wsm RTV-X1120D Instruction manual

RTV-X900,RTV-X1120D
WORKSHOP MANUAL
UTILITY VEHICLE
KiSC issued 01, 2014 A

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
• Safety Decal
• Specifications
• Dimensions
General
This section primarily contains information below.
• Engine Identification
• Model Identification
• General Precautions
• Maintenance Check List
• Check and Maintenance
• Special Tools
Mechanism
This section contains information on the structure and the function of the unit. Before you continue
with the subsequent sections, make sure that you read this section.
Refer to the latest version of Workshop Manual (Code No. 9Y021-01870) for the diesel engine that
this workshop manual does not include.
Servicing
This section primarily contains information below.
• Troubleshooting
• Servicing Specifications
• Tightening Torques
• Checking, Disassembling and Servicing
All illustrations, photographs and specifications contained in this manual are of the newest
information available at the time of publication.
KUBOTA reserves the right to change all information at any time without notice.
Since this manual includes many models, information or illustrations and photographs can show
more than one model.
October, 2013
© KUBOTA Corporation 2013
KiSC issued 01, 2014 A

Record of Revisions
For pdf, use search function {Search word} to find all the revised locations.
Last digit
of the
Code No.
Issue
month Main Revised Point and Corrective Measures {Search word} Reference
Page
12014.01 Correction of charge pressure. 2-M7,
2-M12,
2-S4,
2-S6,
7-M4
Add the disassembling HST. 2-S44
Change the engine cable length. 2-S13
Correction of hydraulic pump displacement. 7-M5
Correction of the part name. 8-S28
KiSC issued 01, 2014 A

I INFORMATION
KiSC issued 01, 2014 A

CONTENTS
1. SAFETY FIRST .............................................................................................................................. I-1
2. SAFETY DECALS .......................................................................................................................... I-4
3. SPECIFICATIONS........................................................................................................................ I-10
4. TRAVELLING SPEEDS................................................................................................................ I-11
5. DIMENSIONS ............................................................................................................................... I-12
INFORMATION
KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-1
1. SAFETY FIRST
WSM000001INI0001US1
BEFORE YOU START SERVICE
• Read all instructions and safety instructions in this
manual and on your machine safety decals.
• Clean the work area and machine.
• Park the machine on a stable and level ground, and
set the parking brake.
• Lower the implement to the ground.
• Stop the engine, then remove the key.
• Disconnect the battery negative cable.
• Hang a "DO NOT OPERATE" tag in the operator
station.
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START SAFELY
• Do not do the procedures below when you start the
engine.
– short across starter terminals
– bypass the safety start switch
• Do not alter or remove any part of machine safety
system.
• Before you start the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
• Do not start the engine when you stay on the ground.
Start the engine only from operator's seat.
WSM000001INI0015US0
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.
• It is essential that you read the instructions and safety regulations before you try to repair or use this
unit.
DANGER
• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
• Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
IMPORTANT
• Indicates that equipment or property damage could result if instructions are not followed.
NOTE
• Gives helpful information.
KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-2
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.
• When 2 or more persons do servicing, make sure
that you do it safely.
• Do not operate below the machine that only a jack
holds. Always use a safety stand to hold the
machine.
• Do not touch the hot parts or parts that turn when the
engine operates.
• Do not remove the radiator cap when the engine
operates, or immediately after it stops. If not, hot
water can spout out from the radiator. Only remove
the radiator cap when it is at a sufficiently low
temperature to touch with bare hands. Slowly loosen
the cap to release the pressure before you remove it
fully.
• Released fluid (fuel or hydraulic oil) under pressure
can cause damage to the skin and cause serious
injury. Release the pressure before you disconnect
hydraulic or fuel lines. Tighten all connections before
you apply the pressure.
• Do not open a fuel system under high pressure.
The fluid under high pressure that stays in fuel lines
can cause serious injury. Do not disconnect or repair
the fuel lines, sensors, or any other components
between the fuel pump and injectors on engines with
a common rail fuel system under high pressure.
• Put on an applicable ear protective device (earmuffs
or earplugs) to prevent injury against loud noises.
• Be careful about electric shock. The engine
generates a high voltage of more than DC100 V in
the ECU and is applied to the injector.
WSM000001INI0012US0
PREVENT A FIRE
• Fuel is very flammable and explosive under some
conditions. Do not smoke or let flames or sparks in
your work area.
• To prevent sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
• The battery gas can cause an explosion. Keep the
sparks and open flame away from the top of battery,
especially when you charge the battery.
• Make sure that you do not spill fuel on the engine.
WSM000001INI0005US0
KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-3
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.
WSM000001INI0006US0
DISCARD FLUIDS CORRECTLY
• Do not discard fluids on the ground, down the drain,
into a stream, pond, or lake. Obey related
environmental protection regulations when you
discard oil, fuel, coolant, electrolyte and other
dangerous waste.
WSM000001INI0007US0
PREVENT ACID BURNS
• Keep electrolyte away from your eyes, hands and
clothing. Sulfuric acid in battery electrolyte is
poisonous and it can burn your skin and clothing and
cause blindness. If you spill electrolyte on yourself,
clean yourself with water, and get medical aid
immediately.
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PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher ready at all
times.
• Keep the emergency contact telephone numbers
near your telephone at all times.
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KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-4
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.
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9Y1210946INI0001US0
KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-5
9Y1210946INI0002US0
KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-6
9Y1210946INI0003US0
KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-7
9Y1210946INI0004US0
KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-8
9Y1210946INI0005US0
KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-9
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.
3. Replace damaged or missing danger, warning and caution labels with new labels.
4. If a component with danger, warning and caution label(s) affixed is replaced with new part, make sure new label(s)
is (are) attached in the same location(s) as the replace component.
5. Mount new danger, warning and caution labels by applying on a clean dry surface and pressing any bubbles to
outside edge.
9Y1210946INI0007US0
KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-10
3. SPECIFICATIONS
NOTE
• The company reserves the right to change the specifications without notice.
• The values in "Ground clearance" and "Weight" are those of the machine equipped with the tires in the table above.
9Y1210946INI0008US0
Model
RTV-X900 RTV-X1120D
General
Purpose
Worksite /
Orange
Worksite /
Camo
Worksite /
Orange
Worksite /
Camo
Engine
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.)
Horsepower 16.1 kw (21.6 HP) 18.5 kw (24.8 HP)
Rated revolution 3200 min-1 (rpm) 3000 min-1 (rpm)
Low idling revolution 1300 to 1400 min-1 (rpm) 1350 to 1450 min-1 (rpm)
Fuel Capacity 30 L (7.9 U.S.gals, 6.6 Imp.gals)
Transmission Continuously variable hydro transmission (VHT)
Wheels, Drive system 4, Rear 2WD or 4WD
Differential lock Standard; foot operated with mechanical holder
Gear selection Hi-Low range forward, neutral, reverse
Brakes Front / Rear Wet disk brake
Parking brake Rear wheel, hand lever
Steering Hydrostatic power
Suspension Front Independent, Dual A-Arm type
Rear
Dimensions
Length 3055 mm
(120.3 in.) 3110 mm (122.5 in.)
Width 1605 mm (63.2 in.)
Height, overall 2020 mm (79.5 in.)
Front tread centers 1240 mm (48.8 in.) HDWS, ATV, 1290 mm (50.8 in.) Turf
Rear tread centers
Wheelbase 2045 mm (80.5 in.)
Ground
clearance
front axle 266 mm (10.5 in.)
rear axle 263 mm (10.4 in.)
Turning diameter 8.0 m (26.2 ft)
Max. Rolling weight (Towing capacity) Rear: 590 kg (1300 lbs), Front: 295 kg (650 lbs)
Payload capacity 755 kg
(1664 lbs) 725 kg (1598 lbs) 685 kg (1510 lbs)
Weight 865 kg
(1907 lbs) 895 kg (1973 lbs) 935 kg (2061 lbs)
Gross Vehicle Weight Rating (GVWR) 1620 kg (3571 lbs)
Cargo bed
Width 1465 mm (57.7 in.)
Length 1030 mm (40.5 in.)
Depth 285 mm (11.2 in.)
Volume 0.43 m3(15.2 cu.ft.)
Bed height (unloaded) 887 mm (34.9 in.)
Cargo bed capacity 500 kg (1102 lbs)
Sound level, operator ear 85 db (A) 84 db (A)
Tire
Front 25 × 10-12 ATV, 6PLY, 25 × 10-12 HDWS, 6PLY
25 × 12-12 Turf, 4PLY
25 × 10-12 ATV, 6PLY,
25 × 10-12 HDWS, 6PLY
Rear 25 × 10-12 ATV, 6PLY, 25 × 10-12 HDWS, 6PLY
25 × 12-12 Turf, 4PLY
25 × 10-12 ATV, 6PLY
25 × 10-12 HDWS, 6PLY
Tilt steering wheel – Standard
Seat belt 2 point type 3 point type
Front deluxe guard – Standard Standard – –
Front deluxe guard with light guard – – – Standard Standard
Body color Orange Orange Camo Orange Camo
Bed lift – Standard Standard Standard Standard
Speedometer Standard Standard Standard Standard Standard
Door – – – Standard Standard
Seat slide – Standard Standard Standard Standard
KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-11
4. TRAVELLING SPEEDS
(At rated engine rpm)
9Y1210946INI0009US0
Model RTV-X900 RTV-X1120D
Range gear shift lever km/h (mph) km/h (mph)
Low 24 (15) 25 (16)
High 40 (25) 46 (29)
Reverse 27 (17) 35 (22)
KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-12
5. DIMENSIONS
RTV-X900
9Y1210946INI0010US0
KiSC issued 01, 2014 A

INFORMATION
RTV-X900, RTV-X1120D, WSM
I-13
RTV-X1120D
9Y1210946INI0011US0
KiSC issued 01, 2014 A

G GENERAL
KiSC issued 01, 2014 A

CONTENTS
1. PRODUCT IDENTIFICATION ...................................................................................................... G-1
2. GENERAL PRECAUTIONS.......................................................................................................... G-2
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .................................... G-3
[1] WIRING .................................................................................................................................. G-3
[2] BATTERY ............................................................................................................................... G-5
[3] FUSE ...................................................................................................................................... G-5
[4] CONNECTOR ........................................................................................................................ G-5
[5] HANDLING OF CIRCUIT TESTER ........................................................................................ G-6
[6] COLOR OF WIRING ..............................................................................................................G-7
4. LUBRICANTS, FUEL AND COOLANT......................................................................................... G-8
5. TIGHTENING TORQUES........................................................................................................... G-12
[1] GENERAL USE SCREWS, BOLTS AND NUTS .................................................................. G-12
[2] STUD BOLTS ....................................................................................................................... G-12
[3] HYDRAULIC FITTINGS ....................................................................................................... G-13
(1) Hydraulic Hose Fittings................................................................................................... G-13
(2) Hydraulic Pipe Cap Nuts ................................................................................................ G-13
(3) Adaptors, Elbows and Others......................................................................................... G-13
[4] METRIC SCREWS, BOLTS AND NUTS .............................................................................. G-14
[5] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF
THREADS ............................................................................................................................ G-14
[6] PLUGS ................................................................................................................................. G-14
6. MAINTENANCE CHECK LIST ................................................................................................... G-15
7. CHECK AND MAINTENANCE ................................................................................................... G-17
[1] DAILY CHECK...................................................................................................................... G-17
[2] CHECK POINTS OF INITIAL 50 HOURS ............................................................................ G-24
[3] CHECK POINTS OF EVERY 50 HOURS ............................................................................ G-30
[4] CHECK POINTS OF EVERY 100 HOURS .......................................................................... G-33
[5] CHECK POINTS OF EVERY 200 HOURS .......................................................................... G-39
[6] CHECK POINT OF EVERY 300 HOURS ............................................................................. G-47
[7] CHECK POINTS OF EVERY 400 HOURS .......................................................................... G-48
[8] CHECK POINT OF EVERY 500 HOURS ............................................................................. G-49
[9] CHECK POINT OF EVERY 800 HOURS ............................................................................. G-49
[10]CHECK POINT OF EVERY 1500 HOURS ........................................................................... G-49
[11]CHECK POINT OF EVERY 3000 HOURS ........................................................................... G-49
[12]CHECK POINT OF EVERY 1 YEAR .................................................................................... G-49
[13]CHECK POINTS OF EVERY 2 YEARS ............................................................................... G-50
[14]CHECK POINT OF EVERY 4 YEARS.................................................................................. G-53
[15]OTHERS............................................................................................................................... G-54
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....................................................................................................... G-74
[4] CARGO BED ........................................................................................................................ G-75
GENERAL
KiSC issued 01, 2014 A