Need the factory numbers for your Bolens DuraTrac? This 104-page Bolens GT 2000 service manual PDF (OEM #1760169) also handles the 5117H, 5118H, 5118HS, 5120H, DGT 1800, and GT 1800, so one download serves the whole family. You get full wiring diagrams with the factory wire color code, hydraulic schematics for the power lift and both spool valves, plus step-by-step hydrostatic, transaxle, and differential teardowns. Troubleshooting guides walk every system, from carburetor adjustments to PTO clutch service, in gas and diesel versions both. Check hydrostatic charge back-pressure at 120 to 160 PSI, then look for 800 PSI minimum from the charge pump with the steering wheel held at full lock. These numbers left the parts counter decades ago. Bookmarked and readable on any device; prop a tablet on the fender and get your tractor running again this season.
What's Inside This Bolens DuraTrac Series Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 3-10 | Identification Numbers, Specifications, Maintenance Chart, Torque Values for Hex Screws, Lubrication Chart |
| Electrical System | 11-29 | Troubleshooting Guide, Wire Color Code, Wiring Diagrams, Testing Electrical System |
| Drive Train | 30-50 | Troubleshooting Guide, Hydrostatic Repair, Hydrostatic Breakdown, Hydrostatic Removal and Re-Installation, Transaxle Removal, Transaxle Disassembly, Differential Disassembly |
| Fuel System | 51-56 | Troubleshooting Guide Gas, Fuel Tank and Valve Gas, Fuel Filter Gas, Air Cleaner Gas, Carburetor Adjustments Gas, Troubleshooting Guide Diesel, Fuel Tank and Valve Diesel |
| Chassis | 57-65 | Front Wheel Alignment, Front Axle Adjustment, Steering Assembly, Steering Assembly Power Assist, Front Wheel Bearings, Brake Adjustments, Hydrostatic Drive Adjustments |
| Hydraulic System | 66-77 | Principle of Operation, Troubleshooting Guide, Hydraulic Test Procedures, Hydraulic Filter, Hydraulic Power Lift, Single-Spool Valve Repair, Two-Spool Valve Repair |
| Engine | 78-94 | Trouble Shooting Guide, Engine Removal Gas, Engine Installation Gas, Starter Removal and Installation Gas, Engine Removal Diesel, Engine Installation Diesel |
| Tractor Attachments | 95-104 | Mower Decks, Tiller, Snowthrowers |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| 5117H | ||
| Charging System | 12V, 35 Amp. Alternator | p. 4 |
| Engine Oil Capacity (5117H) | 3.8 U.S. Qts. (4.2 liters) w/filter | p. 4 |
| All Models | ||
| Battery voltage | 11.5 to 12.5 volts | p. 26 |
| Hydrostatic charge circuit back-pressure | 120-160 PSI | p. 67 |
| Steering system and charge pump pressure minimum | 800 PSI | p. 72 |
| Armature/rotor gap | .010" - .020" (0.25mm - 0.51mm) | p. 94 |
| Electric PTO clutch resistance | 3.2 Ohms | p. 94 |
| Transmission Oil Capacity | 8 Qts. (7.6 liter) | p. 5 |
| Front Tire Pressure | 12 to 14 PSI | p. 61 |
| Rear Tire Pressure | 10 to 12 PSI | p. 61 |
| 5118H, 5118HS | ||
| Engine Oil Capacity (5118H, 5118HS) | 1.75 U.S. Qts. (1.9 liter) w/filter | p. 4 |
| 5120H | ||
| Engine Oil Capacity (5120H) | 1.75 U.S. Qts. (1.9 liter) w/filter | p. 4 |
Bolens DuraTrac Series Common Problems This Manual Covers
Bolens DuraTrac starter will not energize, engine will not crank with key turned to start
Check that the PTO is disengaged and the brake pedal is locked down before anything else. Test battery voltage: a healthy battery reads 11.5 to 12.5 volts and should hold at least 9.0 volts while cranking (page 26). Clean corroded terminals, then work through the interlock switch tests starting on page 11.
Manual Section: Electrical System Troubleshooting p. 11Hydraulic lift will not raise the mower deck, lever moves but nothing happens
Tee a pressure gauge into the charge circuit and run the engine at full RPM. Back-pressure should read 120 to 160 PSI with no load on the lift or steering circuits, per the test on page 68. If it reads low, replace the hydraulic filter and recheck before condemning the pump.
Manual Section: Hydraulic System p. 68Hydrostatic transmission runs hot and loses power on hills under mower load
Check the transmission oil level once the unit cools; total capacity is 8 quarts (7.6 liters, page 5). Clean grass clippings and chaff off the transmission housing and verify the cooling fan turns with the engine running. Work through the drive train troubleshooting chart on page 30 if power loss continues under load.
Manual Section: Drive Train Troubleshooting p. 30Electric PTO clutch will not engage, mower blades stay stopped when switch is pulled
Test the clutch coil with an ohmmeter: resistance should read 3.2 ohms and current draw 3.8 amps (page 94). Measure the armature to rotor gap with a feeler gauge; set it between .010 and .020 inch (0.25 to 0.51 mm) with the switch off. Replace the coil if resistance reads open or far out of spec.
Manual Section: PTO Clutch Troubleshooting p. 94Power assist steering feels dead and wheel is hard to turn at idle
Connect a pressure gauge into the steering circuit and hold the wheel against either stop at full engine RPM. Read the gauge: 800 PSI minimum indicates a healthy charge pump (page 72). Lower readings point to a worn charge pump or internal leakage; recheck the 120 to 160 PSI charge back-pressure spec on page 67 before replacing parts.
Manual Section: Hydraulic System p. 72Frequently Asked Questions
How do I reset the carburetor on a Bolens GT-1800 (5118HS)?
The main fuel and idle fuel adjusting needles on adjustable jet carburetors are set at the factory and normally do not require adjustment. If the engine is hard starting or does not operate properly, refer to the engine manual supplied with your tractor or contact your local dealer for assistance. p. 53
What is the oil capacity for the engine crankcase on a Bolens 5117H?
The engine crankcase oil capacity for the 5117H is 3.8 U.S. quarts (4.2 liters) with the filter, or 3.1 U.S. quarts (3.0 liters) without the filter. p. 4
What is the correct spark plug gap for the 5118H and 5120H engines?
The correct spark plug gap for the 5118H, 5118HS, and 5120H engines is .025 inches (0.63 mm). p. 4
What is the required torque for a 1/2-13 SAE Grade 5 cap screw?
The required torque for a 1/2-13 SAE Grade 5 cap screw is 55 lb. ft. (74.5 Nm). p. 8
How do I perform the hydrostatic neutral adjustment on the 5100 series tractors?
To adjust the hydrostatic neutral, block up the rear of the tractor so the wheels clear the ground. Loosen capscrews (C) and move support plate (D) forward or backward until the wheels stop rotating. Finally, loosen jam nuts (F) and turn rod (G) until the pin enters the slot (H) of the neutral plate with a 1/32 inch gap. p. 64
What format is this Bolens 5117H manual in?
Immediate download of the complete 104-page searchable Service Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Can I print specific sections of this Bolens 5117H Service Manual?
You can. The PDF is unlocked and carries no copy protection, so print the sections you want and keep the file as your backup.
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