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Billy Goat BC2403 Series manual

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Table of contents for the manual

  • Page 1

    Part No 500360 1 Form No F050208A BILLY GOAT ® BC2403 Series Brush Cutter Owner’s Manual Patent Number D386768[...]

  • Page 2

    Part No 500360 2 F050208A BC2403 Series Brush Cutter Owner’s Manual ABOUT THIS MANUAL THANK YOU for purchasing a BILLY GOAT ® Brush Cutter . Your new machine has bee n carefully designed and manufactured to provide years of reliable and productive service. This ma nual provides compl ete operating and maintenance instructions that will hel p to [...]

  • Page 3

    Part No 500360 3 F050208A BC2403 Series Brush Cutter Owner’s Manua l SERIAL PLATE DATA Record the model number, seri al number, date of purchase, and where purchased. Purchase Date: Purchased From: BC 2403 SERIES SPECIFICATIONS BC2403IC BC2403ICF BC2403HF BC2403H BC2403HEB Engine Type Briggs and Stratton INTEK OHV Briggs and Stratton INTEK OHV Ho[...]

  • Page 4

    Part No 500360 4 F050208A BC2403 Series Brush Cutter Owner’s Manual GENERAL SAFETY INSTRUCTIONS and SYMBOLS The safety symbols shown belo w are used throughout th is manual. You should be thoroughly familiar with them before assembling, operati ng or servicing this equipment. This symbol indicates important information t hat will prevent injury t[...]

  • Page 5

    Part No 500360 5 F050208A BC2403 Series Brush Cutter Owner’s Manua l 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 run ning. Allow engine to cool fo r at least two minutes before refueling. DO NOT store gasoline near an op en flame. DO NOT re[...]

  • Page 6

    Part No 500360 6 F050208A BC2403 Series Brush Cutter Owner’s Manual SOUND DATA SOUND LEVEL 93 Dba at Operator’s po sition Sound tests were conduct ed in accordance with 2000/ 14/EEC a nd were performe d 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 refe[...]

  • Page 7

    Part No 500360 7 F050208A BC2403 Series Brush Cutter Owner’s Manua l INSTRUCTION LABELS The labels shown below were installe d on your BILLY GOAT ® Brush Cutter. If any labels are dam aged or missing, replace them before operatin g this equipment. Item numbers from the Illustrate d Parts List and part numbers are provided for convenien ce in ord[...]

  • Page 8

    Part No 500360 8 F050208A BC2403 Series Brush Cutter Owner’s Manual Brush Cutter Assembly Drawing Figure 1[...]

  • Page 9

    Part No 500360 9 F050208A BC2403 Series Brush Cutter Owner’s Manua l ASSEMBLY INSTRUCTIONS Your BILLY GOAT ® BC Self-Prope lled Brush Cutter was shipped i n one carton, completely assemb led except for the u pper handle assembl y and the front guard bar. Mounting har dware for the handle and guard bar is temporarily i nstalled on the lower handl[...]

  • Page 10

    Part No 500360 10 F050208A BC2403 Series Brush Cutter Owner’s Manual OPERATION DO NOT run engine in an enclosed area. Exhaust gases contain carbon mono xide, an odorless and possibly fatal poison. DO NOT start or operate engine if strong odor of ga soline is present. DO NOT start or operate engine if ga soline is spilled. Move equipment away from[...]

  • Page 11

    Part No 500360 11 F050208A BC2403 Series Brush Cutter Owner’s Manua l O PERATOR C ONTROLS The operator’s station is at the rea r of the machine between the handl ebars. The ope rator should STA ND in a position to allow both hand lebars to be grasped firmly and which allows sufficient levera ge to steer the machine. Operator’s controls are sh[...]

  • Page 12

    Part No 500360 12 F050208A BC2403 Series Brush Cutter Owner’s Manual 3. Pull choke out (Honda engine only). Choke 4. Units equipped with electric starters: Press a nd hold ON/OFF button until engine start s. ON/OFF (I/O) Swit ch I-ON O-Off (Manual start shown) DO NOT START equipm ent with drive or blade clutch engag ed. 5. Units equipped with man[...]

  • Page 13

    Part No 500360 13 F050208A BC2403 Series Brush Cutter Owner’s Manua l PULL STARTER CORD slowly until resistance i s 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 corre ct operating speed. C UTTING The best performance is achieved wh en cutting in dr[...]

  • Page 14

    Part No 500360 14 F050208A BC2403 Series Brush Cutter Owner’s Manual Drive Clutch Lever S HUT D OWN 1. Release drive clutch handle to disen gage transaxle. 2. Release blade clutch handle to disen gage 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) positio n. C LEARING A C LOG[...]

  • Page 15

    Part No 500360 15 F050208A BC2403 Series Brush Cutter Owner’s Manua l HANDLING and TRANSPORTING Using four people to lift unit is reco mmended. Lift holding the handles a nd front deck guard. Make sure equipment is properly secured befo re transporting. NEVER lift the machine while the engine is running. STORAGE DO NOT store engine in an en close[...]

  • Page 16

    Part No 500360 16 F050208A BC2403 Series Brush Cutter Owner’s Manual MAINTENANCE P ERIODIC M AINTENANCE Periodic maintenance should be perfo rmed at the following intervals: Maintenance Operation Every Use Daily or Every 5 Hours Every 25 Hours Every 50 Hours Every 100-150 Hours Inspect for worn or damaged parts. z Check for excessive vibration z [...]

  • Page 17

    Part No 500360 17 F050208A BC2403 Series Brush Cutter Owner’s Manua l B LADE R EMOVAL AND S HARPENING READ all safety instructions before servicing unit. Numbers in parenthesi s ( N-N ) refer to figure and item numbers in Illustrated Parts List. Tools r equired: - 5/8” socket, 1/2” drive - torque wrench, 1/2” drive - jack stands or similar [...]

  • Page 18

    Part No 500360 18 F050208A BC2403 Series Brush Cutter Owner’s Manual B LADE D RIVE B ELT T ENSION A DJUSTMENT READ all safety instructions before servicing unit. DISCONNECT spark plug wire before servicing unit. Numbers in parenthesi s ( N-N ) refer to figure and item numbe rs in Illustrated Parts List. 1. Disconnect spark plug wire. 2. Remove tw[...]

  • Page 19

    Part No 500360 19 F050208A BC2403 Series Brush Cutter Owner’s Manua l B LADE C LUTCH A DJUSTMENT 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 squ ealing, adjustment may be required to maintain proper cable ten[...]

  • Page 20

    Part No 500360 20 F050208A BC2403 Series Brush Cutter Owner’s Manual B LADE D RIVE B ELT R EMOVAL AND R EPLACEMENT READ all safety instructions before servicing unit. Numbers in parenthesis (N-N ) refer to figur e and item numbers in Illustrated Parts Li st. Tools r equired: - 1/2” socket, 3/8” drive - ratchet, 3/8” - drive extension, 3/8?[...]

  • Page 21

    Part No 500360 21 F050208A BC2403 Series Brush Cutter Owner’s Manua l Make sure blade drive belt is prope rly seated in clutch/brake drive pulley (6-23) and is not resting in gap between clut ch/brake drive pulley (6-23) and t ransaxle drive pulley (6-46) 12. Tighten four screws (6-103) to secure bel t guides (6-149, 6-150). Make sure belt is cor[...]

  • Page 22

    Part No 500360 22 F050208A BC2403 Series Brush Cutter Owner’s Manual T RANSAX LE D RIVE C LUTCH A DJUSTMENT 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, adju stment may be required to maintain prope r cable[...]

  • Page 23

    Part No 500360 23 F050208A BC2403 Series Brush Cutter Owner’s Manua l T RANSAX LE D RIVE B ELT R EMOVAL AND R EPLACEMENT READ all safety instructions before servicing unit. Numbers in parenthesi s ( N-N ) refer to figure and item numbe rs in Illustrated Parts List. Tools required: ½” socke t and ratchet, ½” universal extension bar, pry bar [...]

  • Page 24

    Part No 500360 24 F050208A BC2403 Series Brush Cutter Owner’s Manual W IRING D IAGRAMS Starter Switch Wiring Figure 3 Starter Circuit Schematic Diagram Figure 4 ON/OFF Switch Circuit Schematic Diagram Figure 5 SWITCH WHITE RED + - STARTER SOLENOID BATTERY BLACK 20A FUSE RED STARTER MOTOR ENGINE GROUND RED BLACK M A1 B MAGNETO ENGINE GROUND ON/OFF[...]

  • Page 25

    Part No 500360 25 F050208A BC2403 Series Brush Cutter Owner’s Manua l TROUBLESHOOTING Problem Possible Cause Correcti ve Action ON/OFF switch is in OF F 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 plu[...]

  • Page 26

    Part No 500360 26 F050208A BC2403 Series Brush Cutter Owner’s Manual ENGINE MAINTENANCE AND REPAIR Refer to the engine manufacturer’ s manual for mainten ance and service information. Wa rranty coverage on the engine is the responsibility of the engine manufa cturer. If your engine requires warranty repair contact your local servicing engine de[...]

  • Page 27

    Part No 500360 27 F050208A BC2403 Series Brush Cutter Owner’s Manua l MAINTENANCE RECORD Date Service Performed[...]

  • Page 28

    Part No 500360 28 F050208A BC2403 Series Brush Cutter Owner’s Manual ILLUSTRATED PARTS LIST Engine and Engine Base Assembly Figure 6[...]

  • Page 29

    Part No 500360 29 F050208A BC2403 Series Brush Cutter Owner’s Manua l BC2403HEB BC2403H BC2403IC ITEM NO DESCRIPTION Part No QTY Part No QTY Part No QTY 4 Base Assembly with labels 500240 1 500240 1 500240 1 7 Door Base Engine 500233 1 500233 1 500233 1 22 Tube Shift With Grip 500171 1 500171 1 500171 1 23 Clutch Brake 500338 1 500338 1 500338 1 [...]

  • Page 30

    Part No 500360 30 F050208A BC2403 Series Brush Cutter Owner’s Manual Handlebar Assembly Figure 7[...]

  • Page 31

    Part No 500360 31 F050208A BC2403 Series Brush Cutter Owner’s Manua l BC2403HEB BC2403H BC2403IC ITEM NO DESCRIPTION Part No QTY Part No QTY Part No QT Y 5 Handle Brace Left 500196 1 500196 1 500196 1 6 Handle Brace Right 500200 1 500200 1 500200 1 17 Cable Clutch Blade BC2402 500259 1 500259 1 500259 1 18 Cable Clutch Drive BC2402 500327 1 50032[...]

  • Page 32

    Part No 500360 32 F050208A BC2403 Series Brush Cutter Owner’s Manual Transaxle and Blade Deck Assem bly Figure 8[...]

  • Page 33

    Part No 500360 33 F032608A BC2403 Series Brush Cutter Owner’s Manua l BC2403HEB BC2403H BC2403IC ITEM NO DESCRIPTION Part No QTY Part No QTY Part No QTY 1 Deck Assembly with Label s 500358 1 500358 1 500358 1 3 Deflector Front BC 2402 500125 1 500125 1 500125 1 8 Transaxle 3 SPD BC 2402 500342 1 500342 1 500342 1 9 Pulley 5.0" OD ‘A’ Sec[...]

  • Page 34

    Part No 500360 34 F050208A BC2403 Series Brush Cutter Owner’s Manual Blade Drive Spindle Assembly Detail Drawing Figure 9[...]

  • Page 35

    Part No 500360 35 F032608A BC2403 Series Brush Cutter Owner’s Manua l BC2403HEB BC2403H BC2403IC ITEM NO DESCRIPTION Part No QTY Part No QTY Part No QTY 134 Spindle Assembly Complete 500242 1 500242 1 500242 1 30 Spacer Spindle BC2402 500232 1 500232 1 500232 1 34 Spindle WA BC2402 500174 1 500174 1 500174 1 35 Bearing 7/8" ID Sealed Press 5[...]

  • Page 36

    Part No 500360 36 F050208A BC2403 Series Brush Cutter Owner’s Manual If you liked this product please feel free to view our full line of quality lawn care, renovation, and debris removal products at www.billygoat.com AERATOR POWER RAKE DL VACUUM FORCE BLOWER MULTI VACUUM HIGH WHEEL MOWER[...]