Bolens Large Frame Tractors Workshop Service Repair Manual

j!1:~:~n ------____,.;1 Balens LARGE FRAME ) TRACTORS SERVICE MANUAL ) FORM 552665·5 REV. 3/85

L F MODEL E ME CTORS 1886s-05 1886s .. o6 (HT 18) 2086 (HT 20) 2087 (HT 20) 2288 (HT 22) 2289 (HT 20) 2389 (HT 23) 2388s {HOT 1 000) 2389s (HT 23) I. GENERAL II II. ELECTRICAL SYSTEM Ill. DRIVETRAIN ~ IV. FUEL SYSTEM II V.CHASSIS m - VI. HYDRAULIC SYSTEM m VII. ENGINE ~ VII I. TRACTOR ATTACHMENTS l: ~

.ARGE FRAME TRACTOR Rev. 3/85 TABLE OF CONTENTS PAGE GROUP I. GENERAL . . . . . . . . . . . . . 1-1 SERIAL NUMBER INFORMATION . . . . . . . . . . . 1-1 SPECIFICATIONS . . . . . . . . . . . 1-2 TORQUE ................... 1~ MAINTENANCE CHART KOHLER ................ 1-4 MAINTENANCE CHART (WISCONSIN/DUCATTI) .... 1-5 LUBRICATION POINTS . . . . . . . 1-6 LUBRICATION CHART ....... 1-7 MAINTENANCE CHART (MITSUBSHI) . . . . . . . . . . . . . 1-8 LUBRICATION CHART . . . . . . . 1-9 GROUP II. ELECTRICAL SYSTEM TROUBLE SHOOTING GUIDE . WIRING DIAGRAM - 18865-05 2-1 2-1 and 06 .................. 2-3 LIGHT CIRCUIT DIAGRAM 2-4 START/RUN CIRCUIT . . . . . . 2-4 CHARGING CIRCUIT . . . . . . 2-5 WIRING DIAGRAM - 2086 and 2087 S/N 01/03 . . . . . . . . . . . 2-6 WIRING DIAGRAM - 2087-04 and 2389 ............... . LIGHT CIRCUIT .......... . START/RUN CIRCUIT - 2-6A 2-7 2086 and 2087-01/03 . . . . . . 2-7 START/RUN CIRCUIT - 2389, 2087-04 and 23895 .. . CHARGING CIRCUIT ..... . CRUISE CONTROL CIRCUIT WIRING DIAGRAM - 23895 ... WIRING DIAGRAM - 2288 and 2289 ............... . CHARGING CIRCUIT ..... . SEAT CIRCUIT .......... . START CIRCUIT ......... . LIGHT CIRCUIT .......... . WIRING DIAGRAM - 23885 .. . START CIRCUIT ......... . RUN CIRCUIT ........... . LIGHT CIRCUIT .......... . CRUISE CONTROL CIRCUIT PREHEAT CIRCUIT ...... . TESTING ELECTRICAL SYSTEM ............... . 2-8 2-8 2-9 2-6B 2-10 2-11 2-12 2-13 2-13 2-14 2-15 2-15 2-16 2-16 2-17 2-15 GROUP Ill. DRIVE TRAIN ......... 3-1 TROUBLE SHOOTING GUIDE 3-1 PRINCIPLES OF HYDROSTATIC OPERATION ............. 3-2 HYDROSTATIC TRANSMISSION FLOW CHART . . . . . . . . . . . . 3-3 IDENTIFICATION ............ 3-4 TESTING HYDRO (SUNDSTRAND) . . . . . . . . . . 3-6 HYDRO REMOVAL AND INSTALLATION (SUNDSTRAND) . . . . . . . . . . 3-7 TESTING HYDRO (EATON) 3-11A HYDRO REMOVAL AND INSTALLATION (EATON) ... 3-11 B HYDROSTATIC REPAIR PAGE (SUNDSTRAND) .......... 3-12 CHARGE PUMP SECTION .... 3-12 PUMP SECTION ............ 3-15 CENTER SECTION .......... 3-18 MOTOR SECTION . . . . . . . . . . . 3-20 TRANSAXLE REMOVAL ...... 3-21A ASSEMBLY PROCEDURE OF CARRIER AND AXLE . . . . . . 3-24 TRANSAXLE ASSEMBLY . . . . . 3-26 TRANSAXLE ASSEMBLY PROCEDURE . . . . . . . . . . . . 3-28 TWO SPEED TRANSAXLE ASSEMBLY 2389, 2288, 23895, 23885, and 2289 . . . . . . . . . . 3-30 GROUP IV. FUEL SYSTEM ........ 4-1 TROUBLE SHOOTING GUIDE . 4-1 FUEL TANK AND VALVE ..... 4-3 FUEL FILTER . . . . . . . . . . . . . . . 4-4 AIR CLEANER . . . . . . . . . . . . . . 4-4 CARBURETOR ADJUSTMENTS 4-5 GROUP V. CHASSIS .. ~ .......... 5-1 FRONT AXLE ............... 5-1 FRONT WHEEL ALIGNMENT . . 5-2 TURNING RADIUS . . . . . . . . . . . 5-2 FRONT WHEEL BEARINGS . . . 5-3 TIRES ..................... 5-3 BRAKES ................... 5-4 POWER TAKE-OFF LEVER AND BELTS . . . . . . . . . . . . . . 5-5 REAR WHEELS . . . . . . . . . . . . . 5-6 TRAVEL PEDAL . . . . . . . . . . . . . 5-6 FOOT BRAKE AND SEAT INTERLOCK SWITCH . . . . . . 5-7 GROUP VI. HYDRAULIC SYSTEM .. 6-1 TROUBLE SHOOTING GUIDE . 6-1 PRINCIPLE OF OPERATION . . 6-2 TI:STING HYDRAULIC SYSTEM 6-4 CHECKING IMPLEMENT RELIEF VALVE ........... 6-4 HYDRAULIC POWER LIFT . . . . 6-4 REPAIRING HYDRAULIC SYSTEM ................ 6-6 DISASSEMBLY . . . . . . . . . . . . . . 6-6 ASSEMBLY . . . . . . . . . . . . . . . . . 6-7 OIL COOLER . . . . . . . . . . . . . . . 6-8 POWER STEERING .......... 6-10 ADJUSTMENT OF STEERING NUT . . . . . . . . . . . . . . . . . . . . 6-11 GROUP VII. ENGINE . . . . . . . . . . . . . 7-1 TROUBLE SHOOTING GUIDE 7-1 ENGINE REMOVAL . . . . . . . . . . 7-3 GROUP VIII. TRACTOR ATTACH· MENTS ...................... 8-1 MOWERS .................. 8-1 SNOW THROWER ........... 8-3 TILLERS . . . . . . . . . . . . . . . . . . . 8-6

GROUP I. GENERAL SERIAL NUMBER INFORMATION Model number of Tractor. Serial number of Tractor. FIGURE 1-1 ·1886s Engine Model Number. Engine Serial Number. Engine Spec. Number. LARGE FRAME TRACTOR PAGE 1-1 Rev. 3/85 FIGURE 1-2 2086,2087 FIGURE 1-3 1886s, 2086, 2087 2389 & 23895 2288,2289

1\RGE FRAME TRACTOR PAGE 1-2 Rev. 3/85 ENGINE 1886s-05 & 06 GENERAL(Continued) SPECIFICATIONS 2086 2087 Manufacturer ........... Kohler .................. Kohler .................. Kohler Model/Spec ............ K482S 35208B & 35113B ... K 5325 53100A ........... K532S 553102A & 53138A Type ................... Harz. shaft, air cooled .... Harz. shaft, air cooled, ... Harz. shaft, air cooled, 2 cyl., 4 cycle ............ 2 cyl., 4 cycle ............ 2 cyl., 4 cycle Bore and Stroke ......... 3-1/4" X 2-7 /8" (82.5 x 73 3-3/8" X 3" (85.7 X 76.2 mm) 3-3/8" X 3" (85.7 X 76.2 mm) mm) .......................................... . Piston Displacement ..... 47.7 Cu. ln. (781.3 cc) ... 53.7 Cu. ln. (879.6 cc) ... 53.7 Cu. ln. (879.6 cc) Mfr's H.P. Rating ........ 18 H.P. at 3600 R.P.M ..... 19.5 H.P. at 3450 R.P.M .... 19.5 H.P. at 3450 R.P.M. Air Cleaner ............. Paper Element Kohler .... Paper Element Kohler .... Paper Element Kohler 277138 . . . . . . . . . . . . . . . . . . . 277138. . . . . . . . . . . . . . . . . . . 277138 Oil Capacity ............ 3 Quarts (2.8 liter) and 3 Quarts (2.8 liter) and 3 Quarts (2.8 liter) and 1 pint (.47 liters) in filter 1 pint (.47 liter) in filter 1 pint (.47 liter) in filter Oil Filter ............... Kohler 277233 ............ Kohler 277233 ............ Kohler 277233 Governor ............... Mechanical .............. Mechanical .............. Mechanical Speed Control .......... Remote, cable operated .. Remote, cable operated .. Remote, cable operated Starter .................. Electric .................. Electric .................. Electric Charging System ........ 30 Amp. Alternator ....... 15 Amp. Alternator ....... 15 Amp. Alternator Spark Plug Size ......... 14 mm .................. 14 mm ............... ·~. 14 mm Spark Plug .............. Champion HR 10 ......... Champion HR 10 ......... Champion HR 10 Spark Plug Gap .......... 025" (0.63 mm) . . . . . . . . . . 025" (0.63 mm) . . . . . . . . . . 025" (0.63 mm) Breaker Point Gap ........ 020" (0.5 mm) . . . . . . . . . . .020" (0.5 mm) . . . . . . . . . . . 020" (0.5 mm) ENGINE Manufacturer .... •.•.. Model/Spec ......... . Type ..• .... • ........ 2288 2289 2389/23895 Ducati ........ •• .... • Teledyne Wisconsin ..... Kohler 21522 ...• ........... WD2·860 .•.•..• ...... K 5828 36272AIK582S 36328 Harz. shaft, air cooled. . • Harz. shaft, air cooled. . . Harz. shaft, air cooled 4 cycle, 2 cyl. Diesel .... 4 cycle, 2 cyl. Diesel .... 2 cyl. 4 cycle Bore and Stroke ...... 3.307" X 3.071 (84 X 3.307" X 3.071" (84 X 3-1/2" x 3" (88.9 mm X Piston Displacement ..• Mfr's H.P. Rating • ..... Air Cleaner ......... . Oil Capacity ..... •... Oil Filter ........... . Governor .......... •. Fuel Filter .......... . Speed Control ....... . Starter .• ............ Charging ........... . 78 mm) ..... • ........ 78 mm) ........ •• .... 76.2 mm) 52.7 Cu. ln. (864 cc) .... 52.7 Cu. ln. (864 cc) .... 57.7 Cu. ln. (946.0 cc) 22 H.P. at 3000 RPM ... 19.9 H.P. at 3000 RPM .. 23 H.P.(17.1 KW)at3600 RPM Bolens 1721457 ....... Bolens 1721457 ....... Paper element Kohler4708303 2.2 Ot. (2 liter) and 1 2.2 Ot. (2 liter) and 1 8 Pts. (2.8 liter) and 1 Pint (.47L) Pint (.47 liter) in filter ... Pint (.47 liter) in filter ... (.47 liter) in filter Bolens 1726450 . . . • . . . Bolens 1726450 ....... Kohler 277233 Mechanical .• .... •..•. Mechanical ...•• ...... Mechanical Bolens 1738804 . . . . . . . Bolens 1738804 Remote, cable operated. . Remote, cable operated .. Electric ............ •. Electric ............. . 9 Amp. Alternator (35 9 Amp. Alternator (35 Amp. alter, kit available). Amp. alter kit available) . Remote, cable operated Electric 15 Amp. Alternator Spark Plug Size ................................................ . 14mm Spark Plug ......... • ........ • .... • ......................... •... Spark Plug Gap ....... • ......................................... Breaker Point Gap ......................... • ..................... Champion HR 10 . 035 (0.89 mm) . 020 (0.51 mm) )

) GENERAL (Continued) LARGE FRAME TRACTOR PAGE 1-3 Rev. 3/85 MODEL 2388s Engine Mfg. . . . . . . . Mitsubshi Model/Spec . . . . . . . . K3D·61 FG Type . . . . . . . . . . . . . . Vertical shaft, water cooled, overhead valve 3 cyl. diesel Bore and Stroke . . . . . 2.87 x 3.07 (73 x 78mm) Piston Displacement . 59.7 cu. in. (0.979 cc) Mrf's H.P. rating .... 22 H.P. (16.4 Kw) at 3200 RPM Air Cleaner . . . . . . . . . Dry Type Oil Capacity . . . . . . . . 3.2 Qt (3.0 L) and 1 pt. (0.47 L) in filter Oil Filter . . . . . . . . . . . Bolens No. 1739922 Governor . . . . . . . . . . . Mechanical Fuel Filter . . . . . . . . . . Bolens No. 1738804 Engine Air Filter . . . . . Bolens No. 1721457 Speed Control . . . . . . Remote, cable operated Starter . . . . . . . . . . . . . Electric Hydrostatic Filter . . . . Bolens No. 1726450 Radiator Capacity . . . 7 Qts (6.6 L) Battery . . . . . . . . . . . . 90 Amp CHASSIS Type .................................. . Length ................................ . Width - With Reg. Tires ................. . 47 in. With Terra Tires ................... . H~g~ ................................ . Wheel Base ............................ . Turning Radius ......................... . Ground Clearance ....................... . Transmission Models 1886, 2086, 2087 .............. . Models 2288, 2388s, 2389, 2389S, 2289 .. . Transmission oil qty ..................... . Speed Infinitely Variable Models 1886, 2086, 2087 .............. . Models 2389, 2288, 2289, 2389s ........ . Model 2388s ......................... . Brakes Steel channel frame 76 in. (192 em) 38 in. (96 em) 47 in. (119 em) 45 in. (114 em) 52 in. (132 em) 80 in. (203 em) 8-1/2 in. (22.6 em) Sundstrand in-line Eaton 10 Qts. (9.4L) Forward - 0-8 MPH (0-12.8 km/h) Rev. - 0-4 MPH (0.64 km/h) Forward - 0-10 MPH (0-16 km/h) Rev. - 0-5 MPH (0·8 km/h) Forward - 0-13.8 MPH (0-22 km/h) Rev. - 0-5 MPH (0·8 km/h) Disc TORQUE SPECIFICATIONS TRANSAXLE Carrier Bolts ...... 25 to 30 Ft. Lbs. (24-40 Nm) Axle Housing Bolts ........ 30 Ft. Lbs. (40 Nm) Wheel Hub Nut ......... 150 Ft. Lbs. (203 Nm) HYDROSTATIC Charge Pump Capscrews ... 20 Ft. Lbs. (27 Nm) Pump, Center and Motor Housing Capscrews ....... 35 Ft. Lbs. (47 Nm) Check Valve Screws ..... 10 Ft. Lbs. (13.5 Nm) Maximum Torque to Rotate Input and Output Shaft After Assembly and Before Running ..... 25 ln. Lbs. (2.8 Ncm) Maximum Torque to Rotate Control Shaft After Assembly .... 25 ln. Lbs. (2.8 Ncm) II

LARGE FRAME TRACTOR PAGE 1-4 Rev. 3/85 GENERAL (Continued) MAINTENANCE CHART KOHLER MODELS Length of MAINTENANCE REQUIRED Operation Engine Oil Filter- 100 Hrs. * Engine Cooling Air Screen - Dally or 10 Hrs. * Engine Air Cleaner- 50 Hrs. * 100 Hrs. * Cooling Fins- (Engine)- Daily or 10 Hrs. Spark Plugs- 100 Hrs. Breaker Points - 500 Hrs. Ignition Timing- 500 Hrs.** Engine Valves- 500 Hrs.** Engine Cylinder Heads- 500 Hrs.** - Fuel Filter- 100 Hrs. Battery - Daily or 10 Hrs. Hydrostatic Transmission 50 Hrs. • - Belts - 50 Hrs. * - Tires- 25 Hrs. Transmission Filter- After First 5 Hours then After Every 100 Hours *More often under extreme conditions. **Services should be performed by an Authorized Kohler Engine Dealer. ' Type of Maintenance Replace Brush Clean Shake Out Dirt Replace Clean- Use Air Hose if Available Service or Replace Service or Replace Adjust Adjust Remove Carbon Clean Check Water Level- Add As Necessary Clean- Use Air Hose if Available Check for Wear and Adjust Check for Damage and Air Pressure Change and Add Oil to Bring to Operating Level Use Only Bolens Filter

GENERAL (Continued) MAINTENANCE CHART WISCONSIN & DUCATI MODELS Length of MAINTENANCE REQUIRED Operation Engine Oil Filter- I 00 Hrs.* Engine Cooling Air Screen - Daily or 10 Hrs.* Engine Air Cleaner- 50 Hrs.* 500 Hrs.* Cooling Fins- (Engine)- Daily or 10 Hrs. Valve Tappet- 200 Hrs. Engine Valves - 500 Hrs.** Engine Cylinder Heads - 500 Hrs. ** Fuel Filter- 100 Hrs. Battery - Daily or . 10 Hrs . Hydrostatic Transmission 50 Hrs.* Belts- 50 Hrs.* Tires- 25 Hrs. Transmission Filter- After First 5 Hours then After Every 100 Hours *More often under extreme conditions. **Services should be performed by an Authorized Wisconsin or Ducati Engine Dealer. LARGE FRAME TRACTOR PAGE 1·5 Rev. 3/85 Type of Maintenance Replace D Brush Clean Shake Out Dirt Replace Clean- Use Air Hose if Available Adjust if Necessary Adjust Remove Carbon Clean Check Water Level- Add As Necessary Clean- Use Air Hose if Available Check for Wear and Adjust Check for Damage and Air Pressure Change and Add Oil to Bring to Operating Level Use Only Bolens ~

LARGE FRAME TRACTOR PAGE 1·6 Rev. 3/85 GENERAL (Continued) LUBRICATION POINTS Models 22S8 & 2289 only All Models )

) GENERAL(Continued) LUBRICATION REQUIRED 1. Engine Crankcase {Kohler) - 1 ---- ftsprmg, Sum~;, Au~mn) (+120° F. to 40° F.) I (+44° C to 4° C) Average r---Twi;ter)-- I (+40° to 0° F.) Temperature! (+4° Cto -18° Cl 1-------- I (Winter) i (Below Zero) 1. Engine Crankcase (Wisconsin & Ducati)- 2. Hydrostatic Transmission - {Capacity 10 qts./9.5 titer) 3. Front Wheel Bearings- 4. Front Wheel Spindles- 5. Front Axle Pivot- 6. Attachment Drive 7 Tie Rod Ends and Drag Links - 8. Steering Shaft - 9. Pivot Shaft - 10. Brake Linkage - 11. Travel Pedal Shaft - 12. Hydrostatic Control Arms - *More often under extreme conditions. **Plus 1 pint when changing oil filter (.47L). * * *Or equivalent. LUBRICATION Length of Type of Operation Lubrication Daily & Engine Oil 10 Hrs. 50 Hrs. 4 SAE 30 Oil Type SO-DE 50 Hrs. • SAE lOW-30 Oil Type SD-SE 50 Hrs. * SAE SW-20 Oil Type SD-SE Daily& 10 Hrs. Engine Oil (Class CC 100 Hrs. or better) Check Weekly Fill with Bolens Oil Or 30 Hrs. 173815 7 (Benzolt TH L 19), or Mobil 423 orTexaco TDH Drain and refill with Botens When Oil is Oil 1738157 (Benzoit TH L Discolored 19). or Mobil 423 or Texaco TDH Once a year Wheel Bearing Grease 10 Hrs. Grease with Multi-Purpose Grease ' • • 10 Hrs. Grease with Multi-Purpose Grease • • • 10 Hrs. Grease with Multi-Purpose Grease • • • 10 Hrs. Oil 10 Hrs. Oil 10 Hrs. Grease with Multi-Purpose Grease ... 10 Hrs. 0" 10 Hrs. Oil 10 Hrs. l1ght Machine Oil LARGE FRAME TRACTOI PAGE 1-7 Rev. 3/85 Amount Required Add Oil To Full Mark Replace JOT (2.84L)' .. Replace 3 OT {2.84LI' '' Replace JOT (2.84L)'' • Add Oil To Full Mark Replace 2.2 Ot. (2 liter) Level must be maintained in the operating zone (Approximately 10 qls. - 9.5 L) Pack 1-2 Strokes 1-2 Strokes 1-2 Strokes Small Amount Small Amount 1·2 Strokes Small Amount Small Amount Small Amount NOTE: A hand type grease gun is recommended when greasing your unit. Hi·pressure type grease guns could cause damage to the fittings and bearing seals. Lubricate all linkages, levers and pins not equipped with grease fittings with lubrication oil once a week, or more often depending on operating conditions.

Bolens Large Frame Tractors Workshop Service Repair Manual

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