Dealer Instructions for

SET-UP and

PRE-DELIVERY SERVICE

FC600

TILLER

© 2004 American Honda Motor Co., Inc.—All Rights Reserved

TO021

PPD53712 (July 2004)

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FC600 TILLER

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 tiller. Any error or oversight made during assembly and servicing of a tiller can result in faulty operation, damage to the tiller or injury to others.



WARNING

Improper service 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.

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

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.

‰

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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FC600 TILLER

Set-up and pre-delivery service must be performed by an authorized Honda tiller 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 their Honda tiller to be correctly assembled, adjusted, and ready for use; test the tiller to be sure that it functions properly. Fill out the Power Equipment Pre-Delivery Check List (TO056) and give the yellow copy to the customer.

How to measure hardware and components:

INCHES

0 1 2 3 4 5 6

0 10

MILLIMETERS

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

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

LENGTH

5 mm 6 mm 8 mm 10 mm

12 mm 14 mm

16 mm

WASHERS ARE SPECIFIED

BY INSIDE DIAMETER

NUTS ARE SPECIFIED

BY INSIDE DIAMETER

(AT THREAD DEPTH)

DIAMETER

INSIDE

DIAMETER

NUT AND BOLT DIAMETER

6 mm pan-head screws

6 mm flange bolts

8 mm flange bolts and nuts

10 mm flange bolts and nuts

STANDARD TORQUE VALUES

N

•

m kg-m ft-lb

9

11

22

34

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

0.9

1.1

2.2

3.5

6.5

8.0

16.0

25.0

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FC600 TILLER

LOOSE PARTS

Open the carton and remove the tiller and cardboard stand. Set the stand on a level surface and then set the tiller on the stand.

Remove all the parts from the carton. Check the parts against these illustrations.

For parts lost or damaged in transit, file a Transportation Claim.

For parts left out from the factory, file a Warranty Claim.

Description Quantity Part Number

Honda Code

Illustration

Owner’s manual 1 31733700

Not Applicable

10 x 80 mm flange bolt 1 95701-10080-00

2545341

10 x 85 mm flange bolt 1 95701-10085-00

3378056

10 mm plain washer

10 mm flange nut

Handle column cover

5 x 12 mm self-tapping screw

5 x 10 mm self-tapping screw

Wire harness clip

2

4

1

3

1

94103-10000

94050-10000

35120-733-E81

(Switch)

54231-733-E80

(Cover)

93903-25280

93903-35110

0914648

0483867

3457512

(Switch)

3458643

(Cover)

0563981

0612663

1 91475-SB6-000

1685684

5 x 14 mm hex bolt 1 92101-05014-0B

4060646

120 mm cable band 2 90674-WA8-003

1641075

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Description

Suction hose band

Quantity Part Number

Honda Code

1 90679-SG9-E01

3522752

Right inner tine assembly 1

N/A

See page 7

N/A

FC600 TILLER

Illustration

Right outer tine assembly 1

N/A

See page 7

N/A

Left inner tine assembly 1

N/A

See page 7

N/A

Left outer tine assembly 1

N/A

See page 7

N/A

Side disc

10 x 53.5 mm pin

10 mm lock pin

2

7

7

72470-733-750

1490374

90757-723-670

0454082

94252-10000

0470088

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FC600 TILLER

Description

Attachment hitch

Quantity Part Number

Honda Code

1 80150-733-W70

7756133

Drag bar Complete 1 80311-733-700

1490424

Front wheel assembly

10 x 40 mm flange bolts

1

N/A

See page 8

N/A

2 95701-10040-00

2756310

Front guard Complete

8 x 20 mm flange bolt

1

4

51120-733-W70

95701-08020-00

7756067

2552552

Illustration

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TINE ASSEMBLY COMPONENTS

Tine assemblies are not available. Component parts are listed below.

FC600 TILLER

No.

Description

1 Pipe (Inner)

2 Pipe (outer)

3 Rotary tine A

4 Rotary tine B

7 10 mm flange nut

8 10 mm lock pin

9 10 x 25 mm flange bolt

Quantity Part Number

16

6

16

8

8

2

2

72110-733-W70

72120-733-750

72461-733-750

72465-733-750

94050-10000

94252-10000

95701-10025-00

Honda Code

7756125

1490317

1490341

1490366

0483867

0470088

2774453

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FC600 TILLER

WHEEL ASSEMBLY COMPONENTS

A wheel assembly is not available. Component parts are listed below.

No.

Description

1 Wheel (8”) *NH31* (McKinley White)

2 Return spring

3 Front wheel shaft

4 Front wheel beam

5 Front wheel arm

9 Chute guide washer

10 10 mm plain washer

11 Front wheel collar

12 8 mm self-lock nut

13 8 mm flange nut

15 Cotter pin

20 8 x 80 mm flange bolt

Quantity Part Number

1

1

1

1

1

1

1

2

1

1

1

1

42710-VA3-J00

43151-733-W70

44311-733-W70

44760-733-W70

44780-733-W70

90420-730-003

94102-10000

91553-733-W70

94011-08000-0S

94050-08000

94201-20350

95701-08080-00

Honda Code

4022034

7756000

7756018

7756026

7756034

1004217

0172551

7756166

0251678

0481143

0058388

2533867

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HANDLE INSTALLATION

1. Remove the tiller and cardboard stand from the shipping container. Place the cardboard stand on a level surface and then set the tiller on the cardboard stand.

FC600 TILLER

3. Tighten the 10 x 85 mm flange bolt, 10 mm washer, and 10 mm flange nut, and then tighten the 10 x 80 mm flange bolt.

10 mm

FLANGE NUT

CARDBOARD STAND

2. Set the handle pipe onto the handle column.

Make sure the clutch cable and throttle cable are underneath the handle column. Loosely tighten the 10 x 80 mm flange bolt, 10 mm washer, and 10 mm flange nut.

HANDLE PIPE

10 mm WASHER

10 mm

FLANGE NUT

10 mm

WASHER

10 x 85 mm

FLANGE BOLT

10 x 80 mm

FLANGE BOLT

4. To install the handle column cover, pass the engine switch ground terminal lead and engine switch lead through the handle column, and then tighten the 5 x 12 mm self-tapping screw through the top of the handle column cover.

5 x 12 mm

SELF-TAPPING

SCREW (3)

HANDLE

COLUMN

COVER

10 x 80 mm

FLANGE BOLT

HANDLE COLUMN

ENGINE

SWITCH

LEAD

ENGINE SWITCH

GROUND

TERMINAL LEAD

Connect the ground terminal lead to bare metal.

5. Attach the engine switch ground terminal and handle column cover to the handle column with one 5 x 12 mm self-tapping screw through the unpainted hole on the bottom of the handle column. Tighten a third 5 x 12 mm self-tapping screw through the remaining hole in the handle column cover.

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FC600 TILLER

6. Place the cable guide on the handle column as shown and tighten the 5 x 10 mm self-tapping screw.

7. Connect the engine switch lead and ignition coil lead. Clamp the engine switch lead with the wire harness clip and tighten the harness clip on the handle column with the 5 x 14 mm hex bolt.

TINE INSTALLATION

1. Install the right outer tine assembly onto the right inner tine assembly using the

10 x 53.5 mm pin and 10 mm lock pin. Note the curve of the tines and rotation direction, shown below.

RIGHT INNER

TINE

ASSEMBLY

10 x 53.5 mm PIN

RIGHT OUTER

TINE ASSEMBLY

CABLE

GUIDE

WIRE HARNESS

CLIP

5 x 14 mm

HEX BOLT

ENGINE

SWITCH LEAD

ROTATION DIRECTION

"R" MARK

10 mm LOCK PIN

5 x 10 mm

SELF-TAPPING

SCREW

IGNITION

COIL

LEAD

8. Install the two 120 mm cable bands and suction hose band as shown.

CLUTCH CABLE

120 mm

CABLE

BAND (2)

"A" MARK

(Viewed from outside)

2. Install the side disc on the right outer tine assembly using the 10 x 53.5 mm pin and

10 mm lock pin.

10 x 53.5 mm PIN

THROTTLE CABLE

SUCTION HOSE

BAND

10 mm LOCK PIN

SIDE DISC

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3. Tilt the tiller forward and install the right tine assembly on the tine axle using the

10 x 53.5 mm pin (through the inner hole) and

10 mm lock pin.

INNER

HOLE

10 x 53.5 mm PIN

FC600 TILLER

5. Install the side disc onto the left outer tine assembly using the 10 x 53.5 mm pin and

10 mm lock pin.

10 x 53.5 mm

RIGHT TINE

ASSEMBLY

10 mm LOCK PIN

4. Install the left outer tine assembly to the left inner tine assembly using the 10 x 53.5 mm pin and 10 mm lock pin. Note the curve of the tines and rotation direction, shown below.

10 x 53.5 mm PIN

LEFT OUTER

TINE

ASSEMBLY

SIDE DISC

6. Install the left tine assembly to the tine axle using the 10 x 53.5 mm pin (through the inner hole) and 10 mm lock pin.

INNER HOLE

10 x 53.5 mm PIN

LEFT TINE

ASSEMBLY

10 mm LOCK PIN

ROTATION DIRECTION

"L" MARK

10 mm LOCK PIN

"B" MARK

(Viewed from outside)

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FC600 TILLER

ATTACHMENT HITCH AND DRAG BAR

INSTALLATION

1. Remove the lock pin and hitch pin.

2. Install the attachment hitch and secure it with the removed hitch pin and lock pin.

HITCH PIN

FRONT WHEEL INSTALLATION

Set the front wheel at the transport position and then install the front wheel on the front frame and tighten the two 10 x 40 mm flange bolts and two

10 mm flange nuts.

10 x 40 mm

FLANGE BOLT (2)

10 X 40 (2)

ATTACHMENT

HITCH

FRONT WHEEL

ASSEMBLY

LOCK PIN

3. Install the drag bar using the 10 x 53.5 mm pin and 10 mm lock pin.

FRONT GUARD PIPE INSTALLATION

Install the front guard pipe and tighten the four

8 x 20 mm flange bolts.

10 mm LOCK PIN

FRONT GUARD

10 x 53.5 mm PIN

DRAG BAR

8 x 20 mm

FLANGE BOLT (4)

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PRE-DELIVERY INSPECTION CHECKLIST

Check all items on the following list. Refer to

Owner’s Manual or Shop Manual for specifications and detailed procedures. Test every unit to be sure that it is functioning properly.

❒

AIR CLEANER—Check element. Clean if necessary.

❒

ENGINE OIL—Check the oil level. Fill to the correct level with the recommended oil if necessary.

Recommended oil

SAE 10W-30

API Service classification SJ or higher

FC600 TILLER

❒

CLUTCH CABLE—Check clutch lever freeplay: 3 - 8 mm (0.12 - 0.31 in). Adjust if necessary.

3 - 8 mm

(0.12 - 0.31 in)

❒

DRIVE BELT—Check drive belt tension.

Specified distance from the top of the belt to the top of the belt tension roller:

60 - 65 mm (2.4 - 2.6 in)

60 - 65 mm

(2.4 - 2.6 in)

❒

FUEL TANK—Inspect and fill.

❒

THROTTLE CABLE—Check throttle lever free play: 5 - 10 mm (0.2 - 0.4 in). Adjust if necessary.

Check the clearance between the belt stopper and the belt.

Specified clearance:

Front lower: 2 - 4 mm (0.08 - 0.16 in)

Front upper: 1 - 3 mm (0.04 - 0.12 in)

Rear: 1 - 3 mm (0.04 - 0.12 in)

FRONT UPPER

1 - 3 mm

(0.04 - 0.12 in)

REAR

1 - 3 mm

(0.04 - 0.12 in)

5 - 10 mm

(0.2 - 0.4 in)

FRONT LOWER

2 - 4 mm

(0.08 - 0.16 in)

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FC600 TILLER

❒

TRANSMISSION OIL—Check transmission oil level. Fill to the correct level with the recommended oil if necessary.

Recommended oil

SAE 10W-30

API Service classification SJ or higher

❒

ALL NUTS, BOLTS, AND OTHER

FASTENERS—Check for looseness and tighten if necessary.

❒

TEST—Start the engine and check operation.

• Check for throttle operation.

• Check for clutch operation.

• Check the engine switch operation.

• Upon completion of the test, check for fuel and oil leaks.

OPERATIONAL TESTS

Test every tiller to be sure that it functions properly.

1. Connect the spark plug cap, turn the engine switch ON, and start the engine.

2. Check the throttle lever operation. Make sure the choke fully closes in the CHOKE position and the throttle fully opens in the FAST position.

3. Use a tachometer and check the engine idle rpm with the throttle lever in the SLOW position. Make sure the drive clutch is disengaged.

IDLE (slow) SPEED:

1,400 ± 150 rpm

4. Use a tachometer and check the engine rpm with the throttle lever in the FAST position.

Make sure the drive clutch is disengaged.

Adjust the maximum speed with the throttle stop screw.

MAXIMUM SPEED:

3,850 ± 150 rpm

5. Engage the clutch and verify the tines operate properly.

6. Turn the engine switch to OFF.

7. Check front wheel operation.

8. Upon completion of the tests, check for fuel or oil leaks. Check all fasteners for looseness and tighten as necessary.

9. Fill out the sales registration form before delivering the unit to the customer. Always be sure to deliver the owner’s manual to the customer.

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10. Fill out the appropriate areas of the Power

Equipment Pre-Delivery Checklist (TO056), and give the yellow copy to the customer.

POWER EQUIPMENT PRE-DELIVERY CHECK LIST

THE FOLLOWING PRE-DELIVERY CHECK LIST IS DESIGNED FOR GENERAL APPLICATION.

THERE ARE INDIVIDUAL EXCEPTIONS TO THIS LIST. REFER TO THE APPROPRIATE SET-UP

INSTRUCTIONS AND SHOP MANUALS FOR DETAILED PROCEDURES AND SPECIFICATIONS.

PRE-DELIVERY INSPECTION

AIR-CLEANER - Check element. Clean if necessary,

ENGINE OIL - Fill to the correct level with recommended oil.

FUEL TANK - Drain, inspect and fill. Check for leaks.

CARBURETOR FLOAT CHAMBER - Drain old gasoline.

COOLANT - Check coolant level. Fill if necessary with a 50/50 solution of distilled water and ethylene glycol anti-freeze.

BATTERY - Check that the electrolyte level is correct and the battery is fully charged.

HYDRAULIC LIFT SYSTEM- Check fluid level and check for leaks.

TRANSMISSION FLUID LEVEL - Check fluid level and check for leaks.

FRONT DIFFERENTIAL OIL - Check level and add oil if necessary.

FRONT & REAR FINAL REDUCTION OIL - Check level and add oil if necessary.

POWER TAKE OFF LEVER FREE PLAY - Check free play and adjust as necessary.

CLUTCH LEVER/PEDAL FREE PLAY - Adjust if necessary.

BLADE CONTROL LEVER - Adjust if necessary.

SHIFT LEVER FREE PLAY - Check free play and adjust if necessary.

AUGER CLUTCH LEVER - Check free play and adjust if necessary.

PARKING BRAKE LOCK LEVER - Check lever for proper operation.

DIFFERENTIAL LOCK PEDAL FREE PLAY - Check free play and adjust if necessary.

MOWER HEIGHT ADJUSTMENT LEVERS - Check operation.

MOWER DECK LEVEL - Check mower deck for proper level.

BLADE BOLTS - Check blade bolts for proper torque.

TIRE PRESSURE - Check for proper tire pressure.

ATTACHMENT INSTALLATION.

ALL NUTS,BOLTS,& OTHER FASTENERS - Check security and tighten if necessary.

PRE-DELIVERY TEST PERFORMED BY:

CHECK SAFETY INTERLOCK SYSTEM OPERATION

NEUTRAL SWITCH PTO SWITCH

PARKING BRAKE SWITCH SEAT SWITCH

CHECK SHIFT LEVER OPERATION.

CHECK HEADLIGHT OPERATION

UPON COMPLETION OF TEST, CHECK FOR FUEL OR OIL LEAKS.

OPERATIONAL TEST PERFORMED BY:

PRINT NAME

PRINT NAME

DATE

GENERATOR OPERATION TEST

CHECK FULL THROTTLE ENGINE SPEED

CHECK AUTO-THROTTLE ENGINE SPEED

PERFORM LOAD BANK TEST

NO LOAD (AC)

VOLTS ___________FREQUENCY ____________

RATED LOAD (AC)

VOLTS ________ AMPS _________FREQUENCY ________

DC BATTERY CHARGE SYSTEM

DC VOLTS __________

GENERATOR OPERATIONAL TEST PERFORMED BY:

DATE

PRINT NAME

CHECK THROTTLE OPERATION.

CHECK IDLE AND FULL THROTTLE ENGINE SPEED.

CHECK GOVERNOR OPERATION.

CHECK PARKING BRAKE OPERATION.

CHECK PARKING BRAKE INDICATOR LIGHT AND/OR WARNING

BUZZER.

CHECK DRIVE BRAKE OPERATION.

CHECK DRIVE CLUTCH OPERATION.

CHECK ATTACHMENT OPERATION.

CHECK PTO/MOWER CONTROL/AUGER CLUTCH OPERATION.

CHECK 2WD/4WD OPERATION.

CHECK HYDRAULIC LIFT OPERATION.

DEALER NAME

DEALER

NUMBER

OPERATIONAL TEST

WHITE COPY - DEALER

YELLOW COPY - CUSTOMER

MODEL

NUMBER

FRAME

NUMBER

ENGINE

NUMBER

DATE

DELIVERY CHECK LIST

REVIEW PRE-DELIVERY CHECK LIST

REVIEW OWNER’S MANUAL

EXPLAIN OPERATION.

REVIEW WARRANTY COVERAGE & POLICIES.

EXPLAIN MAINTENANCE INTERVALS.

EXPLAIN SERVICE AVAILABILITY.

EXPLAIN SAFETY PRECAUTIONS.

FILL OUT OWNER’S I.D. CARD.

TOOL KIT (IF APPLICABLE)

CUSTOMER DELIVERY

I HAVE RECEIVED THE FOLLOWING:

OWNER’S MANUAL

WARRANTY POLICY STATEMENT

OWNER’S I.D. CARD.

ATTACHMENT OPERATOR’S MANUAL(S).

PRE-DELIVERY CHECK LIST (YELLOW COPY)

The operation of this unit was reviewed with me by a representative of the dealership. I have reviewed and understand the warranty policy. I have visually inspected the unit and found no defects.

CUSTOMER

NAME

ADDRESS

CITY

CUSTOMER

CUSTOMER

SIGNATURE

TO056

STATE ZIP CODE

DATE

PPD 12526 (9111)

FC600 TILLER

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