New Holland Rustler 115 Service Manual – PDF DOWNLOAD

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New Holland Rustler 115 Service Manualz

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New Holland Rustler 115 Service Manual

Language : English
Pages : 284
Format : pdf
Part No : CLC103700630
Downloadable : Yes

NEW HOLLAND RUSTLER 115 SERVICE MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

New Holland Rustler 115 Service Manual

FOREWORD:

These vehicles are designed and built to provide the ultimate in performance efficiency; however, proper maintenance and repair are essential for achieving maximum service life and continued safe and reliable operation. This manual provides detailed information for the maintenance and repair of New Holland RustlerTM 115 vehicles, and should be thoroughly reviewed prior to servicing the vehicle.

• The procedures provided must be properly implemented, and the DANGER, WARNING, and CAUTION statements must be heeded. This manual was written for the trained technician who already possesses knowledge and skills in electrical and mechanical repair. If the technician does not have such knowledge and skills, attempted service or repairs to the vehicle may render the vehicle unsafe.
• For this reason, the manufacturer advises that all repairs and/or service be performed by an authorized distributor/dealer representative or by a factory-trained technician. It is the policy of CNH America LLC to assist its dealers in continually updating their service knowledge and facilities so they can provide prompt and efficient service for vehicle owners.
• Regional technical representatives, vehicle service seminars, periodic service bulletins, maintenance and service manuals, and other service publications also represent continuing commitment to customer support. A full line of training and continuing education classes are offered for technicians who want to learn more about our products.
• For more information, contact your local dealer or CNH America LLC for a list of upcoming classes. This manual covers all aspects of typical vehicle service; however, unique situations sometimes occur when servicing a vehicle. If it appears that a service question is not answered in this manual, please contact your nearest authorized dealer for assistance.

TABLE OF CONTENTS:

New Holland Rustler 115 Service Manual

1 Safety................................................................... 11
	Safety Details......................................................... 11
		Personal Safety.................................................... 11
		Machine Safety..................................................... 11
		Information........................................................ 11
	General Warning........................................................ 12
		Disabling the Vehicle.............................................. 14
		Disconnecting the Battery – Gasoline Vehicles...................... 14
		Connecting the Battery – Gasoline Vehicles......................... 14
2 Vehicle Specifications................................................... 15
3 General Information...................................................... 17
	Model Identification................................................... 18
		Identification Numbers............................................. 18
	Storage................................................................ 19
		Preparing the Vehicle for Extended Storage......................... 20
		Returning the Stored Vehicle to Service............................ 21
	Lifting The Vehicle.................................................... 21
		Lifting Only The Front............................................. 21
		Lifting Only The Rear.............................................. 22
		Lifting The Entire Vehicle......................................... 23
	Using a Booster Battery (Jump Starting)................................ 23
		NO TITLE........................................................... 23
4 Body and Trim............................................................ 25
	Cleaning the Vehicle................................................... 25
	Front Body Repair...................................................... 26
		Stress Lines or Streaks............................................ 26
		Minor Impact Damage/Deformations................................... 26
		Minor Scratches and Surface Blemishes.............................. 26
		Small Scratches That Cannot Be Buffed Out.......................... 27
		Gouges, Punctures, Tears, Large Scratches, and Abrasions........... 27
	Front Body............................................................. 28
		Front Fascia Removal............................................... 28
		Front Fascia Installation.......................................... 30
		Front Cowl Removal................................................. 30
		Front Cowl Installation............................................ 33
		Instrument Panel Removal........................................... 33
		Instrument Panel Installation...................................... 34
		Front Fender Removal............................................... 34
		Front Fender Installation.......................................... 35
		Under Pedal Closeout Panel Removal................................. 35
		Under Pedal Closeout Panel Installation............................ 36
	Under Seat Closeout Panels............................................. 36
		Under seat Closeout Panel Removal.................................. 36
		Under seat Closeout Panel Installation............................. 38
	ROPS (Roll Over Protective Structure).................................. 39
		ROPS Removal....................................................... 39
		ROPS Installation.................................................. 41
	Side Panel............................................................. 42
		Side Panel Removal................................................. 42
		Side Panel Installation............................................ 43
	Under Seat Center Panel................................................ 43
		Under seat Center Panel Removal.................................... 43
		Under seat Center Panel Installation............................... 44
	Rear Fender............................................................ 44
		Rear Fender Removal................................................ 44
		Rear Fender Installation........................................... 45
	Cargo Bed.............................................................. 45
		Cargo Bed Removal.................................................. 45
		Cargo Bed Installation............................................. 45
5 Accelerator and Brake Pedal Group........................................ 47
	Accelerator Pedal Removal.............................................. 47
	Accelerator Pedal Installation......................................... 49
	Accelerator Cable Removal.............................................. 50
	Accelerator Cable Installation......................................... 52
	Accelerator Cable Adjustment........................................... 53
	Brake Pedal Removal.................................................... 53
	Brake Pedal Installation............................................... 54
	Brake Pedal Adjustment................................................. 54
6 Brakes................................................................... 57
	General Information.................................................... 57
	Troubleshooting........................................................ 57
		Brake System Troubleshooting....................................... 57
		Brake System Inspection............................................ 60
	Hydraulic and Mechanical Components.................................... 62
		Brake Fluid Reservoir.............................................. 63
		Brake Hose Replacement............................................. 63
		Brake Pads and Caliper............................................. 68
		Brake Discs........................................................ 70
		Master Cylinder Replacement........................................ 71
	Bleeding the Hydraulic Brake System.................................... 72
		Vacuum Bleeding of Brakes on a DOT 5 Fluid Filled System........... 72
		Manual Bleeding of Brakes on a DOT 5 Fluid Filled System........... 73
		Refilling the Hydraulic System..................................... 74
	Park Brake System...................................................... 75
		Park Brake Cable Removal........................................... 75
		Park Brake Cable Installation...................................... 78
		Park Brake Handle Removal.......................................... 80
		Park Brake Handle Installation..................................... 80
		Park Brake Adjustment.............................................. 80
7 Steering and Front Suspension............................................ 83
	Steering Wheel......................................................... 83
		Steering Wheel Removal............................................. 83
		Steering Wheel Installation........................................ 84
	Steering Column........................................................ 84
		Steering Column Removal............................................ 84
		Steering Column Installation....................................... 86
	Rack and Pinion........................................................ 87
		Rack and Pinion Removal............................................ 87
		Rack and Pinion Installation....................................... 88
	Front Suspension....................................................... 89
		Wheel Alignment.................................................... 89
		Strut Removal and Inspection....................................... 90
		Strut Installation................................................. 91
		Steering Knuckle Removal........................................... 91
		Steering Knuckle Installation...................................... 93
		A-Arm Removal...................................................... 93
		A-Arm Installation................................................. 94
		Ball Joint Removal................................................. 94
		Ball Joint Installation............................................ 94
	Front Wheel Bearings and Hubs.......................................... 94
		Front Wheel Free Play Inspection................................... 94
		Front Wheel Bearings and Hub Removal............................... 95
		Front Wheel Bearings and Hub Installation.......................... 95
8 Wheels and Tires......................................................... 97
	General Information.................................................... 97
	Wheels................................................................. 98
		Wheel Removal...................................................... 98
		Wheel Installation................................................. 98
	Tires.................................................................. 98
		Tire Repair........................................................ 98
		Tire Removal....................................................... 99
		Tire Installation.................................................. 99
9 Rear Suspension..........................................................101
	Rear Shock Removal.....................................................101
	Rear Shock Installation................................................102
	Lateral Link Removal...................................................102
	Lateral Link Installation..............................................103
	Trailing Arm Removal...................................................103
	Trailing Arm Installation..............................................105
	Rear Wheel Bearings and Hubs...........................................105
		Rear Wheel Free Play Inspection....................................105
		Rear Wheel Bearings and Hub Removal................................105
		Rear Wheel Bearings and Hub Installation...........................106
	Wheel Alignment........................................................108
10 Periodic Maintenance....................................................109
	General Information....................................................109
	Pre-Operation and Daily Safety Checklist...............................110
		Performance Inspection.............................................111
	Periodic Service Schedule..............................................111
	Periodic Lubrication Schedule..........................................113
	Brake Fluid Reservoir..................................................114
	Engine Oil.............................................................114
		Engine Oil Level Check.............................................114
		Engine Oil and Filter Change.......................................115
		Oil Viscosity......................................................118
	Spark Plugs............................................................118
		Spark Plug Cleaning And Inspection.................................118
		Spark Plug Gap Inspection..........................................119
	Gearcase Lubrication...................................................119
		Lubrication Level Check – Front Differential and Rear Transaxle....119
		Lubrication Change – Front Differential and Rear Transaxle.........119
	Air Intake System......................................................121
		Air Filter Replacement.............................................121
	Fueling Instructions...................................................122
	Battery................................................................123
11 Troubleshooting and Electrical System...................................125
	General Information....................................................125
	Electrical System......................................................125
	Wiring Diagram.........................................................126
	Troubleshooting Guide..................................................128
	Test Procedures........................................................132
12 Electrical Components...................................................159
	Starter and Starter Solenoid...........................................159
	Neutral Switch.........................................................159
		Neutral Switch Removal.............................................159
		Neutral Switch Installation........................................160
	Carburetor Solenoid....................................................160
		Carburetor Solenoid Removal........................................160
		Carburetor Solenoid Installation...................................161
	Voltage Regulator......................................................161
		Voltage Regulator Removal..........................................161
		Voltage Regulator Installation.....................................162
	Warning Lights.........................................................162
		Warning Light Removal..............................................163
		Warning Light Installation.........................................163
	Fuel Gauge/Hour Meter..................................................163
		Fuel Gauge/Hour Meter Removal......................................164
		Fuel Gauge/Hour Meter Installation.................................164
	Key Switch.............................................................165
		Key Switch Removal.................................................165
		Key Switch Installation............................................165
	Light Switch...........................................................165
		Light Switch Removal...............................................165
		Light Switch Installation..........................................166
	Fuse...................................................................166
		Fuse Removal.......................................................166
		Fuse Installation..................................................166
	Fuel Level Sending Unit................................................166
		Fuel Level Sending Unit Removal....................................167
		Fuel Level Sending Unit Installation...............................167
	Ignition Coil And Charge Coil..........................................167
		Ignition Coil And/or Charge Coil Removal...........................167
	Oil Pressure Sensor....................................................167
	Headlights.............................................................167
		Headlight Bulb Removal.............................................168
		Headlight Bulb Installation........................................168
	Wire Harness Diodes....................................................168
		Diode Removal......................................................169
		Diode Installation.................................................169
	Battery................................................................169
		General Information................................................170
13 Engine..................................................................173
	Engine Removal.........................................................173
	Engine Installation....................................................177
	Engine RPM Adjustment..................................................177
		Idle Speed Adjustment..............................................177
14 Fuel System.............................................................181
	Fuel Lines.............................................................181
	Fuel Filter............................................................181
	Fuel Pump..............................................................181
	Carburetor.............................................................182
		Carburetor Jetting.................................................182
	Fuel Level Sending Unit................................................183
		Fuel Level Sending Unit Removal....................................183
		Fuel Level Sending Unit Installation...............................185
	Fuel Tank..............................................................187
		Fuel Tank Removal..................................................187
		Fuel Tank Storage or Disposal......................................188
		Fuel Tank Installation.............................................189
	Carbon Canister (If Equipped)..........................................189
		Carbon Canister Removal............................................190
		Carbon Canister Installation.......................................190
15 Exhaust System..........................................................191
	Muffler Removal........................................................191
	Muffler Installation...................................................191
	Exhaust Pipe Removal...................................................192
	Exhaust Pipe Installation..............................................192
16 Front Differential......................................................193
	Front Differential Removal.............................................193
	Front Differential Installation........................................195
	Front Halfshaft Removal................................................197
	Front Halfshaft Installation...........................................197
17 Transaxle...............................................................199
	General Information....................................................199
		Ratios.............................................................199
		Tools Required For This Section ...................................199
		Exploded Views.....................................................200
	Transaxle Removal......................................................205
	Transaxle Disassembly..................................................210
		Output Shafts......................................................210
		Front Drive (PTO) Unit.............................................210
		Case...............................................................214
		Case Inspection....................................................218
		Input Shaft........................................................218
		Idle Shaft.........................................................219
		Differential.......................................................220
		Reduction Shaft....................................................223
		Shift Fork.........................................................225
		Differential Lock Shaft............................................225
	Transaxle Assembly.....................................................226
		General Information................................................226
		Input Shaft........................................................226
		Idle Shaft.........................................................228
		Reduction Shaft....................................................229
		Fork Shaft.........................................................232
		Differential Lock Shaft............................................233
		Differential.......................................................234
		Case...............................................................237
		Front Drive (PTO) Unit.............................................244
		Output Shafts......................................................250
	Transaxle Installation.................................................252
	Rear Halfshaft Removal.................................................253
	Rear Halfshaft Installation............................................253
	Shifter Cable Adjustment...............................................254
	Four-Wheel Drive Cable Adjustment......................................254
	Differential Lock Cable Adjustment.....................................255
18 Clutches................................................................259
	Clutch Troubleshooting.................................................259
	Outer Clutch Cover.....................................................260
		Outer Clutch Cover Removal.........................................260
		Outer Clutch Cover Installation....................................261
	Drive Belt.............................................................261
		Drive Belt Removal.................................................261
		Drive Belt Installation............................................263
	Drive Clutch...........................................................263
		Drive Clutch Removal...............................................263
		Drive Clutch Cleaning and Inspection...............................264
		Drive Clutch Disassembly...........................................265
		Drive Clutch Component Inspection..................................265
		Drive Clutch Assembly..............................................265
		Drive Clutch Installation..........................................267
	Driven Clutch..........................................................268
		Driven Clutch Removal..............................................268
		Driven Clutch Disassembly..........................................270
		Driven Clutch Assembly.............................................272
		Driven Clutch Installation.........................................272
	Inner Clutch Cover.....................................................273
		Inner Clutch Cover Removal.........................................273
		Inner Clutch Cover Installation....................................273

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
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