Honda HS520A, HS520AS Miscellaneous

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Page 1

Dealer Instructions

for

SETUP

and

PRE-DELIVERY SERVICE

HS520A • HS520AS

SNOWTHROWER

MODEL TYPE FRAME SERIAL NUMBER RANGE

HS520 A 6017207 to subsequent

AS 6100001 to subsequent

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HS520A • HS520AS SNOWTHROWERS

IMPORTANCE OF PROPER SET-UP AND PRE-DELIVERY SERVICE

FOR YOUR CUSTOMER’S SAFETY

Proper set-up and pre-delivery service are essential to the customer’s safety and the reliability of the snowthrower. Any error or oversight made during assembly and servicing of a snowthrower can result in faulty operation, damage to the snowthrower, or injury to others.

FOR YOUR SAFETY

Some of the most important general safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing set-up and pre-delivery service. Only you can decide whether or not you should perform a given task.

 WARNING

Improper set-up or pre-delivery service can create an unsafe condition that can cause your customer or others to be seriously hurt or killed.

Follow the procedures and precautions in this manual and other service materials carefully.

 WARNING

Failure to properly follow instructions and precautions can cause you to be seriously hurt or killed.

Follow the procedures and precautions in this manual carefully.

IMPORTANT SAFETY PRECAUTIONS

 Make sure you have a clear understanding of all basic shop safety practices and that you are wearing

appropriate clothing and safety equipment. When performing set-up and pre-delivery service, be especially careful of the following:

• Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely.

• Protect your eyes by using proper safety glasses, goggles, or face shields any time you hammer, drill, grind, or work around pressurized air or liquids and springs or other stored-energy components. If there is any doubt, put on eye protection.

• Use protective wear when necessary, for example, gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves.

 Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you

to do otherwise. This will help eliminate several potential hazards:

• Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine.

• Burns from hot parts. Let the engine and exhaust system cool before working in those areas.

• Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers, and clothing are out of the way.

 Gasoline vapors are explosive. To reduce the possibility of a fire or explosion, be careful when working

around gasoline or batteries.

• Use only a nonflammable solvent, not gasoline, to clean parts.

• Never drain or store gasoline in an open container.

• Keep all cigarettes, sparks, and flames away from all fuel-related parts.

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HS520A • HS520AS SNOWTHROWERS

Set-up and pre-delivery service must be performed by an authorized Honda snowthrower dealer. These instructions are provided for dealer use.

FOLLOW THESE INSTRUCTIONS CAREFULLY

Proper set-up and pre-delivery service are essential for safe, reliable operation. Your customer expects the Honda snowthrower to be correctly assembled, adjusted, and ready for use; test the snowthrower to be sure that it functions properly. Fill out the Power Equipment Pre-Delivery Check List (TO056) and give it to the customer.

How to measure hardware and components:

INCHES

123

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

MILLIMETERS

5/8 in 9/16 in 1/2 in 7/16 in 3/8 in 5/16 in 1/4 in

5mm 6mm

WASHERS ARE SPECIFIED BY INSIDE DIAMETER

8mm

NUT AND BOLT DIAMETER

10 mm

12 mm

14 mm

16 mm

NUTS ARE SPECIFIED BY INSIDE DIAMETER (AT THREAD DEPTH)

STANDARD TORQUE VALUES

•m kg-m ft-lb

DIAMETERLENGTH

INSIDE DIAMETER

6 mm flange bolts and nuts 11 1.1 8.0

8 mm flange bolts and nuts 22 2.2 16.0

Torque values for special hardware will be called out during the procedure.

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Page 4

HS520A • HS520AS SNOWTHROWERS

UNCRATING

1. Open the carton and remove the handlebar assembly, discharge chute assembly, snowthrower, and parts bag. Verify the contents of the parts bag with the table below.

2. Remove the starter bracket (HS520A) or starter box bracket (HS520AS) from the lower handlebar tube. Save the curved-head bolt and flange nut for later installation of the starter bracket or starter box bracket.

PARTS BAG

Curved head bolt,

8 x 40 mm (4)

PN 90109-VA4-000

Flange nut,

8 mm (4)

PN 94050-08000

Curved washer,

9 mm (4)

PN 90501-898-000

Phillips head shoulder screw,

6 x 12 mm (3)

PN 90112-V10-000

Nylock flange nut,

6 mm (3)

PN 90303-V10-000

Cable tie (2)

(HS520AS only)

PN 32901-VB5-A00

HANG BAG

Owner's Manual

Snowthrower

HS520A HS520AS•

See page 39 for instructions on

setting up your Snowthrower.

Owner’s manual

PN 31V10610

S A L E S R E G IS T R ATIO N

PLEASE COMPLETE & MAIL

HondaHarmony Mowers

Lookon themower deck,jus tinfront ofthe discharge guarddoor spring.

Honda Mini-Tiller

MODEL:

SERIALNO:

XXXXXXXX

XXXX-XXXXXXX

Printthes erial

numberher e.

Serialnumber

Owner'sLast Name

CompanyName

Address

City

Emailaddress

Dateof S ale

MONTH

Lookon thetop of theba ckf ender.

Honda Hand-HeldProducts

Lookontheshaft between the twogr ips.

DearHonda C ustomer,

Thank youfor choosing Honda.

Pleasetake a momentto completeand mailthis Postage-paid sales regis trationc ardto ensureyoureceive information ofproduc t andserviceupdates.

Failure toreturn this card does notdiminis hthe purchaser'swarrantyrights.

PWL51844G(2003.02)

(commercial/rentalusers)

Application

Commercial Non-c ommerc ial R ental

(professionaluse)

YEARDAY

Honda HarmonyII Mowers

Lookontherightrearsection ofthe mowerdeck.

HondaHa rmony Snowthrowers

Lookbetween thewheels onthe lowerframe .

*Dealer S torenumber

*DealerStoreZIPcode

FirstName

Telephone

()

State ZIPCode

(checkone)

(private,homeowneruse) (for-hireuse)

Sales Registration

*Ifavailable

 For concealed damage, file a Concealed Damage warranty claim using the Interactive Network (),

path Service>Warranty Claim.

 For parts left out by the factory, file a Normal warranty claim for missing parts using the Interactive

Network (), path Service>Warranty Claim.

 If the Sales Registration form is missing or damaged, you can:

• Register the product online using the Interactive Network (), path Sales>Sales Registration.

• Use the pre-printed forms sent with the product invoice.

• Contact PE Sales Registration (800)354-6632, option 7, for blank registration forms.

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Page 5

HS520A • HS520AS SNOWTHROWERS

ASSEMBLY

1. Install the handlebar with the hardware shown. Tighten the flange nuts securely.

9 mm CURVED WASHER (4)

8 mm FLANGE NUT (4)

TORQUE:

22 N

•m (16 ft-lb)

8 x 40 mm CURVED HEAD BOLT (4)

3. HS520A: Use the hardware removed in step 2 on page 4 of 10 to attach the starter bracket.

8 mm CURVED HEAD BOLT

STARTER BRACKET

8 mm FLANGE NUT

4. HS520AS: Use the hardware removed in step 2 on page 4 of 10 to attach the starter box bracket, then install the starter rope into the handlebar rope guide.

2. Put the clutch cable end through the auger clutch lever upper hole (closest to the bend) as shown.

AUGER CLUTCH LEVER

CABLE END

8 mm CURVED HEAD BOLT

STARTER BOX BRACKET

9 mm CURVED WASHER

8 mm FLANGE NUT (4)

TORQUE:

22 N

•m (16 ft-lb)

ROPE GUIDE

Install two cable ties around the handlebar and starter cable, then trim off the excess material leaving about 10 mm (3/8 in).

CABLE TIE (2)

Trim to 10 mm (3/8 in)

EQUALLY

SPACED

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Page 6

HS520A • HS520AS SNOWTHROWERS

0W-30

5W-30

SAE

5W-30

AMBIENT TEMPERATURE

-30

-20

-10

010

200-20 40 60 80

40 C

100 F

5. Install the discharge chute using the three 6 mm Phillips head screws and 6 mm nylock flange nuts. Make sure the screws go on the inside and the nuts on the outside.

6 mm NYLOCK FLANGE NUT (3)

TORQUE:

•m (7 ft-lb)

10 N

PRE-DELIVERY SERVICE INSPECTION

Engine

The snowthrower is shipped WITHOUT ENGINE OIL. A bottle of oil is included with the

snowthrower.

1. Remove the oil filler cap/dipstick and add the entire contents of the oil bottle into the oil filler opening to bring the oil level up to the upper limit. Do not overfill.

UPPER LIMIT

PHILLIPS HEAD SHOULDER SCREW (3)

INSIDE

OUTSIDE

6. Lift the spark plug door and attach the spark plug wire to the spark plug.

7. Remove any packing material from the side of the snowthrower.

Use SAE 5W-30 or 0W-30 API SJ or later engine oil only.

2. Fill the fuel tank with fresh, 86 octane unleaded gasoline.

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Page 7

HS520A • HS520AS SNOWTHROWERS

Auger Clutch Lever Freeplay

Pull up the auger clutch lever until resistance is felt, then measure the distance shown.

ENGAGEMENT TRAVEL:

7-1/2 ~ 8 in (190 ~ 205 mm)

AUGER CLUTCH LEVER

If adjustment is necessary:

1. Pull the spring cover up to expose the spring.

2. Change the cable or spring position on the metal plate to change the lever travel.

Belt Tension

1. Pull the spring cover up to expose the spring.

2. Have a helper engage the auger clutch lever.

3. Measure the spring coil length as shown.

SPRING COIL LENGTH: 3 inches (78 mm)

SPRING

COVER

)

78 mm

(

SPRING

COVER

SPRING

1/4 in (6 mm)

3/8 in (10 mm)

Moving the spring makes a 1/4 inch (6 mm) travel change and moving the cable one hole makes a 3/8 inch (10 mm) travel change.

4. If the length of the spring coil is less than 3 inches, move the spring and/or the cable connected to the metal plate so the stretched spring is at least 3 inches long.

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Page 8

HS520A • HS520AS SNOWTHROWERS

Auger Paddle

Measure the distance between the ground and the lowest point on the auger rubber paddle.

PADDLE GROUND CLEARANCE:

1/16 ~ 1/8 inch (1 ~ 3 mm)

If adjustment is necessary:

1. Loosen but do not remove the three self-locking nuts on the scraper blade.

CARRIAGE BOLT (3)

OPERATIONAL TESTS

1. Make sure the spark plug cap is connected.

2. Turn the fuel valve to the ON position.

FUEL VALVE

3. If the engine is cold, pull the choke knob out to the CLOSED position.

CLOSED

4. Start the engine:

Electric Starting (AS model only):

a. Connect an extension cord to the starter box

first, then to a 120 volt ac outlet.

SCRAPER

SELF-LOCKING NUT (3)

2. Move the scraper blade up or down slightly as needed and tighten the self-locking nuts. Recheck the clearance.

3. Repeat the procedure as needed to get the necessary clearance.

Other Items

With the spark plug cap disconnected, check the security of all nuts, bolts and other fasteners. Tighten if necessary.

OUTDOOR EXTENSION CORD

STARTER BOX

Use an outdoor extension cord with a current rating of at least 15 amps. Do not connect and disconnect the extension cord with wet hands. Do not use in the rain.

Be sure to hold the plug when disconnecting the power cord from the electrical outlet or starter box. Do not disconnect by pulling on the power cord.

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HS520A • HS520AS SNOWTHROWERS

b. Turn the engine switch to the ON position.

c. Push the starter button until the engine

starts. After the engine starts, disconnect the extension cord from the electrical 120 volt ac outlet, and then from the starter box.

Manual Starting

a. Turn the engine switch to the ON position.

HS520A

HS520AS

b. Pull the starter grip slowly until resistance is

felt, then pull briskly.

NOTICE

To prevent starter motor damage, do not operate the starter for more than 15 seconds at a time. If the engine fails to start, release the starter button and allow the starter motor to cool for 10 minutes before operating it again.

d. If the choke knob was used to start the

engine, gradually return it to the OPEN position as the engine warms up. Let the engine run for several minutes.

c. Return the starter grip gently.

NOTICE

Do not allow the starter grip to snap back. Return it gently to prevent damage. Do not pull the starter grip while the engine is running. The starter could be damaged.

d. If the choke knob was used to start the

engine, gradually return it to the OPEN position as the engine warms up. Let the engine run for several minutes.

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Page 10

HS520A • HS520AS SNOWTHROWERS

POWER EQUIPMENT PRE-DELIVERY CHECKLIST

THEFOLLOWING PRE-DELIVERY CHECKLIST IS DESIGNEDFOR GENERAL APPLICATION. THEREARE INDIVIDUAL EXCEPTIONS TO THISLIST. REFER TOTHE APPROPRIATE SET-UP INSTRUCTIONSAND SHOP MANUALS FOR DETAILEDPROCEDURES AND SPECIFICATIONS.

WHITECOPY–Dealer YELLOWCOPY–Customer TO056 OTR50671-C(2005.07)

ENGINEOIL - Fill to thecorrect level with recommended oil

FUELTANK - Drain, inspectand fill. Check for leaks

CARBURETORFLOAT CHAMBER - Drainold gasoline

COOLANT- Check coolant level. Fillif necessary with a 50/50solution ofdistilled water and ethylene glycolantifreeze

BATTERY- Check the electrolytelevel is correct and thebattery is fully charged

TRANSMISSIONFLUID LEVEL - Check fluidlevel and check for leaks

CLUTCHLEVER FREE PLAY -Adjust if necessary

BLADECONTROL LEVER - Adjust ifnecessary

SHIFTLEVER FREE PLAY -Check free play and adjustif necessary

AUGERCLUTCH LEVER - Check freeplay and adjust if necessary

MOWERHEIGHT ADJUSTMENT LEVERS - Checkoperation and set alladjustment levers to the sameheight

TIREPRESURE - Check for propertire pressure

BLADEBOLTS - Check bladebolts for proper torque

ATTACHMENTINSTALLATION

ALLNUTS, BOLTS AND OTHERFASTENERS - Check securityand tightenif necessary

PRE-DELIVERYINSPECTION PERFORMED BY:

PRINTNAME:_____________________________ DATE:______________

CHECKTHROTTLE OPERATION

CHECKIDLE AND MAXIMUM ENGINE SPEED

CHECKGOVERNOR OPERATION

CHECKDRIVE BRAKE OPERATION

CHECKDRIVE CLUTCH OPERATION

CHECKATTACHMENT OPERATION

CHECKMOWER CONTROL/AUGER CLUTCH OPERATION

CHECKSAFETY INTERLOCK SYSTEM OPERATION

CHECKSHIFT LEVER OPERATION

CHECKHEADLIGHT OPERATION

UPONCOMPLETION OF TEST, CHECKFOR FUEL OR OIL LEAKS

OPERATIONALTEST PERFORMED BY:

PRINTNAME:____________________________ DATE:________________

CHECKMAXIMUM NO-LOAD ENGINE SPEED (RPM______________)

CHECKAUTO-THROTTLE/ECO-THROTTLE™ OPERATION

PERFORMLOAD BANK TEST

CHECKOUTPUT FROM EACH RECEPTACLE

GENERATOROPERATIONAL TEST PERFORMEDBY:

PRINTNAME:___________________________________ DATE:__________

REVIEWPRE-DELIVERY CHECKLIST

REVIEWOWNER’S MANUAL

EXPLAINOPERATION

REVIEWWARRANTY COVERAGE AND POLICIES

EXPLAINMAINTENANCE INTERVALS

EXPLAINSERVICE AVAILABILITY

EXPLAINSAFETY PRECAUTIONS

FILLOUT OWNER’S I.D. CARD ANDSALES REGISTRATION

TOOLKIT (IF APPLICABLE)

IHAVE RECEIVED THE FOLLOWING:

OWNER’SMANUAL

DISTRIBUTOR’SLIMITED WARRANTY

OWNER’SI.D. CARD

ATTACHMENTOPERATOR’S MANUAL(S)

PRE-DELIVERYCHECKLIST (YELLOW COPY)

Theoperation of this unit wasreviewed with me by arepresentative of the dealership.I have reviewed and understandthe warranty policy. Ihave visually inspectedthe unit and found nodefects.

PRE-DELIVERY INSPECTION

OPERATIONAL TEST

DEALER NAME

MODEL NUMBER

FRAME NUMBER

DEALER NUMBER

ENGINE NUMBER

GENERATOROPERATIONAL TEST

RATEDLOAD (AC)

VOLTS AMPS FREQUENCY

DCBATTERY CHARGE SYSTEM

DCVOLTS

DELIVERY CHECKLIST

CUSTOMER DELIVERY

CUSTOMER NAME

ADDRESS

CITY STATE

ZIP CODE

PHONENUMBER ( )

SIGN ATURE DATE

5. Verify the auger engages when you pull back on the auger clutch lever.

6. Operate the chute guide and make sure it moves smoothly.

7. Start the engine and allow it to warm up to normal operating temperature. Check the engine rpm with the auger disengaged.

MAXIMUM ENGINE SPEED:

3,700 ~ 3,850 rpm If adjustment is necessary, remove the rubber

plug and turn the governor adjustment screw as needed to achieve the specified rpm.

10.Turn the fuel valve to the OFF position. Start the engine and allow the carburetor to run out of gas.

11.Upon completion of tests, check for fuel and oil leaks. Repair if necessary.

12.Fill out the top section of the Sales Registration and the applicable sections of the Power Equipment Pre-Delivery Check List. Put both documents in the documentation hang bag.

S A L E S R E GIS TR ATIO N

PLEASE COMPLETE & MAIL

Honda Harmony Mowers

Look on the mower deck, just in frontof the discha rge guard door spring.

Honda Mini-Tiller

Look on the topof the ba ck fe nder.

Honda Hand-HeldP roducts

Lookontheshaft betwe en the tw o grips .

Dear H onda Customer,

Thank youfor c hoosing Honda.

Please take a momentto complete and mailthis Postage-paid sa les registration c ard to ensureyou receive information o f product andserviceupdates.

Failure toreturn this card does notdiminis h the pu rchaser's warrantyrights.

PWL51844G (2003.02)

MODEL :

SERIALNO:

Printtheserial

Serial number

Owner'sLas t Name

CompanyName

Address

City

Emailaddress

Date of S a le

MONTH

XXXX XXXX

XXXX-XXXXXXX

number here.

(commercial/rentalusers)

YEARDAY

Application

Commercial Non-commercial Rental

(professionaluse)

Honda Harmony II Mowers

Lookontherightrearsection ofthe mower dec k.

Honda Harmony Snowthrowers

Look between the wheels on the lower frame.

*Dealer S tore number

*DealerStoreZIP code

FirstName

Telephone

()

State ZIPCode

(checkone)

(private,homeowner use) (for-hire use)

*Ifav a ilable

GOVERNOR ADJUSTMENT SCREW

8. Verify the auger stops turning when the auger clutch lever is released.

9. Verify the engine stops when the engine switch is moved to the OFF position.

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RUBBER PLUG

13. Remember to complete the Sales Registration and the Pre-Delivery Check List when the snowthrower is delivered to the customer.

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