Grasshopper 721D H2 Operator'S Manual & Parts List Download

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OPERATOR’S

MANUAL & PARTS LIST

RIDING MOWER

MODEL 721D H

THE GRASSHOPPER COMPANY

Moundridge, Kansas 67107 U.S.A.

Phone (620) 345-8621

Fax (620) 345-2301

Price $7.00

Form 172214-070207

Printed in U.S.A.

Summary of Contents for 721D H2

Page 1: ...OPERATOR S MANUAL PARTS LIST RIDING MOWER MODEL 721D H2 THE GRASSHOPPER COMPANY Moundridge Kansas 67107 U S A Phone 620 345 8621 Fax 620 345 2301 Price 7 00 Form 172214 070207 Printed in U S A ...

Page 2: ...thout incurring any obligation to make such changes to products manufactured previously As with all lawn and grounds equipment if han dled carelessly this machine is a dangerous piece of equipment If used incorrectly this machine can cause severe injury You the operator are responsible when operating it Therefore safety is of the utmost importance ATTENTION Read the instructions and warnings care ...

Page 3: ...3 14 Starting the Engine 14 15 Cold Weather Starting Tips 15 Uneven Terrain 15 16 Stopping Engine 16 Moving Unit Without Power 16 Steering Lever Operation 16 18 LUBRICATION AND MAINTENANCE Lubrication 19 Capacities 19 Tire Air Pressure 19 H2 Drive System 19 Crankcase Oil and Air Filter 19 Cooling System 19 Battery Maintenance 20 Checking H2 Drive System Fluid Level 20 Changing H2 Drive System Flui...

Page 4: ... Tension 26 Removing Mower Deck From Traction Kit Equipped Tractor 26 Rear Weight Requirements 26 PARTS LIST AND ILLUSTRATION Tractor Assembly 28 29 Engine Assembly 30 31 Drive Assembly 32 33 Drive Linkage Assembly 34 35 Steering Assembly 36 Reservoir Hose Assembly 37 PTO Shaft Clutch Assembly 38 39 ROPS Seat Assembly 40 41 Wiring Diagram 42 43 Limited Universal Harness 44 Counterweight Mount Kit ...

Page 5: ... control speed and direction of travel Zero turning radius center of machine is pivot point Speed Forward variable 0 to 9 m p h 14 5 km h Reverse variable 0 to 6 m p h 9 6 km h Fuel Tank Capacity 4 3 U S gal 16 3 l Tire Sizes Front Drive Wheels Standard 22 x 11 x 10 4 ply rated Optional 22 x 10 x 10 4 ply rated Tail Wheel 13 x 6 50 x 6 rib 4 ply rated Dimensions of Tractor Seat Back Height 46 1 17...

Page 6: ...uipment The terms CAU TION WARNING and DANGER are used in conjunction with the Safety Alert Symbol a triangle with an exclamation mark to indicate the degree of hazard for items of personal safety Is used for general reminders of good safety practices or to direct attention to unsafe practices Denotes a specific potential hazard Denotes the most serious specific po tential hazard DANGER CAUTION WA...

Page 7: ... SAFETY DECALS Replace Immediately If Damaged Fig 1 04075 Part No 165024 Part No 165345 Part No 165661 Part No 165679 Part No 165721 Part No 165340 Part No 165540 Part No 165090 Part No 165090 Rev 07 05 ...

Page 8: ...t counterweights when certain attachments are installed see specific acces sory installation instructions Inspect area to be cut removing stones branches and other debris that might be thrown causing injury or damage Evaluate the terrain to determine what ac cessories and attachments are needed to properly and safely perform the job Low hanging branches and similar obsta cles can injure the operat...

Page 9: ...ed area with out adequate ventilation Exhaust gases contain carbon monoxide an odorless and deadly poison ment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equip ment on a truck or trailer from a portable container rather than from a gasoline dis penser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in...

Page 10: ...e of waste products prop erly Never attempt to disconnect or alter any part of the safety interlock systems Keep engine free of grass leaves or excess grease to reduce fire hazard and minimize engine overheating Do not change engine governor settings Keep tractor and attachments in good op erating condition and all safety devices in place Periodically tighten all bolts nuts and screws Check that a...

Page 11: ... situation The illustrations and data used in this manual were current at the time of printing but due to possible in line production changes your machine may vary slightly in detail GRASS HOPPER reserves the right to redesign and change the machine as necessary without noti fication Some illustrations in this manual show the equipment with safety shields re moved to provide a better view The mowe...

Page 12: ...hart to determine the grade of bolt and proper torque except when specific torque values are assigned in the manual text Recommended Torque in Foot Pounds Fraction Decimal SAE Grade 2 SAE Grade 5 SAE Grade 8 Bolt Diameter in Inches 0 250 0 312 0 375 0 437 0 500 0 562 0 625 0 750 0 875 1 000 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 6 13 23 37 57 82 111 200 280 350 11 21 38 55 85 125 175 300 450 680...

Page 13: ...he unit can be started There is a safety switch under the operator s seat that will cause the en gine to stop should the operator leave the seat with any control engaged PRESTART CHECK LIST Place tractor on level surface Check crankcase oil level refer to Engine Manual for proper level and type of oil used Never attempt to check oil while en gine is running Check radiator coolant Do not remove rad...

Page 14: ...ering Lever PTO Switch Parking Brake Proper Result Start Circuits Kill Circuits with engine running at 1 2 throttle Test Safety Interlock System Daily Try starting engine Try starting engine Try starting engine Try starting engine Raise off seat Raise off seat Raise off seat Raise off seat Move left steering lever in Out Out Out Out Out Out Out Out Out Out Out Out Out Out In In In In Off Off Off O...

Page 15: ...rp drops Follow manufacturer s recommendation for counterweights for added stability when operating on slopes or using front or rear mounted attachments Remove weights when not required Use extra care with grass catchers or other attachments These can change the stability of the machine Do not use grass catcher on steep slopes Do not operate without ROPS deployed If the engine does not start withi...

Page 16: ... wires from the fuel shut off sole noid item 30 page 31 Push the engine stop lever forward toward the radiator refer to the Engine Manual s il lustration showing the location of the engine stop lever It is important that the operator be familiar with where the parts are located on the en gine MOVING UNIT WITHOUT POWER The hydro pumps are equipped with a dump valve Refer to Fig 3 that allows the un...

Page 17: ...re moved the faster the machine will move At half throttle move both steering levers from swing out neutral inward Move both steering levers forward To turn right advance left lever further forward than right lever To turn left advance right lever further forward than left lever If you leave one steering lever in neu tral and advance the other lever the tractor will turn a complete circle Move the...

Page 18: ...18 Fig 4 93051 FORWARD REVERSE GENTLE LEFT SHARP LEFT SHARP RIGHT GENTLE RIGHT STEERING LEVER OPERATION ...

Page 19: ...d fill expansion tank to proper level through radiator A solution of 50 anti freeze and 50 water must be used freezing point about 34 F 36 C Do not use 100 antifreeze or severe damage will occur WARNING CAUTION CAUTION Always wear safety glasses and ear protection when performing any maintenance function that could cause injury to eyes or ears Read all safety information on pages 6 through 10 Lowe...

Page 20: ...uired add until level is equal to the full mark on the reservoir decal shown below Use Grasshopper Fluid Grasshopper part no 345050 for 1 quart 94 l container CHANGING H2 DRIVE SYSTEM FLUID AND FILTERS Change fluid filter mounted on the panel un der the seat every 1000 hours of use Change fluid every 1000 hours of use To change fluid loosen PTO shield item 14 page 39 and re move Trash Screen item ...

Page 21: ...en linkage is connected 9 Test drive machine for straight line travel with both levers full forward If travel is not in a straight line adjust the steering le ver stop on the side that is the fastest i e if machine goes to the left adjust the right steering stop to slow down the right drive system until travel is straight ahead H2 BELT REPLACEMENT Refer to illustration page 33 1 Remove key from ig...

Page 22: ...d to premature starter failure Connect the fuel shut off solenoid If engine will not start after bleeding air from FUEL SOLENOID ADJUSTMENT Adjust cable between fuel shut off solenoid and enginefuelstopvalvetoprovidefullengagement of the solenoid The solenoid should bottom out be fully engaged before fuel stop valve fully engages stop approx 0625 to 125 1 6 to 3 2 mm gap The solenoid is designed t...

Page 23: ...onnect battery fuel line electrical wires from engine throttle and flex coupling connected to coupling hub Remove the four engine mount bolts to the frame and drive belts from clutch sheave The engine can now be lifted out Consult your local authorized engine dealer for repairs or repair parts WIRINGCIRCUITBOARD REMOVAL Remove the circuit board from the console by compressing the keeper in each of...

Page 24: ... belt idler pulley and remove drive belts item 29 page 39 4 Unplug wires from clutch and remove center bolt item 19 page 39 Slide clutch back then remove the five hex socket head bolts item 10 page 39 to remove clutch and stub shaft together 5 Remove clutch from stub shaft 6 Reverse order to install new clutch 7 Torque stub shaft bolts to 20 ft lbs 8 Torque clutch bolt to 50 ft lbs Run clutch 15 m...

Page 25: ...the front refer to Fig 11 FOOT REST BLOCK INSTALLATION If installing a 33 34 or 95 series deck on a 700 series tractor install the foot rest blocks with the wide end of block toward the front refer to Fig 10 Fig 10 Fig 11 Foot Rest Block Tap Screw 98036 SL96 SL98 Series or 9772 Decks Foot Rest Block Tap Screw 98035 33 34 or 95 Series Decks ...

Page 26: ...9644 3344 w 4 Post Rated ROPS or Enclosure 0 9548 SL9648 3348 AERA vator 40 Brooms Bidirectional Fixed Angle Single Tail Wheel w o Grasscollector Mower Deck Model Snowthrowers 48 60 Other Than Single Tail Wheel w o Grasscollector Deck Tilt Assist Kit Requires an additional 50 lbs of counterweight unless unit is already equipped with 150 lbs of counterweight COUNTERWEIGHT NOT REQUIRED ON UNITS EQUI...

Page 27: ...27 PARTS LISTS AND ILLUSTRATIONS When ordering parts use the description and part number as stated in this manual Also include the serial number of the tractor or attachment the parts are to be used on ...

Page 28: ...05 Fuel Prefilter 29 821713 Hose Fuel Line 312 ID 30 280261 Hose Clamp 312 31 603812 Fuel Tank w Draw Tube includes items 34 35 32 643144 Fuel Tank Mounting Bracket 33 141125 Cap w Fuel Gauge 34 101818 Fuel Draw Tube 35 101817 Fuel Tube 187 36 280257 Hose Clamp Spring 37 821740 Hose Fuel Return Line 38 422065 Square Plug 1 39 643092 Deck Mount Rt 40 643093 Deck Mount Lt 41 247280 Bolt 375 16 x 2 7...

Page 29: ...16 17 17 18 19 20 21 22 23 23 24 24 25 25 26 27 28 29 30 31 32 33 34 35 36 37 38 38 39 40 41 42 42 43 43 44 44 45 46 47 47 48 49 49 50 51 52 53 54 55 55 56 56 57 58 58 59 59 60 60 61 61 65 65 66 66 66 67 68 68 69 68 68 68 68 69 70 71 71 70 62 69 68 68 63 63 59 05057 70 64 72 69 50 ...

Page 30: ...2 Expansion Tank 17 423154 Tie 25 x 15 18 821748 Hose Tank Overflow 19 821749 Hose Radiator Overflow 20 280260 Hose Clamp Spring 25 21 644651 Radiator Mount 22 101612 Radiator 23 101080 Radiator Mount Bushing 24 644671 Grille 25 822636 Trim Grille 26 422090 Isolator 27 604805 Swell Latch Assembly 28 755121 Mount Solenoid Filter 29 101000 Fuel Filter 30 603350 Fuel Solenoid 31 603209 Cable Assembly...

Page 31: ... 3 4 5 6 7 8 8 8 8 9 9 9 9 10 11 12 13 14 14 15 16 17 22 21 47 48 18 19 20 20 24 25 25 26 26 27 28 29 30 31 32 33 33 9 34 35 36 37 38 39 40 45 45 38 38 41 42 43 43 38 38 43 44 44 37 37 37 37 05069B 40 40 40 40 46 46 23 23 23 23 49 27 ...

Page 32: ...ng 28 644118 Coupling Connector 29 902318 Spacer Coupling 30 253192 Whiz Bolt 312 18 x 75 31 253035 Whiz Nut 312 18 32 243335 Bolt 375 16 x 1 25 33 257030 Washer 312 34 254450 Nut 375 16 35 243330 Bolt 375 16 x 1 36 243340 Bolt 375 16 x 1 5 37 824491 Idler Arm Assembly Lower includes items 39 40 38 604450 Idler Arm Assembly Upper includes items 39 40 60 61 39 121756 Oilite Bearing Flange 40 121650...

Page 33: ...44 44 31 53 57 5 1 54 55 2 58 3 4 44 12 21 40 32 44 39 37 34 47 46 45 39 41 42 33 33 36 43 30 48 30 47 34 32 32 19 20 23 56 24 22 56 24 26 26 25 27 25 33 35 33 36 28 17 34 27 35 17 33 29 33 35 29 53 57 1 5 54 55 2 3 4 40 39 45 46 58 41 42 44 38 39 36 43 33 33 05058C 59 59 60 61 LEFT SIDE RIGHT SIDE ...

Page 34: ...Rt 22 729137 Neutral Return Arm Front Lt 23 283823 Extension Spring 24 261284 Clevis Pin 312 x 1 25 822304 Pivot Bearing 26 257030 Washer 312 27 243335 Bolt 375 16 x 1 25 28 253890 Lock Nut 375 16 29 644539 Brake Pivot Linkage Rod 30 732616 Mount Bracket Brake Pivot 31 644588 Mount Brake Caliper 32 247130 Carriage Bolt 312 18 x 75 33 481102 Caliper Brake Assembly CW 603150 Brake Pad Kit 34 481103 ...

Page 35: ...20 18 41 15 25 26 27 22 23 16 40 39 26 43 14 14 35 31 32 32 35 34 39 14 42 10 38 10 37 10 9 30 45 24 26 10 44 39 29 30 45 9 10 37 10 38 10 14 32 32 31 42 39 35 35 14 14 36 28 26 25 19 17 16 11 7 12 13 45 14 8 5 6 4 5 10 9 16 21 23 15 25 26 27 33 04113B RIGHT SIDE LEFT SIDE Rev 06 06 ...

Page 36: ...earings 8 604772 Steering Pivot Lt w Stop Bearings 9 422559 Bearing w Flange 10 422557 Bearing 11 257019 Washer 25 Hard 12 257063 Nylon Washer 13 422556 Bearing w Flange 14 283324 Compression Spring 15 253470 Nut 5 13 Nylon Insert 16 243197 Stop Bolt 312 18 x 75 17 254438 Nut 375 16 Adj Lever Item Order Description No No Item Order Description No No 97023D 1 1 2 2 3 3 4 4 5 5 6 7 8 9 9 9 10 10 9 1...

Page 37: ...3200 Whiz Bolt 375 16 x 75 7 253043 Whiz Nut 375 16 8 253173 Whiz Bolt 25 20 x 5 9 101024 Filter Base 10 100855 Oil Filter 11 360057 Adapter 6MJ 6MB 12 363846 Fitting 6 Beaded Stem 90 13 821792 Hose 375 Hydraulic 3 14 821786 Hose 375 Hydraulic 6 5 15 821784 Hose 375 Hydraulic 11 25 16 280264 Hose Clamp Spring 375 TOC 17 366551 Strainer In Line 375 18 603611 Wheel Motor W Hub 19 360063 Adapter O Ri...

Page 38: ...x 225 17 883803 Retaining Washer 11M x 1 62 18 257412 Lock Washer 375 19 243337 Bolt 375 24 x 1 25 Grade 8 20 824499 Idler Arm includes items 21 37 21 881105 Bearing Pivot Shaft 22 243355 Bolt 375 16 x 2 5 23 415610 Idler Pulley 24 243805 Bolt 625 11 x 1 75 25 257452 Lock Washer 625 26 283820 Spring Extension w Swivel 27 732539 Idler Spring Bracket 28 725118 Clutch Anti Rotation Bracket 29 381914 ...

Page 39: ...PTO SHAFT CLUTCH ASSEMBLY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 29 30 32 33 34 35 36 36 37 37 31 31 31 31 31 31 31 31 31 38 40 39 38 38 38 38 38 38 38 38 38 02066 41 ...

Page 40: ... x 75 15 253035 Whiz Nut 312 18 16 754240 Seat Handle Dual Latch 17 754226 Reinforcement Seat Handle 18 730230 Pivot Pin Seat 19 284408 Torsion Spring 20 260606 Ring Cotter 047 x 312 21 253043 Whiz Nut 375 16 22 253176 Whiz Bolt 25 20 x 5 23 253025 Whiz Nut 25 20 24 324200 Seat Belt Non Retract 25 243551 Bolt 5 13 x 75 26 257063 Nylon Washer 5 27 257062 Washer 5 SAE 28 253470 Nut 5 13 Nylon Insert...

Page 41: ... SEAT ASSEMBLY 29 9 2 1 3 10 27 28 8 5 10 6 26 18 11 24 12 25 22 32 22 8 8 16 22 17 19 20 22 7 24 25 26 3 8 31 8 31 28 27 10 4 6 30 30 31 31 8 23 8 12 35 8 13 36 34 37 21 33 35 36 34 33 14 8 14 13 15 23 05059 ...

Page 42: ...le Switch Interlock 17 181735 Fuse Holder 181470 Fuse 30 Amp Auto 18 141222 Temperature Sender 19 183871 Seat Safety Switch 20 184272 Relay 21 181722 Fuse Block 184458 1 Wire Clip 184460 2 Wire Clip 184472 Double Clip 22 181470 Fuse 30 Amp Auto 181465 Fuse 15 Amp Auto 181462 Fuse 10 Amp Auto 181460 Fuse 7 5 Amp Auto 23 141551 Hour Meter 24 183894 Brake Switch 25 185530 Voltage Regulator 26 180130 ...

Page 43: ...D BLUE BATTERY G BLUE BLUE YELLOW GREEN GREEN 0 BRAKE BLACK RED BLACK GREEN YELLOW GREEN YELLOW W BROWN BLACK WHITE WHITE YELLOW BROWN GLOW PLUG G NO OIL GREEN HOLD 0 COMM YELLOW 0 3 BLACK FUEL 0 1 0 2 4 SEAT BLACK PULL GREEN OIL BROWN SOLENOID BROWN A BLACK BLUE AC BLUE GREEN 30 GREEN 17 19 GREEN ALT TEMP GREEN LT STRG RT STRG ENGINE GREEN STARTER 50 NC I BLACK B GREEN GREEN YELLOW BLUE RED W WHI...

Page 44: ...ARNESS TO ENGINE GROUND GREEN THIS CONNECTOR COMES WITH THE ACCESSORY HARNESS GREEN YELLOW 6 WAY WEATHER PACK CONNECTOR FEMALE TERMINALS 05066 REAR CORNER OF FRAME RELAY MOUNTS IN LEFT BLACK GREEN BROWN 6 WAY WEATHER PACK CONNECTOR MALE TERMINALS BROWN CLUTCH BROWN GREEN YELLOW RED WHITE C E A 40 B A F C D B D F E Item Order Description No No 605957 Limited Universal Harness 1 181475 Fuse Auto 40 ...

Page 45: ... Description No No 503220 Counterweight Mount Kit 1 643915 Weight Mount 2 729691 Weight Cover 3 240151 Hook Bolt 375 16 x 6 4 253203 Whiz Bolt 375 16 x 1 5 253043 Whiz Nut 375 16 Lg Flange 6 503218 Counterweight 50 Not Included in Kit 95043 95043 4 5 2 5 5 6 3 4 3 1 4 ...

Page 46: ...Axle Beam w Bushing Dual 20 830420 Spacer 375 x 1 156 21 483865 Wheel Tire Assembly 13 x 6 5 x 6 w Bearing Spacer 482355 Tire 13 x 6 5 x 6 483306 Wheel Without Tire 6 x 4 5 22 902475 Bearing Spacer 23 120050 Wheel Bearing 24 247725 Bolt 625 x 7 Carriage 25 604365 Rear Fork With Nut 26 282615 Spacer 375 x 1 27 125855 Seal 28 643631 Rear Axle Pivot 29 824510 Axle Beam w Bushing 30 902427 Axle Spacer...

Page 47: ...2 28 8 7 27 17 17 16 15 26 25 3 23 4 24 22 23 4 21 31 33 32 18 18 34 20 5 10 9 33 32 32 6 3 4 30 1 13 2 21 21 99021B 14 12 28 33 35 19 11 7 8 10 9 6 3 4 17 17 16 15 30 13 2 1 20 21 21 99023B 11 7 8 99022B 11 11 36 12 11 7 8 11 Rev 06 06 ...

Page 48: ...2 18 13 604708 Rocker Arm Extension Kit opt includes 2 each of items 11 18 22 14 260523 Hair Pin 094 x 2 15 257040 Washer 375 16 261362 Clevis Pin 375 x 1 75 17 262950 Push on Retainer 18 261339 Clevis Pin 375 x 875 Sq Shank 19 260648 Cotter Pin 125 x 5 20 644706 Extension Rocker Arm 21 253203 Whiz Bolt 375 16 x 1 22 253043 Whiz Nut 375 16 23 820317 Lift Chain 3 Links NOTE Item 13 is not used with...

Page 49: ...W BROWN C A B C B A BLACK RED YELLOW OPTIONAL HYDRAULIC LIFT WIRING DIAGRAM Item Order Description No No 1 144950 Hydraulic Solenoid 2 183710 Tilt Switch 3 183940 Push Button Switch 4 184973 Weather Pack Connector 5 181460 Accessory Fuse 7 5 amp Auto 6 722747 Mount Tilt Switch ...

Page 50: ...7 360005 Adapter Tee NPT Flare 28 360012 Adapter Fitting 29 360040 Adapter M O Ring MPT 30 360045 Adapter m NPT O Ring 31 360050 Adapter M O Ring M Flare 32 360052 Adapter M O Ring M Flare 33 360055 Adapter M O Ring 90 34 360260 Brass Hose Insert 35 363832 Fitting STL O Ring Boss 36 363857 Fitting 90 8 Beaded Stem 37 366115 Reducer Tee 375 x 25 x 25 38 388560 Coupler Sleeve Nylon 39 388576 Coupler...

Page 51: ...10 12 12 12 12 12 13 6 13 12 13 14 60 13 13 16 17 16 17 18 18 20 20 20 2 1 3 4 5 6 11 15 20 20 19 19 19 19 21 21 22 23 24 24 25 26 27 28 29 30 31 32 32 33 34 35 36 37 38 39 40 41 42 42 43 43 44 45 46 47 48 49 50 51 52 53 53 54 59 55 56 14 60 63 64 57 58 58 05043 61 61 62 ...

Page 52: ...TOR COMES WITH THE ACCESSORY HARNESS PURPLE GREEN YELLOW 6 WAY WEATHER PACK CONNECTOR FEMALE TERMINALS 05065 REAR CORNER OF FRAME RELAY MOUNTS IN LEFT BLACK GREEN BROWN BROWN 6 WAY WEATHER PACK CONNECTOR MALE TERMINALS HYDRAULIC DECK LIFT SOLENOID EXISTING WIRE TO DECK LIFT SWITCH BROWN RED WHITE GREEN YELLOW CLUTCH BROWN C E A 40 B A C B F D E F D 605959 Universal Harness 1 181475 Fuse Auto 40 Am...

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