AE Owner’s Manual BILLY GOAT AERATOR Owner's Manual AE400H & AE450 Replacement Parts TINE ROW KIT TINE KIT Complete tine row set for Individual coring tine for replacement of one replacement of worn or complete row of tines. broken tines. Includes mounting plates, spacer, and all hardware. P/N 360197 P/N 360100 Part No 360251 1 Form No F050107A AE Owner’s Manual ABOUT THIS MANUAL THANK YOU for purchasing a BILLY GOAT ® Aerator. 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 machine in top running order. Read this manual carefully before assembling, operating, or servicing your equipment. CONTENTS SERIAL PLATE DATA AND SPECIFICATIONS 3 GENERAL SAFETY 4 -5 INSTRUCTION LABELS 6 PACKING CHECKLIST & ASSEMBLY 7 OPERATION 8-10 MAINTENANCE 11-13 TROUBLESHOOTING AND WARRANTY PROCEDURE 14 MAINTENANCE RECORD 15 ILLUSTRATED PARTS & PARTS LISTS 16-19 Part No 360251 2 Form No F050107A AE Owner’s Manual SERIAL PLATE DATA Record the model number, serial number, date of purchase, and where purchased. Purchase Date: Purchased From: Specifications AE400H AE450 Engine: HP 4.0 (2.98 kW) 5.5 (4.1 kW) Engine: Model GX120K1HX2 1273520049E1 Engine: Type HONDA OHV BRIGGS OHV Engine: Fuel Capacity 2.1 qt. (2.0 L) 3.0 qt (2.84 L) Engine: Oil Capacity 0.63 qt. (0.6 L) 0.66 qt. (0.62 L) Total Unit Weight: 242# (109.8 Kg) 244# (110.7 kg) Max. operating slope 20o 15o Part No 360251 3 Form No F050107A AE Owner’s Manual GENERAL SAFETY INSTRUCTIONS and SYMBOLS The safety symbols shown below are used throughout this manual. You should become 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. This symbol indicates gloves should be worn when servicing this equipment. This symbol indicates that this manual and the engine manufacturer’s manual should be read carefully before assembling, operation, or servicing this equipment. This symbol indicates important information that will prevent damage to your BILLY GOAT ® Aerator. This symbol indicates the engine oil level should be checked before operating this equipment. Read and make sure you thoroughly understand the following safety precautions before assembling, operating or servicing this equipment: READ this manual and the engine manufacturer’s manual carefully before assembling, operating, or servicing this equipment. EAR PROTECTION is recommended when operating this equipment. EYE PROTECTION is recommended when operating this equipment. BREATHING PROTECTION is recommended when operating this equipment. EXHAUST from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. DO NOT operate this equipment on any unimproved forested, brushy, or grass covered land unless a spark arrester is installed on the muffler as required by Section 4442 of the California Public Resources Code. The arrester must be maintained in good working order. Other states may have similar laws. Federal laws apply on federal lands. DO NOT run engine in an enclosed area. Exhaust gases contain carbon monoxide, an odorless and possibly fatal poison. Part No 360251 4 Form No F050107A AE 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. Move equipment away from spill until gasoline has completely evaporated. DO NOT smoke while filling the fuel tank. DO NOT check for spark with spark plug or spark plug wire removed. Use an approved spark tester. DO NOT operate engine without a muffler. Inspect muffler periodically and replace if necessary. If equipped with muffler deflector, inspect deflector periodically and replace if necessary. DO NOT operate engine with grass, leaves or other combustible material near the muffler. DO NOT touch muffler, cylinder, or cooling fins when hot. Contact with hot surfaces may cause severe burns. DO NOT leave equipment unattended while in operation. DO NOT park equipment on a steep grade or slope. DO NOT operate equipment with bystanders in or near the work area. DO NOT allow children to operate this equipment. DO NOT operate equipment with guards removed. DO NOT operate equipment near hot or burning debris or any toxic or explosive materials. DO NOT operate equipment on slopes greater than specified in Specifications section of this manual. DO NOT operate barefoot or wearing open sandals. Always wear substantial footwear DO NOT place hands or feet underneath unit, or near any moving parts. DO NOT operate the machine while under the influence of alcohol or drugs. DO NOT aerate near drop-offs, ditches, or embankments. The operator could lose footing or balance DO NOT start engine without tine height adjust lever in up position and clutch bail engaged. DO NOT change the engine governor setting or overspeed the engine. ALWAYS Stop the tine reel when crossing gravel drives, walks, or roads. ALWAYS Shut the engine off and wait until the tine reel comes to complete stop before performing maintenance. ALWAYS Use equipment only in daylight or good artificial light. ALWAYS wear safety goggles or safety glasses with side shields ALWAYS remove spark plug wire when servicing equipment to prevent accidental starting. ALWAYS check fuel lines and fittings frequently for cracks or leaks. Replace if necessary. ALWAYS store fuel in approved safety containers. WARNING: Important Remove all rocks, wire, string, etc. that can present a hazard during work prior to starting. DO identify and mark all fixed objects to be avoided during work such as sprinkler heads, water valves, limbs, or clothes line anchors, etc. Part No 360251 5 Form No F050107A AE Owner’s Manual INTENDED USE INTENDED USE: This machine is designed for aerating established lawns and large grass covered areas. The machine should not be used for any other purpose than that stated above. DO NOT operate if excessive vibration occurs. If excessive vibration occurs, shut engine off immediately and check for damaged or worn tine reel, loose pulley bolts or set screws, loose engine or lodged foreign objects. (See trouble shooting section on page 14). INSTRUCTION LABELS The labels shown below were installed on your BILLY GOAT ® Aerator. If any labels are damaged or missing, replace them before operating this equipment. Part numbers from the Illustrated Parts List are provided for convenience in ordering replacement labels. The correct position for each label may be determined by referring to the part numbers shown. LABEL WARNING GUARDS LABEL EXPLOSIVE FUEL LABEL PATENT LABEL WARNING UNIT WEIGHT P/N 900327 P/N 400268 P/N 360286 P/N 360188 LABEL LIFT HERE LABEL INSTRUCTIONS AE P/N 360187 P/N 360262 ENGINE LABELS BRIGGS HONDA THROTTLE CONTROLS Brig gs and Stratto n Honda Throttle Set lever to choke position when starting a cold engine Choke Fuel valve Set lever to desired engine speed. Move lever completely to the left to stop engine Part No 360251 6 Form No F050107A AE Owner’s Manual PACKING CHECKLIST Your Billy Goat is shipped from the factory in one carton, completely assembled except for the upper handle assembly, and lift rod. READ all safety instructions before assembling unit. TAKE CAUTION when removing the unit from the box. PUT OIL IN ENGINE BEFORE STARTING P ARTS BAG & LITERATURE ASSY W arranty card P/N- 400972, Owner’s Manual P/N-360251, Declaration of Conformity P/N 360194. 48 Boxing Parts FILL WITH Checklist WATER ONLY! 47 Owner’s Manual AE 360251 Engine Manual Per 118 Model 2 Honda 4.0 HP 83 B&S 5.5 HP 52 46 82 ASSEMBLY 1 . HONDA: Unfold the upper handle (item 48) and slide handle lock loops (item 118) into place to secure the upper h andle to the lower handle (item 82 & 83). 1. BRIGGS Remove the bolts and nuts that are shipped in the upper handle. While holding the lock loops on the handle use the bolts and nuts removed above to attach the upper handle to the hinge bracket on the lower handles and tighten nut against the bracket. NOTE: DO NOT over tighten. The handle should be free to rotate for folding. 2. PIVOT the lift rod (item 46), insert the pin through the lift handle (item 52) then lock in place with lynch pin (item 4 7). Repeat same steps on other side. 3 . FILL the water tank (item 2) to desired weight with water ONLY. 4. CHECK engine oil level and fill to proper level. Also check oil in gear reduction reservoir and fill if necessary. See engine owner’s manual for type and amount of oil to use. Move the tine engagement lever to the down position, to level engine during checking. 5. CONNECT spark plug wire. Set the engine stop switch to the ON position. You will use the stop switch on the h andle during operation. Part No 360251 7 Form No F050107A AE Owner’s Manual OPERATION Like all mechanical tools, reasonable care must be used when operating machine. I nspect machine work area and machine before operating. Make sure that all operators of this equipment are trained in general machine use and safety. PUT OIL IN ENGINE BEFORE STARTING 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. G EAR REDUCTION: See engine manufacturer’s instructions for type and amount of oil used. Engine must be level when checking and filling the gear reduction case. The engine is shipped from the factory with oil in the gear case. I t should be checked before first use. ENGINE SPEED: Controlled by lever on the engine. Under normal conditions, operate at the minimum throttle speed to accomplish your task. NOTE: The unit ground speed varies with the engine speed. F UEL VALVE: Move fuel valve to "ON" position Honda: Located below the air cleaner on the engine. CHOKE: Engage the choke when starting a cold engine. Honda: Located below the air cleaner on the engine. THROTTLE: Move the throttle control lever on the engine to fast position. Pull starting rope to start engine. IF YOUR UNIT FAILS TO START: See Troubleshooting on page 14. NOTE: Honda engines are equipped with a low oil sensor to prevent engine damage. When it senses a low oil condition (i.e. unit is operating or sitting on a steep slope) the engine shuts down. The low oil condition must be c orrected before the engine can be restarted. See the engine owner’s manual for more information. D O NOT operate if excessive vibration occurs. If excessive vibration occurs, shut engine off immediately and check for damaged or worn tine reel, loose pulley bolts or set screws, loose engine or lodged foreign objects. (See trouble shooting section on page 14). Fig 2 HANDLING & TRANSPORTING: CAUTION: This unit is heavy. It requires at least two people to lift it. REMOVE: The aerator is equipped with a water tank as weight. Drain the water using d rain plug before loading and unloading the unit. NOTE: The water tank is also heavy (up to 50 lbs.) when it is full of water. The tank s hould be drained then handled carefully and secured in place during transport. LIFTING: The aerator is equipped with lift handles. After draining the water tank, lift the unit with two people, one on each side of the unit. Grip the unit at the points marked "LIFT HERE" when lifting. Lift using your legs and not your back. See Fig. 2 Lift here Lift here USING RAMPS: Use ramps that are of adequate strength for a unit of this weight. W hen loading the aerator using ramps be sure the ramp is not too steep and that the IT TAKES AT LEAST TWO surface of the ramp provides good traction. PEOPLE. ONE ON EACH SIDE OF THE UNIT Never lift the machine while the engine is running. Part No 360251 8 Form No F050107A AE Owner’s Manual PARKING NEVER PARK THIS UNIT ON A SLOPE OF ANY KIND. Always keep tines in the up position when parking the unit. UNIT 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: 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. Be sure engine is cool. Do not smoke. 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. TINES RAISING/LOWERING The tines are raised or lowered into the ground by operating the tine engagement lever on the upper handle. Tine penetration is very dependent on surface preparation. READ the entire operation section before aerating. AERATING OPERATION MOW: Mow the lawn to its normal cut height. WATER: For the best performance and maximum tine penetration the lawn should be thoroughly watered the day before aeration. INSPECT lawn before beginning work. Remove all rocks, wire, string, or other objects that can present a hazard during work prior to starting. IDENTIFY and mark all fixed objects to be avoided during work, such as sprinkler heads, water valves, buried cables, or clothes line anchors, etc. START ENGINE: See page 8. SET SPEED: The ground speed of your aerator varies with the engine speed. Set the engine at approximately half throttle to start. Speed may Tines up be increased based on the turf conditions (i.e. large flat areas) and transport operator experience. Speed should be lowered when operating under adverse turf conditions (i.e. fenced areas, hills, or slopes). MOVE: Be sure the tine engagement control is in the up position (tines out of the ground) and engage the wheel drive by squeezing the operators clutch bail against the handle. Transport the aerator to the Tines down Aerating work area. Part No 360251 9 Form No F050107A AE Owner’s Manual ENGAGE TINES: With the aerator in the work area, release the clutch bail and push forward on the tine engagement lever, lowering the tines into the dirt. AERATE: Engage the operators clutch bail by pushing it forward to the handle, and start aerating. NOTE: For maximum tine penetration apply downward pressure on the handle. TURNING: At the end of an aerating run, release the clutch bail and liftup on the tine engagement control to lift the tines out of the ground. Using the handle lift the front of the unit to pivot it around and line up for the next pass. TRANSPORT: Be sure to lift the tine engagement lever (tines out of the ground) before transporting away from the work area. AERATING TIPS WATER: For the best performance and maximum tine penetration, the lawn should be thoroughly watered the day before aeration. SLOPES: Do not operate the aerator on steep slopes. Use extreme caution when operating on any sloped surface. For lesser sloped areas operate the unit, traversing up and down at a 45 degree angle to the slope rather than straight across. Extended operation on steep slopes can cause engine damage. NOTE: DO NOT release the operators clutch bail when operating on a slope. This will allow the unit to free wheel and allow the unit to roll down the slope. NOTE: Honda engines are equipped with a low oil sensor to prevent engine damage. When it senses a low oil condition (i.e. unit is operating or sitting on a steep slope) the engine shuts down. The low oil condition must be corrected before the engine can be restarted. See the engine owner’s manual for more information. TINE PENETRATION: Maximum tine penetration is achieved by applying downward pressure on the handle during operation. TURNING: At the end of a pass the tines can be lifted out of the ground to turn by lifting straight up on the operators handle. ADJUSTING HANDLE HEIGHT This unit is equipped with a height adjustable upper handle to allow for multiple operator heights. TO ADJUST THE HANDLE HEIGHT: 1. Remove the lock nuts (item 50) that secure the handle, one on each side, to the lower handle mounting studs. 2. Loosen the handle mounting bolts (item 51), one on each side, (See Fig. 3) and push the handle out and away from the lower handle mounting studs. 3. The handle is now free to rotate. Adjust the handle to the desired height. The BOTTOM handle mounting stud corresponds with the highest handle position. The TOP handle mounting stud corresponds with the lowest handle mounting position. 4. Completely tighten the handle mounting bolts (item 51), and replace the lock nuts (item 50) to secure the handle in place. FOLDING HANDLE This unit is equipped with a folding upper handle for easier storage. TO FOLD THE HANDLE (See Fig. 3): 1. Remove the latch pin (item 47) from the lift rod (item (46). 2. Remove the lift rod from the lift handle (item 52) then pivot the lift rod toward the front of the unit. Repeat same steps on other side. 3. Slide handle lock loops (item 118) and secure on the Fig 3 Fig 4 Part No 360251 10 Form No F050107A