Billy Goat BC2402IC, BC2402H, BC2402HE, BC2402ICE Brush Cutter User Manual

1
ACCESSORIES
2
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
Specifications
3
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
BC2402IC
BC2402H
BC2402HE
13 (9.70 kW)
B&S INTEK OHV
MODEL 21
3.0 qt. (2.8 L)
1.5 qt. (1.4 L)
266# (120.7 kg)
315# (143.2 kg)
58.0# (26.3 kg)
15°
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°
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°
OVERALL LENGTH: 82.5"(2.09 m)
OVERALL WIDTH 32.0" (0.81m)
Page 1 of 12
BC2402ICE
13 (9.70 kW)
B&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# (27.3 kg)
15°
OVERALL HEIGHT43" (1.09m)
Form No. F082704A
IN THE INTEREST OF SAFETY
5
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
laws apply on federal lands.
& /or damage to unit.
13. DO NOT tamper with governor springs,
1. DO NOT run engine in an enclosed
governor links or other parts which may
area. Exhaust gases contain carbon
monoxide, an odorless and deadly poison. change the governed engine speed.
14. DO NOT tamper with the engine speed
selected by the engine manufacturer.
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.
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 muffler area.
8. DO NOT operate engine if gasoline is
spilled. Move machine away from the spill
20. DO NOT use this engine on any forest
and avoid creating any ignition until the
covered, brush covered, or grass covered
gasoline has evaporated.
unimproved land unless a spark arrester is
9. DO NOT transport unit with fuel in tank. installed on the muffler. The arrester must
be maintained in effective working order by
10. DO NOT smoke when filling fuel tank. the operator. In the State of California the
above is required by law (Section 4442 of
11. DO NOT choke carburetor to stop
the California Public Resources Code).
engine. Whenever possible, gradually
Other states may have similar laws. Federal
reduce engine speed before stopping.
12. DO NOT run engine at excessive speeds. This may result in
injury
6
TABLE OF CONTENTS
2
SAFETY INSTRUCTIONS
3
GENERAL SAFETY
3
ASSEMBLY
4
LIT. BAG & CONTROLS
4
LABELS
5, 9
OPERATION
10 - 12
MAINTENANCE
6-8
PARTS DRAWING & LIST
12
TROUBLESHOOTING
12
WARRANTY PROCEDURE
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Part No. 500264
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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
GENERAL CONDITION:
TEMPERATURE:
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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.
8
Sound tests conducted were in accordance with 2000/14/EEC and
were performed on 2/21/2002 under the conditions listed:
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23. DO NOT operate during excessive
vibration!
24. DO NOT leave machine unattended
while in operation.
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:
Sunny
GENERAL CONDITION:
Sunny
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22. DO NOT run engine without air cleaner
or air cleaner cover.
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SOUND
7
21. DO NOT touch hot muffler, cylinder, or
fins because contact may cause burns.
WIND SPEED:
106 dB
80° F (25° C)
2 MPH (3.2 kmh)
South
WIND DIRECTION:
(BC2402HE MODEL)
63.5 %
HUMIDITY:
○
BAROMETRIC PRESSURE:
29.98" Hg (761mm Hg)
Page 2 of 12
TEMPERATURE:
72° F (22.2° C)
WIND SPEED:
5 MPH (8.0 kmh)
WIND DIRECTION:
HUMIDITY:
BAROMETRIC PRESSURE:
South West
67 %
30.06" Hg (763mm Hg)
Form No. F082704A
9
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 recommended 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.
10
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.
11
·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.
Per Model
Check
Handle Upper
Assembly
500256
Check
Bar Guard WA
500235
Check
Literature
Assy
Literature Assy
500263
Check
Briggs & Stratton
Check
Engine
Manual
Honda(English)
Check
Honda W/Electric
Start (English)
Part No. 500264
Page 3 of 12
Form No. F082704A
12
LITERATURE ASSY P/N 500263
13 CONTROLS
Throttle Control
Literature Checklist
BRIGGS &
STRATTON
Check
Owner's
Manual
Owner's
Manual
500264
HONDA
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.
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.
START
START
Check
Warranty
Card
400972
Warranty
Card
Pull to choke
Ty Wrap 900407
Qty: (4)
14
INSTRUCTION LABELS
15
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..
WARNING
ENGINE LABELS
Briggs & Stratton
WARNING
400268
EXPLOSIVE FUEL
STOP
STOP
Label Do Not Fill While
Engine Is Hot
Item 63 Part No.400268
900327
890254
STOP ENGINE AND ALLOW T O
COOL BEFORE REFUELING.
Label Ear Eye Breathing Item
No. 188 Part No. 890254
Label Warning Guards
Item 185 Part No.900327
'
..
..
'
'
DANGER
810736
Read and follow Operating
Instructions before running engine.
N
123
500177
R
Gasoline is flammable. Allow engine
to cool at least 2 minutes before fueling.
Label Read Owner's
Manual Item No. 187
Part No. 890301
Engines emit carbon monoxide,
DO NOT run in enclosed area.
Honda
500176
Label Danger Keep Hands and
Feet Away
Item 180 PartNo.400424
Label Danger Flying
Material Item 184
Part No.810736
Label Shift BC2400
Item No. 186
Part No. 500202
Label Clutch Blade
Item 192
Part No.500177
WHEELS MUST BE CHOCKED
OR BLOCKED WHEN UNIT IS
PARKED ON A SLOPE.
500168
Label Clutch Drive
Item 191
Part No.500176
US DESIGN PATENT
NO: D386768
PART NO. 500279
Label Patent No
Item 190 Part No.500279
Label Chock Wheels Item No. 189 Part No. 500168
Part No. 500264
Page 4 of 12
Form No. F082704A
OPERATION
16
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
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.
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.
BLADE CLUTCH
ENGINE SPEED: Controlled by throttle lever on the handle.
FUEL VALVE: Move fuel valve to "ON" position (when
provided on engine).
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.
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.
Lever Up
Disengages
Clutch
Handle
IF YOUR UNIT FAILS TO START:
See Troubleshooting on page 12.
16.2
Lever
CUTTING OPERATION
Lever
Down
Engages
Clutch
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
Page 5 of 12
Fig. 1.1
Form No. F082704A
18
PARTS DRAWING
BC2402HE, BC2402H, BC2402IC,
BC2402ICE
Part No. 500264
Page 6 of 12
Form No. F082704A
19
PARTS
LIST
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
100
101
102
103
104
105
106
107
108
109
110
111
DESCRIPTION
Deck Assembly with labels
Deck WA BC2401
Deflector Front BC2400
Base Assembly with labels
Handle Brace Left
Handle Brace Right
Door Base Engine
Transaxle 3 SPD BC2400
Pulley 5.0" OD ‘A’ Sec.
Belt Traction Drive
Plate Pivot Idler / Shifter
Shifter Pivot WA
Pulley Idler
Wheel & Tire 16" AG SP LH
Wheel & Tire 16" AG SP RH
Arm Idler WA
Cable Clutch Blade BC2400
Cable Clutch Drive BC2400
Bar Shift T-axle
Angle Support T-axle
Rod Link Shifter
Tube Shift With Grip
Clutch Brake
Grip 3/4 ID - Black
Tube Pointer
Plate Mount Idler WA
Pulley Idler 4.5" OD X 3/8
Hub Cap
Belt Blade Drive
Spacer Spindle BC2401
Bar Guard WA BC2401
Bushing Shifter
Washer Hub Cap
Spindle WA BC2400
Bearing 7/8" ID Sealed Press
Shaft Drive Blade
Spacer Spindle Bearing
Pulley 7" OD x 7/8" BORE
Lever Control Blade
Handle Upper BC2400
Grip Handle 1 ID x 7.5
Lever Control Clutch
Bushing Lever Control
Fitting Mount Cable
Engine 13 HP Honda GXV390 Electric Start
Engine 13 HP Honda GXV390
Engine 13 HP OHV B & S
Engine 13 HP OHV Briggs Electric Start
Pulley Drive Traction BC
Spacer Engine WA 2401
Control Throttle BC2400
Nut Lock 3/8-16 Thin
Blade 24" BC2400
Handle Lower RH BC2400
Handle Lower LH BC2400
Adapter Blade WA
Washer Friction Blade
Guard Hand BC2401
Screwcap 8x3/8 HWH Type B
Bolt Carraige 1/4 - 20 x 3/4
Nut Lock 1/4 - 20
Screw Cap 5/16 - 18 x 1 1/4
Washer Lock 5/16 split
Plate Impeller Washer
Screw Cap 7/16-20 X 3"
SCREWCAP 5/16-18 X 1"
Screw Cap 5/16 - 18 x 2 3/4
Bolt Carraige 5/16 - 18 x 3/4
Washer Flat 1/2"
Pin Cotter 3/32 x 3/4"
Part No. 500264
BC2402HE
Part No
500239
500266
500125
500240
500196
500200
500233
500342
830180
500119
500122
500169
800260
500343
500344
500170
500259
500327
500121
500127
500144
500171
500338
610102
500184
500228
500270
900486
500237
500232
500235
500130
850237
500174
500101
500107
500115
500253
500312
500243-S
500267
500142
500152
500187
500333
500238
500262
500213
8161042
500210
500140
500141
500191
500108
500339
100121
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
2
1
1
1
1
1
2
1
4
2
1
1
1
1
1
1
1
1
1
1
2
2
BC2402H
Part No
500239
500266
500125
500240
500196
500200
500233
500342
830180
500119
500122
500169
800260
500343
500344
500170
500259
500327
500121
500127
500144
500171
500338
610102
500184
500228
500270
900486
500237
500232
500235
500130
850237
500174
500101
500107
500115
500253
500312
500243-S
500267
500142
500152
500187
500334
500238
500262
500213
8161042
500210
500140
500141
500191
500108
500339
100121
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
2
1
1
1
1
1
2
1
4
2
1
1
1
1
1
1
1
1
1
1
2
2
8024021
*8160001
*8041029
*8177011
850443
500269
*8041028
*8041035
8024039
900230
*8197016
4
13
13
11
1
1
9
6
2
1
1
8024021
*8160001
*8041029
*8177011
850443
500269
*8041028
*8041035
8024039
900230
*8197016
4
13
13
11
1
1
9
6
2
1
1
Page 7 of 12
BC2402ICE
Part No
QTY
500239
1
500266
1
500125
1
500240
1
500196
1
500200
1
500233
1
500342
1
830180
1
500119
1
500122
1
500169
1
800260
1
500343
1
500344
1
500170
1
500259
1
500327
1
500121
1
500127
1
500144
1
500171
1
500338
1
610102
1
500184
1
500228
1
500270
1
900486
2
500237
1
500232
1
500235
1
500130
1
850237
2
500174
1
500101
2
500107
1
500115
1
500253
1
500312
1
500243-S
1
500267
2
500142
1
500152
4
500187
2
520039
1
500238
1
500262
1
500213
1
8161042
1
500210
1
500140
1
500141
1
500191
1
500108
1
500339
2
100121
2
8024021
*8160001
*8041029
*8177011
850443
500269
*8041028
*8041035
8024039
900230
*8197016
4
12
13
11
1
1
9
6
2
1
1
BC2402IC
Part No
500239
500266
500125
500240
500196
500200
500233
500342
830180
500119
500122
500169
800260
500343
500344
500170
500259
500327
500121
500127
500144
500171
500338
610102
500184
500228
500270
900486
500237
500232
500235
500130
850237
500174
500101
500107
500115
500253
500312
500243-S
500267
500142
500152
500187
520046
500238
500262
500213
8161042
500210
500140
500141
500191
500108
500339
100121
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
2
1
1
1
1
1
2
1
4
2
1
1
1
1
1
1
1
1
1
1
2
2
8024021
*8160001
*8041029
*8177011
850443
500269
*8041028
*8041035
8024039
900230
*8197016
4
12
13
11
1
1
9
6
2
1
1
Form No. F082704A
19
* Denotes
standard
hardware item,
that may be
purchased
locally.
Part No. 500264
Item
No.
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
180
184
185
186
187
188
189
190
191
192
193
194
195
196
Description
Bolt Shoulder 1/2 x 1
Nut Lock 3/8-16
Bolt Idler
Screw Cap 5/16 x 2"
Nut Jam 5/16 - 18
Nut Lock 5/16 - 18
Bolt Carraige 5/16 - 18 x 1
Screw Cap 5/16 x 1 1/2
Washer 3/8 FC
Terminal Piggyback 3/16
Screw Cap 1/4 - 28 x 1/2 GR5
Washer Lock 5/16 external tooth
Washer 1/4 FC
Screw Self Tap 5/16
Pin Hair Cotter
Washer 5/16 SAE
Pin Cotter 3/32 x 3/4
Washer 3/4 SAE
Washer 0.765 x 1.250 x 0.060
Spacer Engine
Ring Snap 0.750
Key 3/16 x 2 1/8
Spindle Assembly Complete
Screw Cap 7/16 - 20 x 1 1/4 GR8
Washer 1.25 x 0.882 x 0.125
Ty Wrap
Key Sq 3/16 x 5/8
Screw Cap 7/16 - 20 x 2 GR8
Washer Lock 7/16 Tw. Tooth
Washer 5/16 FC
Bracket Clutch Cable Guard
Screw Cap 5/16 - 18 x 1 3/4
Screw Cap 5/16 - 18 x 2 1/2
Guide Rope
Grip Lever
Label Start/Stop Toggle
Screwcap 5/16-18 X 3/4"
Guide Belt LH
Guide Belt RH
Screw Cap 5/16 - 24 x 1
Screw Cap 1/4 - 20 x 1 1/4
Screw Cap 1/4 - 20 x 2 3/4
Screwcap 1/4-20 x 2”
Skid RH BC v-cup WA
Skid LH BC v-cup WA
Switch Box Assy BC
Switch Toggle
Harness Assy
Bushing Strain Relief
Label Throttle
Cable Battery Red W/Charge
Cable Battery Black 10"
Bracket Battery Rear
Strap Hold Down
Label Hot Engine
Bolt Shoulder 5/16 x 1 1/2
Label OPEI
Label Flying Debris
Label Guards
Label Shift BC2400
Label Read
Label Ear Eye Breathe
Label Chock Wheels
Label Patent No
Label Clutch Drive
Label Clutch Blade
Plate Choke Mount BC
Screw Machine 10-32 X 3/4"
Control Cable Choke BC
Ring Retaining External 3/4
BC2402HE
Part No.
500114
*8160003
800888
*8041032
*8142002
*8160002
*8024040
*8041030
*8171004
890010
850408
8181008
*8171002
*8123128
900471
*8172008
8197016
*8172015
850238
830113
850230
9201087
500242
800554
500182
900407
9201072
500188
850132
*8171003
500321
*8041031
*8041034
830533
500181
500329
8041026
500230
500231
*400164
*8041007
*8041013
*8041010
500291
500292
500318
500307
500306
500282
810656
500304
790133
500347
790303
Qty.
400268
500340
400424
810736
900327
500202
890301
890254
500168
500279
500176
500177
500325
430248
500326
520176
1
2
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
3
1
2
2
28
6
4
1
1
1
1
5
1
2
2
1
2
2
1
2
2
1
1
1
4
2
1
3
27
1
7
1
2
2
1
1
1
1
2
3
1
2
1
1
1
1
1
1
1
1
1
1
1
Page 8 of 12
BC2402H
Part No.
500114
*8160003
800888
*8041032
*8142002
*8160002
*8024040
*8041030
*8171004
890010
850408
8181008
*8171002
*8123128
900471
*8172008
8197016
*8172015
850238
830113
850230
9201087
500242
800554
500182
900407
9201072
500188
850132
*8171003
500321
*8041031
*8041034
830533
500181
Qty.
8041026
500230
500231
*400164
*8041007
*8041013
*8041010
500291
500292
500283
500281
890442
500282
810656
-
1
1
1
2
3
1
2
1
1
1
1
1
1
1
-
400268
500340
400424
810736
900327
500202
890301
890254
500168
500279
500176
500177
500325
430248
500326
520176
1
2
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
3
1
2
2
28
6
4
1
1
1
1
5
1
2
2
1
2
2
1
2
2
1
1
1
4
2
1
3
27
1
7
1
2
2
-
BC2402ICE
Part No.
500114
*8160003
800888
*8041032
*8142002
*8160002
*8024040
*8041030
*8171004
850408
8181008
*8171002
*8123128
900471
*8172008
8197016
*8172015
850238
830113
850230
9201087
500242
800554
500182
900407
9201072
500188
850132
*8171003
500321
*8041031
*8041034
Qty.
Qty.
1
3
1
2
2
30
6
4
1
1
1
5
1
2
2
1
2
2
1
2
2
1
1
1
4
2
1
3
23
1
9
1
BC2402IC
Part No.
500114
*8160003
800888
*8041032
*8142002
*8160002
*8024040
*8041030
*8171004
850408
8181008
*8171002
*8123128
900471
*8172008
8197016
*8172015
850238
830113
850230
9201087
500242
800554
500182
900407
9201072
500188
850132
*8171003
500321
*8041031
*8041034
500181
2
500181
2
8041026
500230
500231
*400164
*8041007
*8041013
*8041010
500291
500292
500283
500307
520118
500282
810656
520111
790133
500347
790303
1
1
1
2
3
1
2
1
1
1
1
1
1
1
1
1
1
8041026
500230
500231
*400164
*8041007
*8041013
*8041010
500291
500292
500283
500281
890442
500282
810656
-
1
1
1
2
3
1
2
1
1
1
1
1
1
1
-
400268
500340
400424
810736
900327
500202
890301
890254
500168
500279
500176
500177
1
2
2
1
2
1
1
1
1
1
1
1
400268
500340
400424
810736
900327
500202
890301
890254
500168
500279
500176
500177
1
2
2
1
2
1
1
1
1
1
1
1
520176
1
520176
1
1
3
1
2
2
30
6
4
1
1
1
5
1
2
2
1
2
2
1
2
2
1
1
1
4
2
1
3
23
1
9
1
Form No. F082704A
OPERATION
16
16.3
continued
16.6
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.
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
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
N
123
890254
R
Fig. 1.2
Fig. 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
HANDLING & TRANSPORTING:
Using three people to lift machine is recommended. Lift holding the
handle and front guard for deck. Secure in place during transport.
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
Never lift the unit with the engine running.
Part No. 500264
Page 9 of 12
Form No. F082704A
17
MAINTENANCE
TRANSAXLE DRIVE BELT
Use only a qualified mechanic for
any adjustments, disassembly or
any kind of repair .
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.
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.
17.1
WHEEL DRIVE CLUTCH ADJUSTMENT
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.
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
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 requirements for your unit , and will greatly reduce machine
performance and belt life.
Part No. 500264
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.
Page 10 of 12
Form No. F082704A
17
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.
Engine (See Engine Manual)
BLADE DRIVE BELT TENSION ADJUSTMENT
Check for excessive vibration
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.
Blade Drive Belt
Belt in top groove
of engine pulley
Fig. 3
Maintenance Schedule
Maintenance Operation
Follow these hourly
maintenance intervals.
Every Every 5 hrs Every 25
or (Daily)
hrs
Use
Every 50
hrs
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
STARTER SWITCH WIRING
Part No. 500264
Transaxle
Drive Belt
Belt in bottom groove
of engine pulley
Date of Service
Page 11 of 12
Service Performed
Form No. F082704A
Every
100-150 hrs
MAINTENANCE
17
continued
CLUTCH ADJUSTMENT
17.3
Clutch/Brake Adjustment:
As the clutch/brake wears, adjustments may be required to
maintain proper control 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 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
necessary if adjustment will not allow for proper clutch and
brake engagement.
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.
20
TROUBLESHOOTING
MINIMUM FORCE = 10 LBS.
WHEN FULLY DEPRESSED
MOVE ADJUSTER OUT TO
INCREASE CABLE TENSION
MOVE ADJUSTER IN TO
DECREASE CABLE TENSION
Fig. 4
Before Requesting Service Review These Suggestions
Possible Cause
Problem
Solution
The engine will not start
Stop switch is off. Throttle is not in ON position. Out of gasoline. Bad
or old gasoline. Spark plug wire disconnected. Dirty air cleaner.
Check switch, throttle, & gasoline. 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). Replace 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
release .
Engine is locked, will not
pull over.
Clutch cable out of adjustment.
Adjust clutch cable. See page 10 Wheel Drive Clutch Adjustment.
Debris locked against blade. Engine problem.
Remove debris (see page 5 ). Contact an engine servicing dealer
for engine problems.(see page 10)
22.1
21
WARRANTY PROCEDURE
Engine Service and Warranty
Contact your nearest engine manufacturer's authorized
servicing dealer.
R
Model
lbs.
1803 S.W. Jefferson
Lee's Summit,
MO 64082 / USA
Tel (816) 524-9666
Fax (816) 524-6983
Engine Power
kg
kW
rpm
min-1
Part No. 500264
-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.
Serial No.
Unit(Weight)
Purchase
Date
workmanship, the owner should make a warranty claim as follows:
Record your machine model, serial number and
date-of-purchase and where purchased
Serial Plate
106 dB
Should a Billy Goat Machine fail due to a defect in material and / or
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).
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
Purchased
from
Page 12 of 12
Form No. F082704A