wsm RTV-X1120D Workshop Manual

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WORKSHOP MANUAL

UTILITY VEHICLE

RTV-X900,RTV-X1120D

KiSC issued 01, 2014 A

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Page 1 WORKSHOP MANUAL UTILITY VEHICLE RTV-X900,RTV-X1120D KiSC issued 01, 2014 A...
Page 2 TO THE READER This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of the RTV-X900, RTV-X1120D. It contains 4 parts: "Information", "General", "Mechanism" and "Servicing".  Information This section primarily contains information below. • Safety First •...
Page 3 Record of Revisions For pdf, use search function {Search word} to find all the revised locations. Last digit Issue Reference of the Main Revised Point and Corrective Measures {Search word} month Page Code No. 2014.01 Correction of charge pressure. 2-M7, 2-M12, 2-S4, 2-S6,...
Page 4 INFORMATION KiSC issued 01, 2014 A...
Page 5: Table Of Contents
INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 2. SAFETY DECALS .......................... I-4 3. SPECIFICATIONS........................I-10 4. TRAVELLING SPEEDS........................ I-11 5. DIMENSIONS ..........................I-12 KiSC issued 01, 2014 A...
Page 6: Safety First
INFORMATION RTV-X900, RTV-X1120D, WSM 1. SAFETY FIRST SAFETY FIRST • This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
Page 7 INFORMATION RTV-X900, RTV-X1120D, WSM OPERATE SAFELY • Do not use the machine after you consume alcohol or medication or when you are tired. • Put on applicable clothing and safety equipment. • Use applicable tools only. Do not use alternative tools or parts.
Page 8 INFORMATION RTV-X900, RTV-X1120D, WSM KEEP A GOOD AIRFLOW IN THE WORK AREA • If the engine is in operation, make sure that the area has good airflow. Do not operate the engine in a closed area. The exhaust gas contains poisonous carbon monoxide.
Page 9: Safety Decals
INFORMATION RTV-X900, RTV-X1120D, WSM 2. SAFETY DECALS The following safety decals are installed on the machine. If a decal becomes damaged, illegible or is not on the machine, replace it. The decal part number is listed in the parts list.
Page 10 INFORMATION RTV-X900, RTV-X1120D, WSM 9Y1210946INI0002US0 KiSC issued 01, 2014 A...
Page 11 INFORMATION RTV-X900, RTV-X1120D, WSM 9Y1210946INI0003US0 KiSC issued 01, 2014 A...
Page 12 INFORMATION RTV-X900, RTV-X1120D, WSM 9Y1210946INI0004US0 KiSC issued 01, 2014 A...
Page 13 INFORMATION RTV-X900, RTV-X1120D, WSM 9Y1210946INI0005US0 KiSC issued 01, 2014 A...
Page 14 INFORMATION RTV-X900, RTV-X1120D, WSM 9Y1210946INI0006US0 CARE OF DANGER, WARNING AND CAUTION LABELS 1. Keep danger, warning and caution labels clean and free from obstructing material. 2. Clean danger, warning and caution labels with soap and water, dry with a soft cloth.
Page 15: Specifications
INFORMATION RTV-X900, RTV-X1120D, WSM 3. SPECIFICATIONS RTV-X900 RTV-X1120D Model General Worksite / Worksite / Worksite / Worksite / Purpose Orange Camo Orange Camo Make D902 D1105 Type 3 cylinders, 4-cycle, diesel, OHV Displacement 0.898 L (54.802 cu. in.) 1.123 L (68.530 cu. in.)
Page 16: Travelling Speeds
INFORMATION RTV-X900, RTV-X1120D, WSM 4. TRAVELLING SPEEDS (At rated engine rpm) Model RTV-X900 RTV-X1120D Range gear shift lever km/h (mph) km/h (mph) 24 (15) 25 (16) High 40 (25) 46 (29) Reverse 27 (17) 35 (22) 9Y1210946INI0009US0 I-11 KiSC issued 01, 2014 A...
Page 17: Dimensions
INFORMATION RTV-X900, RTV-X1120D, WSM 5. DIMENSIONS RTV-X900 9Y1210946INI0010US0 I-12 KiSC issued 01, 2014 A...
Page 18 INFORMATION RTV-X900, RTV-X1120D, WSM RTV-X1120D 9Y1210946INI0011US0 I-13 KiSC issued 01, 2014 A...
Page 19 GENERAL KiSC issued 01, 2014 A...
Page 20 8. SPECIAL TOOLS ........................G-57 [1] SPECIAL TOOLS FOR ENGINE ..................G-57 (1) General........................... G-57 (2) RTV-X900........................G-61 (3) RTV-X1120D ........................G-63 [2] SPECIAL TOOLS FOR MACHINE ..................G-66 9. TIRES ............................G-72 [1] TYPE OF TIRES........................G-72 [2] TYPE PRESSURE ....................... G-73 [3] VEHICLE LIMITATIONS.......................
Page 21 [5] SHOCK ABSORBERS......................G-77 KiSC issued 01, 2014 A...
Page 22: Product Identification
GENERAL RTV-X900, RTV-X1120D, WSM 1. PRODUCT IDENTIFICATION When contacting your local KUBOTA distributor, always specify engine serial number, product serial number and hour meter reading. (1) Vehicle Identification Plate [A] RTV-X900 (2) Product Identification Number [B] RTV-X1120D (3) ROPS Serial Number...
Page 23: General Precautions
GENERAL RTV-X900, RTV-X1120D, WSM 2. GENERAL PRECAUTIONS • When you disassemble, carefully put the parts in a clean area to make it easy to find the parts. You must install the screws, bolts and nuts in their initial position to prevent the reassembly errors.
Page 24: Handling Precautions For Electrical Parts And Wiring
GENERAL RTV-X900, RTV-X1120D, WSM 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING To ensure safety and prevent damage to the machine and surrounding equipment, obey the following precautions in handling electrical parts and wiring. IMPORTANT • Check electrical wiring for damage and loosened connection every year.
Page 25: Wiring
GENERAL RTV-X900, RTV-X1120D, WSM • Securely insert grommet. (1) Grommet (A) Correct (B) Incorrect WSM000001GEG0066US0 • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp (Wind Clamp Spirally) (4) Welding Dent (2) Wire Harness WSM000001GEG0067US0 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.
Page 26: Battery
GENERAL RTV-X900, RTV-X1120D, WSM [2] BATTERY • Be careful not to confuse positive and negative terminal posts. • When you remove battery cables, disconnect negative cable first. When you install battery cables, check for polarity and connect positive cable first.
Page 27: Handling Of Circuit Tester
GENERAL RTV-X900, RTV-X1120D, WSM • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make sure that there is no terminal being exposed or displaced. (1) Exposed Terminal (3) Sandpaper (2) Deformed Terminal (4) Rust WSM000001GEG0075US0 • Make sure that there is no female connector being too open.
Page 28: Color Of Wiring
GENERAL RTV-X900, RTV-X1120D, WSM [6] COLOR OF WIRING • Colors of wire are specified to the color codes. • This symbol of "/" shows color with stripe(s). (An example) Red stripe on white color: W/R Color of wiring Color code...
Page 29: Lubricants, Fuel And Coolant
GENERAL RTV-X900, RTV-X1120D, WSM 4. LUBRICANTS, FUEL AND COOLANT Capacity Place Lubricants, fuel and coolant RTV-X900 RTV-X1120D 30 L • No. 2-D diesel fuel Fuel 7.9 U.S.gals • No. 1-D diesel fuel if temperature 6.6 Imp.gals is below −10 °C (14 °F) 6.1 L...
Page 30 GENERAL RTV-X900, RTV-X1120D, WSM Greasing Place No. of greasing point Capacity Type of grease Parking brake lever moderate amount Battery terminal Cargo lift cylinder pivot Until grease overflows Cargo bed pivot moderate amount Until grease overflows VHT link Valve lever link Multipurpose EP2 Grease (NLGI Grade No.
Page 31 GENERAL RTV-X900, RTV-X1120D, WSM For North American market NOTE Engine Oil • Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE Engine Oil according to the ambient temperatures as shown above: • Refer to the following table for the suitable API classification engine oil according to the engine type (with internal EGR, external EGR or non-EGR) and the fuel.
Page 32 GENERAL RTV-X900, RTV-X1120D, WSM For other than North American market NOTE Engine Oil • Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper SAE Engine Oil according to the ambient temperatures as shown above: •...
Page 33: Tightening Torques
GENERAL RTV-X900, RTV-X1120D, WSM 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLTS AND NUTS Tighten screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual according to the table below. Indication on top of bolt No-grade or 4T...
Page 34: Hydraulic Fittings
GENERAL RTV-X900, RTV-X1120D, WSM [3] HYDRAULIC FITTINGS (1) Hydraulic Hose Fittings Tightening torque Hose size Thread side N·m kgf·m lbf·ft 13.8 to 15.6 1.40 to 1.60 10.2 to 11.5 22.6 to 27.4 2.30 to 2.80 16.7 to 20.2 45.2 to 52.9 4.60 to 5.40...
Page 35: Metric Screws, Bolts And Nuts
GENERAL RTV-X900, RTV-X1120D, WSM [4] METRIC SCREWS, BOLTS AND NUTS Grade Property class 8.8 Property class 10.9 Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft 24 to 27 2.4 to 2.8 18 to 20 30 to 34 3.0 to 3.5 22 to 25 48 to 55 4.9 to 5.7...
Page 36: Maintenance Check List
GENERAL RTV-X900, RTV-X1120D, WSM 6. MAINTENANCE CHECK LIST WARNING To avoid serious injury and vehicle damage: • Be sure you have sufficient knowledge, experience, the proper replacement parts and tools before you attempt any vehicle maintenance task. SERVICE INTERVALS IMPORTANT •...
Page 37 GENERAL RTV-X900, RTV-X1120D, WSM Service Interval Refer- After Item ence since 50 100 150 200 250 300 350 400 450 500 550 600 650 700 page every 19 Brake light switch Check G-42     200 hrs every...
Page 38: Check And Maintenance
GENERAL RTV-X900, RTV-X1120D, WSM 7. CHECK AND MAINTENANCE [1] DAILY CHECK For your own safety and maximum service life of the vehicle, make a thorough daily inspection before operating the vehicle to start the engine. WARNING To avoid serious injury: •...
Page 39 GENERAL RTV-X900, RTV-X1120D, WSM Checking Engine Oil Level WARNING To avoid serious injury: • Be sure to stop the engine before checking the oil level. 1. Park the vehicle on a level surface. 2. Raise the cargo bed and mount the safety support.
Page 40 GENERAL RTV-X900, RTV-X1120D, WSM Checking Hydraulic Oil Tank Level 1. Park the vehicle on a level surface. 2. Stop the engine. 3. Open the seat and remove the utility box. 4. Remove the rubber cap. 5. To check the oil level, remove the dipstick, wipe it clean, screw it into filling hole and remove dipstick again.
Page 41 GENERAL RTV-X900, RTV-X1120D, WSM Cleaning Oil Cooler Net WARNING To avoid serious injury: • Allow oil cooler or oil line parts to cool down sufficiently, they can be hot and can cause injury. 1. Park the vehicle on a flat surface.
Page 42 GENERAL RTV-X900, RTV-X1120D, WSM Checking Parking Brake Pull the parking brake lever to apply the brakes. With the key switch at "ON" position, the parking brake indicator on the instrument panel lights up. To release the brakes, push in the button at the side of the parking brake lever and tilt the lever forward the lever.
Page 43 GENERAL RTV-X900, RTV-X1120D, WSM Checking Joint Boot 1. Check to see if the joint boots are not damaged. 2. If the boots are cuts, cracked or deterioration, replace the new one. (1) Joint Boot (Front) [A] Front (2) Front Drive Shaft...
Page 44 GENERAL RTV-X900, RTV-X1120D, WSM Checking Tire Inflation Pressure Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time. Thus, check it everyday and inflate as necessary. Tire sizes Inflation Pressure 25 × 10 − 12 HDWS, Front and Rear 25 ×...
Page 45: Check Points Of Initial 50 Hours
GENERAL RTV-X900, RTV-X1120D, WSM [2] CHECK POINTS OF INITIAL 50 HOURS Changing Engine Oil WARNING To avoid serious injury: • Be sure to stop the engine before changing the oil. • Allow engine to cool down sufficiently, oil can be hot and can burn.
Page 46 GENERAL RTV-X900, RTV-X1120D, WSM Checking Wheel Fastener Torque WARNING To avoid serious injury: • Never operate vehicle with a loose wheel bolts. • Any time bolts are loosened, retighten to the specified torque. • Check all bolts frequently and keep them tight.
Page 47 GENERAL RTV-X900, RTV-X1120D, WSM Replacing Transmission Oil Filter [VHT] WARNING To avoid serious injury: • Be sure to stop the engine before changing the oil filter. • Allow engine to cool down sufficiently, oil can be hot and can burn.
Page 48 GENERAL RTV-X900, RTV-X1120D, WSM Checking Brake Pedal WARNING To avoid serious injury: • Stop the engine and chock the wheels before checking brake pedal. • If movement is outside of the specifications, adjusting the brake.  Checking the brake pedal free travel Proper brake pedal free travel 8 to 18 mm (0.3 to 0.7 in.) on the pedal...
Page 49 GENERAL RTV-X900, RTV-X1120D, WSM Checking Brake Light Switch 1. Park the vehicle on a flat surface. 2. Step on the brake pedal to check if the brake light comes on. 3. If it does not, check the bulb or brake light switch.
Page 50 GENERAL RTV-X900, RTV-X1120D, WSM Checking Brake Hose and Pipe 1. Check to see that brake hose and pipe are not swollen, hardened or cracked. 2. Check the brake hose and pipe joints for oil leaks. 3. If there is any abnormality, replace the new one.
Page 51: Check Points Of Every 50 Hours
GENERAL RTV-X900, RTV-X1120D, WSM [3] CHECK POINTS OF EVERY 50 HOURS Checking Engine Start System WARNING To avoid serious injury: • Do not allow anyone near the vehicle while testing. • If the vehicle does not pass the test do not operate the vehicle.
Page 52 GENERAL RTV-X900, RTV-X1120D, WSM Greasing 1. Apply a small amount of multi-purpose grease to the following points every 50 hours: If you operated the machine in extremely wet and muddy conditions, lubricate grease fittings more often. (1) Parking Brake Lever...
Page 53 GENERAL RTV-X900, RTV-X1120D, WSM (Continued) (10) Unload Link (Spray Type Grease) (A) Left Rear Tire (11) Differential Lock Pedal (Spray Type Grease) (12) Front A-ARM (Grease Fitting) (13) Rear A-ARM (Grease Fitting) (14) Parking Brake Link (Spray Type Grease) 9Y1210946GEG0037US0...
Page 54: Check Points Of Every 100 Hours
GENERAL RTV-X900, RTV-X1120D, WSM [4] CHECK POINTS OF EVERY 100 HOURS Cleaning Muffler [For Swirl Type Spark Arrester] WARNING To avoid serious injury: • Before touching any part of an exhaust system, be absolutely sure that it has sufficient time to cool! •...
Page 55 GENERAL RTV-X900, RTV-X1120D, WSM Checking Battery Condition The factory-installed battery is non-refillable type.If the battery is weak, charge the battery or replace it with new one. DANGER To avoid the possibility of battery explosion: For the refillable type battery, follow the instructions below.
Page 56 GENERAL RTV-X900, RTV-X1120D, WSM (Continued) [RTV-X900] Reserve Cold Normal Battery Volts Capacity at Capacity Cranking Charging Type 20 hrs (A. H.) (min) Amps Rate (A) 526RMF 12.0 [RTV-X1120D] Reserve Cold Normal Battery Volts Capacity at Capacity Cranking Charging Type 20 hrs (A. H.)
Page 57 GENERAL RTV-X900, RTV-X1120D, WSM (Continued)  Direction for Storage 1. When storing the vehicle for a long period, remove the battery from vehicle, adjust the electrolyte to the proper level (refillable type only) and store in a dry place out of direct sunlight.
Page 58 GENERAL RTV-X900, RTV-X1120D, WSM Adjusting Toe-in 5 to 15 mm Proper toe-in 0.2 to 0.59 in. 1. Park vehicle on a flat place. 2. Turn steering wheel so front wheels are in the straight ahead position. 3. Lock the park brake and stop the engine.
Page 59 GENERAL RTV-X900, RTV-X1120D, WSM Cleaning Air Cleaner Primary Element 1. Remove the air cleaner cover and primary element. 2. Clean the primary element: (1) When dry dust adheres to the element, blow compressed air from the inside, turning the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm...
Page 60: Check Points Of Every 200 Hours
GENERAL RTV-X900, RTV-X1120D, WSM [5] CHECK POINTS OF EVERY 200 HOURS Changing Engine Oil WARNING To avoid serious injury: • Be sure to stop the engine before changing the oil. • Allow engine to cool down sufficiently, oil can be hot and can burn.
Page 61 GENERAL RTV-X900, RTV-X1120D, WSM Replacing Engine Oil Filter WARNING To avoid serious injury: • Be sure to stop the engine before changing the oil filter. • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a flat surface.
Page 62 GENERAL RTV-X900, RTV-X1120D, WSM Replacing Transmission Oil Filter [SUCTION] WARNING To avoid serious injury: • Be sure to stop the engine before changing the oil. • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a flat surface.
Page 63 GENERAL RTV-X900, RTV-X1120D, WSM Adjusting Parking Brake Proper parking brake lever free play 1 notch range  Adjusting procedure 1. Park the vehicle on a flat surface. 2. Stop the engine. 3. Jack up the rear wheels. 4. Remove the left rear tire.
Page 64 GENERAL RTV-X900, RTV-X1120D, WSM Checking Front Brake Case 1. Remove the drain plugs and the air-bleeding hole plugs. 2. Check the brake case for brake fluid leak. (1) Drain Plug (3) Air-Bleeding Hole Plug (2) Allen Key 9Y1210946GEG0032US0 Changing Hydraulic Tank Oil...
Page 65 GENERAL RTV-X900, RTV-X1120D, WSM Checking Radiator Hose, Pipe and Clamp Park the vehicle on a flat surface. Raise the cargo bed and mount the safety support. Check to see if radiator hoses are properly fixed every 200 hours of operation or 6 months, whichever comes first.
Page 66 GENERAL RTV-X900, RTV-X1120D, WSM Checking Hydraulic Oil Line 1. Check to see if the hoses and hose clamps are tight and not damaged. 2. If hoses and clamps are found to be worn or damaged, replace or repair them at once.
Page 67 GENERAL RTV-X900, RTV-X1120D, WSM Checking Intake Air Line 1. Check to see if the hoses and hose clamps are tight and not damaged. 2. If hoses and clamps are found to be worn or damaged, replace or repair them at once.
Page 68: Check Point Of Every 300 Hours
GENERAL RTV-X900, RTV-X1120D, WSM Checking Brake Hose and Pipe 1. Check to see that brake hose and pipe are not swollen, hardened or cracked. 2. Check the brake hose and pipe joints for oil leaks. 3. If there is any abnormality, replace the new one.
Page 69: Check Points Of Every 400 Hours
GENERAL RTV-X900, RTV-X1120D, WSM [7] CHECK POINTS OF EVERY 400 HOURS Changing Transmission Fluid WARNING To avoid serious injury: • Be sure to stop the engine before changing the oil. • Allow engine to cool down sufficiently, oil can be hot and can burn.
Page 70: Check Point Of Every 500 Hours
GENERAL RTV-X900, RTV-X1120D, WSM Changing Front Knuckle Case Oil 1. Park the vehicle on a firm, flat and level surface. 2. Remove the tire. 3. To drain the used oil, remove the drain and filling plugs at the LH knuckle case and drain the oil completely into the oil pan.
Page 71: Check Points Of Every 2 Years
GENERAL RTV-X900, RTV-X1120D, WSM [13] CHECK POINTS OF EVERY 2 YEARS Replacing Fuel Line 1. See page G-37. 9Y1210946GEG0061US0 Replacing Radiator Hose, Replace the Hoses and Clamps (Water Pipes) 1. See page G-44. 9Y1210946GEG0062US0 Replacing Hydraulic Oil Line 1. See page G-45.
Page 72 GENERAL RTV-X900, RTV-X1120D, WSM Flushing Cooling System and Changing Coolant WARNING To avoid serious injury: • Do not remove the radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely.
Page 73 GENERAL RTV-X900, RTV-X1120D, WSM  Anti-Freeze WARNING To avoid serious injury: • When using anti-freeze, put on some protection such as rubber gloves. (Anti-freeze contains poison.) • If it is swallowed, seek immediate medical help.Do NOT make a person throw up unless told to do so by poison control or a health care professional.
Page 74: Check Point Of Every 4 Years
GENERAL RTV-X900, RTV-X1120D, WSM (Continued) 5. Adding the LLC (1) Add only water if the coolant level reduces in the cooling system by evaporation. (2) If there is a mixture leak, add the LLC of the same manufacturer and type in the mixing ratio 50 %.
Page 75: Others
GENERAL RTV-X900, RTV-X1120D, WSM [15] OTHERS Bleeding Fuel System Air must be removed: 1. When the fuel filter or lines are removed. 2. When tank is completely empty. 3. After the vehicle has not been used for a long period of time.
Page 76: Rtv-X900
GENERAL RTV-X900, RTV-X1120D, WSM Protected Circuit [RTV-X900] Fuse No. Capacity (A) Protected circuit Glow lamp Starter relay Radiator fan relay AUX / B, Buzzer relay (Option, Lamp) Key stop timer Meter (IGN) Beacon / Fog lamp Head light blinker (Front)
Page 77 GENERAL RTV-X900, RTV-X1120D, WSM Replacing Slow-Blow Fuses The slow-blow fuses are intended to protect the electrical cabling. If any of them have blown out, be sure to pinpoint the cause. Never use any substitute, use only a KUBOTA genuine part.
Page 78 GENERAL RTV-X900, RTV-X1120D, WSM 8. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE (1) General Special Use Puller Set Code No. • 07916-09032 Application • Use exclusively to pull out bearing, gears and other parts with ease. WSM000001GEG0011US0 Piston Ring Compressor Code No.
Page 79 GENERAL RTV-X900, RTV-X1120D, WSM Diesel Engine Compression Tester (for Glow Plug) Code No. • 07909-39081 (Assembly) • 07909-31291 (K) • 07909-31301 (L) • 07909-31311 (M) Application • Use to measure diesel engine compression and diagnosis of need for major overhaul.
Page 80 GENERAL RTV-X900, RTV-X1120D, WSM Connecting Rod Alignment Tool Code No. • 07909-31661 Application • Use to check the connecting rod alignment. Applicable range • Connecting rod big end I.D. 30 to 75 mm dia. (1.2 to 2.9 in. dia.) • Connecting rod length 65.0 to 300 mm (2.56 to 11.8 in.)
Page 81 GENERAL RTV-X900, RTV-X1120D, WSM NOTE • The following special tools are not provided, so make them referring to the figure. 9Y1210946GEG0099US0 Flywheel Stopper Application • Use to loosen and tighten the flywheel screw. 200 mm (7.87 in.) 30 mm (1.18 in.) 20 mm (0.79 in.)
Page 82 GENERAL RTV-X900, RTV-X1120D, WSM (2) RTV-X900 Valve Guide Replacing Tool Application • Use to press out and press fit the valve guide. 220 mm (8.66 in.) 80 mm (3.1 in.) 40 mm (1.6 in.) 20 mm dia. (0.79 in. dia.) 9.960 to 9.980 mm dia.
Page 83 GENERAL RTV-X900, RTV-X1120D, WSM Crankshaft Bearing 1 Replacing Tool Application • Use to press out and press fit the crankshaft bearing 1. [Press Out] 135 mm (5.31 in.) 72 mm (2.8 in.) 40 mm radius (1.6 in. radius) 10 mm (0.39 in.) 22 mm (0.87 in.)
Page 84: Rtv-X1120D
GENERAL RTV-X900, RTV-X1120D, WSM (3) RTV-X1120D Valve Guide Replacing Tool Application • Use to press out and press fit the valve guide. 225 mm (8.86 in.) 70 mm (2.8 in.) 45 mm (1.8 in.) 20 mm dia. (0.79 in. dia.) 11.7 to 11.9 mm dia.
Page 85 GENERAL RTV-X900, RTV-X1120D, WSM Crankshaft Bearing 1 Replacing Tool Application • Use to press out and press fit the crankshaft bearing 1. [Press Out] 135 mm (5.31 in.) 72 mm (2.8 in.) 40 mm radius (1.6 in. radius) 10 mm (0.39 in.) 24 mm (0.94 in.)
Page 86 GENERAL RTV-X900, RTV-X1120D, WSM Crank Sleeve Setter Application • Use to fix the crankshaft sleeve. (1) Auxiliary Socket for Pushing 130 mm (5.12 in.) 112 mm (4.41 in.) 107 mm (4.21 in.) 82 mm (3.2 in.) 72 mm (2.8 in.) 67 mm (2.6 in.)
Page 87: Special Tools For Machine
GENERAL RTV-X900, RTV-X1120D, WSM [2] SPECIAL TOOLS FOR MACHINE Tie-rod End Lifter Code No. • 07909-39051 Application • Use to remove the tie-rod end with ease. WSM000001GEG0029US0 Relief Valve Pressure Tester Code No. • 07916-50045 Application • This allows easy measurement of relief set pressure.
Page 88 GENERAL RTV-X900, RTV-X1120D, WSM Lower Arm Bush Tool Application • Use for removing and installing lower arm rubber bush. 256.5 mm (10.10 in.) 2.6 mm (0.102 in.) 22 mm (0.866 in.) 262.5 mm (10.33 in.) 34.65 mm dia. (1.364 in. dia.) 35 mm dia.
Page 89 GENERAL RTV-X900, RTV-X1120D, WSM Check and High Pressure Relief Valve Assembly Tool Application • Use for Readjusting relief valve pressure. 30 mm (1.181 in.) Chamfer 0.4 mm (0.157 in.) 1.05 rad (10 °) 21 mm (0.827 in.) Chamfer 3 mm (0.118 in.) Chamfer 0.3 mm (0.012 in.)
Page 90 GENERAL RTV-X900, RTV-X1120D, WSM Differential Jig Application • Use for checking backlash and gear and spiral bevel pinion shaft. 24.65 to 24.80 mm dia. (0.970 to 0.976 in. dia.) 122 mm (4.80 in.) 92.0 mm (3.62 in.) 62.0 mm (2.44 in.) 60.0 mm (2.36 in.) full spline...
Page 91 GENERAL RTV-X900, RTV-X1120D, WSM Rear Shock Absorber Spring Compressor 1 35 mm (1.4 in.) 16.5 mm (0.65 in.) 60 mm (2.4 in.) 58.5 mm (2.3 in.) 4.6 mm (0.18 in.) 51 mm (2.0 in.) 13 mm (0.51 in.) 120 mm (4.72 in.) Radius 3.0 mm (0.12 in.)
Page 92 GENERAL RTV-X900, RTV-X1120D, WSM Rear Shock Absorber Spring Compressor 2 15.9 mm dia. (0.626 in. dia.) 10 mm (0.39 in.) 25 mm (0.98 in.) 70 mm (2.8 in.) 21 mm (0.83 in.) Chamfer 1.0 mm (0.039 in.) 130.4 mm (5.134 in.) 43 mm (1.7 in.)
Page 93: Tires
GENERAL RTV-X900, RTV-X1120D, WSM 9. TIRES WARNING To avoid serious injury: • Do not attempt to mount a tire on a rim. This should be done by a qualified person with the proper equipment. • Always maintain the correct tire pressure.
Page 94: Type Pressure
GENERAL RTV-X900, RTV-X1120D, WSM [2] TYPE PRESSURE Checking Tire Inflation Pressure Though the tire pressure is factory-set to the prescribed level, it naturally drops slowly in the course of time. Thus, check it everyday and inflate as necessary. Tire sizes Inflation Pressure 25 ×...
Page 95: Vehicle Limitations
GENERAL RTV-X900, RTV-X1120D, WSM [3] VEHICLE LIMITATIONS The KUBOTA Vehicle has been thoroughly tested for proper performance with implements sold or approved by KUBOTA. Use with implements which are not sold or approved by KUBOTA and which exceed the maximum specifications listed below, or which are otherwise unfit for use with the KUBOTA Vehicle may result in malfunctions or failures of the vehicle, damage to other property and injury to the operator or others.
Page 96: Cargo Bed
GENERAL RTV-X900, RTV-X1120D, WSM [4] CARGO BED General Caution WARNING To avoid serious injury: • Never carry passengers in the cargo bed. They can be tossed about or even thrown off causing serious injury or death. • Never raise the cargo bed when it is loaded. (There is an exception. Only the vehicle equipped with hydraulic dump may do this operation at operator's seat after appropriate confirmation of safety.)
Page 97 (OP) 95 kg (209 lbs) + 535 kg (1180 lbs) - (W) (PA) 95 kg (209 lbs) = [Cabin type] 190 kg (418 lbs) 410 kg (904 lbs) - (W) (RTV-X1120D) [Quick Reference Table for Cargo Load] Option + Cargo bed Permissible Model Occupant *1...
Page 98 GENERAL RTV-X900, RTV-X1120D, WSM [5] SHOCK ABSORBERS Shock Absorber Spring Adjustment WARNING To avoid serious injury: • For shock absorber spring adjustment. (See page 3-S3, 5-S5.) The front and rear shock absorber springs can be adjusted for different riding and loading condition.
Page 99 ENGINE KiSC issued 01, 2014 A...
Page 100 [1] RTV-X900 (D902) ......................... 1-M1 (1) Half-floating Head Cover ....................1-M1 (2) Closed Breather......................1-M1 (3) Piston..........................1-M2 (4) Oil Pan..........................1-M2 [2] RTV-X1120D (D1105) ......................1-M2 (1) Closed Breather......................1-M2 (2) Governor......................... 1-M3 2. LUBRICATING SYSTEM......................1-M5 3. COOLING SYSTEM ........................1-M6 4.
Page 101: Engine Body
ENGINE RTV-X900, RTV-X1120D, WSM 1. ENGINE BODY [1] RTV-X900 (D902) (1) Half-floating Head Cover The rubber packing is fitted in to keep the cylinder head cover 0.5 mm (0.02 in.) or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head.
Page 102: Piston
ENGINE RTV-X900, RTV-X1120D, WSM (3) Piston Piston's skirt coated with molybdenum disulfide*, which reduces the piston slap noise and thus the entire operating noise. *Molybdenum disulfide (MoS The molybdenum disulfide (1) serves as a solid lubricant, like a Graphite or Teflon. This material helps resist metal wears even with little lube oil.
Page 103: Governor
ENGINE RTV-X900, RTV-X1120D, WSM (2) Governor Three Lever Type Fork Lever (for standard type) The governor system is a mechanical governor that used the flyweight (5). The flyweight (5) is mounted on the governor shaft that rotates at the same speed as the crankshaft.
Page 104 ENGINE RTV-X900, RTV-X1120D, WSM (Overloaded Operation) The amount of the movement of the fork lever assembly is limited with the fuel limitation bolt (10) and can not be moved in the direction of the fuel increase. As overload reduces the centrifugal force of the...
Page 105: Lubricating System
ENGINE RTV-X900, RTV-X1120D, WSM 2. LUBRICATING SYSTEM (1) Rocker Arm (2) Oil Pressure Switch (3) Rocker Arm Shaft (4) Valve (5) Idle Gear (6) Crankshaft (7) Oil Pump (8) Oil Strainer (9) Relief Valve (10) Push Rod (11) Tappet (12) Camshaft...
Page 106: Cooling System
ENGINE RTV-X900, RTV-X1120D, WSM 3. COOLING SYSTEM The cooling fin is set up around the oil passage in the gear case. Therefore, the temperature of oil is decreased by the wind generated by the cooling fan. (1) Cooling Fin (RTV-X900)
Page 107: Fuel System
ENGINE RTV-X900, RTV-X1120D, WSM 4. FUEL SYSTEM (1) Injection Nozzle (2) Fuel Overflow Pipe (3) Fuel Tank (4) Fuel Filter (5) Fuel Feed Pump (6) Injection Pump (7) Injection Pipe Fuel from the fuel tank (3) passes through the fuel filter (4), and then enters the injection pump (6) after impurities such as dirt, water, etc.
Page 108 (2) Gear Case and Timing Gears..................1-S48 (3) Piston and Connecting Rod...................1-S54 (4) Flywheel and Crankshaft ....................1-S56 [4] DISASSEMBLING AND ASSEMBLING RTV-X1120D (D1105) ..........1-S59 (1) Cylinder Head and Valve....................1-S59 (2) Gear Cae and Timing Gears ..................1-S62 (3) Piston and Connecting Rod...................1-S66 (4) Flywheel and Crankshaft ....................1-S68...
Page 109 (5) Cylinder........................1-S103 (6) Oil Pump ........................1-S104 KiSC issued 01, 2014 A...
Page 110: Troubleshooting
ENGINE RTV-X900, RTV-X1120D, WSM 1. TROUBLESHOOTING [1] RTV-X900 Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Fill fuel Start Air in the fuel system Bleed G-54 Water in the fuel system Change fuel and G-37 repair or replace fuel...
Page 111 ENGINE RTV-X900, RTV-X1120D, WSM Reference Symptom Probable Cause Solution Page Either White or Blue Excessive engine oil Reduce to specified G-18, G-24 Exhaust Gas Is level Observed Piston ring and cylinder worn or stuck Repair or replace 1-S54, 1-S55, 1-S79,...
Page 112 ENGINE RTV-X900, RTV-X1120D, WSM Reference Symptom Probable Cause Solution Page Low Oil Pressure Engine oil insufficient Fill G-18, G-24 Oil strainer clogged Clean 1-S47 Oil filter clogged Replace G-25 Relief valve stuck with dirt Clean – Relief valve spring weaken or broken Replace –...
Page 113: Rtv-X1120D
ENGINE RTV-X900, RTV-X1120D, WSM [2] RTV-X1120D Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Fill fuel Start Air in the fuel system Bleed G-54 Water in the fuel system Change fuel and G-37 repair or replace fuel...
Page 114 ENGINE RTV-X900, RTV-X1120D, WSM Reference Symptom Probable Cause Solution Page Either White or Blue Excessive engine oil Reduce to specified G-18, G-24 Exhaust Gas Is level Observed Piston ring and cylinder worn or stuck Repair or replace 1-S66, 1-S67, 1-S97,...
Page 115 ENGINE RTV-X900, RTV-X1120D, WSM Reference Symptom Probable Cause Solution Page Low Oil Pressure Engine oil insufficient Fill G-18, G-24 Oil strainer clogged Clean 1-S62 Oil filter clogged Replace G-25 Relief valve stuck with dirt Clean – Relief valve spring weaken or broken Replace –...
Page 116: Servicing Specifications
ENGINE RTV-X900, RTV-X1120D, WSM 2. SERVICING SPECIFICATIONS [1] RTV-X900 (D902) (1) Engine Body Item Factory Specification Allowable Limit Compression Pressure 3.53 to 4.02 MPa 2.55 MPa 36.0 to 41.0 kgf/cm 26.0 kgf/cm 512 to 583 psi 370 psi • Difference among Cylinders –...
Page 117 ENGINE RTV-X900, RTV-X1120D, WSM Item Factory Specification Allowable Limit Tappet to Tappet Bore Oil Clearance 0.016 to 0.052 mm 0.10 mm 0.00063 to 0.0020 in. 0.0039 in. • Tappet O.D. 17.966 to 17.984 mm – 0.70733 to 0.70803 in. • Tappet Bore I.D.
Page 118 ENGINE RTV-X900, RTV-X1120D, WSM Item Factory Specification Allowable Limit Piston Pin to Small End Bushing Oil Clearance 0.015 to 0.075 mm 0.15 mm (Spare Parts) 0.00059 to 0.0029 in. 0.0059 in. • Small End Bushing I.D. 20.026 to 20.077 mm –...
Page 119: Lubricating System
ENGINE RTV-X900, RTV-X1120D, WSM Item Factory Specification Allowable Limit Crankshaft Journal to Crankshaft Bearing 3 Oil Clearance 0.028 to 0.059 mm 0.20 mm (Intermediate) 0.0011 to 0.0023 in. 0.0079 in. • Crankshaft Journal O.D. 43.934 to 43.950 mm – 1.7297 to 1.7303 in.
Page 120: Fuel System
ENGINE RTV-X900, RTV-X1120D, WSM (4) Fuel System Item Factory Specification Allowable Limit Injection Nozzle Injection Pressure 13.73 to 14.70 MPa – 140.0 to 150.0 kgf/cm 1992 to 2133 psi Injection Nozzle Valve Seat Valve Seat When the pressure is –...
Page 121: Rtv-X1120D (D1105)
ENGINE RTV-X900, RTV-X1120D, WSM [2] RTV-X1120D (D1105) (1) Engine Body ENGINE BODY Item Factory Specification Allowable Limit Compression Pressure 3.73 to 4.11 MPa 2.26 MPa 38.0 to 42.0 kgf/cm 23.0 kgf/cm 541 to 597 psi 327 psi • Difference among Cylinders −...
Page 122 ENGINE RTV-X900, RTV-X1120D, WSM Item Factory Specification Allowable Limit Rocker Arm Shaft to Rocker Arm Clearance 0.016 to 0.045 mm 0.10 mm 0.00063 to 0.0017 in. 0.0039 in. • Rocker Arm Shaft O.D. 11.973 to 11.984 mm – 0.47138 to 0.47181 in.
Page 123 ENGINE RTV-X900, RTV-X1120D, WSM Item Factory Specification Allowable Limit Idle Gear Shaft to Gear Bushing • Idle Gear 1 Clearance 0.020 to 0.054 mm 0.10 mm 0.00079 to 0.0021 in. 0.0039 in. • Idle Gear Shaft 1 O.D. 25.967 to 25.980 mm –...
Page 124: Lubricating System
ENGINE RTV-X900, RTV-X1120D, WSM Item Factory Specification Allowable Limit Crankshaft to Crankshaft Bearing 1 Oil Clearance 0.0340 to 0.114 mm 0.20 mm 0.00134 to 0.00448 in. 0.0079 in. • Crankshaft O.D. 47.934 to 47.950 mm – 1.8872 to 1.8877 in.
Page 125: Cooling System
ENGINE RTV-X900, RTV-X1120D, WSM (3) Cooling System Item Factory Specification Allowable Limit Fan Belt Tension 7.0 to 9.0 mm / 98 N – 0.28 to 0.35 in. / 98 N (10 kgf, 22 lbf) Radiator Cap Pressure Falling 10 seconds or more –...
Page 126: Tightning Torques
ENGINE RTV-X900, RTV-X1120D, WSM 3. TIGHTNING TORQUES [1] GENERAL Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to page "5. TIGHTENING TORQUES" on page G-12.) Item N·m...
Page 127 ENGINE RTV-X900, RTV-X1120D, WSM [3] RTV-X1120D NOTE • For "*" marked screws, bolts and nuts on the table, apply engine oil to their threads and seats before tightening. • The letter "M" in Size × Pitch means that the screw, bolt or nut dimension stands for metric. The size is the nominal outside diameter in mm of the threads.
Page 128: Checking, Disassembling And Servicing
ENGINE RTV-X900, RTV-X1120D, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING CAUTION • Be sure to check that the speed is neutrality before the following checks. • When checking, park the machine on flat ground and apply the parking brake.
Page 129 ENGINE RTV-X900, RTV-X1120D, WSM Compression Pressure CAUTION • Work by two people when you measure pressure. 1. Run the engine until it is warmed up. 2. Stop the engine. 3. Remove the muffler covers (1). 4. Remove the air cleaner hose (3), the muffler (2) and all glow plugs.
Page 130 ENGINE RTV-X900, RTV-X1120D, WSM Valve Clearance IMPORTANT • Valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover and the glow plugs and the timing window cover. 2. Align the "1TC" mark (1) on the flywheel and timing window (2) on the transmission case so that the No.
Page 131: Lubricating System
ENGINE RTV-X900, RTV-X1120D, WSM (2) Lubricating System Engine Oil Pressure 1. Remove the engine oil pressure switch, and set an oil pressure tester. (Code No.: 07916-32032) 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
Page 132 ENGINE RTV-X900, RTV-X1120D, WSM CAUTION • Check the injection pressure and condition after you make sure that there is nobody standing in the direction the fume goes. • If the fume from the nozzle directly contacts the human body, cells may be destroyed and blood poisoning may be caused.
Page 133 ENGINE RTV-X900, RTV-X1120D, WSM Nozzle Holder 1. Secure the nozzle retaining nut (7) with a vise. 2. Remove the nozzle holder (1), and remove parts inside. (When reassembling) • Assemble the nozzle in clean fuel oil. • Install the push rod (4), noting its direction.
Page 134: Cooling System
ENGINE RTV-X900, RTV-X1120D, WSM (3) Cooling System Fan Belt Tension 1. Measure the deflection (A), depressing the belt halfway between the fan drive pulley and alternator pulley at specified force 98 N (10 kgf, 22 lbf). 2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust.
Page 135 ENGINE RTV-X900, RTV-X1120D, WSM CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water way gush out, scalding nearby people. 9Y1210946ENS0012US0 Radiator Cap Air Leakage 1. Set a radiator tester (1) and an adaptor (2) on the radiator cap.
Page 136: Fuel System
ENGINE RTV-X900, RTV-X1120D, WSM (4) Fuel System Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid and the timing window cover. 3. Turn the flywheel counterclockwise (viewed from flywheel side) until the fuel fills up to the hole of the delivery valve holder (3) for No.
Page 137 ENGINE RTV-X900, RTV-X1120D, WSM Fuel Tightness of Pump Element 1. Remove the engine stop solenoid. 2. Remove the injection pipes and glow plugs. 3. Install the injection pump pressure tester to the injection pump. 4. Install the injection nozzle (2) jetted with the proper injection pressure to the injection pump pressure tester (1).
Page 138: Preparation
ENGINE RTV-X900, RTV-X1120D, WSM [2] PREPARATION (1) Dismounting Transmission and Engine Cargo Bed 1. Lift up the cargo bed (1) and support it so that the hydraulic cylinder (4) should not drop. (If hydraulic cylinder equipped.) 2. Remove the cotter pin (2) clevis pin (3) and cylinder lock (5). (If hydraulic cylinder equipped.)
Page 139 ENGINE RTV-X900, RTV-X1120D, WSM Draining Coolant WARNING To avoid serious injury: • Do not remove the radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely.
Page 140 ENGINE RTV-X900, RTV-X1120D, WSM Draining Hydraulic Tank Oil WARNING To avoid personal injury: • Be sure to stop the engine before changing the oil • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a level surface.
Page 141 ENGINE RTV-X900, RTV-X1120D, WSM Draining Engine Oil WARNING To avoid personal injury: • Be sure to stop the engine before changing the oil. • Allow engine to cool down sufficiently, oil can be not and can burn. 1. Park the vehicle on a level surface.
Page 142 ENGINE RTV-X900, RTV-X1120D, WSM Seat 1. Remove the connector cover and disconnect the seat switch connector (1). (RTV-X1120D only.) 2. Remove the back seat (2). 3. Remove the seat (3). 4. Remove the seat assembly (4). (1) Seat Switch Connector...
Page 143 ENGINE RTV-X900, RTV-X1120D, WSM Center Lower Cover and Handrail Frame 1. Remove the center lower cover (2). 2. Remove the 4WD grip (3) and hydraulic lift grip (4). 3. Remove the handrail frames (1). (1) Handrail Frame (3) 4WD Grip...
Page 144 ENGINE RTV-X900, RTV-X1120D, WSM Cables 1. Disconnect the hydraulic lift cable (1). 2. Disconnect the 4WD shift cable (2). 3. Disconnect the differential lock cable (3). 4. Disconnect the range gear shift cable (4). 5. Disconnect the parking brake cable (5).
Page 145 ENGINE RTV-X900, RTV-X1120D, WSM Engine Oil Inlet Hose and Intake Air Hose 1. Disconnect the engine oil inlet hose (1). 2. Disconnect the intake air hose (2). (1) Engine Oil Inlet Hose (2) Intake Air Hose 9Y1210946ENS0038US0 Hoses 1. Disconnect the HST drain hose (1) and HST suction hose (4).
Page 146 ENGINE RTV-X900, RTV-X1120D, WSM Rear Shock Absorber 1. Jack up the rear drive shaft. 2. Remove the rear shock absorber (1). (When reassembling) • Apply grease (Shell Godus S5 T100 or equivalent) to the rear shock absorber bushing before inserting collar.
Page 147 ENGINE RTV-X900, RTV-X1120D, WSM Wiring Harness LH 1. Disconnect the starter connectors (3). 2. Disconnect the engine oil pressure switch connector (2). 3. Disconnect the ground cables (4). 4. Disconnect the alternator connectors (1). 5. Disconnect the thermometer switch connector (5).
Page 148 ENGINE RTV-X900, RTV-X1120D, WSM Dismounting Transmission and Engine One Piece Assembly 1. Remove the mission upper support (2) and collars (1). 2. Set the hand pallet trucks (5) as shown figure. 3. Lift the mainframe by using hoist as shown in figure.
Page 149: Separating Transmission And Engine
ENGINE RTV-X900, RTV-X1120D, WSM (2) Separating Transmission and Engine Linkage, Muffler, Starter and Hydraulic Pipe 1. Remove the HST rod (3). 2. Remove the engine cable (7). 3. Remove the HST linkage (1). 4. Remove the muffler (2). 5. Remove the starter (4).
Page 150 ENGINE RTV-X900, RTV-X1120D, WSM Separate the Transmission and Engine One Piece Assembly 1. Remove the engine support (1). 2. Remove the engine mounting screws to separate the engine from the transmission. 3. Install the engine stand. (When reassembling) • Apply grease (RAILMASTER or equivalent) to spline hole of input flange.
Page 151 ENGINE RTV-X900, RTV-X1120D, WSM Outer Parts 1. Remove the input flange (1). 2. Remove the alternator (3) and fan belt (2). 3. Remove the dipstick (6). 4. Remove the engine stop solenoid (4). 5. Remove the hydraulic pump (5). (When reassembling) •...
Page 152: Disassembling And Assembling Rtv-X900 (D902)
ENGINE RTV-X900, RTV-X1120D, WSM [3] DISASSEMBLING AND ASSEMBLING RTV-X900 (D902) (1) Cylinder Head, Valves and Oil Pan Cylinder Head Cover 1. Disconnect the breather hose (1). 2. Remove the cylinder head cover screws (2). 3. Remove the cylinder head cover (3).
Page 153 ENGINE RTV-X900, RTV-X1120D, WSM Nozzle Heat Seal Service Removal Procedure IMPORTANT • Use a plus (phillips head) screw driver (1) that has a diameter which is bigger than the heat seal hole (Approx. 6.0 mm (0.24 in.)). 1. Drive screw driver (1) lightly into the heat seal hole.
Page 154 ENGINE RTV-X900, RTV-X1120D, WSM Cylinder Head and Cylinder Head Gasket 1. Loosen the pipe clamps (1), and remove the water return pipe (2). 2. Remove the cylinder head screw in the order of "n" or "j" to "a". 3. Remove the cylinder head gasket.
Page 155 ENGINE RTV-X900, RTV-X1120D, WSM Valves 1. Remove the valve caps (4). 2. Remove the valve spring collet (3), pushing the valve spring retainer (2) by valve spring replacer (1). 3. Remove the valve spring retainer (2), valve spring (5) and valve stem seal (6).
Page 156 ENGINE RTV-X900, RTV-X1120D, WSM Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws (2). 2. Remove the oil pan (1) by lightly tapping the rim of the pan with a wooden hammer. 3. Remove the oil strainer (3).
Page 157: Gear Case And Timing Gears
ENGINE RTV-X900, RTV-X1120D, WSM (2) Gear Case and Timing Gears Injection Pump, Fuel Feed Pump and Speed Control Plate 1. Remove the socket head screws and nuts, and remove the injection pump (1). 2. Remove the screws and separate the speed control plate (2), being careful not to damage the governor spring (4).
Page 158 ENGINE RTV-X900, RTV-X1120D, WSM (Continued) NOTE • Specific tool (1): 1.2 mm (0.047 in.) diameter hard wire with its end hooked, overall length 200 mm (7.87 in.). The tip of wire is bent like the hook to hang governor springs.
Page 159 ENGINE RTV-X900, RTV-X1120D, WSM (Continued) (When reassembling) 1. Move the fork lever (11) to the gear case side. 2. Hook the start spring (8) to the injection pump control rack pin (12). 3. Put the specific tool (1) through the fork lever hole of cylinder block (14) and hook the start spring (8).
Page 160 ENGINE RTV-X900, RTV-X1120D, WSM Fan Drive Pulley 1. Secure the flywheel to keep it from turning. 2. Remove the fan drive pulley screw. 3. Draw out the fan drive pulley with a puller. (When reassembling) • Install the pulley to crankshaft, aligning the mark (1) on them.
Page 161 ENGINE RTV-X900, RTV-X1120D, WSM Idle Gear 1. Remove the external snap ring (3), the collar (2) and the idle gear (1). 2. Remove the idle gear shaft mounting screws (4). 3. Remove the idle gear shaft (5) (if necessary). (When reassembling) •...
Page 162 ENGINE RTV-X900, RTV-X1120D, WSM Fuel Camshaft 1. Remove the retaining plate (6). 2. Remove the fork lever holder mounting screws (8), then draw out the injection pump gear (1) and fuel camshaft (7) with the governor fork assembly. (When reassembling) •...
Page 163: Piston And Connecting Rod
ENGINE RTV-X900, RTV-X1120D, WSM (3) Piston and Connecting Rod Connecting Rod Cap 1. Remove the connecting rod caps (1) using a bi hexagonal 8 mm socket. (When reassembling) • Align the marks (a) with each other. (Face the marks toward the injection pump.)
Page 164 ENGINE RTV-X900, RTV-X1120D, WSM Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) • When installing the ring, assemble the rings so that the manufacturer's mark (12) near the gap faces the top of the piston.
Page 165: Flywheel And Crankshaft
ENGINE RTV-X900, RTV-X1120D, WSM (4) Flywheel and Crankshaft Flywheel 1. Secure the flywheel to keep it from turning using a flywheel stopper. (Refer to "SPECIAL TOOLS".) 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) •...
Page 166 ENGINE RTV-X900, RTV-X1120D, WSM Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Turn the crankshaft to set the crankpin of the third cylinder to the bottom dead center. Then draw out the crankshaft until the crankpin of the second cylinder comes to the center of the third cylinder.
Page 167 ENGINE RTV-X900, RTV-X1120D, WSM Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (4), and remove the main bearing case assembly 1 (1), being careful with crankshaft bearing 3 (5), (9). 2. Remove the main bearing case assembly 2 (2) and the main bearing case assembly (3) as above.
Page 168: Disassembling And Assembling Rtv-X1120D (D1105)
ENGINE RTV-X900, RTV-X1120D, WSM [4] DISASSEMBLING AND ASSEMBLING RTV-X1120D (D1105) (1) Cylinder Head and Valve Cylinder Head Cover 1. Disconnect the breather hose (1). 2. Remove the cylinder head cover screw (2). 3. Remove the cylinder head cover (3). (When reassembling) •...
Page 169 ENGINE RTV-X900, RTV-X1120D, WSM Nozzle Heat Seal Service Removal Procedure IMPORTANT • Use a plus (phillips head) screw driver (1) that has a diameter which is bigger than the heat seal hole (Approx. 6.0 mm (0.24 in.)). 1. Drive screw driver (1) lightly into the heat seal hole.
Page 170 ENGINE RTV-X900, RTV-X1120D, WSM Cylinder Head and Cylinder Head Gasket 1. Loosen the pipe clamps (1), and remove the water return pipe (2). 2. Remove the cylinder head screw in the order of "n" or "r" to "a" and remove the cylinder head.
Page 171: Gear Cae And Timing Gears
ENGINE RTV-X900, RTV-X1120D, WSM Valves 1. Remove the valve caps (2). 2. Remove the valve spring collet (3), pushing the valve spring retainer (4) by valve spring replacer (1). 3. Remove the valve spring retainer (4), valve spring (5) and valve stem seal (6).
Page 172 ENGINE RTV-X900, RTV-X1120D, WSM Fan Drive Pulley 1. Secure the flywheel to keep it from turning. 2. Remove the fan drive pulley screw. 3. Draw out the fan drive pulley with a puller. (When reassembling) • Install the pulley to crankshaft, aligning the mark (1) on them (3-cylinder engine).
Page 173 ENGINE RTV-X900, RTV-X1120D, WSM Injection Pump 1. Disconnect the start spring (4) on the thrust lever side (5). 2. Align the control rack pin (2) with the notch (1) on the crankcase, and remove the injection pump (3). 3. Remove the injection pump shims.
Page 174 ENGINE RTV-X900, RTV-X1120D, WSM Cam Gear, Idle Gear 1, 2 and Governor Gear 1. Remove the idle gear 1 (4). 2. Remove the fuel camshaft stopper (7). 3. Draw out the fuel cam gear (1) with fuel camshaft (8). 4. Remove the camshaft stopper bolt.
Page 175: Piston And Connecting Rod
ENGINE RTV-X900, RTV-X1120D, WSM (3) Piston and Connecting Rod Connecting Rod 1. Remove the connecting rod cap. (When reassembling) • Align the marks (a) with each other. (Face the marks toward the injection pump.) • Apply engine oil to the connecting rod screws and lightly screw it in by hand, then tighten it to the specified torque.
Page 176 ENGINE RTV-X900, RTV-X1120D, WSM Piston Ring and Connecting Rod 1. Remove the piston rings using a piston ring tool. 2. Remove the piston pin (7), and separate the connecting rod (6) from the piston (5). (When reassembling) • When installing the ring, assemble the rings so that the manufacturer's mark (12) near the gap faces the top of the piston.
Page 177: Flywheel And Crankshaft
ENGINE RTV-X900, RTV-X1120D, WSM (4) Flywheel and Crankshaft Flywheel 1. Secure the flywheel to keep it from turning, using a flywheel stopper. 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) • Apply engine oil to the threads and the undercut surface of the flywheel screw and fit the screw.
Page 178 ENGINE RTV-X900, RTV-X1120D, WSM Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Pull out the crankshaft assembly. IMPORTANT • Be careful to protect crankshaft bearing 1 from scratches, caused by the crank gear, etc.. (Wrap the gear in vinyl tape, etc.)
Page 179: Servicing Rtv-X900 (D902)
ENGINE RTV-X900, RTV-X1120D, WSM [5] SERVICING RTV-X900 (D902) (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head. 2. With the piston at TDC, use grease to affix three or four plastigauges of a diameter 1.5 mm (0.059 in.) × 5.0 to 7.0 mm (0.20 to 0.27 in.) long to the crown of the piston;...
Page 180 ENGINE RTV-X900, RTV-X1120D, WSM Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying.
Page 181 ENGINE RTV-X900, RTV-X1120D, WSM Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (See page G-61.) (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them.
Page 182 ENGINE RTV-X900, RTV-X1120D, WSM Correcting Valve and Valve Seat NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
Page 183 ENGINE RTV-X900, RTV-X1120D, WSM Free Length and Tilt of Valve Spring 1. Measure the free length (B) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring.
Page 184: Timing Gears
ENGINE RTV-X900, RTV-X1120D, WSM Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. 0.25 mm Push rod alignment Allowable limit 0.0098 in.
Page 185 ENGINE RTV-X900, RTV-X1120D, WSM Idle Gear Side Clearance 1. Set a dial indicator with its tip on the idle gear. 2. Measure the side clearance by moving the idle gear to the front and rear. 3. If the measurement exceeds the allowable limit, replace the idle gear collar.
Page 186 ENGINE RTV-X900, RTV-X1120D, WSM Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with a inside micrometer, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the camshaft.
Page 187: Piston And Connecting Rod
ENGINE RTV-X900, RTV-X1120D, WSM (3) Piston and Connecting Rod Piston Pin Bore I.D. 1. Measure the piston pin bore I.D. in both the horizontal and vertical directions with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston.
Page 188 ENGINE RTV-X900, RTV-X1120D, WSM Connecting Rod Alignment NOTE • Since the I.D. of the connecting rod small end bushing is the basis of this check, check bushing for wear beforehand. 1. Install the piston pin into the connecting rod. 2. Install the connecting rod on the connecting rod alignment tool.
Page 189: Crankshaft
ENGINE RTV-X900, RTV-X1120D, WSM Clearance between Piston Ring and Piston Ring Groove 1. Clean the rings and the ring grooves, and install each ring in its groove. 2. Measure the clearance between the ring and the groove with a feeler gauge.
Page 190 ENGINE RTV-X900, RTV-X1120D, WSM Crankshaft Alignment 1. Support the crankshaft with V blocks on the surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Measure the crankshaft alignment. 4. If the measurement exceeds the allowable limit, replace the crankshaft.
Page 191 ENGINE RTV-X900, RTV-X1120D, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance.
Page 192 ENGINE RTV-X900, RTV-X1120D, WSM Replacing Crankshaft Bearing 1 (When removing) 1. Press out the used crankshaft bearing 1 using a crankshaft bearing 1 replacing tool. (See page G-64.) (When installing) 1. Clean a new crankshaft bearing 1 and crankshaft journal bore, and apply engine oil to them.
Page 193 ENGINE RTV-X900, RTV-X1120D, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 and Crankshaft Bearing 3 1. Put a strip of plastigauge on the center of the journal. 2. Install the bearing case and tighten the bearing case screws 1 to the specified torque, and remove the bearing case again.
Page 194: Cylinder
ENGINE RTV-X900, RTV-X1120D, WSM (5) Cylinder Cylinder Wear 1. Measure the cylinder liner I.D. at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.'s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.'s.
Page 195: Oil Pump
ENGINE RTV-X900, RTV-X1120D, WSM (6) Oil Pump Rotor Lobe Clearance 1. Measure the clearance between lobes of the inner rotor and the outer rotor with a thickness gauge. 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.
Page 196: Servicing Rtv-X1120D (D1105)
ENGINE RTV-X900, RTV-X1120D, WSM [6] SERVICING RTV-X1120D (D1105) (1) Cylinder Head and Valves Top Clearance 1. Remove the cylinder head. 2. With the piston at TDC, use grease to affix three or four plastigauges (1) of a diameter 1.5 mm (0.059 in.) × 5.0 to 7.0 mm (0.20 to 0.27 in.) long to the crown of the piston;...
Page 197 ENGINE RTV-X900, RTV-X1120D, WSM Cylinder Head Flaw 1. Prepare an air spray red check. 2. Clean the surface of the cylinder head with detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying.
Page 198 ENGINE RTV-X900, RTV-X1120D, WSM Replacing Valve Guide (When removing) 1. Press out the used valve guide using a valve guide replacing tool. (See page G-63.) (When installing) 1. Clean a new valve guide and valve guide bore, and apply engine oil to them.
Page 199 ENGINE RTV-X900, RTV-X1120D, WSM Correcting Valve and Valve Seat NOTE • Before correcting the valve and seat, check the valve stem and the I.D. of valve guide section, and repair them if necessary. • After correcting the valve seat, be sure to check the valve recessing.
Page 200 ENGINE RTV-X900, RTV-X1120D, WSM Free Length and Tilt of Valve Spring 1. Measure the free length (B) of valve spring with vernier calipers. If the measurement is less than the allowable limit, replace it. 2. Put the valve spring on a surface plate, place a square on the side of the valve spring.
Page 201 ENGINE RTV-X900, RTV-X1120D, WSM Push Rod Alignment 1. Place the push rod on V blocks. 2. Measure the push rod alignment. 3. If the measurement exceeds the allowable limit, replace the push rod. 0.25 mm Push rod alignment Allowable limit 0.0098 in.
Page 202: Timing Gears, Camshaft And Governor Gear
ENGINE RTV-X900, RTV-X1120D, WSM (2) Timing Gears, Camshaft and Governor Gear Timing Gear Backlash 1. Set a dial indicator (lever type) with its tip on the gear tooth. 2. Move the gear to measure the backlash, holding its mating gear.
Page 203 ENGINE RTV-X900, RTV-X1120D, WSM Camshaft Alignment 1. Support the camshaft with V blocks on the surface plate at both end journals. 2. Set a dial indicator with its tip on the intermediate journal. 3. Measure the camshaft alignment. 4. If the measurement exceeds the allowable limit, replace the camshaft.
Page 204 ENGINE RTV-X900, RTV-X1120D, WSM Oil Clearance of Camshaft Journal 1. Measure the camshaft journal O.D. with an outside micrometer. 2. Measure the cylinder block bore I.D. for camshaft with a cylinder gauge, and calculate the oil clearance. 3. If the oil clearance exceeds the allowable limit, replace the camshaft.
Page 205: Piston And Connecting Rod
ENGINE RTV-X900, RTV-X1120D, WSM (3) Piston and Connecting Rod Piston Pin Bore I.D. 1. Measure the piston pin bore I.D. in both the horizontal and vertical directions with a cylinder gauge. 2. If the measurement exceeds the allowable limit, replace the piston.
Page 206 ENGINE RTV-X900, RTV-X1120D, WSM Connecting Rod Alignment NOTE • Since the I.D. of the connecting rod small end bushing is the basis of this check, check bushing for wear beforehand. 1. Install the piston pin into the connecting rod. 2. Install the connecting rod on the connecting rod alignment tool.
Page 207: Crankshaft
ENGINE RTV-X900, RTV-X1120D, WSM Clearance between Piston ring and Piston Ring Groove 1. Clean the rings and the ring grooves, and install each ring in its groove. 2. Measure the clearance between the ring and the groove with a feeler gauge or depth gauge.
Page 208 ENGINE RTV-X900, RTV-X1120D, WSM Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage on the center of the crankpin. 3. Install the connecting rod cap and tighten the connecting rod screws to the specified torque, and remove the cap again.
Page 209 ENGINE RTV-X900, RTV-X1120D, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 1 1. Measure the O.D. of the crankshaft front journal with an outside micrometer. 2. Measure the I.D. of the crankshaft bearing 1 with an inside micrometer, and calculate the oil clearance.
Page 210 ENGINE RTV-X900, RTV-X1120D, WSM Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) 1. Put a strip of plastigage on the center of the journal. 2. Install the bearing case and tighten the baring case screws 1 to the specified torque, and remove the bearing case again.
Page 211 ENGINE RTV-X900, RTV-X1120D, WSM Replacing Crankshaft Sleeve 1. Remove the used crankshaft sleeve. 2. Set the sleeve guide (2) to the crankshaft. 3. Heat a new sleeve to a temperature between 150 and 200 °C (302 and 392 °F), and fix the sleeve to the crankshaft as shown in figure.
Page 212 ENGINE RTV-X900, RTV-X1120D, WSM (5) Cylinder Cylinder Wear 1. Measure the I.D. of the cylinder at the six positions (see figure) with a cylinder gauge to find the maximum and minimum I.D.'s. 2. Get the difference (Maximum wear) between the maximum and the minimum I.D.'s.
Page 213 ENGINE RTV-X900, RTV-X1120D, WSM (6) Oil Pump Rotor Lobe Clearance 1. Measure the clearance between lobes of the inner rotor and the outer rotor with a feeler gauge. 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.
Page 214 TRANSMISSION KiSC issued 01, 2014 A...
Page 215 (2) Oil Flow........................... 2-M6 (3) Function of Components ....................2-M8 (4) HST Oil Flow RTV-X900....................2-M16 (5) HST Oil Flow RTV-X1120D ..................2-M22 (6) HST Control Linkage ....................2-M28 (7) Cables .......................... 2-M30 [2] RANGE GEAR SHIFT SECTION AND FRONT WHEEL DRIVE SECTION....... 2-M31...
Page 216: Structure
TRANSMISSION RTV-X900, RTV-X1120D, WSM 1. STRUCTURE [1] RTV-X900 (1) Range Shift Gear Section (2) Front Wheel Drive Section (3) Input Shaft Section (4) Hydraulic Transmission Section 2-M1 KiSC issued 01, 2014 A...
Page 217: Rtv-X1120D
TRANSMISSION RTV-X900, RTV-X1120D, WSM [2] RTV-X1120D (1) Range Shift Gear Section (2) Front Wheel Drive Section (3) Input Shaft Section (4) Hydraulic Transmission Section 2-M2 KiSC issued 01, 2014 A...
Page 218: Power Train
TRANSMISSION RTV-X900, RTV-X1120D, WSM 2. POWER TRAIN The transmission of this model consists of a series of gears and shafts as shown in previous page. The traveling system chiefly consists of hydrostatic transmission section, range gear shift section and front wheel drive section.
Page 219 TRANSMISSION RTV-X900, RTV-X1120D, WSM [A] RTV-X900 (1) Charge Relief Valve (8) Variable Swashplate (Pump) (15) Control Piston 3 (22) Orifice (2) Servo Piston (9) Guide (16) Charge Pump (23) Unload Spool (3) Regulator Valve Assembly (10) Port Block Cover (17) Piston (Pump)
Page 220 TRANSMISSION RTV-X900, RTV-X1120D, WSM [B] RTV-X1120D (1) Charge Relief Valve (8) Variable Swashplate (Pump) (15) Control Piston 3 (22) Orifice (2) Servo Piston (9) Guide (16) Charge Pump (23) Unload Spool (3) Regulator Valve Assembly (10) Port Block Cover (17) Piston (Pump)
Page 221: Oil Flow
TRANSMISSION RTV-X900, RTV-X1120D, WSM (2) Oil Flow [A] RTV-X900 (1) HST Assembly (7) Anti-cavitation Valve (12) Control Piston 3 (17) Servo Piton (2) Control Lever (Pedal) (8) Control Piston 1 (13) Check Valve (18) Cylinder Block (Pump) (3) Servo Regulator Assembly...
Page 222 TRANSMISSION RTV-X900, RTV-X1120D, WSM [B] RTV-X1120D (1) HST Assembly (7) Anti-cavitation Valve (12) Control Piston 3 (17) Servo Piton (2) Control Lever (Pedal) (8) Control Piston 1 (13) Check Valve (18) Cylinder Block (Pump) (3) Servo Regulator Assembly (9) Control Piston 2...
Page 223: Function Of Components
TRANSMISSION RTV-X900, RTV-X1120D, WSM (3) Function of Components [A] Servomechanism (1) Regulator Valve Assembly (4) Pin B (Fixed with Spool) (7) Servo Piston (10) Servo Piston (2) Regulator Spool (5) Feedback Lever (8) Guide (for Variable (11) Servo Spring (3) Pin A...
Page 224 TRANSMISSION RTV-X900, RTV-X1120D, WSM [B] Regulator and Servo Piston Operation Control Lever at Neutral (1) Servo Adjusting Screw (2) Regulator Valve Assembly (3) Regulator Spool (4) Pin B (Fixed with Spool) (5) Pin A (Fixed with Regulator Shaft) (6) Control Lever...
Page 225 TRANSMISSION RTV-X900, RTV-X1120D, WSM Control Lever Activated (First Step: Moving the Control Lever) (1) Servo Adjusting Screw (2) Regulator Valve Assembly (3) Regulator Spool (4) Pin B (Fixed with Spool) (5) Pin A (Fixed with Regulator Shaft) (6) Control Lever...
Page 226 TRANSMISSION RTV-X900, RTV-X1120D, WSM Control Lever Activated (with Control Lever at Desired Position) (1) Servo Adjusting Screw (2) Regulator Valve Assembly (3) Regulator Spool (4) Pin B (Fixed with Spool) (5) Pin A (Fixed with Regulator Shaft) (6) Control Lever...
Page 227 TRANSMISSION RTV-X900, RTV-X1120D, WSM Control Lever Deactivated (1) Servo Adjusting Screw (2) Regulator Valve Assembly (3) Regulator Spool (4) Pin B (Fixed with Spool) (5) Pin A (Fixed with Regulator Shaft) (6) Control Lever (7) Feedback Lever (8) Servo Piston...
Page 228 TRANSMISSION RTV-X900, RTV-X1120D, WSM [D] Check and High Pressure Relief Valve The cartridge-type check and high-pressure relief valve consists of pressure poppet (2), check valve seat (1), relief valve spring (3), spring guide (4) and check valve spring (5). The spring guide (4) is provided with an anti-rotation, which keeps the threads tight after a pressure has been set.
Page 229 TRANSMISSION RTV-X900, RTV-X1120D, WSM (Continued) Condition • Engine speed: Maximum while transmission stalling [RTV-X900] Valve operating Oil temperature Port pressure 23.5 to 26.5 MPa (P1) 240 to 270 kgf/cm Traveling side 3410 to 3840 psi 45 to 55 °C (113 to 131 °F) 15.0 to 17.0 MPa...
Page 230 TRANSMISSION RTV-X900, RTV-X1120D, WSM [F] Unload Valve When starting from a stopped position on a slope (the brake pedal is not depressed), due to residual pressure in the HST circuit, shifting to the neutral position cannot always be fully achieved.
Page 231: Hst Oil Flow Rtv-X900
TRANSMISSION RTV-X900, RTV-X1120D, WSM (4) HST Oil Flow RTV-X900 [A] Neutral (1) Unload Valve (2) Control Piston 1 (3) Control Piston 2 (4) HST Housing (5) Variable Swashplate (Motor) (6) Output Shaft (7) Cylinder Block (Stationary Motor) (8) Control Piston 3...
Page 232 TRANSMISSION RTV-X900, RTV-X1120D, WSM [B] Half Stroke Movement of Pedal and Light Load Condition (1) Unload Valve (2) Control Piston 1 (3) Control Piston 2 (4) HST Housing (5) Variable Swashplate (Motor) (6) Output Shaft (7) Cylinder Block (Stationary Motor)
Page 233 TRANSMISSION RTV-X900, RTV-X1120D, WSM [C] Low Load When Speed Control Pedal Is Pressed (1) Unload Valve (2) Control Piston 1 (3) Control Piston 2 (4) HST Housing (5) Variable Swashplate (Motor) (6) Output Shaft (7) Cylinder Block (Stationary Motor) (8) Control Piston 3...
Page 234 TRANSMISSION RTV-X900, RTV-X1120D, WSM [D] Swashplate On The Motor Is Starting To Tilt From Low Load When The Speed Control Pedal Is Pressed (1) Unload Valve (2) Control Piston 1 (3) Control Piston 2 (4) HST Housing (5) Variable Swashplate...
Page 235 TRANSMISSION RTV-X900, RTV-X1120D, WSM [E] Horse-power Control When The Speed Control Pedal Is Pressed While Overloaded (1) Unload Valve (2) Control Piston 1 (3) Control Piston 2 (4) HST Housing (5) Variable Swashplate (Motor) (6) Output Shaft (7) Cylinder Block...
Page 236 TRANSMISSION RTV-X900, RTV-X1120D, WSM [F] When Dynamic Brake Is Engaged (1) Unload Valve (2) Control Piston 1 (3) Control Piston 2 (4) HST Housing (5) Variable Swashplate (Motor) (6) Output Shaft (7) Cylinder Block (Stationary Motor) (8) Control Piston 3...
Page 237: Hst Oil Flow Rtv-X1120D
TRANSMISSION RTV-X900, RTV-X1120D, WSM (5) HST Oil Flow RTV-X1120D [A] Neutral (1) Unload Valve (2) Control Piston 1 (3) Control Piston 2 (4) HST Housing (5) Variable Swashplate (Motor) (6) Output Shaft (7) Cylinder Block (Stationary Motor) (8) Control Piston 3...
Page 238 TRANSMISSION RTV-X900, RTV-X1120D, WSM [B] Half Stroke Movement of Pedal and Light Load Condition (1) Unload Valve (2) Control Piston 1 (3) Control Piston 2 (4) HST Housing (5) Variable Swashplate (Motor) (6) Output Shaft (7) Cylinder Block (Stationary Motor)
Page 239 TRANSMISSION RTV-X900, RTV-X1120D, WSM [C] Low Load When Speed Control Pedal Is Pressed (1) Unload Valve (2) Control Piston 1 (3) Control Piston 2 (4) HST Housing (5) Variable Swashplate (Motor) (6) Output Shaft (7) Cylinder Block (Stationary Motor) (8) Control Piston 3...
Page 240 TRANSMISSION RTV-X900, RTV-X1120D, WSM [D] Swashplate On The Motor Is Starting To Tilt From Low Load When The Speed Control Pedal Is Pressed (1) Unload Valve (2) Control Piston 1 (3) Control Piston 2 (4) HST Housing (5) Variable Swashplate...
Page 241 TRANSMISSION RTV-X900, RTV-X1120D, WSM [E] Horse-power Control When The Speed Control Pedal Is Pressed While Overloaded (1) Unload Valve (2) Control Piston 1 (3) Control Piston 2 (4) HST Housing (5) Variable Swashplate (Motor) (6) Output Shaft (7) Cylinder Block...
Page 242 TRANSMISSION RTV-X900, RTV-X1120D, WSM [F] When Dynamic Brake Is Engaged (1) Unload Valve (2) Control Piston 1 (3) Control Piston 2 (4) HST Housing (5) Variable Swashplate (Motor) (6) Output Shaft (7) Cylinder Block (Stationary Motor) (8) Control Piston 3...
Page 243: Hst Control Linkage
TRANSMISSION RTV-X900, RTV-X1120D, WSM (6) HST Control Linkage [A] Speed Control Linkage (1) HST Control Lever (2) HST Control Rod (3) Neutral Lever (4) Neutral Holder (5) Damper (6) Neutral Holder Arm (7) Engine Speed Control Wire (8) Speed Control Pedal Cable (9) Speed Control Pedal The speed control pedal (9) and neutral holder arm (6) are connected with speed control pedal cable (8).
Page 244 TRANSMISSION RTV-X900, RTV-X1120D, WSM [B] Unload Valve Linkage When starting from a stopped position on a slope (the brake pedal (1) is not depressed), due to residual pressure in the HST circuit, shifting to the neutral position cannot always be fully achieved.
Page 245: Cables
TRANSMISSION RTV-X900, RTV-X1120D, WSM (7) Cables (1) Main Shift Lever (3) Differential Lock Pedal (6) 4WD Shift Cable (7) 4WD Lever (2) Shift Cable (4) Differential Lock Holder (5) Differential Lock Cable Each control cable is the structure of figure.
Page 246: Range Gear Shift Section And Front Wheel Drive Section
TRANSMISSION RTV-X900, RTV-X1120D, WSM [2] RANGE GEAR SHIFT SECTION AND FRONT WHEEL DRIVE SECTION Reverse Low Speed High Speed 4 Wheel Drive From HST Output Shaft  Range Gear Shift Section First, power is transmitted to the HST at the back of the transmission case. The HST power is then removed to the front and transmitted further to the range shift section.
Page 247 SERVICING CONTENTS 1. TROUBLESHOOTING.........................2-S1 [1] HYDROSTATIC TRANSMISSION ..................2-S1 [2] TRAVELLING GEAR SHIFT SECTION.................2-S3 [3] DIFFERENTIAL GEAR SECTION ..................2-S3 2. SERVICING SPECIFICATIONS ....................2-S4 3. TIGHTENING TORQUES......................2-S5 4. CHECKING AND ADJUSTING....................2-S6 5. PREPARATION .........................2-S19 [1] SEPARATING HYDRAULIC TRANSMISSION ..............2-S19 [2] DISMOUNTINGTRANSMISSION AND ENGINE ..............2-S23 [3] SEPARATING TRANSMISSION AND ENGINE..............2-S34 6.
Page 248: Troubleshooting
TRANSMISSION RTV-X900, RTV-X1120D, WSM 1. TROUBLESHOOTING [1] HYDROSTATIC TRANSMISSION Reference Symptom Probable Cause Solution Page System Will Not Oil level is low Check oil level or fill G-18 Operate in Both oil to proper level Direction Control linkage or cable damaged (speed control...
Page 249 TRANSMISSION RTV-X900, RTV-X1120D, WSM Reference Symptom Probable Cause Solution Page Loss of Power Oil level is low Check oil level or fill G-18 oil to proper level Control linkage or cable damaged (speed control Repair linkage 2-S32 cable) Charge pressure is too low 1.
Page 250: Travelling Gear Shift Section
TRANSMISSION RTV-X900, RTV-X1120D, WSM [2] TRAVELLING GEAR SHIFT SECTION Reference Symptom Probable Cause Solution Page Noise from Transmission oil insufficient Refill 2-S25 Transmission Gear worn or broken Replace 2-S39 Bearings worn Replace 2-S49 Gear Slip Out of Mesh Shift fork spring tension insufficient...
Page 251: Servicing Specifications
TRANSMISSION RTV-X900, RTV-X1120D, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Charge Relief Valve Setting Pressure RTV-X900 0.43 to 0.83 MPa – 4.4 to 8.6 kgf/cm 63 to 120 psi RTV-X1120D 0.48 to 0.90 MPa – 4.9 to 9.1 kgf/cm...
Page 252: Tightening Torques
TRANSMISSION RTV-X900, RTV-X1120D, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m lbf·ft Muffler bracket mounting bolt and nut 48.0 to 55.9...
Page 253: Checking And Adjusting
TRANSMISSION RTV-X900, RTV-X1120D, WSM 4. CHECKING AND ADJUSTING Checking Charge Relief Pressure CAUTION • If it is necessary to run engine in an enclosed area, use a gas tight exhaust pipe extension to remove the fumes. • Always try to work in a ell-ventilated area.
Page 254 TRANSMISSION RTV-X900, RTV-X1120D, WSM Checking High Pressure Relief Valve Pressure (Traveling Side) CAUTION • If it is necessary to run engine in an enclosed area, use a gas tight exhaust pipe extension to remove the fumes. • Always try to work in a well-ventilated area.
Page 255 TRANSMISSION RTV-X900, RTV-X1120D, WSM (Continued) IMPORTANT • Measure quickly so that the relief valve may not be in operation more than 10 seconds. NOTE • High pressure gauge is 29.4 MPa (300 kgf/cm , 4267 psi) full scale. (When reassembling) •...
Page 256 TRANSMISSION RTV-X900, RTV-X1120D, WSM Checking High Pressure Relief Valve Pressure (Dynamic Brake) CAUTION • If it is necessary to run engine in an enclosed area, use a gas tight exhaust pipe extension to remove the fumes. • Always try to work in a well-ventilated area.
Page 257 TRANSMISSION RTV-X900, RTV-X1120D, WSM (Continued) NOTE • High pressure gauge is 29.4 MPa (300 kgf/cm , 4267 psi) full scale. (When reassembling) • Be careful not to damage O-ring on plug. Condition • Engine speed: Maximum while transmission stalling • Oil temperature: 45 to 55 °C (113 to 131 °F)
Page 258 TRANSMISSION RTV-X900, RTV-X1120D, WSM (Continued) IMPORTANT • When the neutral position of the machine is checked, it is advisable to divide the checking procedure as follows: First check the HST unit alone, and then connect the HST unit to the link for checking.
Page 259 TRANSMISSION RTV-X900, RTV-X1120D, WSM Checking Travelling Speed CAUTION • Park the machine on a hard and level surface. • If it is necessary to run engine in an enclosed area, use a gas tight exhaust pipe extension to remove the fumes.
Page 260 TRANSMISSION RTV-X900, RTV-X1120D, WSM Checking Engine Cable 1. Make sure the mounting position for the engine cable (3) is the position indicated in the figure. 2. Adjust the adjustment nut (1) until there is no deflection in the engine cable (3).
Page 261 (RTV-X900) 1350 min (rpm) (RTV-X1120D) 1400 min (rpm) • Engine maximum speed: (RTV-X900) 3320 to 3420 min (rpm) (RTV-X1120D) 3070 to 3170 min (rpm) (1) Speed Control Pedal Center of thread (2) Bracket Adjust the nuts. (3) Speed Control Pedal Cable...
Page 262 TRANSMISSION RTV-X900, RTV-X1120D, WSM Checking Range Gear Shift Lever Position (Adjusting of the Shift Cable Length and the Select Cable Length) CAUTION • When checking, park the machine on flat ground, and apply the parking brake. • Work by 2 people when you checking and adjusting range gear shift lever position.
Page 263 TRANSMISSION RTV-X900, RTV-X1120D, WSM Checking Four Wheel Drive Lever Position (Adjustment of the 4WD Shift Cable Length) CAUTION • When checking, park the machine on flat ground, apply the parking brake. • Work by two people when you checking and adjusting four wheel drive lever position.
Page 264 TRANSMISSION RTV-X900, RTV-X1120D, WSM Checking Differential Lock Cable (Adjustment of the length of the cable for differential lock) CAUTION • When checking, park the machine on flat ground, apply the parking brake. 1. Check that the cable to the transmission case, with the cable outer section screw being set near the center.
Page 265 TRANSMISSION RTV-X900, RTV-X1120D, WSM Checking VHT Pressure Release Cable (Unload Cable) 1. Check the unload cable (1) connect the brake pedal as shown is figure. 2. Move the arm (4) and spool (5) from side to side by hand and check a play.
Page 266: Preparation
TRANSMISSION RTV-X900, RTV-X1120D, WSM 5. PREPARATION [1] SEPARATING HYDRAULIC TRANSMISSION Cargo Bed 1. Lift up the cargo bed (1) and support it so that the hydraulic cylinder (4) should not drop. (If hydraulic cylinder equipped.) 2. Remove the cotter pin (2) clevis pin (3) and cylinder lock (5). (If hydraulic cylinder equipped.)
Page 267 TRANSMISSION RTV-X900, RTV-X1120D, WSM Draining Hydraulic Tank Oil WARNING To avoid personal injury: • Be sure to stop the engine before changing the oil • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a level surface.
Page 268 TRANSMISSION RTV-X900, RTV-X1120D, WSM Stabilizer Stay and Muffler Bracket 1. Remove the stabilizer stay (2). 2. Remove the muffler bracket (1). (When reassembling) 48.0 to 55.9 N·m Muffler bracket mounting Tightening torque 4.90 to 5.70 kgf·m bolt and nut 35.4 to 41.2 lbf·ft...
Page 269 TRANSMISSION RTV-X900, RTV-X1120D, WSM HST Assembly 1. Disconnect the HST control rod (1). 2. Remove the HST mounting nuts (3). 3. Remove the HST assembly (2). (When reassembling) • Remove the upper cover (4). • Be sure not to damage the O-ring (7).
Page 270: Dismountingtransmission And Engine
TRANSMISSION RTV-X900, RTV-X1120D, WSM [2] DISMOUNTINGTRANSMISSION AND ENGINE Cargo Bed 1. Lift up the cargo bed (1) and support it so that the hydraulic cylinder (4) should not drop. (If hydraulic cylinder equipped.) 2. Remove the cotter pin (2) clevis pin (3) and cylinder lock (5). (If hydraulic cylinder equipped.)
Page 271 TRANSMISSION RTV-X900, RTV-X1120D, WSM Draining Coolant WARNING To avoid serious injury: • Do not remove the radiator cap while coolant is hot. When cool, slowly rotate cap to the first stop and allow sufficient time for excess pressure to escape before removing the cap completely.
Page 272 TRANSMISSION RTV-X900, RTV-X1120D, WSM Draining Hydraulic Tank Oil WARNING To avoid personal injury: • Be sure to stop the engine before changing the oil • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. Park the vehicle on a level surface.
Page 273 (1) Rear Wheel 9Y1210946ENS0029US0 Seat 1. Remove the connector cover and disconnect the seat switch connector (1). (RTV-X1120D only.) 2. Remove the back seat (2). 3. Remove the seat (3). 4. Remove the seat assembly (4). (1) Seat Switch Connector...
Page 274 TRANSMISSION RTV-X900, RTV-X1120D, WSM Seat Under Cover and Seat Belt 1. Remove the center box cover (3). 2. Disconnect the seat belt connector (2). 3. Remove the seat belts (1). (When reassembling) • Be sure to assembling the seat belt assembly as shown in the figure.
Page 275 TRANSMISSION RTV-X900, RTV-X1120D, WSM Center Upper Cover, Mat and Center Step 1. Remove the center upper cover (1). 2. Remove the mat (2). 3. Remove the center step (3). (1) Center Upper Cover (3) Center Step (2) Mat 9Y1210946ENS0181US0 Center Lower Cover 1.
Page 276 TRANSMISSION RTV-X900, RTV-X1120D, WSM Cables 1. Disconnect the hydraulic lift cable (1). 2. Disconnect the 4WD shift cable (2). 3. Disconnect the differential lock cable (3). 4. Disconnect the range gear shift cable (4). 5. Disconnect the parking brake cable (5).
Page 277 TRANSMISSION RTV-X900, RTV-X1120D, WSM Engine Oil Inlet Hose and Intake Air Hose 1. Disconnect the engine oil inlet hose (1). 2. Disconnect the intake air hose (2). (1) Engine Oil Inlet Hose (2) Intake Air Hose 9Y1210946ENS0038US0 Hoses 1. Disconnect the HST drain hose (1) and HST suction hose (4).
Page 278 TRANSMISSION RTV-X900, RTV-X1120D, WSM Rear Shock Absorber 1. Jack up the rear drive shaft. 2. Remove the rear shock absorber (1). (When reassembling) • Apply grease (Shell Godus S5 T100 or equivalent) to the rear shock absorber bushing before inserting collar.
Page 279 TRANSMISSION RTV-X900, RTV-X1120D, WSM Wiring Harness LH 1. Disconnect the starter connectors (3). 2. Disconnect the engine oil pressure switch connector (2). 3. Disconnect the ground cables (4). 4. Disconnect the alternator connectors (1). 5. Disconnect the thermometer switch connector (5).
Page 280 TRANSMISSION RTV-X900, RTV-X1120D, WSM Dismounting Transmission and Engine One Piece Assembly 1. Remove the mission upper support (2) and collars (1). 2. Set the hand pallet trucks (5) as shown figure. 3. Lift the mainframe by using hoist as shown in figure.
Page 281: Separating Transmission And Engine
TRANSMISSION RTV-X900, RTV-X1120D, WSM [3] SEPARATING TRANSMISSION AND ENGINE Linkage, Muffler, Starter and Hydraulic Pipe 1. Remove the HST rod (3). 2. Remove the engine cable (7). 3. Remove the HST linkage (1). 4. Remove the muffler (2). 5. Remove the starter (4).
Page 282 TRANSMISSION RTV-X900, RTV-X1120D, WSM Separate the Transmission and Engine One Piece Assembly 1. Remove the engine support (1). 2. Remove the engine mounting screws to separate the engine from the transmission. 3. Install the engine stand. (When reassembling) • Apply grease (RAILMASTER or equivalent) to spline hole of input flange.
Page 283: Disassembling And Assembling
TRANSMISSION RTV-X900, RTV-X1120D, WSM 6. DISASSEMBLING AND ASSEMBLING [1] TRANSMISSION (1) Removing HST Assembly HST Assembly for RTV-X900 1. Remove the piston case (1), spring (3) and piston (4). 2. Remove the HST assembly (2). (When reassembling) • Remove the upper cover (5).
Page 284 TRANSMISSION RTV-X900, RTV-X1120D, WSM HST Assembly for RTV-X1120D 1. Remove the charge pipe (1). 2. Remove the piston case (3) and piston (4). 3. Remove the HST assembly (2). (When reassembling) • Remove the upper cover (5). • Be sure not to damage the O-rings (6).
Page 285: Disassembling Transmission
TRANSMISSION RTV-X900, RTV-X1120D, WSM (2) Disassembling Transmission Fly Wheel Cover 1. Remove the fly wheel cover (1). (When reassembling) • Be sure not to damaged the O-ring (2). • Apply liquid gasket (Three Bond 1216E or equivalent) to joint face the fly wheel cover and front cover.
Page 286 TRANSMISSION RTV-X900, RTV-X1120D, WSM Front Cover and Dipstick 1. Remove the front cover (1) with input shaft (2). 2. Remove the dipstick (4). (When reassembling) • Be sure set the shims (3) to front cover (1). (1) Front Cover (3) Shim...
Page 287 TRANSMISSION RTV-X900, RTV-X1120D, WSM Control Valve 1. Remove the valve cover (1) with control valve (3). (When reassembling) • Be sure not to damage the O-ring (2). (1) Valve Cover (3) Control Valve (2) O-ring 9Y1210946TRS0029US0 Brake Cylinder 1. Remove the brake cylinder (1).
Page 288 TRANSMISSION RTV-X900, RTV-X1120D, WSM Side Cover LH, Differential Gear Shaft and Final Gear 1. Remove the side cover LH (1). 2. Remove the brake disks (5) and friction plate (4). 3. Remove the brake plate (3). 4. Remove the differential gear shaft (2) with differential lock clutch (6) and spring (7).
Page 289 TRANSMISSION RTV-X900, RTV-X1120D, WSM Side Cover RH, Differential Shaft and Final Gear 1. Remove the side cover RH (1). 2. Remove the brake disks (4) and friction plate (5). 3. Remove the brake plate (3). 4. Remove the differential gear shaft (2).
Page 290 TRANSMISSION RTV-X900, RTV-X1120D, WSM Differential Gear Assembly 1. Remove the bearing holder (1), nothing the number of right shims (2). 2. Remove the differential gear assembly (3), nothing the number of shims (2). (When reassembling) • Use same number oh shims as before disassembling.
Page 291: Disassembling Hst
TRANSMISSION RTV-X900, RTV-X1120D, WSM (3) Disassembling HST Port Block Cover 1. Remove the plug (2) and install the M10 × pitch 1.0 mm screw. 2. Remove the snap ring (3) and washer (4). 3. Remove the bearing holder (5). 4. Remove the port block cover (6).
Page 292 TRANSMISSION RTV-X900, RTV-X1120D, WSM Cylinder Block 1. Remove the filters (1). 2. Remove the motor cylinder block (2) with motor shaft (3). 3. Remove the pump cylinder block (5). (1) Filter (6) Swashplate (2) Cylinder Block (Motor) (7) Thrust Bearing...
Page 293 TRANSMISSION RTV-X900, RTV-X1120D, WSM Pump Shaft 1. Remove the external snap ring (1) and swashpalte (2). 2. Remove the internal snap ring (6) and plug (5). 3. Remove the external snap ring (9) and pump shaft (3). 4. Remove the charge pump case (4).
Page 294 TRANSMISSION RTV-X900, RTV-X1120D, WSM Servo Piston Assembly 1. Remove the servo piston assembly mounting hex. head screw. 2. Pull out the servo piston assembly (2) sightly by the hand. (When reassembling) • Replace the gasket with new one. NOTE • Be careful not to do damage the surface of servo piston.
Page 295: Servicing
TRANSMISSION RTV-X900, RTV-X1120D, WSM 7. SERVICING [1] TRANSMISSION Cable 1. Check that the cable moves smoothly within the cable outer. 2. If the cable movement is not smooth, or if the cable is frayed, or if the cable outer is damaged, replace the cable.
Page 296 TRANSMISSION RTV-X900, RTV-X1120D, WSM Mission Frame and Rubber Bush 1. Visually check the engine support LH (2), engine support RH (1), mission upper bracket (5), mission bracket (4) and rubber bushes (3). 2. If the hole is miss happen, discolored, hardened or been otherwise damaged, replace the rubber bush.
Page 297 TRANSMISSION RTV-X900, RTV-X1120D, WSM Checking Gear 1. Visually check the tooth of gear which comes in contact. 2. If there is any doubt as to the condition of gears, replace it. 9Y1210946TRS0037US0 13T Spiral Bevel Pinion Shaft, Gear and Ball Bearing 1.
Page 298 TRANSMISSION RTV-X900, RTV-X1120D, WSM Backlash between Differential Pinion and Differential Side 1. Set a dial indicator (lever type) on the tooth of the differential pinion. 2. Hold the differential side gear and move the differential pinion to measure the backlash.
Page 299 TRANSMISSION RTV-X900, RTV-X1120D, WSM Backlash and Tooth Contact between Spiral Bevel Gear and Spiral Bevel Pinion Shaft 1. Set the dial indicator (lever type) with its finger on the tooth surface. 2. Measure the backlash by fixing the spiral bevel pinion shaft and moving the spiral bevel gear.
Page 300: Hst
TRANSMISSION RTV-X900, RTV-X1120D, WSM More than 35 % red lead contact area on the gear tooth surface. The center of tooth contact at 1/2 to 1/3 of the entire width from the small end. (A) Proper Contact 9Y1210946FAS0025US0 Change the adjusting collar to smaller size, and change the adjusting collar to larger size.
Page 301 TRANSMISSION RTV-X900, RTV-X1120D, WSM Swashplate and Cradle Bearing 1. Check the surface of swashplate (1) and cradle bearings (2) for scratches and excessive wear. 2. If worn or scored, replace them. (1) Swashplate (2) Cradle Bearing 9Y1210946TRS0045US0 Cylinder Block Bore and Pistons 1.
Page 302 TRANSMISSION RTV-X900, RTV-X1120D, WSM Check and High Pressure Relief Valve 1. Check the check plug (1), spring (2), (5), poppet (3) and check and high pressure relief valve (4) for scratches and damage. 2. Check the valve seat (7), spring (8) and valve holder (9) for scratches and damage.
Page 303 TRANSMISSION RTV-X900, RTV-X1120D, WSM Readjustment of Relief Valve (When the HST does not work due to its loose hexagon socket head screw) IMPORTANT • The KUBOTA does not recommend the readjustment of relief valve. And KUBOTA will recommend the exchange with genuine parts.
Page 304 TRANSMISSION RTV-X900, RTV-X1120D, WSM Cylinder Block Face and Valve Plate 1. Check the polished face (1) of cylinder block for scoring. 2. If scored, replace cylinder block assembly. 3. Check the spring (2) for breakage. 4. If broken, replace cylinder block assembly.
Page 305: Rear Axle
REAR AXLE KiSC issued 01, 2014 A...
Page 306 MECHANISM CONTENTS 1. STRUCTURE..........................3-M1 KiSC issued 01, 2014 A...
Page 307 REAR AXLE RTV-X900, RTV-X1120D, WSM 1. STRUCTURE (1) Shock Absorber (2) Upper Arm (3) Lower Arm (4) Stabilizer The suspension is double wishbone type. The suspension is made up of upper and lower arms (2), (3), a shock absorbers (1), and a stabilizer (4).
Page 308 SERVICING CONTENTS 1. TROUBLESHOOTING.........................3-S1 2. TIGHTENING TORQUES......................3-S2 3. CHECKING, DISASSEMBLING AND SERVICING ..............3-S3 [1] ADJSUTING ..........................3-S3 [2] PREPARATION ........................3-S4 (1) Rear Knuckle Case......................3-S4 (2) Rear Shock Absorber ......................3-S5 [3] DISASSEMBLING AND ASSEMBLING ................3-S6 (1) Rear Knuckle Case......................3-S6 [4] SERVICING ...........................3-S6 KiSC issued 01, 2014 A...
Page 309: Troubleshooting
REAR AXLE RTV-X900, RTV-X1120D, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Noise When Start CV joint bearing worn Replace 3-S4 Noise While Forward CV joint bearing worn Replace 3-S4 And Reverse Noise Bearings damaged or broken Replace 3-S6...
Page 310: Tightening Torques
REAR AXLE RTV-X900, RTV-X1120D, WSM 2. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m lbf·ft...
Page 311: Checking, Disassembling And Servicing
REAR AXLE RTV-X900, RTV-X1120D, WSM 3. CHECKING, DISASSEMBLING AND SERVICING [1] ADJSUTING Adjusting Rear Shock Absorber CAUTION To avoid personal injury: • Be sure to work on a firm, flat an level surface with the engine shut off and parking brake "ON".
Page 312: Preparation
REAR AXLE RTV-X900, RTV-X1120D, WSM [2] PREPARATION (1) Rear Knuckle Case Rear Wheel 1. Jack up the rear end after placing a wooden block under the bottom plate of the transmission frame. 2. Remove the rear wheels. (When reassembling) 90 to 110 N·m Rear aluminum wheel 9.2 to 11.2 kgf·m...
Page 313: Rear Shock Absorber
REAR AXLE RTV-X900, RTV-X1120D, WSM (2) Rear Shock Absorber Rear Wheel 1. Jack up the rear end after placing a wooden block under the bottom plate of the transmission frame. 2. Remove the rear wheels. (When reassembling) 90 to 110 N·m Rear aluminum wheel 9.2 to 11.2 kgf·m...
Page 314: Disassembling And Assembling
REAR AXLE RTV-X900, RTV-X1120D, WSM [3] DISASSEMBLING AND ASSEMBLING (1) Rear Knuckle Case Rear Knuckle Case 1. Tap out the rear axle (7). 2. Remove the oil seal (6). 3. Remove the internal snap ring (5) and spacer (4). 4. Remove the ball bearing (3).
Page 315 BRAKES KiSC issued 01, 2014 A...
Page 316 MECHANISM CONTENTS 1. GENERAL OUTLINE ........................4-M1 2. KNUCKLE (FRONT BRAKE)...................... 4-M2 3. REAR BRAKE..........................4-M3 4. MASTER CYLINDER........................4-M4 5. BRAKE OIL..........................4-M5 6. PARKING BRAKE ........................4-M6 KiSC issued 01, 2014 A...
Page 317: General Outline
BRAKES RTV-X900, RTV-X1120D, WSM 1. GENERAL OUTLINE (1) Brake Pipe (3) Parking Brake Lever (5) Parking Brake Cable (7) Brake Cylinder (2) Master Cylinder (4) Brake Hose (6) Equalizer (8) Brake Cam Lever Description of the brake system with an illustration with all its component parts in place.
Page 318: Knuckle (Front Brake)
BRAKES RTV-X900, RTV-X1120D, WSM 2. KNUCKLE (FRONT BRAKE) Basically, the brake body is similar to that of the mechanical wet disk brake. It is designed to brake when the brake disk (10) rotating together with the front axle (1) is pressed.
Page 319: Rear Brake
BRAKES RTV-X900, RTV-X1120D, WSM 3. REAR BRAKE (1) Brake Cylinder (4) Break Disk (7) Cam Plate (Actuator) (10) Bearing Holder (2) Brake Piston (5) Brake Cam Lever RH (8) Friction Plate (11) Equalizer (3) Brake Cam Lever LH (6) Steel Ball...
Page 320: Master Cylinder
BRAKES RTV-X900, RTV-X1120D, WSM 4. MASTER CYLINDER (1) Cup (2) Diaphragm (3) Filter (4) Reserve Tank (5) Master Cylinder Body (6) Needle (7) Pin (8) Primary Piston (9) Secondary Piston (10) Internal Circlip (11) Boot (12) Push Rod (13) Yoke...
Page 321: Brake Oil
BRAKES RTV-X900, RTV-X1120D, WSM 5. BRAKE OIL Non-mineral oil is used for the brake oil. The brake oil for the machine is a brand of vegetable oil, that is basically the same as the DOT3 (FMVSS No. 116 Brake Fluid Standard) used on automotives and motorcycles.
Page 322: Parking Brake
BRAKES RTV-X900, RTV-X1120D, WSM 6. PARKING BRAKE (1) Parking Brake Cable (3) Brake Cylinder (5) Brake Cam Lever RH To Parking Brake Lever (2) Mechanical Equalizer (4) Brake Cam Lever LH The parking brake is mechanical type which is connected to the brake cam levers (4), (5) by the parking brake cable (1).
Page 323 SERVICING CONTENTS 1. TROUBLESHOOTING.........................4-S1 2. SERVICING SPECIFICATIONS ....................4-S2 3. TIGHTENING TORQUES......................4-S3 4. CHECKING, DISASSEMBLING AND SERVICING ..............4-S4 [1] CHECKING AND ADJUSTING....................4-S4 [2] PREPARATION ........................4-S8 (1) Front Brake........................4-S8 (2) Master Cylinder ......................4-S12 [3] DISASSEMBLING AND ASSEMBLING ................4-S13 (1) Front Brake........................4-S13 (2) Master Cylinder ......................4-S15 (3) Rear Brake ........................4-S15 [4] SERVICING .........................4-S16 (1) Front Brake........................4-S16...
Page 324: Troubleshooting
BRAKES RTV-X900, RTV-X1120D, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Poor Braking Force Brake pedal play excessive Adjust 4-S4 Brake disk worn Replace 4-S16, 4-S17 Brake fluid insufficient or improper Fill or change with 4-S5 specified oil Brake fluid leakage from brake pipes, bleeder,...
Page 325: Servicing Specifications
BRAKES RTV-X900, RTV-X1120D, WSM 2. SERVICING SPECIFICATIONS TRAVELLING BRAKE Item Factory Specification Allowable Limit Brake Pedal Free Travel 8 to 18 mm – 0.3 to 0.7 in. Stroke Less than – 150 mm 5.91 in. Brake Disk Thickness (Front) 3.3 to 3.5 mm 3.0 mm...
Page 326: Tightening Torques
BRAKES RTV-X900, RTV-X1120D, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m lbf·ft...
Page 327: Checking, Disassembling And Servicing
BRAKES RTV-X900, RTV-X1120D, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Brake Pedal CAUTION • When checking, park the tractor on flat ground, and stop the engine. 1. Measure the free play by depressing the brake pedal (1).
Page 328 BRAKES RTV-X900, RTV-X1120D, WSM Brake Fluid Change CAUTION • Use only DOT-3 brake fluid from a sealed container. Conforms to motor vehicle safety standard No. 116. Using other type of ail ruins synthetic resin or rubber installed in brake system components, and may cause brake failure.
Page 329 BRAKES RTV-X900, RTV-X1120D, WSM Brake Line Air Bleeding CAUTION • Use only DOT-3 brake fluid from a sealed container. Conforms to motor vehicle safety standard No. 116. Using other type of ail ruins synthetic resin or rubber installed in brake system components, and may cause brake failure.
Page 330 BRAKES RTV-X900, RTV-X1120D, WSM Parking Brake Lever (Adjustment of the Parking Brake Cable) CAUTION • When checking, parking the machine on flat ground. • Work by two people when you measure pressure. 1. Adjust the length of the parking brake cable (1) outer section so that the cable does not pull the parking brake bracket (3).
Page 331: Preparation
BRAKES RTV-X900, RTV-X1120D, WSM [2] PREPARATION (1) Front Brake Draining Knuckle Case Oil 1. Park the vehicle on a firm, flat, and level surface, 2. Remove the wheel. 3. To drain the used oil, remove the drain the filling plugs at the LH knuckle case and drain the oil completely into the oil pan.
Page 332 BRAKES RTV-X900, RTV-X1120D, WSM Front Wheel and Front Axle Nut WARNING To avoid serious injury, death or vehicle damage: • Do not work under the vehicle unless it is secured by safe stands or suitable blocking. 1. Jack up at the plate under the front axle case only.
Page 333 BRAKES RTV-X900, RTV-X1120D, WSM Tie-rod End, Brake Hose and Breather Hose CAUTION • When the brake hose is removed, the brake fluid come out. Be careful not to stain other hoses or rubber boot with the brake fluid. Brake fluid stains should be washed and wiped off immediately.
Page 334 BRAKES RTV-X900, RTV-X1120D, WSM Knuckle Case NOTE • CV joint shall not exceed the allowable bend angle ±25 ° when being reassembled or disassembled. 1. Remove the lower arm (2) and upper arm (1) mounting screws and nuts. 2. Support the CV joint (4) by something like a clamp (5) to prevent the CV joint (4) falling before removing the knuckle case assembly (3).
Page 335: Master Cylinder
BRAKES RTV-X900, RTV-X1120D, WSM (2) Master Cylinder Master Cylinder Assembly CAUTION • Use only DOT-3 brake fluid from a sealed container. Conforms to motor vehicle safety standard No. 116. Using other type of ail ruins synthetic resin or rubber installed in brake system components, and may cause brake failure.
Page 336: Disassembling And Assembling
BRAKES RTV-X900, RTV-X1120D, WSM [3] DISASSEMBLING AND ASSEMBLING (1) Front Brake Front Axle 1. Remove the oil seal (1). 2. Remove the snap ring collar (2) and remove the external snap ring (3). 3. Tap out the front axle (5) with plastic hammer.
Page 337 BRAKES RTV-X900, RTV-X1120D, WSM Brake Piston CAUTION • The brake seal 1 (5), 2 (6) are used for brake fluid only. • The brake seal 3 (4), 4 (3) are used for transmission fluid only. • Degrees both the piston (7) and the knuckle case (1) before installing each brake seal.
Page 338: Master Cylinder
BRAKES RTV-X900, RTV-X1120D, WSM (2) Master Cylinder Master Cylinder Inner Parts 1. Remove the reservoir (3) from master cylinder body (1). 2. Pushing in the piston (4), remove the internal snap ring (2). 3. Remove the piston from master cylinder body.
Page 339: Servicing
BRAKES RTV-X900, RTV-X1120D, WSM [4] SERVICING (1) Front Brake Brake Disk and Friction Plate Wear 1. Measure the brake disk thickness and the friction plate thickness with an outside micrometer. 2. If the thickness is less than the allowable limit, replace it.
Page 340: Brake Piston
BRAKES RTV-X900, RTV-X1120D, WSM Height of Cam Plate and Ball 1. Measure the height of the cam plate with the boll installed. 2. If the measurement is less than the allowable limit, replace the cam plate and balls. 3. Inspect the ball holes of cam plate for uneven wear.
Page 341 FRONT AXLE KiSC issued 01, 2014 A...
Page 342 MECHANISM CONTENTS 1. STRUCTURE..........................5-M1 [1] FRONT AXLE ........................5-M1 [2] FRONT SUSPENSION......................5-M2 [3] LIMITED SLIP DIFFERENTIAL (LSD).................. 5-M3 (1) Structure ......................... 5-M3 (2) Operation........................5-M4 KiSC issued 01, 2014 A...
Page 343: Structure
FRONT AXLE RTV-X900, RTV-X1120D, WSM 1. STRUCTURE [1] FRONT AXLE (1) Transmission Output Shaft (4) Knuckle (7) Lower Arm (10) Bevel Gear Shaft (8T) (2) Propeller Shaft (5) Front Axle (8) Front Case (11) Bevel Gear (35T) (3) Strut (6) Constant Velocity (CV) Joint (9) Face Cam The front axle consists mainly of knuckles (right and left), front case and CV (constant velocity) joint.
Page 344: Front Suspension
FRONT AXLE RTV-X900, RTV-X1120D, WSM [2] FRONT SUSPENSION (1) Shock Absorber (2) Upper Arm (3) Lower Arm (4) Stabilizer The suspension is double wishbone type. The suspension is made up of upper and lower arms (2), (3), a shock absorber (1), and a stabilizer (4).
Page 345: Limited Slip Differential (Lsd)
FRONT AXLE RTV-X900, RTV-X1120D, WSM [3] LIMITED SLIP DIFFERENTIAL (LSD) (1) Structure The configuration of the differential gear is as shown in the figure. The differential gear is prepared with an LSD function. This is torque sensitive; therefore, even if the temperature of the LSD rises, the TBR (Torque Bias Ratio) is not reduced.
Page 346: Operation
FRONT AXLE RTV-X900, RTV-X1120D, WSM (2) Operation (1) Cam Follower A (2) Cam Follower B (3) Face Cam (Move) (4) Face Cam (Fix) The two face cams are described linearly and schematically. This shows the difference in cross sectional shape of the cam followers A (1), B (2).
Page 347 SERVICING CONTENTS 1. TROUBLESHOOTING.........................5-S1 2. SERVICING SPECIFICATIONS ....................5-S2 3. TIGHTENING TORQUES......................5-S3 4. CHECKING, DISASSEMBLING AND SERVICING ..............5-S4 [1] CHECKING AND ADJUSTING....................5-S4 [2] PREPARATION ........................5-S6 (1) Knuckle Case ........................5-S6 (2) Front Differential Case....................5-S10 (3) Front Shock Absorber....................5-S15 [3] DISASSEMBRING AND ASSEMBRING ................5-S16 (1) Knuckle Case ........................5-S16 (2) Front Differential Case....................5-S17 (3) Front Shock Absorber....................5-S20...
Page 348: Troubleshooting
FRONT AXLE RTV-X900, RTV-X1120D, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Front Wheels Wander Tire pressure uneven Adjust G-23 to Right or Left Improper toe-in adjustment (improper alignment) Adjust 5-S4 Tie-rod end loose Tighten 5-S4 Air sucked in power steering circuit Bleed –...
Page 349: Servicing Specifications
FRONT AXLE RTV-X900, RTV-X1120D, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Front Wheel Alignment Toe-in 5 to 15 mm – 0.2 to 0.59 in. Bevel Pinion Shaft Turning Torque 0.79 to 0.98 N·m – 0.080 to 0.10 kgf·m 0.058 to 0.72 lbf·ft...
Page 350: Tightening Torques
FRONT AXLE RTV-X900, RTV-X1120D, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m lbf·ft...
Page 351: Checking, Disassembling And Servicing
FRONT AXLE RTV-X900, RTV-X1120D, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Checking Toe-in 1. Park vehicle on a flat place. 2. Turn steering wheel so front wheels are in the straight ahead position. 3. Lock the park brake and stop the engine.
Page 352 FRONT AXLE RTV-X900, RTV-X1120D, WSM Adjusting Front Shock Absorber CAUTION To avoid personal injury: • Be sure to work on a firm, flat an level surface with the engine shut off and parking brake "ON". • Keep the position of the left right rear shock absorber equal.
Page 353: Preparation
FRONT AXLE RTV-X900, RTV-X1120D, WSM [2] PREPARATION (1) Knuckle Case Draining Knuckle Case Oil 1. Park the vehicle on a firm, flat, and level surface, 2. Remove the wheel. 3. To drain the used oil, remove the drain the filling plugs at the LH knuckle case and drain the oil completely into the oil pan.
Page 354 FRONT AXLE RTV-X900, RTV-X1120D, WSM Front Wheel and Front Axle Nut WARNING To avoid serious injury, death or vehicle damage: • Do not work under the vehicle unless it is secured by safe stands or suitable blocking. 1. Jack up at the plate under the front axle case only.
Page 355 FRONT AXLE RTV-X900, RTV-X1120D, WSM Tie-rod End, Brake Hose and Breather Hose CAUTION • When the brake hose is removed, the brake fluid come out. Be careful not to stain other hoses or rubber boot with the brake fluid. Brake fluid stains should be washed and wiped off immediately.
Page 356 FRONT AXLE RTV-X900, RTV-X1120D, WSM Knuckle Case NOTE • CV joint shall not exceed the allowable bend angle ±25 ° when being reassembled or disassembled. 1. Remove the lower arm (2) and upper arm (1) mounting screws and nuts. 2. Support the CV joint (4) by something like a clamp (5) to prevent the CV joint (4) falling before removing the knuckle case assembly (3).
Page 357: Front Differential Case
FRONT AXLE RTV-X900, RTV-X1120D, WSM (2) Front Differential Case Draining Front Axle Case Oil 1. Park the vehicle on a firm, flat and level surface. 2. Turn over the rubber sheet. 3. To drain the used oil, remove the drain and filling plugs at the front axle case and drain the oil completely into the oil pan.
Page 358 FRONT AXLE RTV-X900, RTV-X1120D, WSM Front Wheel and Front Axle Nut WARNING To avoid serious injury, death or vehicle damage: • Do not work under the vehicle unless it is secured by safe stands or suitable blocking. 1. Jack up at the plate under the front axle case only.
Page 359 FRONT AXLE RTV-X900, RTV-X1120D, WSM Tie-rod End, Brake Hose and Breather Hose CAUTION • When the brake hose is removed, the brake fluid come out. Be careful not to stain other hoses or rubber boot with the brake fluid. Brake fluid stains should be washed and wiped off immediately.
Page 360 FRONT AXLE RTV-X900, RTV-X1120D, WSM Knuckle Case NOTE • CV joint shall not exceed the allowable bend angle ±25 ° when being reassembled or disassembled. 1. Remove the lower arm (2) and upper arm (1) mounting screws and nuts. 2. Support the CV joint (4) by something like a clamp (5) to prevent the CV joint (4) falling before removing the knuckle case assembly (3).
Page 361 FRONT AXLE RTV-X900, RTV-X1120D, WSM Upper Arm, Steering Cylinder and Propeller Shaft 1. Remove the front shock absorber lower bolt and nut (3). 2. Remove the stabilizer nut (1). 3. Remove the upper arm (2). 4. Disconnect the propeller shaft (4).
Page 362: Front Shock Absorber
FRONT AXLE RTV-X900, RTV-X1120D, WSM (3) Front Shock Absorber Front Shock Absorber WARNING To avoid serious injury, death or vehicle damage: • Do not work under the vehicle unless it is secured by safe stands or suitable blocking. 1. Jack up at the palte under the front axle case only.
Page 363: Disassembring And Assembring
FRONT AXLE RTV-X900, RTV-X1120D, WSM [3] DISASSEMBRING AND ASSEMBRING (1) Knuckle Case Front Axle 1. Remove the oil seal (1). 2. Remove the snap ring collar (2) and remove the external snap ring (3). 3. Tap out the front axle (5) with plastic hammer.
Page 364: Front Differential Case
FRONT AXLE RTV-X900, RTV-X1120D, WSM (2) Front Differential Case Front Differential Assembly 1. Remove the front differential case cover mounting screws and separate the front differential case cover (1). 2. Remove the differential gear assembly (2). (When reassembling) • Use same number of shims as before disassembling.
Page 365 FRONT AXLE RTV-X900, RTV-X1120D, WSM Differential Gear (LSD) 1. Remove the differential case cap (1). 2. Remove the disc springs (2) and thrust washer (3). 3. Remove the cam face (6). 4. Remove the cam followers (4), (5). 5. Remove the cam face (8).
Page 366 FRONT AXLE RTV-X900, RTV-X1120D, WSM Bevel Pinion Gear Assembly 1. Remove the O-ring (1) and plug (2). 2. Remove the oil seal (3). 3. Remove the internal snap ring (4) and tap out the bevel pinion shaft (7) from front.
Page 367: Front Shock Absorber
FRONT AXLE RTV-X900, RTV-X1120D, WSM (3) Front Shock Absorber Shock Absorber and Spring 1. Set the spring compressor (1). 2. Shorten spring with a spring compressor (1). 3. Remove the retainer (3) and spacer (4). 4. Remove the spring (2).
Page 368: Servicing
FRONT AXLE RTV-X900, RTV-X1120D, WSM [4] SERVICING Checking Bearing 1. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness. 2. Apply transmission fluid to the bearing, and hold the inner race.
Page 369 FRONT AXLE RTV-X900, RTV-X1120D, WSM Tooth Contact between Bevel Pinion Shaft and Bevel Gear (When checking) • Use same number of shims as before disassembling. • Use same thickness of collar as before disassembling. 1. Apply red lead (or prussian blue) lightly on the teeth of spiral bevel pinion shaft.
Page 370 FRONT AXLE RTV-X900, RTV-X1120D, WSM More than 35 % red lead contact area on the gear tooth surface. The center of tooth contact at 1/2 to 1/3 of the entire width from the small end. (A) Proper Contact 9Y1210946FAS0025US0 Change the adjusting collar to smaller size, and change the adjusting collar to larger size.
Page 371 FRONT AXLE RTV-X900, RTV-X1120D, WSM Backlash between Bevel Pinion Shaft and Bevel Gear 1. Put the solder (0.5 mm (0.020 in.) thickness) on the position where the tooth proper contact of bevel pinon shaft. 2. Reassemble the differential assembly and front case cover, and rotate the bevel pinion shaft carefully.
Page 372 STEERING KiSC issued 01, 2014 A...
Page 373 MECHANISM CONTENTS 1. STRUCTURE..........................6-M1 [1] RTV-X900 ..........................6-M1 [2] RTV-X1120D ........................6-M2 2. HYDRAULIC CIRCUIT ....................... 6-M3 3. STEERING CONTROLLER......................6-M4 4. STEERING CYLINDER ......................6-M6 KiSC issued 01, 2014 A...
Page 374: Structure
STEERING RTV-X900, RTV-X1120D, WSM 1. STRUCTURE [1] RTV-X900 (1) Steering Wheel (4) Tie-rod (7) Return Hose (10) Hydraulic Pump (2) Power Steering Controller (5) Power Steering Cylinder (8) Hydraulic Control Valve (11) Suction Hose (3) Power Steering Cylinder Hose (6) Hydraulic Oil Tank (9) Delivery Hose The full hydrostatic type power steering is used on RTV-X900.
Page 375: Rtv-X1120D
(3) Power Steering Cylinder Hose (6) Hydraulic Oil Tank (9) Delivery Hose The full hydrostatic type power steering is used on RTV-X1120D. This steering system consists of steering wheel, steering controller, steering cylinder and other components shown in the figure. 9Y1210946STM0002US0...
Page 376: Hydraulic Circuit
STEERING RTV-X900, RTV-X1120D, WSM 2. HYDRAULIC CIRCUIT This model is provided with a full hydrostatic power steering. In the full hydrostatic power steering, the steering controller is connected to the steering cylinder (1) with only the hydraulic piping. Accordingly, it does not have mechanical transmitting parts such as steering gear, pitman arm, drag link, etc.
Page 377: Steering Controller
STEERING RTV-X900, RTV-X1120D, WSM 3. STEERING CONTROLLER The steering controller consists of a control valve (3) and a metering device (2).  Control Valve The control valve is a rotating spool type. When the steering wheel is not turned, the position of the spool (6) and sleeve (8) is kept neutral by the centering spring (7).
Page 378 STEERING RTV-X900, RTV-X1120D, WSM  Relief Valve The relief valve (1) is located in the steering controller. It controls the maximum pressure of the power steering system. Its setting pressure is as follows. 8.00 to 9.00 MPa (81.6 to 91.7 kgf/cm...
Page 379: Steering Cylinder
STEERING RTV-X900, RTV-X1120D, WSM 4. STEERING CYLINDER (1) Rod (4) Guide (7) Center Piston (10) Cylinder Tube (2) Wiper Ring (5) O-ring (8) Piston O-ring (11) Rod O-ring (3) Internal Snap Ring (6) Seal Ring (9) External Snap Ring The steering cylinder is single piston both rod double-acting type. This steering cylinder is installed parallel to the front axle and connected to tie-rods.
Page 380 SERVICING CONTENTS 1. TROUBLESHOOTING.........................6-S1 2. SERVICING SPECIFICATIONS ....................6-S2 3. TIGHTENING TORQUES......................6-S3 4. CHECKING AND DISASSEMBLING...................6-S4 [1] CHECKING AND ADJUSTING....................6-S4 [2] PREPARATION ........................6-S5 (1) Separating Power Steering Controller ................6-S5 (2) Separating Power Steering Cylinder ................6-S9 (3) Removing Power Steer Hoses ..................6-S10 [3] DISASSEMBLING AND ASSEMBLING ................6-S14 (1) Power Steering Cylinder....................6-S14 KiSC issued 01, 2014 A...
Page 381 STEERING RTV-X900, RTV-X1120D, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Cannot Be Steered Hose broken Replace 6-S14 Steering controller malfunctioning Replace 6-S5 Hard Steering Power steering oil improper Change with specified G-43 Hydraulic pump malfunctioning Replace 7-S6 Steering controller malfunctioning...
Page 382: Servicing Specifications
STEERING RTV-X900, RTV-X1120D, WSM 2. SERVICING SPECIFICATIONS POWER STEERING BODY Item Factory Specification Allowable Limit Relief Valve Operating 8.00 to 9.00 MPa – Pressure 81.6 to 91.7 kgf/cm 1160 to 1300 psi 9Y1210946STS0002US0 6-S2 KiSC issued 01, 2014 A...
Page 383 STEERING RTV-X900, RTV-X1120D, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m lbf·ft...
Page 384: Checking And Disassembling
STEERING RTV-X900, RTV-X1120D, WSM 4. CHECKING AND DISASSEMBLING [1] CHECKING AND ADJUSTING Relief Valve Operating Pressure CAUTION • When checking, park the machine on flat ground, apply the parking brake. • Set the range gear shift lever in NEUTRAL position.
Page 385: Preparation
STEERING RTV-X900, RTV-X1120D, WSM [2] PREPARATION (1) Separating Power Steering Controller Battery CAUTION • When disconnecting the battery cables, disconnect the negative cable from the battery first. When connecting, connect the positive cable to the battery first. 1. Remove the battery cover (1).
Page 386 STEERING RTV-X900, RTV-X1120D, WSM Steering Wheel 1. Remove the steering wheel cover (2). 2. Remove the steering wheel nut (3). 3. Remove the steering wheel (1). (When reassembling) 29 to 49 N·m Steering wheel mounting Tightening torque 3.0 to 4.9 kgf·m 22 to 36 lbf·ft...
Page 387 STEERING RTV-X900, RTV-X1120D, WSM Panel 1. Remove the grips for the range gear shift lever (3), tilt lever (2) and parking brake lever (1). 2. Remove the glove box cover (4). 3. Remove the glove box (5). 4. Disconnect the connector for light switch (7), key switch (8), accessory plug (9) and meter panel (10).
Page 388 STEERING RTV-X900, RTV-X1120D, WSM Steering Controller 1. Disconnect the power steering hoses from the power steering Controller (1). 2. Remove the power steering controller (1). (When reassembling) • Be sure to connect the power steering hoses to their original position, and tighten them to the specified torque.
Page 389: Separating Power Steering Cylinder
STEERING RTV-X900, RTV-X1120D, WSM (2) Separating Power Steering Cylinder Power Steering Cylinder 1. Place jack stands under both RH and LH side of the frame. 2. Remove the front wheels. 3. Remove the cotter pins and slotted nuts (2) for the tie-rod ends (1).
Page 390: Removing Power Steer Hoses
STEERING RTV-X900, RTV-X1120D, WSM (3) Removing Power Steer Hoses Battery CAUTION • When disconnecting the battery cables, disconnect the negative cable from the battery first. When connecting, connect the positive cable to the battery first. 1. Remove the battery cover (1).
Page 391 STEERING RTV-X900, RTV-X1120D, WSM Steering Wheel 1. Remove the steering wheel cover (2). 2. Remove the steering wheel nut (3). 3. Remove the steering wheel (1). (When reassembling) 29 to 49 N·m Steering wheel mounting Tightening torque 3.0 to 4.9 kgf·m 22 to 36 lbf·ft...
Page 392 STEERING RTV-X900, RTV-X1120D, WSM Panel 1. Remove the grips for the range gear shift lever (3), tilt lever (2) and parking brake lever (1). 2. Remove the glove box cover (4). 3. Remove the glove box (5). 4. Disconnect the connector for light switch (7), key switch (8), accessory plug (9) and meter panel (10).
Page 393 STEERING RTV-X900, RTV-X1120D, WSM Steering Controller 1. Disconnect the power steering hoses from the power steering Controller (1). 2. Remove the power steering controller (1). (When reassembling) • Be sure to connect the power steering hoses to their original position, and tighten them to the specified torque.
Page 394: Disassembling And Assembling
STEERING RTV-X900, RTV-X1120D, WSM Power Steering Hose 1. Remove the power steering cylinder hose LH (1) and power steering cylinder hose RH (1). 2. Remove the return hose (3) and delivery hose (4). (When reassembling) 22.0 to 25.0 N·m Power steering hose Tightening torque 2.25 to 2.54 kgf·m...
Page 395 STEERING RTV-X900, RTV-X1120D, WSM Power Steering Cylinder 1. Carefully clamp the cylinder in a vise. 2. Push one of the guide assembly (3) to inside of cylinder tube (2). 3. Drill a hole (2.5 mm dia., 0.1 in. dia.) on the cylinder tube (2) just over the snap ring (4) as shown figure left.
Page 396: Hydraulic System
HYDRAULIC SYSTEM KiSC issued 01, 2014 A...
Page 397 MECHANISM CONTENTS 1. STRUCTURE..........................7-M1 [1] RTV-X900 ..........................7-M1 [2] RTV-X1120D ........................7-M2 2. HYDRAULIC CIRCUIT ....................... 7-M3 [1] RTV-X900 ..........................7-M3 [2] RTV-X1120D ........................7-M4 3. HYDRAULIC PUMP........................7-M5 4. HYDRAULIC LIFT CYLINDER ....................7-M6 5. CONTROL VALVE........................7-M7 [1] DOUBLE ACTING TYPE 1 ....................
Page 398: Structure
HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM 1. STRUCTURE [1] RTV-X900 (1) Control Valve (4) Return Hose (7) Power Steering Cylinder (10) Hydraulic Hose (2) Delivery Hose (5) Oil Cooler (8) Oil Tank (11) Hydraulic Lift Cylinder (3) Hydraulic Pump (6) Power Steering Unit...
Page 399: Rtv-X1120D
(6) Power Steering Unit (9) Suction Hose The hydraulic system of RTV-X1120D consists of the hydraulic pump (3), control valve (1), hydraulic cylinder (11), power steering controller (6), power steering cylinder (7), oil tank (8) and other components as shown in the figure.
Page 400 HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM 2. HYDRAULIC CIRCUIT [1] RTV-X900 (1) Check and High Pressure (4) Hydraulic Lift Cylinder (8) Hydraulic Pump (11) Power Steering Cylinder Relief Valve (5) Control Valve Relief Valve (9) Power Steering Unit Relief (12) Charge Relief Vale...
Page 401: Rtv-X1120D
HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM [2] RTV-X1120D (1) Check and High Pressure (4) Hydraulic Lift Cylinder (8) Hydraulic Pump (11) Power Steering Cylinder Relief Valve (5) Control Valve Relief Valve (9) Power Steering Unit Relief (12) Charge Relief Vale (2) HST Assembly...
Page 402 HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM 3. HYDRAULIC PUMP The hydraulic pump (1) consists of the casing (4), cover (5), and two spur gears (drive gear (3) and driven gear (5)) that are in mesh. Hydraulic pump (1) is driven by the input shaft in the transmission case.
Page 403: Hydraulic Lift Cylinder
HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM 4. HYDRAULIC LIFT CYLINDER The external type hydraulic lift cylinder is used for cargo bed lifting system. This hydraulic lift cylinder is single double type, and it is installed directly between main frame arm cargo bed.
Page 404: Control Valve
HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM 5. CONTROL VALVE [1] DOUBLE ACTING TYPE 1 (1) Floating with Detent Valve [A] Neutral (1) Spool (2) Check Valve A Port (Lift Cylinder) B Port (Lift Cylinder) From Hydraulic Pump To Oil Tank Pressure-fed oil from the hydraulic pump is delivered into the P port, and flows to the oil tank through T port.
Page 405 HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM [C] Down (1) Spool (2) Check Valve A Port (Lift Cylinder) B Port (Lift Cylinder) From Hydraulic Pump To Oil Tank When the spool (1) is moved in the direction of the arrow, the pressure-fed oil in the P port opens the check valve (2) and flows to the implement cylinder via A port.
Page 406 SERVICING CONTENTS 1. TROUBLESHOOTING.........................7-S1 2. SERVICING SPECIFICATIONS ....................7-S2 3. TIGHTENING TORQUES......................7-S3 4. CHECKING AND DISASSEMBLING...................7-S4 [1] CHECKING AND ADJUSTING....................7-S4 (1) Hydraulic Control Valve, Pump and Cylinder ..............7-S4 [2] PREPARATION ........................7-S6 (1) Removing Hydraulic Pump ....................7-S6 (2) Removing Hydraulic Cylinder LIft Cylinder ..............7-S7 [3] DISASSEMBLING AND ASSEMBLING ................7-S8 (1) Hydraulic Pump .......................7-S8 (2) Hydraulic Lift Cylinder......................7-S9...
Page 407 HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Implement Does Not Control valve broken Replace 2-S40 Rise (No Noise) Control valve improperly assembled Repair 2-S40 Relief valve spring damaged Replace 7-S10 Spool sticks Repair 7-S10...
Page 408: Servicing Specifications
HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Relief Valve Setting Pressure 12.5 to 13.5 MPa – 128 to 137 kgf/cm 1820 to 1950 psi 9Y1210946HYS0002US0 7-S2 KiSC issued 01, 2014 A...
Page 409 HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m lbf·ft...
Page 410: Checking And Disassembling
HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM 4. CHECKING AND DISASSEMBLING [1] CHECKING AND ADJUSTING (1) Hydraulic Control Valve, Pump and Cylinder Cargo Bed 1. Lift up the cargo bed (1) and support it so that the hydraulic cylinder (4) should not drop. (If hydraulic cylinder equipped.) 2.
Page 411 HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM Checking Hydraulic Lift Cable 1. Set the hydraulic lift cylinder lever (1) to neutral position. 2. Set the restricting plate (2). 3. Check that the cable is fixed to the stay, with the cable outer section screw being set near the center "A".
Page 412: Preparation
HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM [2] PREPARATION (1) Removing Hydraulic Pump Cargo Bed 1. Lift up the cargo bed (1) and support it so that the hydraulic cylinder (4) should not drop. (If hydraulic cylinder equipped.) 2. Remove the cotter pin (2) clevis pin (3) and cylinder lock (5). (If hydraulic cylinder equipped.)
Page 413: Removing Hydraulic Cylinder Lift Cylinder
HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM (2) Removing Hydraulic Cylinder LIft Cylinder Cargo Bed 1. Lift up the cargo bed (1) and support it so that the hydraulic cylinder (4) should not drop. (If hydraulic cylinder equipped.) 2. Remove the cotter pin (2) clevis pin (3) and cylinder lock (5). (If hydraulic cylinder equipped.)
Page 414: Disassembling And Assembling
HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM [3] DISASSEMBLING AND ASSEMBLING (1) Hydraulic Pump Hydraulic Pump 1. Secure the hydraulic pump with a vise, and remove the hydraulic pump cover (4). 2. Remove the side plate (3). 3. Remove the drive gear (2) and driven gear (5) from the casing (1).
Page 415: Hydraulic Lift Cylinder
HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM (2) Hydraulic Lift Cylinder Piston Rod Assembly 1. Drain hydraulic oil from the hydraulic lift cylinder, and set the tube end of the hydraulic lift cylinder in a vise. 2. Remove the cylinder head (1) with the adjustable gland nut wrench (4).
Page 416: Control Valve
HYDRAULIC SYSTEM RTV-X900, RTV-X1120D, WSM (3) Control Valve Relief Valve and Control Valve 1. Remove the relief valve plug (8), shims (6), spring (5), poppet (4) and seat (3). 2. Remove the control valve (1). (When reassembling) • Be careful not to damage the O-ring.
Page 417: Electrical System
ELECTRICAL SYSTEM KiSC issued 01, 2014 A...
Page 418 [1] RTV-X900 ........................... 8-M13 [2] RTV-X1120D ........................8-M14 6. COOLING SYSTEM ......................... 8-M15 [1] COOLING SYSTEM FOR RTV-X900 ................. 8-M15 [2] COOLING SYSTEM FOR RTV-X1120D ................8-M16 [3] FAN MOTOR ........................8-M16 [4] RADIATOR FAN MOTOR SWITCH ................... 8-M17 (1) RTV-X900........................8-M17 (2) RTV-X1120D ........................
Page 419: Wiring Diagram
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM 1. WIRING DIAGRAM [1] RTV-X900 8-M1 KiSC issued 01, 2014 A...
Page 420: Rtv-X1120D
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [2] RTV-X1120D 8-M2 KiSC issued 01, 2014 A...
Page 421: Electrical Circuit
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM 2. ELECTRICAL CIRCUIT 8-M3 KiSC issued 01, 2014 A...
Page 422: Starting System
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM 3. STARTING SYSTEM [1] RTV-X900 (1) Key Switch (5) Fuse (15A) (9) Starter Relay (13) Fuse (5A) (2) Slow Blow Fuse (60A) (6) Key Stop Solenoid (10) Safety Switch (Neutral Switch) (14) Fuse (5A) (3) Slow Blow Fuse (60A)
Page 423: Rtv-X1120D
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [2] RTV-X1120D (1) Key Switch (5) Fuse (30A) (9) Starter Relay (13) Fuse (5A) (2) Slow Blow Fuse (60A) (6) Solenoid Relay (10) Safety Switch (Neutral Switch) (14) Fuse (5A) (3) Slow Blow Fuse (60A)
Page 424: Starter
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [3] STARTER (1) Structure The starter is a reduction type starter with heat-resistant and vibration-resistant features that has a small, high-speed motor, and the revolutions of the armature drive the pinion gear approximately one-third the speed to increase torque.
Page 425: Overrunning Clutch
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM When Engine Has Started When the engine starts and drives the pinion gear (1) with the ring gear (3), the overrunning clutch (4) disengages to prevent the armature (2) from being driven by the engine.
Page 426: Magnetic Switch
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (4) Magnetic Switch The plunger (4), contact plate (3) and plunger shaft (6) are mode as one unit. When the key switch is turned to START position, the plunger is drawn in and thus clutch pinion shaft is forced out.
Page 427: Safety Switch (Neutral Switch)
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [5] SAFETY SWITCH (NEUTRAL SWITCH) The safety switch (1) prevents current from flowing to the starter when the point of contact is released. This is to ensure safe starting. The location of the safety switch is located at the range gear shift lever of the transaxle case.
Page 428: Engine Stop Solenoid
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [6] ENGINE STOP SOLENOID (1) RTV-X900 The timer relay is provided to actuate the engine stop solenoid approx. 10 seconds to stop after the key switch is turned from ON position to OFF position. Flowing of the battery current into the coil while the timer relay contact point is closed attracts the plunger to actuate the stop lever of the injection pump.
Page 429: Charging System
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM 4. CHARGING SYSTEM (1) Alternator (3) Slow Blow Fuse (60A) (5) Fuse (7) Battery (2) Slow Blow Fuse (60A) (4) Key Switch (6) Battery Charge Lamp To Panel The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs.
Page 430: Ic Regulator
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [2] IC REGULATOR (1) Alternator (2) Rectifier (3) Stator Coil (4) Rotor Coil (5) IC Regulator (6) Charge Lamp (7) Key Switch (8) Battery (9) Load An IC regulator uses solid state transistors, chips or other semiconductor elements instead of the relays in a conventional regulator.
Page 431: Lighting System
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM 5. LIGHTING SYSTEM [1] RTV-X900 (1) Key Switch (8) Brake Lamp Switch (15) Combination Lamp (RH) (19) Engine Water Temperature (2) Glow Plug (9) Work Light Relay (Option) (Option) Sensor (3) Slow Blow Fuse (60A)
Page 432: Rtv-X1120D
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [2] RTV-X1120D (1) Key Switch (8) Brake Lamp Switch (15) Combination Lamp (RH) (19) Engine Water Temperature (2) Glow Plug (9) Work Light Relay (Option) (Option) Sensor (3) Slow Blow Fuse (60A) (10) Beacon or Fog Lamp Relay...
Page 433: Cooling System
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM 6. COOLING SYSTEM [1] COOLING SYSTEM FOR RTV-X900 (1) Battery (4) Fuse (6) Fuse (5A) (8) Radiator Fan Motor Switch (2) Slow Blow Fuse (60A) (5) Key Switch (7) Radiator Fan Motor Relay (9) Radiator Fan Motor (3) Slow Blow Fuse (60A) The cooling system consists of radiator fan motor switch, relay, fan motor, etc.
Page 434: Cooling System For Rtv-X1120D
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [2] COOLING SYSTEM FOR RTV-X1120D (1) Battery (4) Fuse (6) Fuse (5A) (8) Radiator Fan Motor Switch (2) Slow Blow Fuse (60A) (5) Key Switch (7) Radiator Fan Motor Relay (9) Radiator Fan Motor (3) Slow Blow Fuse (60A) The cooling system consists of radiator fan motor switch, relay, fan motor, etc.
Page 435: Radiator Fan Motor Switch
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [4] RADIATOR FAN MOTOR SWITCH (1) RTV-X900 The radiator fan motor switch is installed to the water flange of engine, and its tip is in touch with the coolant. The fan motor rotates when the radiator fan motor goes up more than the specified value.
Page 436: Gauges
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM 7. GAUGES (1) Battery (4) Key Switch (6) Fuel Sensor (8) Fuse (5A) (2) Slow Blow Fuse (60A) (5) Meter Panel (CPU) (7) Engine Water Temperature (9) Speed Sensor (3) Slow Blow Fuse (60A) Sensor The fuel quantity and engine water temperature sensor are indicated by the ammeters.
Page 437: Fuel Quantity
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [1] FUEL QUANTITY Fuel The remaining fuel quantity is detected by the fuel level sensor installed in the fuel tank and indicated on the fuel gauge. For detection, a float and a resistor are used.
Page 438: Traveling Speed Sensor
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [3] TRAVELING SPEED SENSOR Measure the traveling speed with the rotation sensor at the left side of the transmission case. The sensor unit is a MRE (magnetic resistance element) type. For the MRE type, when the pulsar passes the sensor, the magnetic resistance changes and the voltage passing through the sensor changes.
Page 439: Meter Panel
The parking brake indicator in the Easy Checker™ comes on if the parking brake is applied.  Seat Belt WARNING Indicator [RTV-X1120D only] With the key switch ON, when the operator or passenger does not fasten the seat belt, seat belt warning lamp comes on.
Page 440 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Oil Pressure Switch While oil pressure is high and the force applied to the diaphragm (3) is larger than the spring tension, the terminal contact (2) is open separated from the body contact (4). If the pressure drops below approx. 49 kPa (0.5 kgf/cm...
Page 441: Error Code Display
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [2] ERROR CODE DISPLAY If trouble should occur at the meter panel, the indicator flashes and error code appears as a warning. If the trouble is not corrected by restarting the machine, solve the problem according to the following table.
Page 442 SERVICING CONTENTS 1. TROUBLESHOOTING.........................8-S1 2. SERVICING SPECIFICATIONS ....................8-S5 3. TIGHTENING TORQUES......................8-S6 4. CHECKING, DISASSEMBLING AND SERVICING ..............8-S7 [1] CHECKING AND ADJUSTING....................8-S7 (1) Battery ..........................8-S7 (2) Key Switch........................8-S9 (3) Starter..........................8-S11 (4) Glow Plug ........................8-S12 (5) Safety Switch.........................8-S12 (6) Engine Stop Solenoid ....................8-S13 (7) Timer Relay for Stop Solenoid (RTV-X900) ..............8-S14 (8) Charging System ......................8-S15 (9) Lighting System ......................8-S17...
Page 443 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page All Electrical Battery discharged or damaged Recharge or replace G-34, 8-S8 Equipments Does Not Battery positive cable disconnected or improperly Repair or replace 8-S7 Operate connected Battery negative cable disconnected or...
Page 444 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM STARTING SYSTEM Reference Symptom Probable Cause Solution Page Starter Motor Does Battery discharged or damaged Recharge or replace 8-S8 Not Work Slow blow fuse blown Replace G-56 Safety switch improperly adjusted or damaged Repair or replace...
Page 445 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM LIGHTING SYSTEM Reference Symptom Probable Cause Solution Page Head Light Does Not Fuse blown (15A) Replace G-54 Light Light switch damaged Replace 8-S17 Bulb blown Replace G-56 Wiring harness disconnected or improperly Repair or replace –...
Page 446 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM GAUGES Reference Symptom Probable Cause Solution Page Fuel Gauge Does Not Fuel gauge damaged Replace the panel – Function Fuel level sensor damaged Replace 8-S25 Wiring harness disconnected or improperly Repair or replace – connected...
Page 447: Servicing Specifications
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Battery Voltage More then – 12 V Potential Less than – Difference 0.1 V Charging Current 10 to 15A – Charging Voltage 140 to 15A – Dynamo speed...
Page 448 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM 3. TIGHTENING TORQUES Tightening torques of screws, bolts and nuts on the table below are especially specified. (For general use screws, bolts and nuts: Refer to "5. TIGHTENING TORQUES" on page G-12.) Item N·m kgf·m lbf·ft...
Page 449: Checking, Disassembling And Servicing
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING CAUTION • To avoid accidental short circuit, be sure to attach the positive cable to the positive terminal before the negative cable is attached to the negative terminal.
Page 450 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Battery Condition and Charging NOTE • Follow the manufacture's instructions when you change battery or do maintenance. IMPORTANT • Mishandling the battery shortens the service life and adds to maintenance costs. The original battery is maintenance free, but needs some servicing.
Page 451: Key Switch
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (2) Key Switch Key Switch 1. Disconnect the connector (1) and remove the key switch (2). 2. Perform the following checks. (1) Connector (2) Key Switch 9Y1210946ELS0008US0 Connector Voltage 1. Measure the voltage with a voltmeter across the connector B (red) terminal and chassis.
Page 452 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Terminal Continuity 1. Remove the key switch from the instrument panel. 2. Measure the resistance with an ohmmeter across terminals when the key switch is set at "OFF", "ON", "GLOW" and "START" position. 3. If the resistance values specified below are not indicated, the key switch is faulty.
Page 453: Starter
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (3) Starter Motor Test CAUTION • Secure the starter to prevent it from jumping up and down while testing the motor. 1. Disconnect the battery negative cable from the battery. 2. Disconnect the battery positive cable from the battery.
Page 454: Glow Plug
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (4) Glow Plug Lead Terminal Voltage 1. Disconnect the wiring lead (1) from the glow plug (2) after turning the key switch off. 2. Turn the key switch key to the "PREHEAT" position, and measure the voltage between the lead terminal and the chassis.
Page 455: Engine Stop Solenoid
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (6) Engine Stop Solenoid [A] RTV-X900 Engine Stop Solenoid Test 1. Disconnect the 1P connector (2) from the engine stop solenoid. 2. Remove the engine stop solenoid from the engine. 3. Connect the jumper leads from the battery positive terminal to the 1P connector, and from the battery negative terminal to the engine stop solenoid body.
Page 456: Timer Relay For Stop Solenoid (Rtv-X900)
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (7) Timer Relay for Stop Solenoid (RTV-X900) Timer Relay Connector Voltage 1. Disconnect the connector from the timer relay after turning the key switch off. 2. Measure the voltage with a voltmeter across the connector terminal 4 and chassis.
Page 457: Charging System
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (8) Charging System Battery Charging Current 1. After starting the engine, disconnect the battery positive cord (+), and connect an ammeter and voltmeter. Then switch on all electrical loads (such as head lights) and measure the charging current.
Page 458 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Connector Voltage 1. Turn the key switch OFF. Measure the voltage between the B terminal (1) and the chassis. 2. Turn the key switch ON. Measure the voltage between the IG terminal (3) and the chassis.
Page 459: Lighting System
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (9) Lighting System Light Switch 1. Disconnect the connector (1) and remove the light switch (2). 2. Remove the light switch (2) and perform the following checks 1). (1) Connector (2) Light Switch 9Y1210946ELS0025US0 1) Connector Voltage 1.
Page 460 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM 3) Head Light Switch Continuity when Setting Switch at "ON" Position 1. Set the light switch to the ON position. 2. Measure the resistance with an ohmmeter across the red / yellow lead (1) to the orange lead (3) and the red / yellow lead (1) to the yellow lead (2).
Page 461 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Engine Oil Pressure Switch Continuity 1. Measure the resistance with an ohmmeter across the switch terminal and the chassis. 2. If 0 ohm is not indicated in the normal state, the switch is faulty. 3. If infinity is not indicated at pressure over 49 kPa (0.50 kgf/cm 7.1 psi), the switch is faulty.
Page 462 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Seat Switch Continuity (RTV-X1120D Only) 1. Disconnect the 2P connectors (2) from seat switch (1). 2. Connect the circuit tester to the terminals. When switch is pushed Continuity Resistance When switch is released Infinity (1) Seat Switch...
Page 463 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Brake Lamp Switch Continuity 1. Remove the brake lamp switch leads. 2. Connect the circuit tester to the brake lamp switch leads. 3. Measure the resistance between leads. 4. If the safety switch is problem, replace it.
Page 464: Cooling System
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (10) Cooling System [A] RTV-X900 Radiator Fan Motor Wiring Harness 1. Disconnect the wiring lead from the coolant temperature switch after turning the key switch OFF. 2. Turn the key switch ON and connect a jumper lead from the lead to the chassis.
Page 465 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Radiator Fan Motor 1. Disconnect the 2P connector (1) of fan motor after turning the key switch OFF. 2. Connect a jumper lead from the 1 terminal (3) to the battery positive terminal post. 3. Connect a jumper lead momentarily between the 2 terminal (4) and the battery negative terminal post.
Page 466 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Radiator Fan Motor Switch 1. Measure the resistance with an ohmmeter across the switch terminals. 2. If infinity is not indicated when the coolant temperature is lower than 83 °C (181 °F), the switch is faulty.
Page 467: Gauges
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Radiator Fan Motor 1. Disconnect the 2P connector (1) of fan motor after turning the key switch OFF. 2. Connect a jumper lead from the 1 terminal (3) to the battery positive terminal post. 3. Connect a jumper lead momentarily between the 2 terminal (4) and the battery negative terminal post.
Page 468 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Engine Water Temperature Sensor 1) Lead Terminal Voltage 1. Disconnect the lead from the engine water temperature sensor after turning the key switch OFF. 2. Turn the key switch ON and measure the voltage with a voltmeter across the lead terminal and the chassis.
Page 469 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Traveling Speed Sensor Connector Voltage NOTE • Since it is not possible to do unit checking for this sensor, judge the sensor is faulty if the relating electric circuit is normal. 1. Disconnect the connector, and turn the main key switch "ON"...
Page 470: Relays
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (12) Relays [A] RTV-X900 Relay 1. Turn the key switch OFF. 2. Raise the seat. 3. Remove the relay which should be checked. 4. Connect the jumper load across the battery positive terminal to relay terminal 1 "a", and the battery negative terminal to relay terminal 2 "b".
Page 471: Others
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (13) Others Horn Switch Continuity 1. Disconnect the wiring leads from horn switch and remove it. 2. Measure the resistance with an ohmmeter across the horn switch terminals in each position. 3. If the resistance differs from the factory specifications, the horn switch is faulty.
Page 472: Disassembling And Assembling
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [2] DISASSEMBLING AND ASSEMBLING (1) Starter Motor 1. Remove the B terminal nut (1), and disconnect the connecting lead (2) from the magnet switch. 2. Remove the motor through screws (3), and then remove the yoke (4).
Page 473 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Magnet Switch 1. Remove the drive end frame mounting screws (1). 2. Remove the overrunning clutch (2), steel ball (3), spring (4), idle gear (7), rollers (5) and retainer (6). (When reassembling) • Apply grease the gear teeth of the idle gear (7) and the overrunning clutch (2), and the steel ball (3).
Page 474: Alternator
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (2) Alternator Pulley 1. Secure the hexagonal end of the pulley shaft with a double-ended ratchet wrench as shown in the figure. 2. Loosen the pulley nut with a socket wrench and remove it. (When reassembling) 58.4 to 78.9 N·m...
Page 475 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Rear End Frame 1. Remove the two nuts and two screws holding the drive end frame and the rear end frame. 2. Remove the rear end frame (1). (1) Rear End Frame WSM000001ELS0028US0 Rotor 1. Press out the rotor (1) from drive end frame (3).
Page 476: Servicing
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM [3] SERVICING (1) Starter Overrunning Clutch 1. Inspect the pinion for wear or damage. 2. If there is any problem, replace the overrunning clutch assembly. 3. Check that the pinion turns freely and smoothly in the overrunning direction and does not slip in the cranking direction.
Page 477 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Brush Holder 1. Check the continuity across the brush holder and the holder support with an ohmmeter. 2. If it conducts, replace the brush holder. Brush holder – Resistance Infinity Holder support 9Y1210946ELS0053US0 Armature Coil 1.
Page 478: Alternator
ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM (2) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. WSM000001ELS0039US0 Stator 1. Measure the resistance across each lead of the stator coil with an ohmmeter.
Page 479 ELECTRICAL SYSTEM RTV-X900, RTV-X1120D, WSM Rectifier 1. Check the continuity across each diode of rectifier with an analog ohmmeter. Conduct the test in the (R x 1) setting. 2. The rectifier is normal if the diode in the rectifier conducts in one direction and does not conduct in the reverse direction.
Page 480 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ks_g.ksos-pub@kubota.com Printed in Japan 2014. 01, S, EI, EI, engusa Code No.9Y111-09461 2013.

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Rtv-x900

wsm RTV-X1120D Workshop Manual

Information

General

1 Product Identification

2 General Precautions

3 Handling Precautions for Electrical Parts and Wiring

4 Lubricants, Fuel and Coolant

5 Tightening Torques

6 Maintenance Check List

7 Check and Maintenance

9 Tires

Mechanism

1 Engine Body

2 Lubricating System

3 Cooling System

4 Fuel System

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Tightning Torques

4 Checking, Disassembling and Servicing

Mechanism

1 Structure

2 Power Train

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Tightening Torques

4 Checking and Adjusting

5 Preparation

6 Disassembling and Assembling

7 Servicing

Servicing

1 Troubleshooting

2 Tightening Torques

3 Checking, Disassembling and Servicing

Mechanism

Servicing

Mechanism

Servicing

Mechanism

1 Structure

2 Hydraulic Circuit

3 Steering Controller

4 Steering Cylinder

Servicing

2 Servicing Specifications

4 Checking and Disassembling

Mechanism

1 Structure

4 Hydraulic Lift Cylinder

5 Control Valve

Servicing

2 Servicing Specifications

4 Checking and Disassembling

Mechanism

1 Wiring Diagram

2 Electrical Circuit

3 Starting System

4 Charging System

5 Lighting System

6 Cooling System

7 Gauges

8 Meter Panel

Servicing

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for wsm RTV-X1120D