BILLY GOAT ® BC2402 Series Brush Cutter Owner’s Manual Patent Number D386768 Part No 500264 1 Form No F061207B
BC2402 Series Brush Cutter Owner’s Manual ABOUT THIS MANUAL THANK YOU for purchasing a BILLY GOAT ® Brush Cutter. Your new machine has been carefully designed and manufactured to provide years of reliable and productive service. This manual provides complete operating and maintenance instructions that will help to maintain your Brush Cutter in top running order. Read this manual carefully before assembling, operating or servicing your equipment. CONTENTS Serial Plate Data ..................................
BC2402 Series Brush Cutter Owner’s Manual SERIAL PLATE DATA Record the model number, serial number, date of purchase, and where purchased. Purchase Date: Purchased From: BC 2402 SERIES SPECIFICATIONS BC2402IC BC2402H BC2402HE Honda GXV BC2402ICE Engine Type Briggs and Stratton INTEK OHV Honda GXV Model Number 21A902-0149-E1 GXV390UTIDABG GXV390K1DE33 21A907-0147-E1 Horsepower 13.0 (9.7 kW) 13.0 (9.7 kW) 13.0 (9.7 kW) 13.0 (9.7 kW) Fuel Capacity 3.0 qt (2.80 L) 2.3 qt (2.18L) 2.3 qt (2.
BC2402 Series Brush Cutter Owner’s Manual GENERAL SAFETY INSTRUCTIONS and SYMBOLS The safety symbols shown below are used throughout this manual. You should be thoroughly familiar with them before assembling, operating or servicing this equipment. This symbol indicates important information that will prevent injury to yourself or others. This symbol indicates ear protection is recommended when operating this equipment. This symbol indicates eye protection is recommended when operating this equipment.
BC2402 Series Brush Cutter Owner’s Manual DO NOT run this equipment indoors or in any poorly ventilated area. Refueling outdoors is recommended. DO NOT refuel this equipment while the engine is running. Allow engine to cool for at least two minutes before refueling. DO NOT store gasoline near an open flame. DO NOT remove gas cap while engine is running. DO NOT start or operate engine if strong odor of gasoline is present. DO NOT start or operate engine if gasoline is spilled.
BC2402 Series Brush Cutter Owner’s Manual SOUND DATA SOUND LEVEL 93 Dba at Operator’s position Sound tests were conducted in accordance with 2000/14/EEC and were performed on 2/21/2002 under the conditions listed below. Sound power level listed is the highest value for any model covered in this manual. Please refer to serial plate on the unit for the sound power level for your model. General Conditions: Temperature: Wind Speed: Wind Direction: Humidity: Barometric Pressure: Sunny 80oF (25oC) 2.0 mph (3.
BC2402 Series Brush Cutter Owner’s Manual INSTRUCTION LABELS The labels shown below were installed on your BILLY GOAT ® Brush Cutter. If any labels are damaged or missing, replace them before operating this equipment. Item numbers from the Illustrated Parts List and part numbers are provided for convenience in ordering replacement labels. The correct position for each label may be determined by referring to the Figure and Item numbers shown.
BC2402 Series Brush Cutter Owner’s Manual Brush Cutter Assembly Drawing Figure 1 Part No 500264 8 F061207B
BC2402 Series Brush Cutter Owner’s Manual ASSEMBLY INSTRUCTIONS Your BILLY GOAT ® BC Self-Propelled Brush Cutter was shipped in one carton, completely assembled except for the upper handle assembly and the front guard bar. Mounting hardware for the handle and guard bar is temporarily installed on the lower handle and the front of the deck assembly. READ all safety instructions before assembling unit. Electric start units are shipped without a battery.
BC2402 Series Brush Cutter Owner’s Manual OPERATION DO NOT run engine in an enclosed area. Exhaust gases contain carbon monoxide, an odorless and possibly fatal poison. DO NOT start or operate engine if strong odor of gasoline is present. DO NOT start or operate engine if gasoline is spilled. Move equipment away from spill until gasoline has completely evaporated. DO NOT operate engine without a muffler. Inspect muffler periodically and replace if necessary.
BC2402 Series Brush Cutter Owner’s Manual 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.
BC2402 Series Brush Cutter Owner’s Manual 3. Pull choke out (Honda engine only). Choke 4. Units equipped with electric starters: Press and hold ON/OFF button until engine starts. ON/OFF (I/O) Switch I-ON O-Off (Manual start shown) DO NOT START equipment with drive or blade clutch engaged. 5. Units equipped with manual starters: Pull starter rope to start engine.
BC2402 Series Brush Cutter Owner’s Manual PULL STARTER CORD slowly until resistance is felt. Then pull cord rapidly to avoid kickback. 6. Push choke in (Honda engine only). 7. Pull throttle control back to and allow engine to reach correct operating speed. CUTTING The best performance is achieved when cutting in dry conditions. The quality of the cut is directly related to ground speed during cutting. Under most conditions cutting should be done in first or second gear.
BC2402 Series Brush Cutter Owner’s Manual Drive Clutch Lever SHUT DOWN 1. Release drive clutch handle to disengage transaxle. 2. Release blade clutch handle to disengage blade. 3. Pull throttle control all the way back to the STOP position. 4. Place the ON/OFF (I/O) switch in the OFF (O) position. CUTTING HEIGHT ADJUSTMENT Cutting height can be adjusted to allow a 1” (2.54 cm) lower cutting height. This is particularly useful for cutting grasses that tend to lay over when overgrown (i.e.
BC2402 Series Brush Cutter Owner’s Manual HANDLING and TRANSPORTING Using four people to lift unit is recommended. Lift holding the handles and front deck guard. Make sure equipment is properly secured before transporting. NEVER lift the machine while the engine is running. STORAGE DO NOT store engine in an enclosed or poorly ventilated area where fuel fumes may reach an open flame or spark from a furnace, water heater, clothes dryer or similar devices.
BC2402 Series Brush Cutter Owner’s Manual MAINTENANCE PERIODIC MAINTENANCE Periodic maintenance should be performed at the following intervals: Maintenance Operation Every Use Inspect for worn or damaged parts. Daily or Every 5 Hours Every 25 Hours Every 50 Hours z Check for excessive vibration z Inspect for loose parts. z Sharpen blade. z Inspect belts for wear. z Lubricate throttle control cable and linkage. z Check blade clutch cable tension.
BC2402 Series Brush Cutter Owner’s Manual BLADE REMOVAL AND SHARPENING READ all safety instructions before servicing unit. Numbers in parenthesis ( N-N ) refer to figure and item numbers in Illustrated Parts List. Tools required: - 5/8” socket, 1/2” drive - torque wrench, 1/2” drive - jack stands or similar device adequate to support weight of machine. DISCONNECT spark plug wire before servicing unit. 1. Disconnect spark plug wire. 2. Lift and support front of unit to allow access to underside.
BC2402 Series Brush Cutter Owner’s Manual BLADE DRIVE BELT TENSION ADJUSTMENT READ all safety instructions before servicing unit. DISCONNECT spark plug wire before servicing unit. Numbers in parenthesis ( N-N ) refer to figure and item numbers in Illustrated Parts List. 1. Disconnect spark plug wire. 2. Remove two screws holding engine base door (6-7) and remove door. 3. Examine condition of belt and not position of idler assembly and amount of tension on belt. 4.
BC2402 Series Brush Cutter Owner’s Manual BLADE CLUTCH ADJUSTMENT READ all safety instructions before servicing unit. DISCONNECT spark plug wire before servicing unit. 1. Disconnect spark plug wire. 2. As the clutch/brake wears or begins slipping or squealing, adjustment may be required to maintain proper cable tension and clutch engagement. A properly adjusted blade clutch should require 10 lbs of force to depress the end of the clutch lever. The blade clutch cable spring should stretch 1/4” to 3/8” (6.
BC2402 Series Brush Cutter Owner’s Manual BLADE DRIVE BELT REMOVAL AND REPLACEMENT READ all safety instructions before servicing unit. Numbers in parenthesis (N-N ) refer to figure and item numbers in Illustrated Parts List. Tools required: - 1/2” socket, 3/8” drive - ratchet, 3/8” - drive extension, 3/8” drive - universal joint, 3/8” drive - pry bar or long screwdriver - jack stands or similar device adequate to support weight of machine. DISCONNECT spark plug wire before servicing unit. 1.
BC2402 Series Brush Cutter Owner’s Manual Make sure blade drive belt is properly seated in clutch/brake drive pulley (6-23) and is not resting in gap between clutch/brake drive pulley (6-23) and transaxle drive pulley (6-46) 12. Tighten four screws (6-103) to secure belt guides (6-149, 6-150). Make sure belt is correctly routed. (See Figure 2). 13.
BC2402 Series Brush Cutter Owner’s Manual TRANSAXLE DRIVE CLUTCH ADJUSTMENT READ all safety instructions before servicing unit. DISCONNECT spark plug wire before servicing unit. 1. Disconnect spark plug wire. 2. As the belt wears or begins slipping or squealing, adjustment may be required to maintain proper cable tension and clutch engagement. A properly adjusted transaxle drive clutch should require 3 lbs of force to depress the end of the clutch lever. 3.
BC2402 Series Brush Cutter Owner’s Manual TRANSAXLE DRIVE BELT REMOVAL AND REPLACEMENT READ all safety instructions before servicing unit. Numbers in parenthesis ( N-N ) refer to figure and item numbers in Illustrated Parts List. Tools required: ½” socket and ratchet, ½” universal extension bar, pry bar or long screwdriver, adequate support for machine.
BC2402 Series Brush Cutter Owner’s Manual WIRING DIAGRAMS Starter Switch Wiring Figure 3 RED FUSE B RED RED 20A SWITCH STARTER SOLENOID A1 WHITE + BATTERY STARTER MOTOR - M BLACK BLACK ENGINE GROUND Starter Circuit Schematic Diagram Figure 4 MAGNETO ON/OFF SWITCH SPARK PLUG ENGINE GROUND ON/OFF Switch Circuit Schematic Diagram Figure 5 Part No 500264 24 F061207B
BC2402 Series Brush Cutter Owner’s Manual TROUBLESHOOTING Problem Possible Cause Corrective Action Engine will not start. ON/OFF switch is in OFF position. Move switch to START position. Out of gasoline. Fill gas tank. Old or contaminated gasoline. Drain gas tank and fill with fresh gasoline. Spark plug wire disconnected. Connect spark plug wire. Dirty air cleaner. Clean or replace air cleaner. Starter does not turn. Battery low or dead. Charge or replace battery.
BC2402 Series Brush Cutter Owner’s Manual ENGINE MAINTENANCE AND REPAIR Refer to the engine manufacturer’s manual for maintenance and service information. Warranty coverage on the engine is the responsibility of the engine manufacturer. If your engine requires warranty repair contact your local servicing engine dealer. Have your engine model number and serial number ready when you contact the dealer.
BC2402 Series Brush Cutter Owner’s Manual MAINTENANCE RECORD Date Part No 500264 Service Performed 27 F061207B
BC2402 Series Brush Cutter Owner’s Manual ILLUSTRATED PARTS LIST Engine and Engine Base Assembly Figure 6 Part No 500264 28 F061207B
BC2402 Series Brush Cutter Owner’s Manual ITEM NO DESCRIPTION BC2402HE BC2402H BC2402ICE BC2402IC Part No QTY Part No QTY Part No QTY Part No QTY 4 Base Assembly with labels 500240 1 500240 1 500240 1 500240 1 7 Door Base Engine 500233 1 500233 1 500233 1 500233 1 22 Tube Shift With Grip 500171 1 500171 1 500171 1 500171 1 23 Clutch Brake 500338 1 500338 1 500338 1 500338 1 24 Grip 3/4 ID - Black 610102 1 610102 1 610102 1 610102 1 26 Plate M
BC2402 Series Brush Cutter Owner’s Manual Handlebar Assembly Figure 7 Part No 500264 30 F061207B
BC2402 Series Brush Cutter Owner’s Manual ITEM NO BC2402HE DESCRIPTION BC2402H BC2402ICE BC2402IC Part No QTY Part No QTY Part No QTY Part No QT Y 5 Handle Brace Left 500196 1 500196 1 500196 1 500196 1 6 Handle Brace Right 500200 1 500200 1 500200 1 500200 1 17 Cable Clutch Blade BC2402 500259 1 500259 1 500259 1 500259 1 18 Cable Clutch Drive BC2402 500327 1 500327 1 500327 1 500327 1 39 Lever Control Blade 500312 1 500312 1 500312 1 500312 1
BC2402 Series Brush Cutter Owner’s Manual Transaxle and Blade Deck Assembly Figure 8 Part No 500264 32 F061207B
BC2402 Series Brush Cutter Owner’s Manual ITEM NO 1 3 8 9 10 11 12 13 14 15 16 19 20 21 28 29 30 31 33 34 35 36 37 38 49 50 53 54 101 102 103 104 107 108 109 111 112 113 114 116 117 119 122 123 124 125 126 128 129 130 132 133 135 136 138 139 140 141 152 155 156 180 184 197 200 201 DESCRIPTION BC2402HE BC2402H BC2402ICE BC2402IC Part No QTY Part No QTY Part No QTY Part No QTY Deck Assembly with Labels Deflector Front BC2402 Transaxle 3 SPD BC2402 Pulley 5.
BC2402 Series Brush Cutter Owner’s Manual Blade Drive Spindle Assembly Detail Drawing Figure 9 Part No 500264 34 F061207B
BC2402 Series Brush Cutter Owner’s Manual ITEM NO DESCRIPTION BC2402HE Part No QTY BC2402H Part No QTY BC2402ICE Part No QTY BC2402IC Part No QTY 134 Spindle Assembly Complete 500242 1 500242 1 500242 1 500242 1 30 Spacer Spindle BC2402 500232 1 500232 1 500232 1 500232 1 34 Spindle WA BC2402 500174 1 500174 1 500174 1 500174 1 35 Bearing 7/8" ID Sealed Press 500101 2 500101 2 500101 2 500101 2 36 Shaft Drive Blade 500107 1 500107 1 500107 1 500107 1
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