MODEL 68 SR TRIPLEX MOWER MODEL 68 DL TRIPLEX MOWER OWNER'S MANUAL Includes Operation, Maintenance and Parts List NATIONAL MOWER CO. 700 Raymond Ave., P.O. Box 14299 St. Paul, Minnesota 55114-0299, U.S.A. Phone (651) 646-4079 ­ Fax (651) 646-2887 www.nationalmower.com June 2003 ONE YEAR LIMITED WARRANTY For the period of one year from the date of purchase (45 days if the product is used for rental purposes), National Mower Company will repair or replace free of charge, for the original purchaser, any part or parts found by inspection to be defective by our Factory Authorized Service Station or by the Factory at St. Paul, Minnesota to be defective in material or workmanship or both. All transportation charges on parts submitted for repair or replacement under this warranty shall be paid for by the purchaser. This warranty does not include engines, engine parts or tires which are covered under separate warranties furnished by their manufacturer or supplier. All service under this warranty will be furnished and performed by our Factory Authorized Service Stations. THERE IS NO OTHER WARRANTY EXPRESSED OR IMPLIED Warranties, including those of merchantability and fitness for a particular purpose, are limited to one year from purchase or 45 days if the product is rented, and to the extent permitted by law, any and all implied warranties are excluded. The above remedy of repair and replacement of defective parts is the purchaser's exclusive remedy for any defect, malfunction, or breach of warranty. Liability for incidental or consequential damages under any and all warranties is excluded to the extent permitted by law. NATIONAL MOWER COMPANY P.O. Box 14299 700 Raymond Avenue St. Paul, Minnesota 55114-0299, U.S.A. Phone (651) 646-4079 Fax (651) 646-2887 www.nationalmower.com 2 68OM-06/03 ® NATIONAL 68 SR & DL TRIPLEX TABLE OF CONTENTS Warranty ................................................................................................... 2 Introduction ............................................................................................... 3 Safety Information .................................................................................... 4 Safety and Control Decals ........................................................................ 7 Receipt of Shipment ............................................................................... 11 Uncrating Instructions ............................................................................. 11 Assembly ................................................................................................ 12 Preparation ............................................................................................. 14 Operation ................................................................................................ 14 Maintenance ........................................................................................... 18 Maintenance Record .............................................................................. 26 Troubleshooting ...................................................................................... 27 Parts List ................................................................................................. 28 Frame & Running Gear ................................................................... 28 Running Gear & Misc. Parts - 68 DL ............................................... 30 Seat Mounting & Belt Guards .......................................................... 31 Drive Mechanism - Upper Portion ................................................... 32 Drive Mechanism - Middle Portion .................................................. 34 Drive Mechanism - Lower Portion ................................................... 35 Drive Mechanism - 68 DL ................................................................ 36 Rear Axle & Differential ................................................................... 38 Wing Cutting Units ........................................................................... 40 Rear Cutting Unit ............................................................................. 42 Skids, Reel End Shields & Guards ................................................. 44 Roller & Standard Scrapers ............................................................ 45 Roller Scraper Kit, Dial-A-HeightTM ................................................. 46 Dial-A-HeightTM Roller Adjuster Kit ................................................. 47 Dial-A-HeightTM Adjuster ................................................................. 48 Safety Switches ...................................................................................... 49 Electrical Diagrams ................................................................................. 50 Electrical Parts ........................................................................................ 51 Specifications .......................................................................................... 52 Parts Ordering Information ..................................................................... 53 Declaration of Conformity ....................................................................... 55 INTRODUCTION This manual has been prepared by National Mower Company as an aid to users in the assembly, safe operation, maintenance, adjustment and ordering replacement parts. Additional information will gladly be furnished by calling or writing the manufacturer or his authorized agent. Please furnish us with the Model Number, Serial Number and Date of Purchase when contacting us about your machine. Designations of right, left, front add rear are used as if the operator was sitting in the mower seat. 68OM-06/03 Before operating mower, carefully and completely read this manual. The contents provide you with an understanding of safety instructions and controls during normal operation and maintenance. Understand all safety precautions provided in the manuals. Review control functions and operation of the mower. Do not operate the mower unless all controls function as described in this manual. Review recommended lubrication, maintenance, and adjustments. 3 SAFETY INFORMATION The safety alert words below are used in this manual to identify potentially hazardous conditions. Their definitions are: safety guards are in place at all times, except during servicing. Keep all nuts, bolts, and screws tight. 3. OPERATION Wear approved safety glasses or goggles when operating the mower. Do not allow children to operate mower. Do not allow adults to operate mower without proper instruction. Do not carry passengers. Keep children and pets at a safe distance from an operating mower. Stop the mower if anyone approaches the mower. Disengage all cutting-unit clutches and shift into neutral before attempting to start the engine. Disengage main clutch before shifting cutting-unit clutches. Disengage power to the cutting units and stop the engine before leaving the operator's position. Disengage power to the cutting units and stop the engine before making any repairs or adjustments. Disengage power to the cutting units when transporting or not in use. These symbols mean: ATTENTION! PERSONAL SAFETY IS INVOLVED! BECOME ALERT! OBEY THE MESSAGE! Take all possible precautions when leaving the mower unattended, including shifting into neutral, setting the parking brake, stopping the engine and removing the ignition key. Watch for dangerous traffic when crossing or near roadways. Never direct the discharge of material from operating reels toward bystanders nor allow anyone near the mower. The mower and reels should be stopped and inspected for damage after striking a foreign object. The damage should be repaired before restarting and operating the mower. Proceed as follows when mowing: · Mow only in daylight or in good artificial light. · Never make a cutting height adjustment while the engine is running. · Shut the engine off when removing grass or unclogging reels. This machine is to be used only as a grass cutter or lawn mower. Never operate the mower while using drugs, medications, or alcohol. Safe operation requires complete and unimpaired attention. Never allow anyone to operate the mower when their alertness or coordination is impaired. Do not wear loose clothing or loose shoelaces, which may become entangled in mower controls or drive components. 68OM-06/03 DANGER means "IMMINENTLY HAZARDOUS SITUATION! If not avoided, WILL RESULT in death or serious injury." means "POTENTIALLY HAZARDOUS SITUATION! If not avoided, COULD RESULT in death or injury." WARNING CAUTION means "POTENTIALLY HAZARDOUS SITUATION! If not avoided, MAY RESULT in minor or moderate injury." It may also be used to alert against unsafe practices. The safety alert triangle symbols on your mower point out important safety precautions. NATIONAL MOWER SAFE OPERATING PRACTICES 1. TRAINING Know the control functions and how to stop quickly. READ THE OWNER'S MANUAL. 2. PREPARATION Clear the work place of objects which might be picked up by the blades and thrown. Handle fuel with CAUTION - it is highly flammable. · Use an approved fuel container. · Never remove the fuel tank cap or add fuel to a running or hot engine. Never fill the fuel tank indoors. Wipe up spilled fuel immediately. · Open garage doors to allow ventilation if engine is run inside ­ exhaust fumes are dangerous. Do not run engine in any enclosed area. Keep the mower in safe operating condition. Make sure that all safety switches are operating properly and all 4 ® NATIONAL 68 SR & DL TRIPLEX Do not mow in reverse, unless absolutely necessary. Always look down and behind before and during reverse motion. Shut off and raise the cutting units before operating the mower at transport speed. (Model 68 DL only.) Do not reverse battery connections. Damage to the mower can result. Battery gases are explosive and can cause death or injury. Keep open flames, sparks, and smoking materials away from batteries. Battery fluid contains sulfuric acid. Contact with skin, eyes, or clothing can cause chemical burns. Wash immediately and seek medical assistance. Wear protective clothing and safety glasses when handling a battery. (Model 68 DL only.) 4. HILL OPERATION Do not stop or start suddenly when going uphill or downhill. Mow up and down the face of steep slopes -- never across steep slopes. Do not exceed a slope of 15o in any direction. Reduce travel speed on slopes and in sharp turns to prevent tipping or loss of control. Use extreme caution when changing direction on slopes. Watch for holes in the terrain and other hidden hazards. Do not shift into neutral and coast downhill. Use extreme care when mowing near dropoffs or embankments. The mower could roll over if a wheel goes over the edge, or if an edge caves in. If mower stops going uphill, disengage power to the cutting units and slowly back down. 5. MAINTENANCE Never store the mower, with fuel in the tank, inside a building where fumes could reach an open flame or spark. Allow the engine to cool before storing in any enclosure. Keep the engine free of grass, leaves or excessive grease to reduce a fire hazard. Do not change the engine governor settings or overspeed the engine. Keep non-skid surfaces clean. Replace the non-skid material if worn, damaged, or missing. Wear appropriate safety gear, including safety glasses and gloves, while servicing the mower. Never mow while people, especially children, or pets are nearby. Keep in mind that the operator or user is responsible for accidents or hazards occurring to other people or their property. Do not carry passengers. All drivers should seek and obtain professional and practical instruction. Such instruction should emphasize: · the need for care and concentration when working with ride-on machines; · control of a ride-on machine sliding on a slope will not be regained by the application of the brake. The main reasons for loss of control are: · insufficient wheel grip; · being driven too fast; · inadequate braking; · the type of machine is unsuitable for the task: do not use mower for unsuitable tasks; · lack of awareness of the effect of ground conditions, especally slopes; · hitching and load distribution: do not hitch or tow other devices. 2. PREPARATION Gasoline (petrol) is highly flammable. Store fuel in containers specifically designed for this purpose. Refuel outdoors only. Do not smoke while refuelling. Add fuel before starting the engine. Never remove the cap of the fuel tank or add fuel while the engine is running or when the engine is hot. If fuel is spilled, do not attempt to start the engine but move the machine away from the area of spillage and avoid creating any sources of ignition until fuel vapors have dissipated. Replace all fuel tanks and container caps securely. WARNING While mowing, always wear substantial footwear and long trousers. Do not operate the equipme ...