATTERY TERMINAL ON BATTERY RED CONDUCTOR a TO GROUND BLACK CONDUCTOR Part No 500264 Page 11 of 12 Blade Drive Belt Transaxle Drive Belt Belt in bottom groove of engine pulley Fig 3 Maintenance Schedule Belt in top groove of engine pulley Follow these hourly maintenance intervals Every 5 hrs Every 25 Every 50 or Daily hrs hrs Every Maintenance Operation 100 150 hrs 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 Service Performed Date of Service Form No F082704A MAINTENANCE continued CLUTCH ADJUSTMENT Clutch Brake Adjustment As the clutch brake wears adjustments may be required to maintain proper con
27. trol cable tension and clutch engagement 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 ofthe 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 necessary if adjustment will not allow for proper clutch and brake engagement MINIMUM FORCE 10 LBS WHEN FULLY DEPRESSED MOVE ADJUSTER OUT TO INCREASE CABLE TENSION MOVE ADJUSTER IN TO WARNING If the clutch begins to squeal or slip do not 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 DECREASE CABLE TENSION Fig 4 TROUBLESHOOTING Before Requesting Service Review These Suggestions Problem The engine will not start Possible Cause Stop switch is off Throttle is not in ON position Out of gasoline Bad or old gasoline Spark plug wire disconnected Dirty air cleaner Solution Check switch throttle amp gasolin
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Billy Goat BC2402IC BC2402H BC2402HE BC2402ICE Brush Cutter User Manual