Kubota RTV1140CPX Workshop Manual

WORKSHOP MANUAL

UTILITY VEHICLE

RTV1140CPX

KiSC issued 05, 2014 A

TO THE READER

This Workshop Manual tells the servicing personnel about the mechanism, servicing and maintenance of the RTV1140CPX. It contains 4 parts:

"Information"

,

"General"

,

"Mechanism"

and

"Servicing"

.



Information

This section contains information below.

• Safety First

• Safety Label

• Specification

• Dimension



General

This section 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 / 9Y021-18200) for the diesel engine / tractor mechanism that this workshop manual does not include.



Servicing

This section 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.

June, 2009

© KUBOTA Corporation 2009

KiSC issued 05, 2014 A

Record of Revisions

For pdf, use search function {Search word} to find all the revised locations.

Last digit of the

Code No.

2

Issue month

2014.05

Main Revised Point and Corrective Measures {Search word}

The topic of steering cylinder is corrected.

Reference

Page

6-M5,

6-S14

KiSC issued 05, 2014 A

I

INFORMATION

KiSC issued 05, 2014 A

INFORMATION

CONTENTS

1. SAFETY FIRST .............................................................................................................................. I-1

2. SAFETY DECALS .......................................................................................................................... I-4

3. SPECIFICATIONS........................................................................................................................ I-12

4. TRAVELING SPEEDS.................................................................................................................. I-13

5. DIMENSIONS ............................................................................................................................... I-14

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. SAFETY FIRST

INFORMATION

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.

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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.

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I-2

INFORMATION

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.

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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.

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I-3

INFORMATION

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.

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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.

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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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RTV1140CPX, WSM

INFORMATION

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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I-4

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INFORMATION

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I-5

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INFORMATION

I-6

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INFORMATION

I-7

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INFORMATION

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I-8

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INFORMATION

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INFORMATION

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INFORMATION

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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 replace with new part, make sure new label(s) is (are) attached in the same locations(s) as the replace component.

5. Mount new danger, warning and caution labels by applying on a clean dry surface and pressure any bubbles to outside edge.

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I-11

KiSC issued 05, 2014 A

RTV1140CPX, WSM

3. SPECIFICATIONS

INFORMATION

Engine

Fuel capacity

Transmission

Wheels, drive section

Differential lock

Gear selection

Brakes

Front / Rear

Parking brake

Steering

Model

Make

Type

Displacement

Horsepower

Rated revolution

Low idling revolution

Suspension

Dimensions

Front

Rear

Length

Width

Height, overall

Front tread centers

Rear tread centers

Wheelbase

Ground clearance

Front axle

Rear axle

Turning diameter

Max. rolling weight (Towing capacity)

Payload capacity

Weight

Width

Length (1 row / 2 row)

Cargo bed

Depth

Volume (1 row / 2 row)

Bed height (unloaded)

Cargo bed capacity

(1 row / 2 row)

Sound level, operator ear

Worksite/Orange

KUBOTA D1105-E3-UV

3 cylinders, 4-cycle, diesel, OHV

1.123 L (68.53 cu.in.)

18.5 kW (24.8 HP)

3000 min

-1

(rpm)

1300 to 1400 min

-1

(rpm)

30 L (7.9 U.S.gals, 6.6 Imp.gals)

Worksite/Camo

Continuously variable hydro transmission (VHT)

4, Rear 2WD or 4WD

Standard; foot operated with mechanical holder

Hi-Med-Lo range forward, neutral, reverse

Wet disk brake

Rear wheel, hand lever

Hydrostatic power

Independent, MacPherson strut-type

Semi-independent, DeDion axle with leaf springs and shock absorber

3480 mm (137.0 in.)

1550 mm (61.0 in.)

2000 mm (78.7 in.)

1150 mm (45.3 in.) HDWS, ATV / 1180 mm (46.5 in.) Turf

1180 mm (46.5 in.) HDWS, ATV / 1210 mm (47.6 in.) Turf

2415 mm (95.1 in.)

190 mm (7.5 in.)

190 mm (7.5 in.)

10 m (32.8 ft)

590 kg (1300 lbs)

730 kg (1609 lbs)

1075 kg (2370 lbs)

1320 mm (52 in.)

1360 mm (53.5 in.) / 860 mm (33.9 in.)

290 mm (11.4 in.)

0.52 m

3

(18.4 cu.ft) / 0.33 m

3

(11.7 cu.ft)

850 mm (33.5 in.)

500 kg (1102 lbs) / 300 kg (661 lbs)

85 dB (A)

Tires

Front

Rear

Front deluxe guard

Body color

Bed lift

Speedometer

25 x 10-12 HDWS, 6 PLY

25 x 10-12 ATV, 6 PLY

25 x 12-12 Turf, 4 PLY

25 x 10-12 HDWS, 6 PLY

25 x 11-12 ATV, 6 PLY

25 x 12-12 Turf, 4 PLY

Std.

Orange

Std.

Std.

25 x 10-12 HDWS, 6 PLY

25 x 10-12 ATV, 6 PLY

25 x 10-12 HDWS, 6 PLY

25 x 11-12 ATV, 6 PLY

Std.

Camo

Std.

Std.

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.

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I-12

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RTV1140CPX, WSM

4. TRAVELING SPEEDS

Rear gear shift lever

Low

Medium

High

Reverse

km/h (mph)

13 (8)

25 (16)

40 (25)

16 (10)

INFORMATION

(At rated engine rpm)

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I-13

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5. DIMENSIONS

INFORMATION

I-14

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G

GENERAL

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GENERAL

CONTENTS

1. PRODUCT IDENTIFICATION ...................................................................................................... G-1

[1] CYLINDER NUMBER............................................................................................................. 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-10

[1] GENERAL USE SCREWS, BOLTS AND NUTS .................................................................. G-10

[2] STUD BOLTS ....................................................................................................................... G-10

[3] METRIC SCREWS, BOLTS AND NUTS.............................................................................. G-11

[4] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC OR UNF

THREADS ............................................................................................................................ G-11

[5] PLUGS ................................................................................................................................. G-11

6. MAINTENANCE CHECK LIST ................................................................................................... G-12

7. CHECK AND MAINTENANCE ................................................................................................... G-14

[1] DAILY CHECK...................................................................................................................... G-14

[2] CHECK POINTS OF INITIAL 50 HOURS ............................................................................ G-20

[3] CHECK POINTS OF EVERY 50 HOURS ............................................................................ G-24

[4] CHECK POINTS OF EVERY 100 HOURS .......................................................................... G-27

[5] CHECK POINTS OF EVERY 200 HOURS .......................................................................... G-32

[6] CHECK POINT OF EVERY 300 HOURS............................................................................. G-35

[7] CHECK POINTS OF EVERY 400 HOURS .......................................................................... G-35

[8] CHECK POINT OF EVERY 500 HOURS............................................................................. G-36

[9] CHECK POINT OF EVERY 800 HOURS............................................................................. G-36

[10]CHECK POINT OF EVERY 1500 HOURS........................................................................... G-36

[11]CHECK POINT OF EVERY 3000 HOURS........................................................................... G-37

[12]CHECK POINT OF EVERY 1 YEAR .................................................................................... G-37

[13]CHECK POINTS OF EVERY 2 YEARS ............................................................................... G-37

[14]CHECK POINT OF EVERY 4 YEARS.................................................................................. G-40

[15]OTHERS............................................................................................................................... G-40

8. SPECIAL TOOLS ....................................................................................................................... G-43

[1] SPECIAL TOOLS FOR ENGINE.......................................................................................... G-43

[2] SPECIAL TOOLS FOR MACHINE ....................................................................................... G-48

9. TIRES ......................................................................................................................................... G-53

[1] TYPE OF TIRE ..................................................................................................................... G-53

[2] TIRE PRESSURE................................................................................................................. G-54

[3] VEHICLE LIMITATIONS....................................................................................................... G-54

[4] CARGO BED ........................................................................................................................ G-55

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

1. PRODUCT IDENTIFICATION

When contacting your local KUBOTA distributor, always specify engine serial number, product serial number and hour meter reading.

(1) Vehicle Serial Number

(2) Vehicle Identification Number

(3) Engine Serial Number

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[1] CYLINDER NUMBER

The cylinder numbers of KUBOTA diesel engine are designated as shown in the figure.

The sequence of cylinder numbers is given as No.1, No.2 and

No.3 starting from the gear case side.

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GENERAL

2. GENERAL PRECAUTIONS

• During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Screws, bolts and nuts should be installed in their original position to prevent reassembly errors.

• When special tools are required, use KUBOTA genuine special tools. Special tools which are not frequently used should be made according to the drawings provided.

• Before disassembling or servicing electrical wires, always disconnect the ground cable from the battery first.

• Remove oil and dirt from parts before measuring.

• Use only KUBOTA genuine parts for parts replacement to maintain machine performance and to assure safety.

• Gaskets and O-rings must be replaced during reassembly.

Apply grease to new O-rings or oil seals before assembling.

See the figure left side.

• When reassembling external snap rings or internal snap rings, they must be positioned so that sharp edge faces against the direction from which a force is applied. See the figure left side.

• When inserting spring pins, their splits must face the direction from which a force is applied. See the figure left side.

• To prevent damage to the hydraulic system, use only specified fluid or equivalent.

(1) Grease

(2) Force

(3) Sharp Edge

(4) Axial Force

(5) Rotating Movement

(A) External Snap Ring

(B) Internal Snap Ring

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GENERAL

3. HANDLING PRECAUTIONS FOR ELECTRICAL

PARTS AND WIRING

To ensure safety and prevent damage to the machine and surrounding equipment, heed the following precautions in handling electrical parts and wiring.

IMPORTANT

• Check electrical wiring for damage and loosened connection every year. To this end, educate the customer to do his or her own check and at the same time recommend the dealer to perform periodic check for a fee.

• Do not attempt to modify or remodel any electrical parts and wiring.

• When removing the battery cables, disconnect the negative cable first. When installing the battery cables, connect the positive cable first.

(1) Negative Terminal (2) Positive Terminal

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[1] WIRING

• Securely tighten wiring terminals.

(1) Correct

(Securely tighten)

(2) Incorrect

(Loosening leads to faulty contact)

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• Do not let wiring contact dangerous part.

(1) Wiring (Correct)

(2) Wiring (Incorrect)

(3) Dangerous Part

(4) Dangerous Part

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• Securely insert grommet.

(1) Grommet

(A) Correct

(B) Incorrect

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GENERAL

• Securely clamp, being careful not to damage wiring.

(1) Clamp

(Wind Clamp Spirally)

(2) Wire Harness

(3) Clamp

(4) Welding Dent

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• Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.

(1) Wiring

(2) Clamp

(A) Correct

(B) Incorrect

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• In installing a part, take care not to get wiring caught by it.

(1) Wiring

(A) Incorrect

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• After installing wiring, check protection of terminals and clamped condition of wiring, only connect battery.

(1) Cover

(Securely Install Cover)

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[2] BATTERY

[3] FUSE

[4] CONNECTOR

GENERAL

• Take care not to confuse positive and negative terminal posts.

• When removing battery cables, disconnect negative cable first.

When installing battery cables, check for polarity and connect positive cable first.

• Do not install any battery with capacity other than is specified

(Ah).

• After connecting cables to battery terminal posts, apply high temperature grease to them and securely install terminal covers on them.

• Do not allow dirt and dust to collect on battery.

CAUTION

• Take care not to let battery liquid spill on your skin and clothes. If contaminated, wash it off with water immediately.

• Before recharging the battery, remove it from the machine.

• Before recharging, remove cell caps.

• Do recharging in a well-ventilated place where there is no open flame nearby, as hydrogen gas and oxygen are formed.

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• Use fuses with specified capacity.

Neither too large nor small capacity fuse is acceptable.

• Never use steel nor copper wire in place of fuse.

• Do not install working light, radio set, etc. on machine which is not provided with reserve power supply.

• Do not install accessories if fuse capacity of reserve power supply is exceeded.

(1) Fuse

(2) Fusible Link

(3) Slow Blow Fuse

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• For connector with lock, push lock to separate.

(A) Push

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• In separating connectors, do not pull wire harnesses.

• Hold connector bodies to separate.

(A) Correct (B) Incorrect

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GENERAL

• Use sandpaper to remove rust from terminals.

• Repair deformed terminal. Make sure that there is no terminal being exposed or displaced.

(1) Exposed Terminal

(2) Deformed Terminal

(3) Sandpaper

(4) Rust

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• Make sure that there is no female connector being too open.

(A) Correct (B) Incorrect

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• Make sure that plastic cover is large enough to cover whole connector.

(1) Cover

(A) Correct

(B) Incorrect

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[5] HANDLING OF CIRCUIT TESTER

• Use tester correctly following manual provided with tester.

• Check for polarity and range.

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[6] COLOR OF WIRING

GENERAL

• 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

Black

Brown

Green

Gray

Blue

Light Green

Orange

Pink

Purple

Red

Sky Blue

White

Yellow

Color code

B

Br

G

Gy or Gr

L

Lg

Or

P

Pu or V

R

Sb

W

Y

(1) Wire Color (2) Stripe

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4. LUBRICANTS, FUEL AND COOLANT

No.

1 Fuel tank

2

Place

Coolant (with reserve tank)

3 Engine crankcase

4 Transmission case

5 Front axle case

6 Knuckle case

7

Brake fluid

(reservoir and lines)

8 Hydraulic tank oil

Capacity

30 L

7.9 U.S.gals

6.6 Imp.gals

5.2 L

5.5 U.S.qts

4.6 Imp.qts

(Filter exchanged)

4.1 L

4.3 U.S.qts

3.6 Imp.qts

(Filter non-exchanged)

3.8 L

4.0 U.S.qts

3.3 Imp.qts

11 L

2.9 U.S.gals

2.4 Imp.gals

0.6 L

0.6 U.S.qts

0.5 Imp.qts

Ref. 0.15 L

Ref. 0.16 U.S.qts

Ref. 0.13 Imp.qts

0.87 L

0.92 U.S.qts

0.77 Imp.qts

14.5 L

15.3 U.S.qts

12.8 Imp.qts

GENERAL

Lubricants

• No. 2-D diesel fuel

• No. 1-D diesel fuel if temperature is below –10 °C (14 °F)

Fresh clean water with anti-freeze

Engine oil

API Service Classification CD, CE or CF

• Above 0 °C (32 °F)

SAE10W, SAE10W-30 or 15W-40

• 0 to 25 °C (32 to 77 °F)

SAE20, SAE10W-30 or 15W-40

• Below 25 °C (77 °F)

SAE10W or SAE10W-30

KUBOTA UDT or SUPER UDT fluid*

KUBOTA UDT or SUPER UDT fluid*

KUBOTA UDT or SUPER UDT fluid

KUBOTA DOT3 GENUINE BRAKE FLUID

KUBOTA UDT or SUPER UDT fluid*

Type of grease Greasing

Parking brake linkage

Battery terminal

Cargo lift cylinder pivot

Cargo bed pivot

VHT link

Range gear shift lever pivot

4WD lever pivot

Rear drive shaft

VHT pressure release pivot

Throttle cable

No. of greasing point

4

2

2

2

2

2

2

2

2

1

NOTE

• * KUBOTA original transmission hydraulic fluid.

Capacity

Moderate amount

Until grease overflows

Moderate amount

Multipurpose EP2 grease

(NLGI Grade No. 2)

Silicone grease

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RTV1140CPX, WSM

GENERAL

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 in table.

• Fuel

– Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures below − 20 °C or elevations above 1500 m.

– If diesel fuel with sulfur content greater than 0.5 % sulfur content is used, reduce the service interval for engine oil and filter by 50 %.

– Do not use diesel fuel with sulfur content greater than 1.0 %.

– Diesel fuels specified to EN 590 or ASTM D975 are recommended.

– No. 2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE

J313 JUN87)

– Since this engine adopts EPA Tier 4 and INterim Tier 4 standards, the use of low sulfur fuel or ultra low sulfur fuel is mandatory in EPA regulated area (North America). Therefore, please use No. 2-D

S500 or S15 diesel fuel as an alternative to No. 2-D, or use No. 1-D S500 or S15 diesel fuel as an alternative to No. 1-D if outside air temperature is below − 10 °C.

• Transmission oil

The oil used to lubricate the transmission is also used as hydraulic fluid. To insure proper operation of the hydraulic system and complete lubrication of the transmission, it is important that a multi-grade transmission fluid be used in this system. We recommend the use of KUBOTA SUPER UDT fluid for optimum protection and performance.

Do not mix different brands or grades.

• Brake fluid

Always use KUBOTA DOT3 GENUINE BRAKE FLUID from a sealed container. If it is not available, you should use only DOT3 fluid as a temporary replacement from a sealed container.

However, the use of any non-KUBOTA brake fluid can cause corrosion and decrease the lift of the system.

Have the brake system flushed and refilled with KUBOTA DOT3 GENUINE BRAKE FLUID as soon as possible.

• Indicated capacity of water and oil are manufacturer's estimate.

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RTV1140CPX, WSM

GENERAL

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 7T 9T

Indication on top of nut

Material of opponent part

Unit

M6

M8

M10

M12

M14

M16

M18

M20

[2] STUD BOLTS

246 to

284

334 to

392

108 to

125

167 to

191

40 to

45

63 to

72

No-grade or 4T

Ordinariness Aluminum Ordinariness Aluminum

6T

Ordinariness

N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft

7.9 to

9.3

18 to

20

0.80 to

0.95

1.8 to

2.1

5.8 to

6.8

13 to

15

7.9 to

8.8

17 to

19

0.80 to

0.90

1.7 to

2.0

5.8 to

6.5

13 to

14

9.81 to

11.2

24 to

27

1.00 to

1.15

2.4 to

2.8

7.24 to

8.31

18 to

20

7.9 to

8.8

18 to

20

0.80 to

0.90

1.8

to

2.1

5.8

to

6.5

13 to

15

12.3 to

14.2

30 to

34

1.25 to

1.45

3.0 to

3.5

9.05 to

10.4

22 to

25

4.0 to

4.6

6.4 to

7.4

11.0 to

12.8

17.0 to

19.5

29 to

33

47 to

53

79.6 to

92.5

123 to

141

32 to

34

–

–

–

3.2 to

3.5

–

–

–

24 to

25

–

–

–

48 to

55

78 to

90

124 to

147

197 to

225

4.9 to

5.7

7.9 to

9.2

12.6 to

15.0

20.0 to

23.0

36 to

41

58 to

66

91.2 to

108

145 to

166

40 to

44

63 to

72

–

–

4.0 to

4.5

6.4 to

7.4

–

–

29 to

32

47 to

53

–

–

61 to

70

103 to

117

167 to

196

260 to

304

6.2 to

7.2

10.5 to

12.0

17.0 to

20.0

26.5 to

31.0

123 to

144

192 to

224

45 to

52

76.0 to

86.7

25.0 to

29.0

34.0 to

40.0

181 to

209

246 to

289

–

–

–

–

–

–

275 to

318

368 to

431

28.0 to

32.5

37.5 to

44.0

203 to

235

272 to

318

–

–

–

–

–

–

344 to

402

491 to

568

35.0 to

41.0

50.0 to

58.0

254 to

296

362 to

419

WSM000001GEG0001US0

Material of opponent part

Unit

M8

M10

M12

M14

M16

M18

98.1 to

112

172 to

201

30 to

49

62 to

73

Ordinariness Aluminum

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

12 to

15

25 to

31

1.2 to

1.6

2.5 to

3.2

8.7 to

11

18 to

23

8.9 to

11

20 to

25

0.90 to

1.2

2.0 to

2.6

6.5 to

8.6

15 to

18

3.0 to

5.0

6.3 to

7.5

10.0 to

11.5

17.5 to

20.5

22 to

36

46 to

54

72.4 to

83.1

127 to

148

31

–

–

–

3.2

–

–

–

23

–

–

–

WSM000001GEG0002US0

G-10

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[3] METRIC SCREWS, BOLTS AND NUTS

GENERAL

Grade

Unit

M8

M10

M12

M14

M16

N·m

24 to 27

48 to 55

78 to 90

124 to 147

197 to 225

Property class 8.8

kgf·m

2.4 to 2.8

4.9 to 5.7

7.9 to 9.2

12.6 to 15.0

20.0 to 23.0

lbf·ft

18 to 20

36 to 41

58 to 66

91.2 to 108

145 to 166

N·m

30 to 34

61 to 70

103 to 117

167 to 196

260 to 304

Property class 10.9

kgf·m

3.0 to 3.5

6.2 to 7.2

10.5 to 12.0

17.0 to 20.0

26.5 to 31.0

lbf·ft

22 to 25

45 to 52

76.0 to 86.7

123 to 144

192 to 224

WSM000001GEG0003US0

[4] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH

UNC OR UNF THREADS

Grade

Unit

1/4

5/16

3/8

1/2

9/16

5/8

N·m

11.7 to 15.7

23.1 to 27.7

48 to 56

110 to 130

150 to 178

204 to 244

SAE GR.5

kgf·m

1.19 to 1.61

2.35 to 2.83

4.9 to 5.8

11 to 13

15.2 to 18.2

20.8 to 24.8

lbf·ft

8.61 to 11.6

17.0 to 20.5

35.0 to 42.0

80 to 96

110 to 132

150 to 180

N·m

16.3 to 19.7

33 to 39

61 to 73

150 to 178

217 to 260

299 to 357

SAE GR.8

kgf·m

1.66 to 2.01

3.4 to 4.0

6.3 to 7.4

15.2 to 18.2

22.2 to 26.5

30.5 to 36.4

lbf·ft

12.0 to 14.6

24 to 29

45 to 54

110 to 132

160 to 192

220 to 264

WSM000001GEG0082US0

[5] PLUGS

Material of opponent part

Shape

Tapered screw

Straight screw

Size

R1/8

R1/4

R3/8

R1/2

G1/4

G3/8

G1/2

N·m

13 to 21

25 to 44

49 to 88

58.9 to 107

25 to 34

62 to 82

49 to 88

Ordinariness kgf·m

1.3 to 2.2

2.5 to 4.5

5.0 to 9.0

6.00 to 11.0

2.5 to 3.5

6.3 to 8.4

5.0 to 9.0

lbf·ft

9.4 to 15

18 to 32

37 to 65

43.4 to 79.5

18 to 25

46 to 60

37 to 65

N·m

13 to 19

25 to 34

49 to 58

59 to 78

–

–

–

Aluminum kgf·m

1.3 to 2.0

2.5 to 3.5

5.0 to 6.0

6.0 to 8.0

–

–

–

lbf·ft

9.4 to 14

18 to 25

37 to 43

44 to 57

–

–

–

WSM000001GEG0005US0

G-11

KiSC issued 05, 2014 A

RTV1140CPX, WSM

6. MAINTENANCE CHECK LIST

GENERAL

CAUTION

To avoid personal injury and vehicle damage

• Be sure you have sufficient knowledge, experience, the proper replacement parts and tools before you attempt any vehicle maintenance task.

IMPORTANT

• The jobs indicated by



must be done after the first 50 hours of operation.

*1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions.

*2 Every year or every 6 times of cleaning.

*3 Replace only if necessary.

*4 When the battery is used for less than 100 hours per year, check the battery condition by reading the indicator annually.

• The items listed below (@ marked) are registered as emission related critical parts by KUBOTA in the

U.S.EPA non road emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the below instruction. Please see Warranty

Statement in detail.

No.

Item

Indication of Hour Meter

50 100 150 200 250 300 350 400 450 500 550 600 650 700

After

700 hrs

Reference page

Important

1 Engine oil

2 Engine oil filter

Change

Replace

3 Transmission fluid Change

















 every

200 hrs every

200 hrs every

400 hrs

G-20

G-20

G-35

4

5

Transmission oil filter (HST)

(Yellow color)

Transmission oil filter (Suction)

(Orange color)

Replace

Replace















 every

200 hrs every

200 hrs

G-32

G-32

6 Engine start system Check

7 Greasing

8

Muffler

(Spark arrester)

9 Wheel bolt torque Check

10 Battery condition

11 Alternator belt

12 VHT neutral spring Check

13

VHT pressure release

14 Toe-in

15 Fuel filter element

16 Fuel line

17 Air cleaner element

Apply

Clean

Check

Adjust

Check

Adjust

Check

Replace

Check

Replace

Clean

Replace

             

             



 









































































































































 every

50 hrs every

100 hrs every

100 hrs every

100 hrs every

500 hrs every

100 hrs every

2 years every

100 hrs every

1 year every

50 hrs every

100 hrs every

100 hrs every

100 hrs every

100 hrs every

100 hrs

G-24

G-25

G-27

G-21

G-28

*4

G-29

G-29

G-30

G-30

G-31

G-36

G-31

G-37

*3

G-32

*1

G-37

*2

@

@

@

G-12

KiSC issued 05, 2014 A

RTV1140CPX, WSM

No.

Item

18 Brake pedal Check

19 Parking brake lever Adjust

20 Brake light switch Check

21 Front brake case Check

22 Hydraulic tank oil Change

23 Hydraulic oil line Check

24

25

Power steering oil line

Hydraulic tank oil filter

Check

Replace

26

Radiator hose and clamp

Check

Replace

27 Intake air line

28

Brake hose and pipe

Check

Replace

Check

Replace

29 Tire wear Check

30 Front axle case oil Change

31 Knuckle case oil

32

33

Engine valve clearance

Fuel injection nozzle injection pressure

34 Injection pump

35

Brake master cylinder

(inner parts)

Change

Adjust

Check

Check

Replace

36 Brake fluid Change

37

38

Remote hydraulic hose

Replace

Rear brake cylinder seal

Replace

39 Front brake seal Replace

40 Cooling system

41 Coolant

42 Fuel system

43 Fuse

44 Light bulb

Flush

Change

Bleed

Replace

Replace

GENERAL

Indication of Hour Meter

50 100 150 200 250 300 350 400 450 500 550 600 650 700

After

700 hrs

















































































 every

200 hrs every

2 years every

200 hrs every

2 years every

200 hrs every

4 years every

300 hrs every

400 hrs every

400 hrs every

800 hrs every

200 hrs every

200 hrs every

200 hrs every

200 hrs every

200 hrs every

200 hrs every

200 hrs every

400 hrs

Reference page

Important

G-32

G-32

G-32

G-32

G-33

G-33

G-34

G-36

G-34

G-37

G-34

G-37

G-35

G-40

G-35

G-35

G-36

G-36

*3

@ every

1500 hrs every

3000 hrs

G-36

G-37

@

@ every

2 years

G-37

every

2 years every

2 years every

2 years every

2 years every

2 years every

2 years

Service as required

G-37

G-37

G-37

G-37

G-38

G-38

G-40

G-41

G-42

9Y1210293GEG0001US0

G-13

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

7. CHECK AND MAINTENANCE

[1] DAILY CHECK

To prevent trouble from occurring, it is important to know the condition of the vehicle well. Check it before starting.

CAUTION

• Be sure to check and service the vehicle on a level surface with the engine shut off and the parking brake

"ON" and implement lowered to the ground if equipped.

9Y1210293GEG0005US0

Walk Around Inspection

1. Look around and under the vehicle for such items as loose bolts, trash build-up, oil or coolant leaks, broken or worn parts.

9Y1210293GEG0006US0

G-14

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Checking and Refueling

CAUTION

• Do not smoke while refueling.

• Be sure to stop the engine before refueling.

1. Turn the key switch to

"ON"

check the amount of furl by fuel gauge.

2. Fill fuel tank when fuel gauge shows 1/4 or less fuel in tank.

3. Use grade No. 2-Diesel fuel at temperatures above − 10 °C

(14 °F).

Use grade No. 1-Diesel fuel at temperatures below − 10 °C

(14 °F).

Fuel tank capacity

30 L

7.9 U.S.gals

6.0 Imp.gals

IMPORTANT

• Do not permit dirt or trash to get into the fuel system.

• Be careful not to let the fuel tank become empty, otherwise air will enter the fuel system, necessitating bleeding before next engine start.

• Be careful not to spill during refueling. If should spill, wipe it off at once, or it may cause a fire.

• To prevent water condensation from accumulating in the fuel tank, fill the tank before parking overnight.

NOTE

• No. 2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN87)

• Grade of Diesel Fuel Oil According to ASTM D975.

Flash point °C

(°F)

Min

52 (125)

Water and

Sediment, volume %

Max

0.05

Carbon Residue on, 10 percent

Residuum, %

Min

0.35

Ash, weight %

Max

0.01

Distillation

Temperatures, °C (°F)

90 % Point

Min

282 (540)

Max

338 (640)

Sulfur, weight %

Max

0.50

(1) Fuel Tank Cap

Viscosity Kinematics cSt or mm

2

/S at 40 °C

Min

1.9

Max

4.1

Copper strip Corrosion

Max

No.3

Viscosity Saybolt,

SUS at 100 °F

Min

32.6

Max

40.1

Cetane Number

Min

40

9Y1210293GEG0007US0

G-15

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Checking Engine Oil Level

CAUTION

• Be sure to stop the engine before checking the oil level.

1. Park the machine on a flat surface.

2. Check engine oil before starting the engine or 5 minutes or more after the engine has stopped.

3. To check the oil level, draw out the dipstick, wipe it clean, replace it, and draw it out again. Check to see that the oil level lies between the two notches.

If the level is too low, add new oil to the prescribed level at the dipstick.

IMPORTANT

• When using an oil of different maker or viscosity from the previous one, remove all of the old oil.

Never mix two different types of oil.

• If oil level is low, do not run engine.

Engine oil capacity

Oil filter exchanged

Oil filter non-exchanged

4.1 L

4.3 U.S.qts

3.6 Imp.qts

3.8 L

4.0 U.S.qts

3.3 Imp.qts

(1) Oil Inlet

(2) Dipstick

A: Oil level is acceptable within this range.

9Y1210293GEG0008US0

Checking Hydraulic Tank Oil Level

1. Park the vehicle on a flat surface.

2. Stop the engine and remove the key.

3. Tilt the seat.

4. To check the oil level, remove the dipstick, wipe it clean, screw it into filling hole and remove dipstick again.

If the level is too low, add new oil to the prescribed level at the

filling plug with dipstick (1). (See page G-8.)

IMPORTANT

• If oil level is low, do not run engine.

(1) Filling Plug with Dipstick

A: Oil level is acceptable within this range.

9Y1210293GEG0009US0

Checking Transmission Fluid Level

1. Park the machine on a flat surface, lower the implement and shut off engine.

2. To check the oil level, draw out the dipstick, wipe it clean, replace it, and draw it out again. Check to see that the oil level lies between the two notches.

If the level is too low, add new oil to the prescribed level at the

dipstick (2). (See page G-8.)

IMPORTANT

• If oil level is low, do not run engine.

Transmission oil capacity

11 L

2.9 U.S.gals

2.4 Imp.gals

(1) Oil Inlet

(2) Dipstick

A: Oil level is acceptable within this range.

9Y1210293GEG0010US0

G-16

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Checking Coolant Level

CAUTION

• Do not remove 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.

1. Park the vehicle on a flat surface, raise the cargo bed, mount the safety support and shut off the engine.

2. Check to see that the coolant level is between the

"FULL"

and

"LOW"

marks of recovery tank.

3. When the coolant level drops due to evaporation, add water only up to the full level.

In case of leakage, add anti-freeze and water in the specified mixing ratio up to the full level.

See "Flush Cooling System and Changing Coolant" in this section.

IMPORTANT

• If the radiator cap has to be removed, follow the caution above and securely retighten the cap.

• Use clean, fresh water and anti-freeze to fill the recovery tank.

• If water should leak, check the cooling system.

(1) Recovery Tank

A: FULL

B: LOW

9Y1210293GEG0011US0

Cleaning Radiator Screen

CAUTION

• Be sure to stop the engine before removing the screen.

1. Park the vehicle on flat surface.

2. Remove the radiator cover.

3. Detach the screen and remove all foreign materials.

IMPORTANT

• Radiator screen must be clean from debris to prevent engine from overheating.

(1) Radiator Screen

A: DETACH

9Y1210293GEG0012US0

G-17

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Checking Brake Fluid Level

CAUTION

• Never operate the vehicle, if the brake fluid is below the

"MIN" mark.

• Use only KUBOTA DOT3 GENUINE BRAKE FLUID from a sealed container. Using other type of oil ruins synthetic resin or rubber installed in brake system components, and may cause brake failure.

• Avoid contamination of the brake fluid. Thoroughly clean area around the filler cap before removing. Do not open the brake fluid reservoir cap unless absolutely necessary.

• Use extreme care when filling the reservoir. If brake fluid is spilled on power steering hose, wash off with water immediately. Brake fluid quickly ruins synthetic resin or rubber hoses.

1. Park the vehicle on level ground and open hood.

2. Check to see that the brake fluid level is between the

"MAX"

and

"MIN"

marks.

3. If it is below the

"MIN"

mark, add brake fluid to the

"MAX"

mark.

Brake fluid Tank capacity

0.87 L

0.92 U.S.qts

0.77 Imp.qts

(1) Oil Tank Cap

A: MAX

B: MIN

9Y1210293GEG0013US0

Checking Parking Brake

1. 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 tip of the parking brake lever and tilt down the lever.

NOTE

• Make sure the parking brake warning lamp on the Easy

Checker™ goes off when parking brake lever is down.

(1) Parking Brake Lever

(2) Release Button

A: Pull

B: Release

9Y1210293GEG0014US0

Checking Brake Pedal

CAUTION

To avoid personal injury:

• Stop the engine and chock the wheels before checking brake pedal.

1. Inspect the brake pedals for free travel, and smooth operation.

2. Adjust if incorrect measurement is found. (See page G-22.)

(1) Brake Pedal

A: Free Travel

B: Pedal Stroke

9Y1210293GEG0015US0

Checking Gauges, Meter and Easy Checker™

1. Inspect the instrument panel for broken gauge(s), meter(s) and

Easy Checker™ lamps.

2. Replace if broken.

9Y1210293GEG0016US0

G-18

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Checking Head Light, Turn Signal Light etc.

1. Inspect the lights for broken bulbs and lenses.

2. Replace if broken.

9Y1210293GEG0017US0

Checking Seat Belt and ROPS

1. Always check condition of seat belt and ROPS attaching hardware before operating vehicle.

2. Replace if damaged.

9Y1210293GEG0018US0

Checking Joint Boot

1. Check to see if the joint boots are not damaged.

2. If the boots are cut, cracked or deterioration, replace the new

one. (See page 5-S22.)

(1) Joint Boot (Front)

(2) Front Drive Shaft

(3) Tie-rod

(4) Joint Boot (Rear)

(5) Rear Drive Shaft

(6) Grease Nipple

(7) Joint Boot

(8) Drive Shaft

F: Front

R: Rear

9Y1210293GEG0019US0

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.

Inflation pressure Tire sizes

25 x 10 - 12 HDWS, Front and Rear

25 x 10 - 12 Turf, Front and Rear

25 x 10 - 12 ATV, Front

25 x 11 - 12 ATV, Rear

170 kPa (1.7 kgf/cm

2

, 24 psi)

(1) Ground

(A) Insufficient

(B) Normal

(C) Excessive

9Y1210293GEG0002US0

G-19

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Checking Backup Beeper (If equipped)

1. Sit on the operator's seat.

2. Set the parking brake and stop the engine.

3. Shift the range gear shift lever to

"NEUTRAL"

position.

4. Turn the key to

"ON"

position.

5. Shift the range gear shift lever to the

"REVERSE"

position.

6. If the backup beeper does not beep, check the electrical system.

(1) Range Gear Shift Lever

(2) Backup Beeper (If equipped)

R: Reverse

9Y1210293GEG0020US0

[2] CHECK POINTS OF INITIAL 50 HOURS

Changing Engine Oil

CAUTION

• Be sure to stop the engine before changing the oil.

• Allow engine to cool down sufficiently, oil can be hot and may cause burns.

1. Park the vehicle on a flat surface, raise the cargo bed and mount the safety support.

2. To drain the used oil, remove the drain plug (3) at the bottom of the engine and completely drain the oil into an oil pan.

All the used oil can be drained out easily when the engine is still warm.

3. After draining, reinstall the drain plug (3).

4. Fill with the new oil up to the upper notch on the dipstick. (See

page G-8.)

Engine oil capacity (with filter)

4.1 L

4.3 U.S.qts

3.6 Imp.qts

(1) Oil Inlet

(2) Dipstick

(3) Drain Plug

A: Oil level is acceptable within this range.

9Y1210293GEG0021US0

Replacing Engine Oil Filter

CAUTION

• Be sure to stop the engine before changing the oil filter cartridge.

• Allow engine to cool down sufficiently, oil can be hot and may cause burns.

1. Park the vehicle on flat surface and raise the cargo bed.

2. Remove the engine oil filter (1).

3. Put a film of clean engine oil on the rubber seal of the new filter.

4. Tighten the filter quickly until it contacts the mounting surface.

Tighten filter by hand an additional 1/2 turn only.

5. After the new filter has been replaced, the engine oil normally decreases a little. Make sure that the engine oil does not leak through the seal and be sure to check the oil level on the dipstick. Then, replenish the engine oil up to the prescribed level.

IMPORTANT

• To prevent serious damage to the engine, use only a

KUBOTA genuine filter.

(1) Engine Oil Filter

9Y1210293GEG0022US0

G-20

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Replacing Transmission Oil Filter

CAUTION

To avoid personal injury:

• Be sure to stop the engine before changing the oil filter.

• Allow engine to cool down sufficiently, oil can be hot and may cause burns.

1. Park the vehicle on a flat surface, raise the cargo bed, and mount the safety support.

2. Remove the rear guard (3) and hose guard (4).

3. Remove the oil filters.

4. Put a film of clean transmission oil on the rubber seal of the new filters.

5. Quickly tighten the filter until it contacts the mounting surface, then, with a filter wrench, tighten it an additional 1 turn only.

6. After the new filter has been replaced, fill the transmission oil up to the upper notch on the dipstick.

7. After running the engine for a few minutes, stop the engine and check the oil level again, add oil to the prescribed level.

8. Make sure that the transmission fluid does not leak past the seal on the filters.

9. Install the rear guard (3), and the hose guard (4).

IMPORTANT

• To prevent serious damage to the transmission, use only a

KUBOTA genuine filter.

(1) Transmission Oil Filter (HST)

(Yellow Color)

(2) Transmission Oil Filter

(Suction) (Orange Color)

(3) Rear Guard

(4) Hose Guard

9Y1210293GEG0023US0

Checking Wheel Screw Torque

CAUTION

• Never operate vehicle with a loose wheel screw.

• Any time screws are loosened, retighten to the specified torque.

• Check all screw frequently and keep them tight.

1. Check wheel mounting screws (1) regularly especially when new. If they are loose, tighten them as follows.

Tightening torque Wheel mounting screw

75 to 90 N·m

7.6 to 9.2 kgf·m

55.3 to 66.4 lbf·ft

(1) Wheel Mounting Screw

9Y1210293GEG0024US0

G-21

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Adjusting Brake Pedal

CAUTION

• Stop the engine and chock the wheels before checking brake pedal.

• If movement is outside of the specifications, adjust the brake.



Checking brake pedal free travel

1. Release the parking brake.

2. Slightly depress the brake pedal (1) and measure free travel at the top of the pedal stroke.

3. If brake pedal free travel is outside of the specifications, adjust

the brake pedal free travel. (See page 4-S4.)

Proper brake pedal free travel on the pedal

Factory specification

7 to 14 mm

0.3 to 0.6 in.



Checking brake pedal stroke

1. Release the parking brake.

2. Step on the pedal (1) and measure the pedal stroke.

3. If brake pedal stroke is outside of the specifications, check the

brake system. (See page 4-S6.)

Pedal stroke on the pedal

Factory specification

Less than

120 mm

4.7 in.

(1) Brake Pedal

A: Free Travel

B: Pedal Stroke

9Y1210293GEG0025US0

Adjusting Parking Brake Lever

1. Release the parking brake.

2. Loosen the lock nut, and adjust the cable wire length.

3. Tighten the lock nut (2), and check the free play.

4. If free play is outside of specifications, adjust the parking brake

cable. (See page 4-S6.)

Proper parking brake lever free play range

Factory specification 1 notch

(1) Parking Brake Lever (2) Lock Nut

9Y1210293GEG0026US0

Checking Brake Light Switch

1. Park the vehicle on a flat surface and raise the cargo bed.

2. Turn the key switch to the

"ON"

position.

3. Step on the brake pedal to check if the brake light comes on.

4. If it does not come on, check the bulb or brake light switch (1).

(1) Brake Light Switch

9Y1210293GEG0027US0

G-22

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Checking Front Brake Case

1. Remove the drain plug.

2. Check the brake case for brake fluid leak.

3. If there is brake fluid leak, check the brake seals. (See page

4-S11.)

(1) Drain Plug (2) Allen Wrench

9Y1210293GEG0028US0

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 (1) and pipe joints for oil leaks.

3. If there is any abnormality, replace the new one.

(1) Brake Hose (2) Brake Pipe

9Y1210293GEG0029US0

G-23

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Checking Tire

1. Check to see if tires are not damaged.

2. If the tires are cracked, bulged, or cut, or they are worn out, replace or repair them at once.



Tire Tread Depth

Always replace the tires when the tread depth is worn to minimum depth.

A: 3 mm (0.12 in.)

9Y1210293GEG0030US0

[3] CHECK POINTS OF EVERY 50 HOURS

Checking Engine Start System

NOTE

To avoid personal injury:

• Do not allow anyone near the vehicle while testing.

• If the vehicle does not pass the test, do not operate the vehicle.



Preparation before testing

1. Place all control levers in the

"NEUTRAL"

position.

2. Set the parking brake and stop the engine.



Test: Range gear shift lever safety switch

1. Sit on the operator's seat.

2. Shift the range gear shift lever to

"H"

,

"M"

,

"L"

or

"REVERSE"

position.

3. Return the speed control pedal to the

"NEUTRAL"

position.

4. Shift the hydraulic lift cylinder lever to the

"NEUTRAL"

position.

5. Turn the key to

"START"

position.

6. The engine must not crank.

7. If it cranks, adjust or replace the required safety switch.

(1) Range Gear Shift Lever

(2) Hydraulic Lift Cylinder Lever

(3) Speed Control Pedal

9Y1210293GEG0031US0

G-24

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Greasing

1. Apply a small amount of multi-purpose EP2 grease to the following points every 50 hours. If you operated the vehicle in extremely wet and muddy conditions, lubricate grease fittings more often.

(1) Parking Brake Pivot

(Spray Type Grease)

(2) Battery Terminal

(3) Cargo Lift Cylinder Pivot

(Spray Type Grease)

(4) Cargo Bed Pivot

(Spray Type Grease)

(5) VHT Link (Grease Fitting)

(6) Range Gear Shift Lever Pivot

(Spray Type Grease)

(7) 4WD Lever Pivot

(Spray Type Grease)

(To be continued)

G-25

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(Continued)

GENERAL

(8) 4WD Lever Pivot (Spray Type

Grease)

(9) Rear Drive Shaft (Grease Fitting)

(10) VHT Pressure Release Pivot

(Grease Fitting)

9Y1210293GEG0032US0

Greasing (Silicone Grease)

1. Apply a small amount of silicone grease to the accelerator wire

(1) every 50 hours.

(1) Accelerator Wire

9Y1210293GEG0033US0

G-26

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[4] CHECK POINTS OF EVERY 100 HOURS

Cleaning Muffler (Spark Arrester)

GENERAL

CAUTION

• Before touching any part of an exhaust system, be absolutely sure that it has sufficient time to cool.

• Always wear safety goggles and a (face) mask.

• The particulate matter contained in the muffler contains chemicals that are harmful to people, animals and marine life.



Cleaning spark arrester of muffler

This screen type spark arrester (3) was examined, tested, and qualified in accordance with the USDA Forest Service Standard

5100-1c, "Spark Arresters for Internal Combustion Engines" for the

RTV1140.



Maintenance and cleanout procedure

The screen type spark arrester (3) should be removed, cleaned, and inspected after every 100 hours of use.

1. The spark arrester (3) is located inside of the exhaust pipe, and is fastened with two screws (2).

2. Unfasten the bolt and remove the spark arrester (3).

3. Shake loosened particles out of the screen assembly and lightly clean the screen with a wire brush. Soak in solvent and again clean with wire brush if necessary.

4. If any breaks in the screen or weldments are discovered, the assembly must be replaced.

5. Return the spark arrester (3) to the muffler body and refasten the bolts.

IMPORTANT

• Visually check the muffler for cracks or holes in the body, weldment or pipes at regular intervals.

• USDA approval requires clearance between spark arrester sleeve and exhaust pipe to be no larger than 0.584 mm

(0.023 in.).

• Replace the entire muffler if it is damaged.

• Do not operate the vehicle with a damage muffler.

(1) Muffler

(2) Screw

Checking Wheel Screw Torque

• See page G-21.

(3) Spark Arrester

(4) Gasket

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9Y1210293GEG0035US0

G-27

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Checking Battery Condition

DANGER

To avoid the possibility of battery explosion:

For the refillable type battery, follow the instructions below.

• Do not use or charge the refillable type battery if the fluid level is below the LOWER (lower limit level) mark.

Otherwise, the battery component parts may prematurely deteriorate, which may shorten the battery's service life or cause an explosion. Check the fluid level regularly and add distilled water as required so that the fluid level is between the UPPER and LOWER levels.

CAUTION

• Never remove the vent caps while the engine is running.

• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately and get medical attention.

• Wear eye protection and rubber gloves when working around the battery.

The factory-installed battery is of non-refillable type. If the battery is weak, charge the battery or replace it with new one.



Battery Charging

CAUTION

• When the battery is being activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery.

• When charging the battery, ensure the vent caps are securely in place (if equipped).

• When disconnecting the cable from the battery, start with the negative terminal first. When connecting the cable to the battery, start with the positive terminal first.

• Never check battery charge by placing a metal object across the posts.

Use a voltmeter or hydrometer.

1. Tilt the seat and remove the utility box.

2. Stop the engine and remove the key.

3. To slow charge the battery, connect the battery positive terminal to the charger positive terminal and the negative to the negative, then recharge in the standard fashion.

4. A boost charge is only for emergencies. It will partially charge the battery at a high rate and in a short time.

When using a boost-charged battery, it is necessary to recharge the battery as early as possible.

Failure to do this will shorten the battery's service life.

5. When exchanging an old battery for a new one, use battery of equal specification shown below.

Battery Type

624FMF

Volts (V)

12

Reserve

Capacity

(min.)

120

Cold

Cranking

Amps

650

Recommended

Charging

Voltage at

26.7 °C (V)

15.5

(1) Battery

(2) Negative Cable

(3) Positive Cable

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G-28

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL



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.

2. The battery self-discharges while it is stored.

Recharge it once every three months in hot seasons and once every six months in cold seasons.

9Y1210293GEG0037US0

Adjusting Alternator Belt Tension

CAUTION

• Be sure to stop the engine before checking belt tension.

1. Park the vehicle on a flat surface and raise the cargo bed.

2. Stop the engine and remove the key.

3. Apply moderate thumb pressure to belt between pulleys.

4. If tension is incorrect, loosen the alternator mounting bolts and using a lever placed between the alternator and the engine block, pull the alternator out until the deflection of the belt falls within acceptable limits.

5. Replace alternator belt if it is damaged.

Proper alternator belt tension

Factory specification

A deflection of between 7 to 9 mm (0.28 to 0.34 in.) when the belt is pressed in the middle of the span.

(1) Bolt

A: Check Belt Tension

B: To Tighten

9Y1210293GEG0038US0

Adjusting VHT Neutral Spring

1. Park the vehicle on a flat place.

2. Set the parking brake.

3. Shift the range gear shift lever to the neutral position.

4. Lock the hydraulic lift cylinder lever to

"NEUTRAL"

position with restricting plate.

5. Start the engine.

6. Make sure that the rotation speed of the engine returns to the idling rotation immediately when taking the foot off the pedal, after depressing the speed control pedal several times.

If the above does not occur immediately, check the speed control cable.

If cable movement is not smooth, replace the new one.

If cable is OK, adjust the neutral spring tension (length of tension bolt).

(1) Neutral Spring

9Y1210293GEG0039US0

G-29

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Checking VHT Pressure Release

CAUTION

To avoid personal injury:

• Do not touch muffler or exhaust pipes while they are hot; severe burns could result.

1. Park the vehicle on a level ground and set the parking brake.

2. Start the engine and shut off it soon.

3. Check the points as shown in the figures.

4. If the result corresponds to either of the following (a) or (b). (See

page 2-S16.)

a) The clearance

"X"

is more than 1 mm (0.04 in.).

b) Spring needs adjusting.

(1) VHT Pressure Release Arm

(2) VHT Pressure Release Valve

(3) Spring

A: Normal position of spring

B: The position that adjustment is necessary for spring

9Y1210293GEG0040US0

Adjusting 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.

4. Measure distance between tire beads at front of tire, at hub height.

5. Measure distance between tire beads at fear of tire, at hub height.

6. Front distance should be shorter than rear distance. If not, adjust tie-rod length.

Proper toe-in

(1) Lock Nut

(2) Tie-rod

Factory specification

0 to 20 mm

0 to 0.79 in.



Adjusting procedure

1. Loosen the lock nut (1) and turn the tie-rod (2) to adjust the rod length until the proper toe-in measurement is obtained.

2. Retighten the lock nut (1).

IMPORTANT

• Keep the length of the left and right tie-rod equal.

A: Wheel to Wheel Distance at Rear

B: Wheel to Wheel Distance at Front

C: Front

9Y1210293GEG0041US0

G-30

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Checking Fuel Line and Fuel Filter

CAUTION

• Be sure to stop the engine and remove the key when attempting to make the following checks and changes.

• Never fail to check the fuel lines periodically. The fuel lines are subject to wear and aging. Fuel may leak out onto the running engine, and causing a fire.

The fuel line connections should be checked annually or every

100 service hours, whichever comes first.

1. Park the vehicle on a flat surface and raise the cargo bed.

2. The fuel line is made of rubber and ages regardless of service period.

3. If the fuel line and clamps are found to be damaged or deteriorated, replace them.

4. Remove the under guard.

5. Check fuel filter, if it is clogged by debris or contaminated with water, replace it.

6. Install the under guard.

IMPORTANT

• When the fuel line is disconnected for maintenance or repair, close both ends of the fuel line with a piece of clean cloth or paper to prevent dust and dirt from entering. In addition, particular care must be taken not to admit dust and dirt into the fuel pump. Entrance of even a small amount of dust or dirt causes premature wear and malfunction of the fuel pump and injector components.

(1) Under Guard

(2) Pipe Clamp

(3) Fuel Line

(4) Fuel Filter

(5) Fuel Pump

9Y1210293GEG0042US0

G-31

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Cleaning Air Cleaner Primary Element

1. Remove the air cleaner cover and primary element (2).

2. Clean the primary element;

• 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

2

, 30 psi).

• When carbon or oil adheres to the element, soak the element in detergent for 15 minutes then wash it several times in water, rinse with clean water and dry it naturally. After element is fully dried, inspect inside of the element with a light and check if it is damaged or not.

3. Replace the primary element.

Once yearly or after every sixth cleaning, whichever comes first.

NOTE

• Check to see if the evacuator valve is blocked with dust.

• Check rubber seal. Replace if damaged.

IMPORTANT

• The air cleaner uses a dry element, and never apply oil.

• Do not run the engine with filter element removed.

• Be sure to refit the cover with the arrow (on the rear of cover) upright. If the cover is improperly fitted, evacuator valve will not function and dust will adhere to the element.

• Do not touch the secondary element (1) except in cases where replacing is required.

See "Replacing Air Cleaner Secondary Element" in Every 1

Year maintenance.



Evacuator Valve

Open the evacuator valve once a week under ordinary conditions - or daily when used in a dusty place - to get rid of large particles of dust and dirt.

(1) Secondary (Safety) Element

(2) Primary Element

(3) Rubber Seal

(4) Evacuator Valve

(5) Cover

9Y1210293GEG0043US0

[5] CHECK POINTS OF EVERY 200 HOURS

Changing Engine Oil

• See page G-16.

9Y1210293GEG0044US0

Replacing Engine Oil Filter

• See page G-20.

9Y1210293GEG0045US0

Replacing Transmission Oil Filter

• See page G-21.

9Y1210293GEG0046US0

Adjusting Brake Pedal

• See page G-22.

9Y1210293GEG0047US0

Adjusting Parking Brake Lever

• See page G-22.

9Y1210293GEG0048US0

Checking Brake Light Switch

• See page G-22.

9Y1210293GEG0049US0

Checking Front Brake Case

• See page G-23.

9Y1210293GEG0050US0

G-32

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Changing Hydraulic Tank Oil

CAUTION

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 may cause burns.

1. Park the vehicle on a firm, flat and level surface.

2. Tilt the seat.

3. Remove the under guard.

4. To drain the used oil, remove the drain plug and filling plug and drain the oil completely into the oil pan.

5. After draining, reinstall the drain plug.

6. Install the under guard.

7. Fill with new KUBOTA SUPER UDT fluid up to the upper notch

on the filling plug. (See page G-8.)

How to check:

Wipe filling plug clean with a rag and screw it into filling hole.

Remove filling plug again to see if the oil level is between the upper and lower notch.

8. After filling, reinstall the filling plug.

Oil capacity

14.5 L

15.3 U.S.qts

12.8 Imp.qts

(1) Under Guard

(2) Drain Plug

(3) Filling Plug with Dipstick

A: Oil level is acceptable within this range.

9Y1210293GEG0051US0

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 worn or damaged, replace or repair them at once.

(a) Hydraulic Pump to Hydraulic Control Valve

(b) Hydraulic Pump to Steering Controller

(c) Hydraulic Control Valve to Hydraulic Tank Oil Filter

(d) Hydraulic Pipe to Hydraulic Cylinder

(e) Steering Controller to Steering Cylinder

9Y1210293GEG0052US0

G-33

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Checking Power Steering Line

1. Check to see that all lines and hose clamps are tight and not damaged.

2. If hoses and clamps are found worn or damaged, replace or repair them at once.

(1) Power Steering Pressure Hose

9Y1210293GEG0053US0

Checking Radiator Hose and Clamp

Park the vehicle on a flat surface and raise the cargo bed,

Check to see if radiator hoses (1) are properly fixed every 200 hours of operation or six months, whichever comes first.

1. If hose clamps (2) are loose or water leaks, tighten bands securely.

2. Replace hoses and tighten hose clamps securely, if radiator hoses are swollen, hardened or cracked.

Replace hoses and hose clamps every 2 years or earlier if checked and found that hoses are swollen, hardened or cracked.



Precaution at Overheating

Take the following actions in the event the coolant temperature be nearly or more than the boiling points, what is called

"Overheating".

1. Stop the machine operation in a safe place and keep the engine unloaded idling speeds.

2. Do not stop the engine suddenly, but stop it after about 5 minutes of unloaded idling speeds.

3. Keep yourself well away from the machine for further 10 minutes or while the steam blown out.

4. Checking if there is no danger such as burn, get rid of the causes of overheating according to the manual, see

"Troubleshooting" section, and then, start again the engine.

(1) Radiator Hose (2) Clamp Band

9Y1210293GEG0055US0

Checking Intake Air Line

1. Check to see if the hoses (1) and hose clamps (2) are tight and not damaged

2. If hoses and clamps are found worn or damaged, replace or repair them at once.

(1) Hose (2) Hose Clamp

9Y1210293GEG0056US0

G-34

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Checking Brake Hose and Pipe

• See page G-23.

[6] CHECK POINT OF EVERY 300 HOURS

Checking Tire

• See page G-24.

[7] CHECK POINTS OF EVERY 400 HOURS

Changing Transmission Oil

GENERAL

9Y1210293GEG0057US0

9Y1210293GEG0058US0

CAUTION

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 may cause burns.

1. Park the vehicle on a flat surface, raise the cargo bed, mount the safety support.

2. To drain the used oil, remove the drain plug at the bottom of the transmission case and drain the oil completely into the oil pan.

3. After draining, reinstall the drain plug.

4. Fill with the new KUBOTA SUPER UDT fluid up to the upper notch on the dipstick.

(Refer to "LUBRICANTS, FUEL AND COOLANT" in

"MAINTENANCE".) (See page G-8.)

5. After running the engine for a few minutes, stop the engine and check the oil level again; add oil to prescribed level.

IMPORTANT

• Do not operate the vehicle immediately after changing the transmission fluid.

Run the engine at medium speed for a few minutes to prevent damage to the transmission.

Transmission oil capacity

11 L

2.9 U.S.gals

2.4 Imp.gals

(1) Oil Inlet

(2) Dipstick

A: Oil level is acceptable within this range.

9Y1210293GEG0059US0

Changing Front Axle Case Oil

1. Park the vehicle on a firm, flat and level surface.

2. 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.

3. After draining, reinstall the drain plug.

4. Fill with new oil up to the upper notch on the dipstick of filling plug. Refer to "LUBRICANTS, FUEL AND COOLANT". (See

page G-8.)

5. After filling, reinstall the filling plug.

Front axle case oil Capacity

0.6 L

0.6 U.S.qts

0.5 Imp.qts

(1) Drain Plug

(2) Filling Plug with Dipstick

A: Oil level is acceptable within this range.

9Y1210293GEG0060US0

G-35

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Changing 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

L.H. knuckle case and drain the oil completely into the oil pan.

4. After draining, reinstall the drain plug (1).

5. Fill the new oil up to the filling port level. Refer to

"LUBRICANTS, FUEL AND COOLANT". (See page G-8.).

6. After filling, reinstall the filling plug (2).

7. Use the same procedure to change the RH knuckle case oil.

Knuckle case oil

Reference capacity

(one side)

0.15 L

0.16 U.S.qts

0.13 Imp.qts

(1) Drain Plug (2) Filling Plug

9Y1210293GEG0061US0

Replacing Hydraulic Tank Oil Filter

CAUTION

To avoid personal injury:

• Be sure to stop the engine before changing the oil filter cartridge.

• Allow engine to cool down sufficiently, oil can be hot and may cause burns.

1. Park the vehicle on a firm, flat and level surface.

2. Tilt the seat.

3. Remove the oil filter. (Take care of the oil that spills from filter.)

4. Put a film of clean KUBOTA SUPER UDT OIL on the rubber seal of the new filter.

5. Quickly tighten the filter until it contacts the mounting surface, then, with a filter wrench, tighten it an additional 1 turn only.

6. After running the engine for a few minutes, stop the engine and check the oil level, add oil to the prescribed level.

7. Make sure that the hydraulic tank oil does not leak past the seal on the filter.

IMPORTANT

• Receive the spilt oil with rags or trays.

Be careful not to spill oil.

If you should spill oil, wipe it off at once.

• To prevent serious damage to the hydraulic line, use only a

KUBOTA genuine filter.

(1) Hydraulic Tank Oil Filter (Return)

9Y1210293GEG0054US0

[8] CHECK POINT OF EVERY 500 HOURS

Replacing Fuel Filter

• See page G-31.

9Y1210293GEG0062US0

[9] CHECK POINT OF EVERY 800 HOURS

Adjusting Engine Valve Clearance

• See page 1-S11.

9Y1210293GEG0063US0

[10] CHECK POINT OF EVERY 1500 HOURS

Checking Fuel Injection Nozzle Injection Pressure

• See page 1-S18.

9Y1210293GEG0064US0

G-36

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

[11] CHECK POINT OF EVERY 3000 HOURS

Checking Injection Pump

• See page 1-S15.

9Y1210293GEG0065US0

[12] CHECK POINT OF EVERY 1 YEAR

Replacing Air Cleaner Primary Element and Secondary

Element

1. Replace the both primary and secondary elements.

See page G-32.

9Y1210293GEG0066US0

[13] CHECK POINTS OF EVERY 2 YEARS

Replacing Fuel Hose

• See page G-31.

9Y1210293GEG0067US0

Replacing Radiator Hose (Water Pipes)

• See page G-34.

9Y1210293GEG0068US0

Replacing Intake Air Line

• See page G-34.

9Y1210293GEG0069US0

Replacing Inner Parts of Brake Master Cylinder

• See page 4-S16.

9Y1210293GEG0070US0

Changing Brake Fluid

• See page G-18.

9Y1210293GEG0071US0

Replacing Remote Hydraulic Hose

• See page G-33.

9Y1210293GEG0072US0

Replacing Rear Brake Cylinder Seal

• See page 4-S18.

9Y1210293GEG0073US0

Replacing Front Brake Seal

• See page 4-S11.

9Y1210293GEG0074US0

G-37

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Flush Cooling System and Changing Coolant

CAUTION

• 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.

1. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain plug (1) and remove radiator cap (3). The radiator cap must be removed to completely drain the coolant.

3. After all coolant is drained, close the drain plug.

4. Fill with clean water and cooling system cleaner.

5. Follow directions of the cleaner instruction.

6. After flushing, fill with clean water and anti-freeze until the coolant level is just below the radiator cap.

Install the radiator cap securely.

7. Fill with fresh water up to the

"FULL"

mark on the recovery tank.

8. Start and operate the engine for few minutes.

9. Stop the engine and let cool.

10. Check coolant level of recovery tank and add coolant if necessary.

Coolant Capacity

5.2 L

5.5 U.S.qts

4.6 Imp.qts

IMPORTANT

• Do not start engine without coolant.

• Use clean, fresh water and anti-freeze to fill the radiator and recovery tank.

• When the anti-freeze is mixed with water, the anti-freeze mixing ratio must be less than 50 %.

• Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

(1) Drain Plug

(2) Rear Tire (L.H.)

(3) Radiator Cap

(4) Recovery Tank

A: FULL

B: LOW

9Y1210293GEG0075US0

G-38

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Anti-Freeze

CAUTION

• When using antifreeze, put on some protection such as rubber gloves. (Antifreeze contains poison.)

• If you should drink antifreeze, throw up at once and take medical attention.

• When antifreeze comes in contact with the skin or clothing, wash it off immediately.

• Do not mix different types of antifreeze.

The mixture can produce chemical reaction causing harmful substances.

• Antifreeze is extremely flammable and explosive under certain conditions. Keep fire and children away from antifreeze.

• When draining fluids from the engine, place some container underneath the engine body.

• Do not pour waste onto the grounds, down a drain, or into any water source.

• Also, observe the relevant environmental protection regulations when disposing of antifreeze.

If it freezes, coolant can damage the cylinders and radiator. If the ambient temperature falls below 0 °C (32 °F) or before a long-term storage, let out coolant completely, or mix fresh water with long-life coolant and fill the radiator and recovery tank with the mixture.

1. Long-life coolant (hereafter LLC) comes in several types. Use ethylene glycol (EG) type for this engine.

2. Before employing LLC-mixed coolant, fill the radiator with fresh water and empty it again.

Repeat this procedure 2 or 3 times to clean up the inside.

3. Mixing the LLC

Put the LLC in coolant in the percentage (%) for a target temperature. When mixing, stir it up well, and then fill into the radiator.

4. The procedure for the mixing of water and antifreeze differs according to the make of the antifreeze and the ambient temperature. Refer to SAE J1034 standard, more specifically also to SAE J814c.

IMPORTANT

• When the antifreeze is mixed with water, the antifreeze mixing ratio must be less than 50 %.

Vol %

Anti-freeze

40

50

Freezing Point

°C °F

− 24

− 37

− 12

− 34

°C

Boiling Point *

°F

106

108

222

226

* At 1.013 x 10 Pa (760 mmHg) pressure (atmospheric). A higher boiling point is obtained by using a radiator pressure cap which permits the development of pressure within the cooling system.

(To be continued)

G-39

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

(Continued)

5. Adding the LLC.

• Add only water if the mixture reduces in amount by evaporation

• If there is a mixture leak, add the LLC of the same manufacturer and type in the same mixture percentage.

• Never add any long-life coolant of different manufacturer.

(Different brands may have different additive components, and the engine may fail to perform as specified.)

6. When the LLC is mixed, do not employ any radiator cleaning agent. The LLC contains anticorrosive agent. If mixed with the cleaning agent, sludge may build up, adversely affecting the engine parts.

7. KUBOTA's genuine long-life coolant has a service life of 2 years. Be sure to change the coolant every 2 years.

NOTE

• The above data represent industry standard that necessitate a minimum glycol content in the concentrated antifreeze.

• When the coolant level drops due to evaporation, add water only to keep the antifreeze mixing ratio less than 50 %. In case of leakage, add antifreeze and water in the specified mixing ratio before filling into the radiator.

9Y1210293GEG0076US0

[14] CHECK POINT OF EVERY 4 YEARS

Replacing Brake Hose

• See page G-23.

9Y1210293GEG0077US0

[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.



Bleeding procedure is as follows

1. Fill the fuel tank with fuel.

2. Start the engine and run for about 30 seconds, and the stop the engine.

9Y1210293GEG0078US0

G-40

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Replacing Fuse

The vehicle electrical system is protected from potential damage by fuses.

A blown fuse indicates that there is an overload or short somewhere in the electrical system.

If any of the fuses should blow, replace with a new one of the same capacity.

IMPORTANT

• Before replacing a blown fuse, determine why the fuse blew and make any necessary repairs.



Replacement procedure

1. Disconnect the negative cord of the battery.

2. Remove the cover (1) and the fuse box cover (2).

3. Pull out the blown fuse using fuse puller (4) in the fuse box.

4. Insert a new fuse into the fuse box.

5. Install the fuse box cover and the cover (1).

6. Connect the negative battery cable.

(1) Cover

(2) Fuse Box Cover

(3) Slow Blow Fuse Box Cover

(4) Fuse Puller

(5) Fuse

9Y1210293GEG0079US0

Protected Circuit

11

12

13

14

7

8

9

10

15

16

Fuse No.

1

2

3

4

5

6

Capacity (A)

Slow blow fuse (60) Alternator

Slow blow fuse (50) Key switch

Protected circuit

15

5

30

10

Alternator, Fan motor relay

Panel

Radiator fan

Horn

20

10

15

30

15

15

5

5

–

5, 10, 15, 20

(Work light)

Head light, Tail lamp

Engine stop solenoid relay

Glow lamp

Engine stop solenoid

12 V DC output

Brake lamp, (Hazard)

Spare

Fuse puller

Spare

9Y1210293GEG0080US0

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 causes. Never use any substitute, use only a KUBOTA genuine part.



Replacement procedure

1. Disconnect the negative cord of the battery.

2. Open the slow blow fuse box cover.

3. Pull out the slow blow fuse.

4. Insert a new slow blow fuse into the slow blow fuse box.

5. Close the slow blow fuse box cover.

6. Connect the negative battery cable.

(1) Cover (2) Slow Blow Fuse Box Cover

9Y1210293GEG0081US0

G-41

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Replacing Light Bulb

1. Head lights:

Take the bulb out of the light body and replace with a new one.

2. Other lights:

Detach the lens and replace the bulb.

Light

Head lights

Tail light

Brake light

Easy Checker™

Turn signal light (front)

Turn signal light (rear)

Work light

Instrument panel light

Capacity

37.5 W

5 W

21 W

3.8 W (14 V, 0.27 A)

20 W (if equipped)

21 W (if equipped)

27 W (if equipped)

3.8 W (14 V, 0.27 A)

(1) Easy Checker ™ and Instrument

Panel Light Bulb

(2) Head Light Bulb

(3) Tail Light Bulb

9Y1210293GEG0082US0

G-42

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

8. SPECIAL TOOLS

[1] SPECIAL TOOLS FOR ENGINE

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.

• 07909-32111

Application

• Use exclusively to push in the piston with piston rings into the cylinder.

WSM000001GEG0012US0

Piston Ring Tool

Code No.

• 07909-32121

Application

• Use exclusively to remove or install the piston ring with ease.

WSM000001GEG0013US0

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.

(1) Gauge

(2) Hose Assembly

(3)

L

Joint

(4) Adaptor

K

(5) Adaptor

L

(6) Adaptor

M

WSM000001GEG0096US0

G-43

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Diesel Engine Compression Tester (for Injection Nozzle)

Code No.

• 07909-30208 (Assembly)

• 07909-30934 (

A

to

F

)

• 07909-31211 (

E

and

F

)

• 07909-31231 (

H

)

• 07909-31251 (

G

)

• 07909-31271 (

I

)

• 07909-31281 (

J

)

Application

• Use to measure diesel engine compression and diagnostics of need for major overhaul.

(1) Gauge

(2)

L

Joint

(3) Adaptor

A

(4) Adaptor

B

(5) Adaptor

C

(6) Adaptor

E

(7) Adaptor

F

(8) Adaptor

G

(9) Adaptor

H

(10) Adaptor

I

(11) Adaptor

J

Oil Pressure Tester

Code No.

• 07916-32032

Application

• Use to measure lubricating oil pressure.

(1) Gauge

(2) Cable

(3) Threaded Joint

(4) Adaptor

1

(5) Adaptor

2

(6) Adaptor

3

(7) Adaptor

4

(8) Adaptor

5

WSM000001GEG0014US0

WSM000001GEG0015US0

Valve Seat Cutter

Code No.

• 07909-33102

Application

• Use to reseat valves.

Angle

• 0.79 rad (45 °)

• 0.26 rad (15 °)

Diameter

• 28.6 mm (1.13 in.)

• 31.6 mm (1.24 in.)

• 35.0 mm (1.38 in.)

• 38.0 mm (1.50 in.)

• 41.3 mm (1.63 in.)

• 50.8 mm (2.00 in.)

WSM000001GEG0016US0

Radiator Tester

Code No.

• 07909-31551

Application

• Use to check of radiator cap pressure, and leaks from cooling system.

Remarks

• Adaptor (1) BANZAI Code No. RCT-2A-30S.

(1) Adaptor

WSM000001GEG0017US0

G-44

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

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.)

WSM000001GEG0020US0

Nozzle Tester

Code No.

• 07909-31361

Application

• Use to check the fuel injection pressure and spray pattern of nozzle.

Measuring range

• 0 to 50 MPa (0 to 500 kgf/cm

2

, 0 to 7200 psi)

WSM000001GEG0021US0

Plastigauge

Code No.

• 07909-30241

Application

• Use to check the oil clearance between crankshaft and bearing, etc..

Measuring range

• Green: 0.03 to 0.07 mm (0.001 to 0.003 in.)

• Red: 0.05 to 0.1 mm (0.002 to 0.006 in.)

• Blue: 0.1 to 0.2 mm (0.004 to 0.009 in.)

WSM000001GEG0022US0

Red Check

Code No.

• 07909-31371

Application

• Use to check cracks on cylinder head, cylinder block, etc..

WSM000001GEG0023US0

G-45

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Valve Guide Replacing Tool

Application

• To press out and press fit the valve guide.

G

H

I

J

C

D

A

B

E

F

K

L

C1

C2

C0.3

225 mm (8.86 in.)

70 mm (2.8 in.)

45 mm (1.8 in.)

20 mm dia. (0.79 in. dia.)

12.7 to 12.9 mm dia. (0.500 to 0.507 in. dia.)

7.50 to 7.60 mm dia. (0.296 to 0.299 in. dia.)

25 mm dia. (0.98 in. dia.)

7.70 to 8.00 mm dia. (0.304 to 0.314 in. dia.)

5 mm (0.2 in.)

20 mm dia. (0.79 in. dia.)

13.5 to 13.8 mm dia. (0.532 to 0.543 in. dia.)

8.90 to 9.10 mm (0.351 to 0.358 in.)

Chamfer 1.0 mm (0.039 in.)

Chamfer 2.0 mm (0.079 in.)

Chamfer 0.3 mm (0.01 in.)

Bushing Replacing Tool

Application

• Use to press out and press fit the bushing.

[For small end bushing]

A

157 mm (6.18 in.)

M00000003GEG0058US1

C2 a b

D

E

B

C

F

C1

24 mm (0.94 in.)

120 mm (4.72 in.)

21.8 to 21.9 mm dia. (0.859 to 0.862 in. dia.)

24.8 to 24.9 mm dia. (0.977 to 0.980 in. dia.)

20 mm dia. (0.79 in. dia.)

Chamfer 1.0 mm (0.039 in.)

Chamfer 2.0 mm (0.079 in.)

6.3 µm (250 µin.)

6.3 µm (250 µin.)

9Y1210293GEG0083US0

Flywheel Stopper

Application

• Use to loosen and tighten the flywheel screw.

C

D

E

A

B

F

G

200 mm (7.87 in.)

30 mm (1.18 in.)

20 mm (0.79 in.)

15 mm (0.59 in.)

15 mm dia. (0.59 in. dia.)

8 mm (0.31 in.)

10 mm dia. (0.39 in. dia.)

9Y1210284GEG0046US0

G-46

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

Crankshaft Bearing 1 Replacing Tool

Application

• Use to press out and press fit the crankshaft bearing 1.

[Press Out]

A

135 mm (5.31 in.)

B

72 mm (2.83 in.)

G

H

C1

C2

C0.3

C

D

E

F

40 mm radius (1.57 in. radius)

10 mm (0.39 in.)

22 mm (0.87 in.)

20 mm dia. (0.79 in. dia.)

47.90 to 47.95 mm dia. (1.8858 to 1.8878 in. dia.)

43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)

Chamfer 1.0 mm (0.039 in.)

Chamfer 2.0 mm (0.079 in.)

Chamfer 0.3 mm (0.012 in.)

[Press Fit]

A

130 mm (5.12 in.)

H

C1

C2

C0.3

D

E

B

C

F

G

72 mm (2.83 in.)

40 mm radius (1.57 in. radius)

9 mm (0.35 in.)

24 mm (0.95 in.)

20 mm dia. (0.79 in. dia.)

68 mm dia. (2.68 in. dia.)

43.90 to 43.95 mm dia. (1.7283 to 1.7303 in. dia.)

Chamfer 1.0 mm (0.039 in.)

Chamfer 2.0 mm (0.079 in.)

Chamfer 0.3 mm (0.012 in.)

9Y1210293GEG0084US0

G-47

KiSC issued 05, 2014 A

RTV1140CPX, WSM

GENERAL

[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.

(1) Gauge (07916-50322)

(2) Cable (07916-50331)

(3) Threaded Joint (07916-50401)

(4) Threaded Joint (07916-50341)

(5) Adaptor

B

(M18 × P1.5)

(07916-50361)

(6) Adaptor

C

(PS3/8) (07916-50371)

(7) Adaptor

D

(PT1/8) (07916-50381)

(8) Adaptor

E

(PS3/8) (07916-50392)

(9) Adaptor

F

(PF1/2) (07916-62601)

(10) Adaptor

58

(PT1/4) (07916-52391)

WSM000001GEG0027US0

Hydrostatic Transmission Tester and HST Adaptor Set

Code No.

• 07916-52040 (Hydrostatic Transmission Tester)

• 07916-53072 (HST Adaptor Set)

Application

• This allows easy measurement of hydrostatic transmission pressure.

(1) Hydrostatic Transmission Tester

(07916-52040)

(2) Gasket (04714-00200)

(3) Connector

3

(07916-51331)

(4) Vacuum Gauge (07916-51331)

(5) Pressure Gauge (Low Pressure)

(07916-51301)

(6) Pressure Gauge (High Pressure)

(in Relief Valve Set Pressure

Tester)

(07916-50321)

(7) HN Tube (in Relief Valve Set

Pressure Tester) (07916-50331)

(8) Valve Seat Driver (07916-60841)

(9) Connector

1

(07916-60811)

(10) Connector

2

(07916-60821)

(11) Long Connector (07916-60831)

(12) Adaptor

1

(07916-52621)

(13) Adaptor

2

with Collar

(07916-52632)

(14) Adaptor

3

with Collar

(07916-52642)

(15) HST Adaptor Set

(07916-53072)

WSM000001GEG0104US0

G-48

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Axle Support

Application

• Use for removing and installing rear axle bracket.

GENERAL

A

B

C

D

E

F

G

H

254.0 mm (10.0 in.)

12.7 mm (0.50 in.)

38.1 mm (1.50 in.)

12.7 mm (0.50 in.)

63.5 mm (2.50 in.)

203.2 mm (8.0 in.)

19 mm (0.75 in.)

44.5 mm (1.75 in.)

I

J

K

L

M

N

O

P

28.7 mm dia. (1.13 in. dia.)

3.3 mm dia. (0.13 in. dia.)

50.8 mm (2.0 in.)

127.0 mm (5.0 in.)

381.0 mm (15.0 in.)

965.2 mm (38.0 in.)

79.5 mm (3.13 in.)

69.9 mm (2.75 in.)

V

W

T

U

Q

R

S

3.81 mm (1.50 in.)

25.4 mm (1.0 in.)

0.52 rad (30 °)

R6.4 (R0.25)

6.35 mm (1/4 in.)

76 mm (3.0 in.)

95.2 mm (3.75 in.)

9Y1210293GEG0085US0

G-49

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Power Train Support

Application

• Use for dismounting and mounting transmission and engine one piece assembly.

GENERAL

C

D

E

A

B

F

G

186.9 mm (7.36 in.)

69.9 mm (2.75 in.)

25.4 mm dia. (1.00 in. dia.)

1/4 in. thick rubber strip

825.5 mm (32.5 in.)

25.4 mm (1.0 in.)

19.1 mm (R0.75 in.)

J

K

L

H

I

M

N

313.2 mm (12.33 in.)

203.2 mm (8.0 in.)

317.5 mm (12.5 in.)

190.5 mm (7.5 in.)

50.8 mm (2.0 in.)

63.5 mm (2.5 in.)

44.5 mm (1.75 in.)

Q

R

S

O

P

T

U

3.3 mm (0.13 in.)

28.7 mm dia. (1.13 in. dia.)

280.2 mm (11.03 in.)

50.8 mm (2.0 in.)

4.2 mm (1/6 in.)

9.5 mm dia. (3/8 in. dia.)

381.0 mm (15.0 in.)

9Y1210293GEG0086US0

G-50

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Lower Arm Bush Tool

Application

• Use for removing and installing lower arm rubber bush.

GENERAL

G

H

I

J

K

L

C

D

A

B

E

F

256.5 mm (10.10 in.)

262.5 mm (10.33 in.)

12 mm dia. (0.472 in. dia.)

14 mm dia. (0.551 in. dia.)

22 mm dia. (0.866 in. dia.)

28 mm dia. (1.102 in. dia.)

32 mm dia. (1.260 in. dia.)

15 mm (0.591 in.)

7 mm (0.276 in.)

5.5 mm (0.217 in.)

1 mm (0.0394 in.)

112.6 mm (4.433 in.)

S

T

U

V

W

X

O

P

M

N

Q

R

2.6 mm (0.102 in.)

34.65 mm dia. (1.364 in. dia.)

14.1 mm dia. (0.555 in. dia.)

38 mm dia. (1.496 in. dia.)

50 mm (1.969 in.)

5 mm (0.197 in.)

90 mm (3.543 in.)

3 mm (0.118 in.)

40 mm dia. (1.575 in. dia.)

45.4 mm dia. (1.787 in. dia.)

50 mm dia. (1.969 in. dia.)

21 mm (0.827 in.)

e f

C0.5

C1

C2 a b

Y

Z c d

22 mm (0.866 in.)

35 mm dia. (1.378 in. dia.)

47.6 mm dia. (1.874 in. dia.)

40 mm (1.575 in.)

30 mm (1.181 in.)

24 mm (0.945 in.)

55 mm (2.165 in.)

16 mm (0.630 in.)

Chamfer 0.5 mm (0.020 in.)

Chamfer 1 mm (0.039 in.)

Chamfer 2 mm (0.079 in.)

9Y1210293GEG0087US0

G-51

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Check and High Pressure Relief Valve Assembly Tool

Application

• Use for readjusting relief valve pressure.

GENERAL

H

I

L

M

J

K

D

E

F

A

B

C

G

30 mm (1.181 in.)

21 mm (0.827 in.)

1 mm (0.039 in.)

0.52 rad (30 °)

50 mm dia. (1.969 in. dia.)

10 mm dia. (0.394 in. dia.)

9.1 to 9.3 mm dia.

(0.359 to 0.366 in.)

34 mm dia. (1.336 in. dia.)

M36 x 1.5 mm Pitch

10 mm (0.394 in.)

16 mm (0.630 in.)

41 mm (1.614 in.)

Chamfer 1 mm (0.039 in.)

U

V

Y

Z

W

X

Q

R

S

N

O

P

T

Chamfer 0.4 mm (0.157 in.)

Chamfer 3 mm (0.118 in.)

Chamfer 2 mm (0.079 in.)

21.4 mm (0.843 in.)

19 mm (0.748 in.)

17 mm (0.669 in.)

10 mm (0.393 in.)

50 mm dia. (1.969 in. dia.)

9.8 mm dia. (0.386 in. dia.)

34.5 mm dia. (1.358 in. dia.)

34.5 mm dia. (1.358 in. dia.)

38 mm dia. (1.496 in. dia.)

25 mm (0.984 in.)

G-52

h i d e f a b c g

(1)

(2)

(3)

1.05 rad (10 °)

Chamfer 0.3 mm (0.012 in.)

23 mm (0.906 in.)

10 mm (0.394 in.)

1 mm (0.039 in.)

6.5 mm (0.256 in.)

Chamfer 0.5 mm (0.020 in.)

11.1 to 11.3 mm

(0.437 to 0.445 in.)

18.8 to 19.0 mm

(0.740 to 0.748 in.)

Spacer

Block

Cap

9Y1210293GEG0088US0

KiSC issued 05, 2014 A

RTV1140CPX, WSM

9. TIRES

GENERAL

CAUTION

• Do not attempt to mount a tire. This should be done by a qualified person with the proper equipment.

• Always maintain the correct tire pressure.

Do not inflate tires above the recommended pressure as shown next page.

IMPORTANT

• Do not use tires other than those approved by KUBOTA.

9Y1210293GEG0089US0

[1] TYPE OF TIRE

(1) Heavy Duty Work Site Tire (HDWS)

(2) Turf Tire

(3) All Terrain Vehicle Tire (ATV)

9Y1210293GEG0090US0

G-53

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[2] TIRE PRESSURE

GENERAL

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.

Inflation pressure Tire sizes

25 x 10 - 12 HDWS, Front and Rear

25 x 10 - 12 Turf, Front and Rear

25 x 10 - 12 ATV, Front

25 x 11 - 12 ATV, Rear

170 kPa (1.7 kgf/cm

2

, 24 psi)

(1) Ground

(A) Insufficient

(B) Normal

(C) Excessive

9Y1210293GEG0002US0

[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. [Any malfunctions or failures of the vehicle resulting from use with improper implements are not covered by the warranty.

Max. cargo loading weight (W1)

Max. cargo load should not exceed

"CBC" or "PCL".

Rear trailer hitch

Max. rolling weight (W2)

590 kg (1300 lbs)

Rear trailer hitch

Max. rolling weight (W4)

295 kg (650 lbs)

[1 Row Seating Mode]

CBC: 500 kg (1100 lbs)

PCL = 730 kg (1609 lbs) - (operator

+ one passenger + option + accessory) weight

[2 Row Seating Mode]

CBC: 300 kg (661 lbs)

PCL = 730 kg (1609 lbs) - (operator

+ passengers + option + accessory) weight

CBC: Cargo Bed Capacity

PCL: Permissible Cargo Load

Max. tongue weight (W3)

50 kg (110 lbs)

Max. tongue weight (W5)

50 kg (110 lbs)

Rolling weight: Trailer weight + Cargo load

• Above mentioned specifications are based on level ground condition.

G-54

9Y1210293GEG0091US0

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[4] CARGO BED

GENERAL

WARNING

• 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. (If hydraulic dump is not equipped.)

• Driving with the cargo bed tilted may be hazardous.

Always lower the bed and lock the hydraulic lift cylinder lever (if hydraulic dump is equipped) or latch the bed (if hydraulic dump is not equipped) before driving.

• Be careful not to put any part your body, such as hands or arms, between the bed and vehicle.

• Drive slowly when it is loaded.



Permissible Cargo Load

Operator Passenger Implement Cargo Bed Capacity

1 row seating mode

95 kg (209 lbs)

95 kg (209 lbs)

–

95 kg (209 lbs)

500 kg (1100 lbs)

500 kg (1100 lbs)

2 row seating mode

95 kg (209 lbs)

95 kg (209 lbs)

95 kg (209 lbs)

95 kg (209 lbs)

–

95 kg (209 lbs)

95 kg (209 lbs) x 2

95 kg (209 lbs) x 3

Blade

Winch

300 kg (661 lbs)

300 kg (661 lbs)

300 kg (661 lbs)

300 kg (661 lbs)

IMPORTANT

• Cargo Bed Capacity (CBC) is 500 kg (1100 lbs) for 1 row seating mode and 300 kg (661 lbs) for 2 row seating mode.

• Never carry loads exceeding the Permissible Cargo Load (PCL).

NOTE

• Max. Cargo load should not exceed "CBC" or "PCL".

PCL = PC - (operator + passengers + option + accessory + cabin) weight

(PCL: Permissible Cargo Load / CBC: Cargo Bed Capacity / PC: Payload Capacity)

Payload capacity 730 kg (1609 lbs)

9Y1210293GEG0092US0

G-55

KiSC issued 05, 2014 A

1

ENGINE

KiSC issued 05, 2014 A

MECHANISM

CONTENTS

1. ENGINE BODY........................................................................................................................... 1-M1

2. LUBRICANTING SYSTEM ......................................................................................................... 1-M2

3. COOLING SYSTEM ................................................................................................................... 1-M3

4. FUEL SYSTEM........................................................................................................................... 1-M4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. ENGINE BODY

ENGINE

Closed Breather

Closed breather system has been adopted to prevent the release of blow-by gas into the atmosphere.

After its oil content is filtered by oil shield (4), the blow-by gas is fed back to the intake manifold through breather valve (3) to be used for re-combustion.

(1) Breather Tube

(2) Cylinder Head Cover

(3) Breather Valve

(4) Oil Shield

(5) Rubber Packing

9Y1210293ENM0001US0

1-M1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

2. LUBRICANTING SYSTEM

(1) Rocker Arm

(2) Oil Pressure Switch

(3) Rocker Arm Shaft

(4) Valve

(5) Governor Shaft

(6) Idle Gear

(7) Crankshaft

(8) Oil Pump

(9) Oil Strainer

(10) Relief Valve

(11) Push Rod

(12) Tappet

(13) Camshaft

(14) Piston

(15) Connecting Rod

(16) Oil Filter Cartridge

ENGINE

This engine's lubricating system consists of oil strainer (9), oil pump (8), relief valve (10), oil filter cartridge (16) and oil pressure switch (2).

The oil pump sucks lubricating oil from the oil pan through the oil strainer and the oil flows down to the filter cartridge, where it is further filtered. Then the oil is forced to crankshaft (7), connecting rods (15), idle gear (6), governor shaft (5), camshaft (13) and rocker arm shaft (3) to lubricate each part.

Some part of oil, splashed by the crankshaft or leaking and dropping from gaps of each part, lubricates these parts: piston (14), cylinders, small ends or connecting rods, tappets (12), push rods (11), inlet and exhaust valves (4) and timing gears.

9Y1210293ENM0002US0

1-M2

KiSC issued 05, 2014 A

RTV1140CPX, WSM

3. COOLING SYSTEM

ENGINE

(1) Radiator

(2) Fan Drive Motor

(3) Radiator Fan

(4) Water Pump

(5) Thermostat

(6) Cylinder Head

(7) Cylinder Block

a: From Transmission Oil

Cooler b: To Transmission Oil Cooler c: To Air Conditioner Unit d: From Air Conditioner Unit

The cooling system consists of a radiator (1), a radiator fan (3), a centrifugal water pump (4) and a thermostat (5).

The coolant is cooled through the radiator core.

The radiator fan (3) is driven by the fan drive motor (2). The motor (2) moves or stops according to the coolant temperature. When the coolant temperature is high, the motor moves to pull cooling air to the radiator core. When the coolant temperature is low, the motor stops.

The water pump (4) receives coolant from the radiator or from the cylinder head, and forces it into the cylinder block (7). And the coolant flows to the transmission oil cooler through cylinder block (7).

Also, the coolant flows to the air conditioner unit from the water pump (4), when the water valve in the air conditioner unit opens.

The thermostat (5) opens or closes according to the coolant temperature. When the coolant temperature is high, the thermostat opens to allow the water to flow from the cylinder head to the radiator. When the coolant temperature is low, the thermostat closes to flow the coolant only to the water pump.

9Y1210293ENM0003US0

1-M3

KiSC issued 05, 2014 A

RTV1140CPX, 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

ENGINE

Fuel from the fuel tank (3) passes through the fuel filter (5), and then enters the injection pump (8) after impurities such as dirt, water, etc. are removed.

The fuel pressurized by the injection pump to the opening pressure (13.73 to 14.71 MPa, 140 to 150 kgf/cm

2

, 1990 to 2133 psi), of the injection nozzle (1) is injected into the combustion chamber.

Part of the fuel fed to the injection nozzle (1) lubricates the moving parts of the needle valve inside the nozzle, then returns to the fuel tank through the fuel overflow pipe (2) from the upper part of the nozzle holder.

9Y1210293ENM0004US0

1-M4

KiSC issued 05, 2014 A

SERVICING

CONTENTS

1. TROUBLESHOOTING.................................................................................................................1-S1

2. SERVICING SPECIFICATIONS ..................................................................................................1-S4

[1] ENGINE BODY......................................................................................................................1-S4

[2] LUBRICATING SYSTEM.......................................................................................................1-S7

[3] COOLING SYSTEM ..............................................................................................................1-S7

[4] FUEL SYSTEM......................................................................................................................1-S8

3. TIGHTENING TORQUES............................................................................................................1-S9

4. CHECKING, DISASSEMBLING AND SERVICING ...................................................................1-S10

[1] CHECKING AND ADJUSTING............................................................................................1-S10

(1) Engine Body ..................................................................................................................1-S10

(2) Lubricating System ........................................................................................................1-S12

(3) Cooling System .............................................................................................................1-S13

(4) Fuel System...................................................................................................................1-S15

[2] PREPARATION...................................................................................................................1-S19

(1) Removing Outer Components .......................................................................................1-S19

(2) Separating Rear Axle ....................................................................................................1-S24

(3) Separating Transmission Assembly ..............................................................................1-S25

(4) Separating Engine .........................................................................................................1-S27

[3] DISASSEMBLING AND ASSEMBLING ..............................................................................1-S27

(1) External Components ....................................................................................................1-S27

(2) Cylinder Head and Valve...............................................................................................1-S28

(3) Gear Case and Timing Gears........................................................................................1-S31

(4) Piston and Connecting Rod...........................................................................................1-S35

(5) Crankshaft .....................................................................................................................1-S37

[4] SERVICING.........................................................................................................................1-S39

(1) Cylinder Head and Valves .............................................................................................1-S39

(2) Timing Gears, Camshaft and Governor Gear................................................................1-S44

(3) Piston and Connecting Rod...........................................................................................1-S47

(4) Crankshaft .....................................................................................................................1-S49

(5) Cylinder .........................................................................................................................1-S53

(6) Oil Pump........................................................................................................................1-S54

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. TROUBLESHOOTING

Symptom

Engine Does Not

Start

(Starter Does Not

Run)

Engine Revolution Is

Not Smooth

Either White or Blue

Exhaust Gas Is

Observed

ENGINE

Probable Cause Solution

No fuel

Air in the fuel system

Water in the fuel system

Replenish fuel

Bleed

Change fuel and repair or replace fuel system

Clean Fuel pipe clogged

Fuel filter clogged

Excessively high viscosity of fuel or engine oil at low temperature

Change

Use specified fuel or engine oil

Fuel with low cetane number Use specified fuel

Fuel leak due to loose injection pipe retaining nut Tighten retaining nut

Incorrect injection timing

Fuel camshaft worn

Injection nozzle clogged

Injection pump malfunctioning

Seizure of crankshaft, camshaft, piston, cylinder or bearing

Compression leak from cylinder

Adjust

Replace

Repair or replace

Replace

Repair or replace

Improper valve timing

Piston ring and cylinder worn

Excessive valve clearance

Battery discharged

Starter malfunctioning

Main switch malfunctioning

Main shift lever switch defective

Wiring disconnected

Fuel filter clogged or dirty

Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder

Correct or replace timing gear

Repair or replace

Adjust

Charge

Repair or replace

Replace

Replace

Connect

Change

Air cleaner clogged Clean or replace

Fuel leak due to loose injection pipe retaining nut Tighten retaining nut

Injection pump malfunctioning

Incorrect nozzle injection pressure

Replace

Adjust

Injection nozzle stuck or clogged

Governor malfunctioning

Excessive engine oil

Repair or replace

Repair

Reduce to specified level

Repair or replace Piston ring and cylinder worn or stuck

Incorrect injection timing

Deficient compression

Adjust

Adjust top clearance

Reference

Page

G-8

G-40

–

G-31

G-31

G-8

G-8

1-S28

1-S15

1-S34

1-S28

1-S33

–

1-S28,

1-S30

1-S34

1-S36

1-S15

1-S39

G-32

1-S28

1-S33

1-S28

1-S28

–

G-8

1-S36

1-S11

G-28

8-S26

8-S9

8-S13

–

G-31

1-S1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Symptom

Either Black or Dark

Gray Exhaust Gas Is

Observed

Probable Cause

Overload

Low grade fuel used

Fuel filter clogged

Air cleaner clogged

Deficient nozzle injection

Deficient Output

Incorrect injection timing

Engine's moving parts seem to be seizing

Uneven fuel injection

Deficient nozzle injection

Compression leak

Excessive Lubricant

Oil Consumption

Piston ring's gap facing the same direction

Fuel Mixed into

Lubricant Oil

Oil ring worn or stuck

Piston ring groove worn

Valve stem and valve guide worn

Oil leaking due to defective seals or packing

Injection pump's plunger worn

Deficient nozzle injection

Water Mixed into

Lubricant Oil

Low Oil Pressure

Injection pump broken

Head gasket defective

Cylinder block or cylinder head flawed

Engine oil insufficient

Oil strainer clogged

Relief valve stuck with dirt

Relief valve spring weaken or broken

Excessive oil clearance of crankshaft bearing

Excessive oil clearance of rocker arm

Oil passage clogged

Different type of oil

High Oil Pressure

Oil pump defective

Different type of oil

Relief valve defective

ENGINE

Solution

Lessen load

Use specified fuel

Replace

Clean or replace

Repair or replace nozzle

Adjust

Repair or replace

Replace

Replace

Replace

Replenish

Clean

Clean

Replace

Replace

Replace

Clean

Replace injection pump

Repair or replace nozzle

Replace head gasket, tighten cylinder head screw, glow plug and nozzle holder

Shift ring gap direction

Replace

Replace piston

Replace

Replace

Replace

Repair or replace nozzle

Use specified type of oil

Repair or replace

Use specified type of oil

Replace

Reference

Page

–

G-8

G-31

G-32

1-S18,

1-S28

1-S15

–

1-S33

1-S18,

1-S28

1-S28,

1-S30

1-S35

1-S54

G-8

–

1-S33

1-S30

–

G-8

1-S31

–

–

1-S51

1-S43

–

G-8

1-S36

1-S49

1-S41

–

1-S33

1-S18,

1-S28

1-S2

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Symptom

Engine Overheated

Probable Cause

Engine oil insufficient

Alternator belt broken or elongated

Cooling water insufficient

Radiator net and radiator fin clogged with dust

Inside of radiator corroded

Coolant flow route corroded

Radiator cap defective

Overload running

Head gasket defective

Incorrect injection timing

Unsuitable fuel used

ENGINE

Solution

Replenish

Replace or adjust

Replenish

Clean

Clean or replace

Clean or replace

Replace

Loosen load

Replace

Adjust

Use specified fuel

Reference

Page

G-8

G-29,

1-S13

G-8

–

G-17

G-17

–

–

1-S30

1-S15

G-8

9Y1210293ENS0002US0

1-S3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

2. SERVICING SPECIFICATIONS

[1] ENGINE BODY

Item

Compression Pressure

Factory Specification

3.14 to 3.53 MPa

32.0 to 36.0 kgf/cm

2

456 to 512 psi

• Difference among Cylinders

Valve Clearance (Cold)

Top Clearance

Cylinder Head Surface Flatness

–

0.145 to 0.185 mm

0.00571 to 0.00728 in.

0.55 to 0.70 mm

0.022 to 0.027 in.

–

Valve Recessing

Valve Stem to Valve Guide

• Valve Stem

• Valve Guide

Valve Face

Valve Seat

Valve Spring

Rocker Arm Shaft to Rocker Arm

• Rocker Arm Shaft

• Rocker Arm

Intake and Exhaust

Clearance

O.D.

I.D.

Angle (Intake)

Angle (Exhaust)

Angle (Intake)

Angle (Exhaust)

Width

Tilt

Free Length

Setting Load

Clearance

O.D.

I.D.

Allowable Limit

2.26 MPa

23.0 kgf/cm

2

327 psi

10 % or less

–

–

ENGINE

− 0.050 to 0.25 mm

− 0.0020 to 0.0098 in.

0.035 to 0.065 mm

0.0014 to 0.0025 in.

6.960 to 6.975 mm

0.2741 to 0.2746 in.

7.010 to 7.025 mm

0.2760 to 0.2765 in.

1.0 rad

60 °

0.79 rad

45 °

1.0 rad

60 °

0.79 rad

45 °

2.12 mm

0.0835 in.

–

0.05 mm

0.002 in.

0.40 mm

0.016 in.

0.10 mm

0.0039 in.

–

–

–

–

–

–

–

37.0 to 37.5 mm

1.46 to 1.47 in.

117.4 N / 31.0 mm

11.97 kgf / 31.0 mm

26.39 lbf / 1.22 in.

0.016 to 0.045 mm

0.00063 to 0.0017 in.

11.973 to 11.984 mm

0.47138 to 0.47181 in.

12.000 to 12.018 mm

0.47244 to 0.47314 in.

1.0 mm

0.039 in.

36.5 mm

1.44 in.

100.0 N / 31.0 mm

10.20 kgf / 31.0 mm

22.48 lbf / 1.22 in.

0.10 mm

0.0039 in.

–

–

1-S4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Push Rod

Tappet to Tappet Guide

• Tappet

• Tappet Guide

Timing Gear

• Crank Gear to Idle Gear 1

• Idle Gear 1 to Cam Gear

Item

Alignment

Clearance

O.D.

I.D.

Backlash

Backlash

• Idle Gear 1 to Injection Pump Gear Backlash

Governor Gear

• Governor Gear to Injection Pump Gear Backlash

Idle Gear

• Idle Gear 1

Camshaft

Side Clearance

Side Clearance

Cam Height

Alignment

Intake

Camshaft Journal to Cylinder Block Bore

Exhaust

Oil Clearance

• Camshaft Journal

• Cylinder Block Bore

Idle Gear Shaft to Gear Bushing

• Idle Gear 1

O.D.

I.D.

Oil Clearance

O.D.

• Idle Gear Shaft 1

• Idle Gear Bushing

Piston Pin Bore

I.D.

I.D.

1-S5

Factory Specification

–

0.020 to 0.062 mm

0.00079 to 0.0024 in.

19.959 to 19.980 mm

0.78579 to 0.78661 in.

20.000 to 20.021 mm

0.78740 to 0.78822 in.

0.0320 to 0.115 mm

0.00126 to 0.00452 in.

0.0360 to 0.114 mm

0.00142 to 0.00448 in.

0.0340 to 0.116 mm

0.00134 to 0.00456 in.

0.0300 to 0.116 mm

0.00119 to 0.00460 in.

0.20 to 0.51 mm

0.0079 to 0.020 in.

0.070 to 0.22 mm

0.0028 to 0.0086 in.

–

28.80 mm

1.134 in.

29.0 mm

1.142 in.

0.050 to 0.091 mm

0.0020 to 0.0035 in.

35.934 to 35.950 mm

1.4147 to 1.4153 in.

36.000 to 36.025 mm

1.4173 to 1.4183 in.

0.020 to 0.054 mm

0.00079 to 0.0021 in.

25.967 to 25.980 mm

1.0223 to 1.0228 in.

26.000 to 26.021 mm

1.0237 to 1.0244 in.

22.000 to 22.013 mm

0.86615 to 0.86665 in.

ENGINE

Allowable Limit

0.25 mm

0.0098 in.

0.07 mm

0.003 in.

–

–

–

0.10 mm

0.0039 in.

–

–

22.03 mm

0.8673 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.15 mm

0.0059 in.

0.80 mm

0.031 in.

0.30 mm

0.012 in.

0.01 mm

0.0004 in.

28.75 mm

1.132 in.

28.95 mm

1.140 in.

0.15 mm

0.0059 in.

–

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Item

Piston Pin to Small End Bushing

• Piston Pin

• Small End Bushing

Connecting Rod

Piston Ring Gap

Piston Ring to Piston Ring Groove

• Second Ring

• Oil Ring

Crankshaft

Crankpin to Crankpin Bearing

• Crankpin

• Crankpin Bearing

Crankshaft to Crankshaft Bearing 1

• Crankshaft Journal

• Crankshaft Bearing 1

Crankshaft to Crankshaft Bearing 2

• Crankshaft Journal

• Crankshaft Bearing 2

Oil Clearance

O.D.

I.D.

Alignment

Top Ring

Second Ring

Oil Ring

Clearance

Clearance

Side Clearance

Alignment

Oil Clearance

O.D.

I.D.

Oil Clearance

O.D.

I.D.

Oil Clearance

O.D.

I.D.

Factory Specification

0.014 to 0.038 mm

0.00055 to 0.0014 in.

22.002 to 22.011 mm

0.86622 to 0.86657 in.

22.025 to 22.040 mm

0.86713 to 0.86771 in.

–

0.30 to 0.45 mm

0.012 to 0.017 in.

0.30 to 0.45 mm

0.012 to 0.017 in.

0.25 to 0.40 mm

0.0099 to 0.015 in.

0.0850 to 0.112 mm

0.00335 to 0.00440 in.

0.020 to 0.055 mm

0.00079 to 0.0021 in.

0.15 to 0.31 mm

0.0059 to 0.012 in.

–

0.029 to 0.091 mm

0.0011 to 0.0036 in.

39.959 to 39.975 mm

1.5732 to 1.5738 in.

40.040 to 40.050 mm

1.5764 to 1.5767 in.

0.0340 to 0.114 mm

0.00134 to 0.00448 in.

47.934 to 47.950 mm

1.8872 to 1.8877 in.

47.984 to 48.048 mm

1.8892 to 1.8916 in.

0.034 to 0.095 mm

0.0014 to 0.0037 in.

47.934 to 47.950 mm

1.8872 to 1.8877 in.

47.984 to 48.029 mm

1.8892 to 1.8909 in.

ENGINE

Allowable Limit

0.15 mm

0.0059 in.

–

–

0.20 mm

0.0079 in.

–

–

0.20 mm

0.0079 in.

–

–

–

0.05 mm

0.002 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

1.25 mm

0.0492 in.

0.20 mm

0.008 in.

0.15 mm

0.0059 in.

0.50 mm

0.020 in.

0.02 mm

0.0008 in.

0.20 mm

0.0079 in.

–

1-S6

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Item

Crankshaft to Crankshaft Bearing 3

• Crankshaft Journal

• Crankshaft Bearing 3

Cylinder Liner I.D.

Cylinder (Oversized)

Inner Rotor to Outer Rotor

Outer Rotor to Pump Body

Inner Rotor to Cover

[3] COOLING SYSTEM

Fan Belt

Radiator Cap

Radiator

Item

Thermostat

• Valve Opening Temperature

• Valve Opening Temperature

Oil Clearance

O.D.

I.D.

[2] LUBRICATING SYSTEM

Item

Engine Oil Pressure At Idle Speed

At Rated Speed

Clearance

Clearance

Clearance

Allowable Limit

0.20 mm

0.0079 in.

–

ENGINE

Factory Specification

0.0340 to 0.103 mm

0.0013 to 0.0038 in.

51.921 to 51.940 mm

2.0442 to 2.0448 in.

51.974 to 52.024 mm

2.0463 to 2.0481 in.

78.000 to 78.019 mm

3.0709 to 3.0716 in.

78.500 to 78.519 mm

3.0906 to 3.0912 in.

–

78.15 mm

3.077 in.

78.65 mm

3.096 in.

9Y1210293ENS0003US0

Factory Specification

More than 49 kPa

0.5 kgf/cm

2

7 psi

197 to 441 kPa

2.00 to 4.50 kgf/cm

28.5 to 64.0 psi

2

0.060 to 0.18 mm

0.0024 to 0.0071 in.

0.100 to 0.180 mm

0.00394 to 0.00708 in.

0.025 to 0.075 mm

0.00099 to 0.0029 in.

Allowable Limit

–

147 kPa

1.50 kgf/cm

2

21.3 psi

–

–

–

9Y1210293ENS0004US0

Tension

Pressure Falling

Time

Water Leakage

Test Pressure

At Beginning

Opened

Completely

1-S7

Factory Specification

7.0 to 9.0 mm / 98 N

0.28 to 0.35 in. / 98 N

(10 kgf, 22 lbf)

10 seconds or more

88 → 59 kPa

0.9 → 0.6 kgf/cm

2

13 → 9 psi

No leak at specified pressure

177 kPa

1.80 kgf/cm

25.7 psi

2

80.5 to 83.5 °C

176.9 to 182.3 °F

95 °C

203 °F

Allowable Limit

–

–

–

–

–

9Y1210293ENS0005US0

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[4] FUEL SYSTEM

Item

Injection Pump

Pump Element

Delivery Valve

Injection Nozzle

Injection Nozzle Valve Seat

ENGINE

Injection Timing

Fuel Tightness

Fuel Tightness

Injection Pressure

Valve Seat

Tightness

Factory Specification

0.3011 to 0.3185 rad

(17.25 to 18.75 °) before T.D.C.

–

Allowable Limit

–

10 seconds

13.73 → 12.75 MPa

140.0 → 130.0 kgf/cm

2

1991 → 1849 psi

13.73 to 14.71 MPa

140 to 150 kgf/cm

2

1991 to 2134 psi

When the pressure is

12.75 MPa

(130.0 kgf/cm

2

,

1849 psi), the valve seat must be fuel tightness.

13.73 MPa

140.0 kgf/cm

2

1991 psi

5 seconds

13.73 → 12.75 MPa

140.0 →

130.0 kgf/cm

2

1991 → 1849 psi

–

–

9Y1210293ENS0006US0

1-S8

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ENGINE

3. TIGHTENING TORQUES

Tightening torques of screws bolts and nuts on the table below are especially specified.

(For general use screws, bolts and nuts: See page G-10.)

Item

Rear wheel mounting screw

Leaf spring mounting bolt and nut

Lock nut

Mission frame mounting bolt and nut

Transmission case bottom set screw

Transmission case side set screw

Engine set screw

Engine mounting screw

Cylinder head cover cap nut

Injection pipe retaining nut

Nozzle holder assembly

Nozzle holder

Overflow pipe assembly retaining nut

Glow plug

*Rocker arm bracket nut

*Cylinder head screw

*Fan drive pulley screw

*Connecting rod screw

*Flywheel screw

Bearing case cover screw

*Main bearing case screw 2

*Main bearing case screw 1

35 to 39

20 to 24

7.9 to 14

22 to 26

64 to 68

236 to 245

42 to 46

54 to 58

9.81 to 11.2

49 to 53

30 to 34

N·m

75 to 90

48.0 to 55.9

24.0 to 28.0

77.4 to 90.2

39.2 to 44.1

62.7 to 72.5

48.0 to 55.9

17.7 to 20.5

7 to 8

25 to 34

49 to 68

3.5 to 4.0

2.0 to 2.5

0.80 to 1.5

2.2 to 2.7

6.5 to 7.0

24.0 to 25.0

4.2 to 4.7

5.5 to 6.0

1.00 to 1.15

5.0 to 5.5

3.0 to 3.5

kgf·m

7.6 to 9.2

4.90 to 5.70

2.45 to 2.85

7.90 to 9.19

4.00 to 4.49

6.40 to 7.39

4.90 to 5.70

1.80 to 2.10

0.7 to 0.9

2.5 to 3.5

5.0 to 7.0

26 to 28

15 to 18

5.8 to 10

16 to 19

47 to 50

174 to 180

31 to 33

40 to 43

7.24 to 8.31

37 to 39

22 to 25

lbf·ft

55.3 to 66.4

35.4 to 41.2

17.7 to 20.6

57.1 to 66.5

29.0 to 32.5

46.3 to 53.4

35.4 to 41.2

13.1 to 15.1

5 to 6

18 to 25

36 to 50

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 or the threads. The pitch is the nominal distance in mm between two threads.

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KiSC issued 05, 2014 A

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ENGINE

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING

(1) Engine Body

Compression Pressure

1. Run the engine until it is warmed up.

2. Stop the engine.

3. Remove the air cleaner, the muffler and all glow plugs (or nozzles).

4. Set a compression tester with the adaptor to the glow plug hole

(or nozzle hole).

Nozzle hole: Adaptor

H

(07909-31231)

Glow plug hole: Adaptor

L

(07909-31301)

5. After making sure that the stop lever is set at the stop position

(non-injection), run the engine with the starter and measure the compression pressure.

6. Repeat steps 4 and 5 for each cylinder.

7. If the measurement is below the allowable limit, apply a small amount of oil to the cylinder wall through the glow plug hole (or nozzle hole) and measure the compression pressure again.

8. If the compression pressure is still less than the allowable limit, check the top clearance, valve clearance and cylinder head.

9. If the compression pressure increases after applying oil, check the cylinder wall and piston rings.

NOTE

• Check the compression pressure with the specified valve clearance.

• Always use a fully charged battery for performing this test.

• Variances in cylinder compression values should be under

10 %.

Compression pressure

Factory specification

Allowable limit

3.14 to 3.53 MPa

32.0 to 36.0 kgf/cm

2

456 to 512 psi

2.26 MPa

23.0 kgf/cm

2

327 psi

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ENGINE

Valve Clearance

IMPORTANT

• Valve clearance must be checked and adjusted when engine is cold.

1. Remove the cylinder head cover and the glow plugs.

2. Align the

"1TC"

mark (1) on the flywheel with alignment mark

(2) on the rear end plate so that the No. 1 piston comes to the compression top dead center.

3. Check the following valve clearance marked with "



" using a thickness gauge.

4. If the clearance is not within the factory specifications, adjust with the adjusting screw.

5. Then turn the flywheel 6.28 rad (360 °), and align the "1TC" mark (1) on the flywheel and center of timing window (2) on the rear end plate so that the No. 1 piston comes to the overlap position.

6. Check the following valve clearance marked with "



" using a feeler gauge.

Adjustable cylinder location of piston

When No. 1 piston is at compression top dead center

When No. 1 piston is at overlap position

1st

2nd

3rd

1st

2nd

3rd

Number of cylinders

Valve arrangement

3 cylinder

IN.

EX.

 









Intake and exhaust valve clearance (Cold)

Factory specification

0.145 to 0.185 mm

0.00571 to 0.00728 in.

7. If the clearance is not with in the factory specifications, adjust with the adjusting screw.

NOTE

• The sequence of cylinder numbers is given as No. 1, No. 2 and No. 3 starting from the gear case side.

• After adjusting the valve clearance, secure the adjusting screw with the lock nut.

(1)

"1TC"

Mark (2) Timing Window

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(2) Lubricating System

ENGINE

Engine Oil Pressure

1. Remove the engine oil pressure switch (1), and install an oil pressure tester (2).

2. Start the engine. After warming up, measure the oil pressure at both idle and rated speeds.

3. If the oil pressure is less than the allowable limit, check the following.

• Engine oil insufficient

• Oil pump defective

• Oil strainer clogged

• Oil filter cartridge clogged

• Oil gallery clogged

• Excessive oil clearance

• Foreign matter in the relief valve

Engine oil pressure

At idle speed

At rated speed

Allowable limit

Factory specification

Allowable limit

More than

49 kPa

0.5 kgf/cm

2

7 psi

197 to 441 kPa

2.00 to 4.50kgf/cm

2

28.5 to 64.0 psi

147 kPa

1.50 kgf/cm

2

21.3 psi

(When reassembling)

• After checking the engine oil pressure, tighten the engine oil pressure switch to the specified torque.

Tightening torque Oil pressure switch

15 to 19 N·m

1.5 to 2.0 kgf·m

11 to 14 lbf·ft

(1) Oil Pressure Switch (2) Oil Pressure Tester

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(3) Cooling System

ENGINE

Alternator 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 Ibf).

2. If the measurement is not within the factory specifications, loosen the alternator mounting screws and relocate the alternator to adjust.

Deflection

(A)

Factory specification

7.0 to 9.0 mm

0.28 to 0.35 in.

(A) Deflection

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Alternator Belt Damage and Wear

1. Check the belt for damage.

2. If the belt is damaged, replace it.

3. Check if the belt is worn and sunk in the pulley groove.

4. If the belt is nearly worn out and deeply sunk in the pulley groove, replace it.

(A) Good (B) Bad

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ENGINE

CAUTION

• When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down.

Otherwise, there is risk of scalding to yourself and people rearby from steam and hot water.

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Radiator Cap Air Leakage

1. Install radiator cap (1) on adaptor (3) and radiator tester (2).

2. Apply the specified pressure (88 kPa, 0.9 kgf/cm

2

, 13 psi), and measure the time for the pressure to fall to 59 kPa (0.6 kgf/cm

2

,

9 psi).

3. If the measurement is less than the factory specification, replace the radiator cap

Pressure falling time Factory specification

More than 10 seconds for pressure fall from

88 to 59 kPa

(from 0.9 to 0.6 kgf/cm

2

, from 13 to 9 psi)

(1) Radiator Cap

(2) Radiator Tester

(3) Adaptor

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Radiator Water Leakage

1. Pour a specified amount of water into the radiator.

2. Install a radiator tester (1) and an adapter (2), and raise the water pressure to the specified pressure.

3. Check the radiator for water leaks.

4. For water leak from a pinhole, repair with the radiator cement.

When water leak is excessive, replace the radiator.

Radiator water leakage test pressure

Factory specification

177 kPa

1.80 kgf/cm

2

25.7 psi

(1) Radiator Tester (2) Adaptor

9Y1210293ENS0015US0

Thermostat Valve Opening Temperature

1. Suspend the thermostat in the water by a string with its end inserted between the valve and seat.

2. Heating the water gradually, read the temperature when the valve opens and leaves the string.

3. Continue heating and read the temperature when the valve opens approx. 8 mm (0.315 in.).

4. If the measurement is not within the factory specifications, replace the thermostat.

Thermostat's valve opening temperature

Thermostat's at which thermostat completely opens

Factory specification

Factory specification

80.5 to 83.5 °C

176.9 to 182.3 °F

95 °C

203 °F

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(4) Fuel System

ENGINE

Injection Timing

1. Remove the injection pipes.

2. Remove the engine stop solenoid.

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. 1 cylinder.

4. After the fuel fills up to the hole of the delivery valve holder for

No. 1 cylinder, turn back (clockwise) the flywheel around

1.57 rad (90 °).

5. Turn the flywheel counterclockwise to set at around 0.44 rad

(25 °) before T.D.C..

6. Slowly turn the flywheel counterclockwise and stop turning when the fuel begins to come up, to get the present injection timing.

7. Check to see the degree on flywheel.

The flywheel is marked

"1TC"

,

"10"

and

"20"

for the crank angle before the top dead center of No. 1 cylinder.

8. If injection timing is out of adjustment, readjust the timing with shims.

Injection timing Factory specification

0.3011 to 0.3185 rad

(17.25 to 18.75 °) before T.D.C.

NOTE

• The liquid gasket is not required for assembling.

• Shims are available in thickness of 0.20 mm (0.0079 in.),

0.25 mm (0.0098 in.) and 0.30 mm (0.0118 in.). Combine these shims for adjustments.

• Addition or reduction of shim (0.05 mm, 0.0020 in.) delays or advances the injection timing by approx. 0.0087 rad

(0.5 °).

• In disassembling and replacing the injection pump, be sure to use the same number of new shims with the same thickness.

(1) Timing Line

(2) Timing Window

(3) Delivery Valve Holder

(4) Shim (Soft Metal Gasket Shim)

(5) Two-holes: 0.20 mm (0.0079 in.)

(6) One-hole: 0.25 mm (0.0098 in.)

(7) Without hole: 0.30 mm (0.0118 in.)

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ENGINE

CAUTION

• If spray from injection nozzle comes in contact with human body, fuel can be injected under skin. Blood poisoning and death may occur.

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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 (1) jetted with the proper injection pressure to the injection pump pressure tester (2). (Refer to the figure.)

5. Set the speed control lever to the maximum speed position.

6. Run the starter to increase the pressure.

7. If the pressure can not reach the allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.

Fuel tightness of pump element

Allowable limit

13.73 MPa

140.0 kgf/cm

2

1991 psi

NOTE

• Never try to disassemble the injection pump assembly. For repairs, you must contact a Kubota-authorized pump service shop.

(1) Injection Nozzle

(2) Injection Pump Pressure Tester

(3) Protection Cover for Jetted Fuel

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ENGINE

Fuel Tightness of Delivery Valve

1. Remove the engine stop solenoid.

2. Remove the injection pipes and glow plugs.

3. Install a pressure tester to the fuel injection pump.

4. Install the injection nozzle (1) jetted with the proper injection pressure to the injection pump pressure tester (2).

5. Run the starter to increase the pressure.

6. Stop the starter when the fuel jets from the injection nozzle.

After that, turn the flywheel by the hand and raise the pressure to approx. 13.73 MPa (140 kgf/cm

2

, 1991 psi).

7. Now turn the flywheel back about half a turn (to keep the plunger free). Maintain the flywheel at this position and clock the time taken for the pressure to drop from 13.73 to 12.75 MPa (from

140 to 130 kgf/cm

2

, from 1991 to 1849 psi).

8. Measure the time lapse for fuel pressure to drop to: 12.75 MPa

(130 kgf/cm

2

, 1849 psi).

9. If the measurement is less than allowable limit, replace the pump with new one or repair with a Kubota-authorized pump service shop.

Fuel tightness of delivery valve

Factory specification

Allowable limit

10 seconds

13.73 → 12.75 MPa

140.0 → 130.0 kgf/cm

2

1991 → 1849 psi

5 seconds

13.73 → 12.75 MPa

140.0 → 130.0 kgf/cm

2

1991 → 1849 psi

NOTE

• Never try to disassemble the injection pump assembly. For repairs, you must contact a Kubota-authorized pump service shop.

(1) Injection Nozzle

(2) Injection Pump Pressure Tester

(3) Protection Cover for Jetted Fuel

9Y1210293ENS0020US0

CAUTION

• Check the injection pressure and condition after confirming 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.

9Y1210293ENS0021US0

Nozzle Spraying Condition

1. Set the injection nozzle to a nozzle tester (Code No.

07909-31361), and check the nozzle spraying condition.

2. If the spraying condition is defective, replace the nozzle piece.

(a) Good (b) Bad

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ENGINE

Fuel Injection Pressure

1. Set the injection nozzle to a nozzle tester (Code No.

07909-31361).

2. Slowly move the tester handle to measure the pressure at which fuel begins jetting out from the nozzle.

3. If the measurement is not within the factory specifications, replace the adjusting washer (1) in the nozzle holder to adjust it.

(Reference)

• Pressure variation with 0.01 mm (0.0004 in.) difference of adjusting washer thickness.

Approx. 235 kPa (2.4 kgf/cm

2

, 34 psi)

Fuel injection pressure Factory specification

13.73 to 14.71 MPa

140 to 150 kgf/cm

2

1991 to 2134 psi

(1) Adjusting Washer

9Y1210293ENS0023US0

Nozzle Holder

1. Secure the nozzle retaining nut (7) with a vise.

2. Remove the nozzle holder (1), and take out parts inside.

(When reassembling)

• Assemble the nozzle in clean fuel.

• Install the push rod (4), noting its direction.

• After assembling the nozzle, be sure to adjust the fuel injection pressure.

Tightening torque

Nozzle holder

Overflow pipe retaining nut

Nozzle holder assembly

35 to 39 N·m

3.5 to 4.0 kgf·m

26 to 28 lbf·ft

20 to 24 N·m

2.0 to 2.5 kgf·m

15 to 18 lbf·ft

49 to 68 N·m

5.0 to 7.0 kgf·m

36 to 50 lbf·ft

(1) Nozzle Holder

(2) Adjusting Washer

(3) Nozzle Spring

(4) Push Rod

(5) Distance Piece

(6) Nozzle Piece

(7) Nozzle Retaining Nut

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[2] PREPARATION

(1) Removing Outer Components

Battery

ENGINE

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. Set the seat to 1 row.

2. Remove the battery cover (1).

3. Remove the air cleaner hose (2).

4. Disconnect the negative cable (3) from the battery (4).

(1) Battery Cover

(2) Air Cleaner Hose

(3) Negative Cable

(4) Battery

(5) Positive Cable

9Y1210293ENS0025US0

Cargo Bed

1. Lift up the cargo bed (1) by hand and support it with the safety support so that the hydraulic cylinder should not drop.

2. Remove the cotter pin and clevis pin (2).

3. Disconnect the connector (3) from main harness, then separate the harness for the tail lamps.

4. Loosen the lock nut (4) and remove the hinge bolt (5) and nut.

(1) Cargo Bed

(2) Clevis Pin

(3) Connector

(4) Lock Nut

(5) Hinge Bolt

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ENGINE

Draining Coolant

CAUTION

• 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.

1. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain plug (1) and remove radiator cap (3). The radiator cap must be removed to completely drain the coolant.

3. After all coolant is drained, close the drain plug.

(When refilling)

• Fill with clean water and cooling system cleaner.

• Follow directions of the cleaner instruction.

• After fill with clean water and anti-freeze until the coolant level is just below the radiator cap.

Install the radiator cap securely.

• Fill with fresh water up to the

"FULL"

mark on the recovery tank.

• Start and operate the engine for few minutes.

• Stop the engine and let cool.

• Check coolant level of recovery tank and add coolant if necessary.

Coolant Capacity

5.2 L

5.5 U.S.qts

4.6 Imp.qts

IMPORTANT

• Do not start engine without coolant.

• Use clean, fresh water and anti-freeze to fill the radiator and recovery tank.

• When the anti-freeze is mixed with water, the anti-freeze mixing ratio must be less than 50 %.

• Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

(1) Drain Plug

(2) Rear Tire (L.H.)

(3) Radiator Cap

(4) Recovery Tank

A: FULL

B: LOW

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ENGINE

Draining Hydraulic Tank Oil

CAUTION

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 may cause burns.

1. Park the vehicle on a firm, flat and level surface.

2. Tilt the seat.

3. Remove the under guard.

4. To drain the used oil, remove the drain plug and filling plug and drain the oil completely into the oil pan.

5. After draining, reinstall the drain plug.

6. Install the under guard.

(When refilling)

• Fill with new KUBOTA SUPER UDT fluid up to the upper notch

on the dipstick. (See page G-8.)

How to check:

Wipe dipstick clean with a rag and screw filling plug into filling hole. Remove filling plug again to see if the oil level is between the upper and lower notch.

• After filling, reinstall the filling plug.

Oil capacity

14.5 L

15.3 U.S.qts

12.8 Imp.qts

(1) Under Guard

(2) Drain Plug

(3) Filling Plug with Dipstick

A: Oil level is acceptable within this range.

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ENGINE

Muffler Cover, Muffler, Transmission Rear Guard and

Hydraulic Cylinder

1. Remove the stay (1) and muffler cover (2).

2. Remove the muffler (4) and muffler pipe (7).

3. Remove the transmission rear guard (5).

4. Disconnect the quick couplers (6).

5. Remove the hydraulic cylinder (3).

(1) Stay

(2) Muffler Cover

(3) Hydraulic Cylinder

(4) Muffler

(5) Rear Guard

(6) Quick Coupler

(7) Muffler Pipe

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Air Cleaner

1. Remove the air cleaner body (2) and intake hose (1) together.

(1) Intake Hose (2) Air Cleaner Body

9Y1210293ENS0028US0

Rear Wheel

1. Remove the rear fenders (1).

2. Remove the rear wheels (2).

(When reassembling)

Tightening torque

Rear wheel mounting screw

75 to 90 N·m

7.6 to 9.2 kgf·m

55.3 to 66.4 lbf·ft

(1) Rear Fender (2) Rear Wheel

9Y1210293ENS0029US0

Wiring Harness

1. Disconnect the wiring harness from engine, glow plug (1), coolant temperature switch (2), engine stop solenoid (3) and oil pressure switch (4).

2. Disconnect the wiring harness from transmission, safety switch

(5) and rotation sensor (6).

(1) Glow Plug

(2) Coolant Temperature Switch

(3) Engine Stop Solenoid

(4) Oil Pressure Switch

(5) Safety Switch

(6) Rotation Sensor

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ENGINE

Brake Hoses and Cables

1. Disconnect the select cable (1), main shift cable (2) and engine wire (3).

2. Disconnect the speed control pedal cable (4), parking brake cable R.H. (5), brake hose R.H. (6) and differential lock cable

(7).

3. Disconnect the unload valve cable (8).

4. Disconnect the parking brake cable L.H. (9), brake hose L.H.

(10) and 4WD shift cable (11).

(When reassembling)

• Adjust the length of main shift cable (2) and select cable (1).

• Adjust the length of speed control pedal cable (4).

• Adjust the length of differential lock cable (7).

• Adjust the length of parking brake cables (5), (9).

• Adjust the length of 4WD shift cable (11).

NOTE

• See "[1] CHECKING AND ADJUSTING" on page 2-S6.

(1) Select Cable

(2) Main Shift Cable

(3) Engine Wire

(4) Speed Control Pedal Cable

(5) Parking Brake Cable R.H.

(6) Brake Hose R.H.

(7) Differential Lock Cable

(8) Unload Valve Cable

(9) Parking Brake Cable L.H.

(10) Brake Hose L.H.

(11) 4WD Shift Cable

9Y1210293ENS0031US0

Hydraulic Hoses

1. Disconnect the delivery hose 1 (1) and delivery hose 2 (2).

2. Disconnect the suction hose (3).

(1) Delivery Hose 1

(to Hydraulic Control Valve)

(2) Delivery Hose 2 (to Power Steering)

(3) Suction Hose

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ENGINE

Wiring Harness from Engine

1. Disconnect the coolant temperature sensor connector (3).

2. Disconnect the wiring connector from alternator (1).

3. Disconnect the wiring connector from starter motor (2).

(1) Alternator

(2) Starter Motor

(3) Coolant Temperature Sensor

Connector

9Y1210293ENS0033US0

Radiator Hoses and Ground Cable

1. Disconnect the radiator hoses (1), (2) from engine.

2. Disconnect the ground cable (3).

(1) Radiator Upper Hose

(2) Radiator Lower Hose

(3) Ground Cable

9Y1210293ENS0034US0

Fuel Hose Line

1. Disconnect the fuel hose (1) and return hose (2).

(1) Fuel Hose (2) Return Hose

9Y1210293ENS0035US0

(2) Separating Rear Axle

Rear Axle Bracket

1. Remove the boot band (4) on both sides.

2. Place the stand under the both side of frame.

3. Remove the leaf spring mounting bolt (3) and flange nut, and remove the rear axle bracket assembly (5) by use the axle support (6).

(When reassembling)

• Align the master spline of propeller shaft and rear axle shaft.

• Replace the boot band (4) with new one.

• Apply anti-fretting grease (NISSEKI PYRONOC UNIVERSAL

N6C or its equivalents) to spline of rear axle shaft.

Tightening torque

Leaf spring mounting bolt and flange nut

Lock nut

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

24.0 to 28.0 N·m

2.45 to 2.85 kgf·m

17.7 to 20.6 lbf·ft

(1) Lock Nut

(2) Flange Nut

(3) Leaf Spring Mounting Bolt

(4) Boot Band

(5) Rear Axle Bracket Assembly

(6) Axle Support

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ENGINE

(3) Separating Transmission Assembly

Dismounting Transmission and Engine One Piece Assembly

1. Remove the unload linkage (1).

2. Set the power train support (6) and remove the mission frame

(4) mounting bolt (2) and nut.

3. Lift up the main frame by hoist.

4. Remove the transmission and engine one piece assembly (5).

(When reassembling)

• The bolt can be put through the rubber bushing more easily if soap water is applied to the bolt. Never hit the bolt.

• Assemble the mission-frame in such a manner as to insert two bolts in the from and then two bolts in the rear, instead of inserting the four bolts at a time.

• When reassembling the transmission and engine one piece assembly (mission frame) into the main frame, do not forget to assemble the 4WD propeller shaft (3) as well.

• Apply anti-fretting grease (NISSEKI PYRONOC UNIVERSAL

N6C or its equivalents) to splines of 4WD propeller shaft (3).

Tightening torque

Mission frame mounting bolt and nut

77.4 to 90.2 N·m

7.90 to 9.19 kgf·m

57.1 to 66.5 lbf·ft

(1) Unload Linkage

(2) Mission Frame Mounting Bolt

(3) 4WD Propeller Shaft

(4) Mission Frame

(5) Transmission and Engine One

Piece Assembly

(6) Power Train Support

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ENGINE

Mission Frame

1. Remove the mission frame (2) from engine and transaxle one piece assembly.

(When reassembling)

• Tighten the screws (7) of bottom in the first.

• When inserting the bushes (9) in mission frame (2), align the tags (8) of bushes with alignment marks (10) on the mission frame (2).

Tightening torque

Transmission case bottom set screw

Transmission case side set screw

Engine set screw

39.2 to 44.1 N·m

4.00 to 4.49 kgf·m

29.0 to 32.5 lbf·ft

62.7 to 72.5 N·m

6.40 to 7.39 kgf·m

46.3 to 53.4 lbf·ft

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

(1) Transmission and Engine One

Piece Assembly

(2) Mission Frame

(3) Engine Set Screw

(4) Washer

(5) Transmission Case Side Set Screw

(6) Washer

(7) Transmission Case Bottom Set

Screw

(8) Tag

(9) Bush

(10) Alignment Mark

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(4) Separating Engine

ENGINE

Separate the Transmission and Engine One Piece Assembly

1. Remove the engine mounting screw and starter motor (1) mounting screws.

2. Disconnect the oil cooler hoses (2).

3. Disconnect the accelerator wire (3).

4. Separate the engine from transmission assembly.

(When reassembling)

• Apply liquid gasket (Three Bond 1215E, Locktite 5699 or equivalents) to joint face of engine rear-end plate and the transmission case.

• Apply anti-fretting grease (NISSEKI PYRONOC UNIVERSAL

N6C or its equivalents) to splines of engine output shaft.

Tightening torque Engine mounting screw

17.7 to 20.5 N·m

1.80 to 2.10 kgf·m

13.1 to 15.1 lbf·ft

(1) Starter Motor

(2) Oil Cooler Hose

(3) Accelerator Wire

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[3] DISASSEMBLING AND ASSEMBLING

(1) External Components

External Components

1. Remove the oil filter cartridge (3).

2. Remove the alternator (2) and belt (1).

3. Remove the engine stop solenoid (4).

4. Remove the hydraulic pump (5).

(1) Belt

(2) Alternator

(3) Oil Filter Cartridge

(4) Engine Stop Solenoid

(5) Hydraulic Pump

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(2) Cylinder Head and Valve

ENGINE

Cylinder Head Cover

1. Disconnect the breather hose.

2. Remove the head cover nut.

3. Remove the cylinder head cover (1).

(When reassembling)

• Check to see if the cylinder head cover gasket is not defective.

Tightening torque Cylinder head cover nut

7 to 8 N·m

0.7 to 0.9 kgf·m

5 to 6 lbf·ft

(1) Cylinder Head Cover

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Injection Pipes

1. Loosen the screws to the pipe clamp (1).

2. Detach the injection pipes (2).

(When reassembling)

• By using compressed air, clean out the injector pipes (2). Then, reassemble the pipes in the reverse order.

Tightening torque Injection pipe retaining nut

25 to 34 N·m

2.5 to 3.5 kgf·m

18 to 25 lbf·ft

(1) Pipe Clamp (2) Injection Pipe

9Y1210293ENS0042US0

Nozzle Holder Assembly and Glow Plug

1. Remove the overflow pipe (1).

2. Remove the nozzle holder assemblies (4).

3. Remove the copper gasket (5) and heat seal (6).

4. Remove the lead (2) from the glow plugs (3).

5. Remove the glow plugs (3).

(When reassembling)

• Replace the copper gasket and heat seal with new one.

Tightening torque

Overflow pipe retaining nut

Nozzle holder assembly

Glow plug

20 to 24 N·m

2.0 to 2.5 kgf·m

15 to 18 lbf·ft

49 to 68 N·m

5.0 to 7.0 kgf·m

37 to 50 lbf·ft

7.9 to 14 N·m

0.80 to 1.5 kgf·m

5.8 to 10 lbf·ft

(1) Overflow Pipe

(2) Lead

(3) Glow Plug

(4) Nozzle Holder Assembly

(5) Copper Gasket

(6) Heat Seal

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ENGINE

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 mm (1/4 in.)).

1. Drive screw driver (1) lightly into the heat seal hole.

2. Turn screw driver three or four times each way.

3. While turning the screw driver, slowly pull the heat seal (4) out together with the injection nozzle gasket (3).

4. If the heat seal drops, repeat the above procedure.

(When reassembling)

• Heat seal and injection nozzle gasket must be changed when the injection nozzle is removed for cleaning or for service.

(1) Plus Screw Driver

(2) Nozzle Holder

(3) Injection Nozzle Gasket

(4) Heat Seal

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Rocker Arm and Push Rod

1. Remove the rocker arm bracket nut.

2. Detach the rocker arm assembly (1).

3. Remove the push rods (2).

(When reassembling)

• When refitting the push rods (2) into the tappets (3), make sure the push rod locates correctly into the tappet seat.

IMPORTANT

• After installing the rocker arm, be sure to adjust the valve clearance.

Tightening torque Rocker arm bracket nut

22 to 26 N·m

2.2 to 2.7 kgf·m

16 to 19 lbf·ft

(1) Rocker Arm Assembly

(2) Push Rod

(3) Tappet

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ENGINE

Cylinder Head and Cylinder Head Gasket

1. Loosen the pipe clamps (1), and remove the water return hose

(2).

2. Remove the cylinder head screw in the order of

"n"

to

"a"

and remove the cylinder head.

3. Remove the cylinder head gasket.

(When reassembling)

• Replace the cylinder head gasket with a new one.

• Tighten the cylinder head screws after applying sufficient oil.

• Tighten the cylinder head screws in several steps and specified sequence

"a"

to

"n"

.

• Retighten the cylinder head screws after running the engine for

30 minutes.

• By using a torque wrench, correctly tighten the cylinder head screws to correct torque figure.

• The different type of screw (4) is used for the positions

"j"

and

"n"

in illust.

Tightening torque Cylinder head screw

64 to 68 N·m

6.5 to 7.0 kgf·m

47 to 50 lbf·ft

(1) Clamp

(2) Return Hose

(3) Cylinder Head Screw

(4) Cylinder Head Screw

n to a: To Loosen a to n: To Tighten

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Tappets

1. Remove the tappets (1) from the crankcase.

(When reassembling)

• Visually check the contact between tappets and cams for proper rotation. If defect is found, replace tappets.

• Before installing the tappets, apply engine oil thinly around them.

IMPORTANT

• Replace the tappets (1) in the same order they were removed from.

(1) Tappet

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ENGINE

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).

4. Remove the valve (7).

(When reassembling)

• Wash the valve stem and valve guide hole, and apply engine oil sufficiently.

• After installing the valve spring collets, lightly tap the stem to assure proper fit with a plastic hammer.

IMPORTANT

• Don't change the combination of valve and valve guide.

(1) Valve Spring Replacer

(2) Valve Cap

(3) Valve Spring Collet

(4) Valve Spring Retainer

(5) Valve Spring

(6) Valve Stem Seal

(7) Valve

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Thermostat Assembly

1. Remove the thermostat cover mounting screws (1), and remove the thermostat cover (2).

2. Remove the thermostat assembly (4).

(When reassembling)

• Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (3).

(1) Thermostat Cover Mounting Screw

(2) Thermostat Cover

(3) Thermostat Cover Gasket

(4) Thermostat Assembly

9Y1210293ENS0049US0

(3) Gear Case and Timing Gears

Oil Pan and Oil Strainer

1. Remove the oil pan mounting screws.

2. Remove the oil pan (2).

3. Remove the oil strainer (1).

(When reassembling)

• After cleaning the oil strainer, check to see that the filter mesh in clean, and install it.

• Visually check the O-ring, apply engine oil, and install it.

• Securely fit the O-ring to the oil strainer.

• To avoid uneven tightening, tighten oil pan mounting screws in diagonal order form the center.

IMPORTANT

• Scrape off the old adhesive completely. Wipe the sealing surface clan using waste cloth soaked with gasoline.

• Apply liquid gasket (Three Bond 1207D or equivalent) about 3.0 to 5.0 mm (0.12 to 0.19 in.) thick. Within 20 minutes after the application of liquid gasket, reassemble the components.

(1) Oil Strainer (2) Oil Pan

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ENGINE

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).

• Apply engine oil to the fan drive pulley retaining screw. And tighten it.

Tightening torque Fan drive pulley screw

236 to 245 N·m

24.0 to 25.0 kgf·m

174 to 180 lbf·ft

(1) Aligning Mark

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Gear Case

1. Remove the fuel feed pump.

2. Remove the gear case.

(When reassembling)

• Grease thinly to the oil seal, and install it, ensuring the lip does not come off.

(1) Gear Case

a: Bolt Length = 45 mm (1.8 in.) b: Bolt Length = 50 mm (2.0 in.) c: Bolt Length = 55 mm (2.2 in.) d: Bolt Length = 65 mm (2.6 in.) e: Bolt Length = 68 mm (2.7 in.) f: Bolt Length = 70 mm (2.8 in.) g: Bolt Length = 85 mm (3.3 in.) h: Nut

9Y1210293ENS0052US0

Speed Control Plate

1. Remove the engine stop solenoid.

2. Remove the speed control plate (1).

3. Remove the governor spring (2). Be careful not to drop spring into crankcase.

(When reassembling)

• Apply a liquid gasket (Three Bond 1215 or equivalent) to both sides of the solenoid cover gasket and control plate gasket.

• Be careful not to drop the governor spring (2) into the crankcase.

(1) Speed Control Plate (2) Governor Spring

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ENGINE

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.

4. The injection pump should not be disassembled.

(When reassembling)

• When installing the injection pump, insert the control rack pin (2) firmly into the groove (6) of the thrust lever of fork lever.

NOTE

• Addition or reduction of shim (0.05 mm, 0.002 in.) delays or advances the injection timing by approx. 0.0087 rad (0.5 °).

• In disassembling and replacing, be sure to use the same number or new gasket shims with the same thickness.

(1) Notch

(2) Control Rack Pin

(3) Injection Pump

(4) Start Spring

(5) Thrust Lever

(6) Groove

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ENGINE

Cam Gear, Idle Gear 1 and Governor Gear

1. Remove the idle gear 1 (4).

2. Remove the fuel camshaft stopper (6).

3. Draw out the fuel cam gear (1) with fuel camshaft (7).

4. Remove the camshaft stopper bolt.

5. Remove the cam gear (5) with camshaft.

6. Remove the external snap ring (8) from the governor shaft (9).

7. Remove the governor gear (2) with governor shaft (9).

NOTE

• Three-lever type fork lever

To remove the governor shaft (9), follow the procedures in

5, 6 above and never remove fork lever and the max torque limiter.

(When reassembling)

• Apply engine oil thinly to the fuel camshaft (7) before installation.

• Make sure to assemble the external snap ring (8) of the governor shaft (9).

• Check the governor shaft (9) for smooth rotation.

IMPORTANT

• When replacing the ball bearing of governor shaft, securely fit the ball bearing (10) to the crankcase, apply an adhesive

(Three Bond 1324B or equivalent) to the set screw (11), and tighten the screw until its tapered part contacts the circumferential end of the ball bearing.

• When installing the idle gear, be sure to align the alignment marks (12) on each gears.

(1) Fuel Cam Gear

(2) Governor Gear

(3) Crank Gear

(4) Idle Gear 1

(5) Cam Gear

(6) Fuel Camshaft Stopper

(7) Fuel Camshaft

(8) External Snap Ring

(9) Governor Shaft

(10) Ball Bearing

(11) Set Screw

(12) Alignment Mark

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ENGINE

(4) 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.

If the connecting rod screw is difficult to turn, clean the threads.

If the connecting rod screw is still hard to turn or screw in, replace it.

Tightening torque Connecting rod screw

42 to 46 N·m

4.2 to 4.7 kgf·m

31 to 33 lbf·ft

(a) Mark

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Pistons

1. Turn the flywheel and bring the piston to top dead center.

2. Draw out the piston upward by lightly tapping it from the bottom of the crankcase with the handle of a hammer.

3. Draw out the other pistons in the same method as above.

(When reassembling)

• Before inserting the piston into the cylinder, apply enough engine oil to the piston.

• When inserting the piston into the cylinder, face the mark on the connecting rod to the injection pump.

IMPORTANT

• Do not change the combination of cylinder and piston.

Make sure of the position of each piston by marking. For example, mark "1" on the No.1 piston.

• When installing the piston into the cylinder, place the gaps of all the piston rings as shown in the figure.

• Carefully insert the pistons using a piston ring compressor

(1). Otherwise, their chrome-plated section may be scratched, causing problem inside the cylinder.

(1) Piston Ring Compressor

(a) 0.79 rad (45 °)

(b) 0.79 rad (45 °)

(c) 1.6 rad (90 °) (A) Top Ring Gap

(B) Second Ring Gap

(C) Oil Ring Gap

(D) Piston Pin Hole

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ENGINE

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.

• When installing the oil ring onto the piston, place the expander joint (10) on the opposite side of the oil ring gap (11).

• Apply engine oil to the piston pin.

• When installing the connecting rod to the piston, immerse the piston in 80 °C (176 °F) oil for 10 to 15 minutes and insert the piston pin to the piston.

• When installing the connecting rod to the piston, align the mark

(8) on the connecting rod to the fan-shaped concave (9).

NOTE

• Mark the same number on the connecting rod and the piston so as not to change the combination.

(1) Top Ring

(2) Second Ring

(3) Oil Ring

(4) Piston Pin Snap Ring

(5) Piston

(6) Connecting Rod

(7) Piston Pin

(8) Mark

(9) Fan-shaped Concave

(10) Expander Joint

(11) Oil Ring Gap

(12) Manufacturer's Mark

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(5) Crankshaft

ENGINE

Flywheel

1. Remove the input flange (1).

2. Secure the flywheel to keep it from turning, using a flywheel stopper.

3. Remove all flywheel screws (2) and then remove the flywheel

(4).

(When reassembling)

• With No. 1 piston at TDC, align the

"1TC"

mark

(a)

on the outer surface of the flywheel horizontally with the alignment mark

(b)

on the rear end plate. Now fit the flywheel in position.

• Apply engine oil to the threads and the undercut surface of the flywheel screw and fit the screw.

Tightening torque Flywheel screw

54 to 58 N·m

5.5 to 6.0 kgf·m

40 to 43 lbf·ft

(1) Input Flange

(2) Flywheel Screw

(3) O-ring

(4) Flywheel

(a) 1TC Mark

(b) Alignment Mark

9Y1210293ENS0059US0

Bearing Case Cover

1. Remove the bearing case cover mounting screws.

2. Remove the bearing case cover (6).

IMPORTANT

• The length of inside screws (1) and outside screws (2) are different. Do not take a mistake using inside screws and outside screws.

(When reassembling)

• Fit the bearing case gasket (3) and the bearing case cover gasket (4) in the correct location.

• Install the bearing case cover (6) to position the casting mark

"UP"

on it upward.

• Apply engine oil to the oil seal (5) lip and take care that it is not rolled when installing.

• Tighten the bearing case cover mounting screws with even force on the diagonal line.

Tightening torque Bearing case cover screw

9.81 to 11.2 N·m

1.00 to 1.15 kgf·m

7.24 to 8.31 lbf·ft

(1) Bearing Case Cover Mounting

Screw (Inside) (Long)

(2) Bearing Case Cover Mounting

Screw (Outside) (Short)

(3) Bearing Case Gasket

(4) Bearing Case Cover Gasket

(5) Oil Seal

(6) Bearing Case Cover

(a) Upside

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ENGINE

Crankshaft Assembly

1. Remove the main bearing case screw 2 (1).

2. Pull out the crankshaft assembly.

IMPORTANT

• Take care to protect crankshaft bearing 1 from scratches, caused by the crank gear, etc.. (Wrap the gear in vinyl tape, etc.)

(When reassembling)

• Clean the oil passage of the crankshaft with compressed air.

• Apply oil to the main bearing case screw 2 (1).

• Install the crankshaft assembly, aligning the screw hole of main bearing case with the screw hole of crankcase.

• Clean the oil passage of the crankshaft with compressed air.

Tightening torque Main bearing case screw 2

49 to 53 N·m

5.0 to 5.5 kgf·m

37 to 39 lbf·ft

(1) Main Bearing Case Screw 2

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Main Bearing Case Assembly

1. Remove the two main bearing case screws 1 (2) of each main bearing cases.

2. Remove the main bearing case from crankshaft.

(When reassembling)

• Clean the oil passage in the main bearing cases.

• Apply clean engine oil on the bearings.

• Install the main bearing case assemblies in the original positions. Since diameters of main bearing cases vary, install them in order of makings

(b)

from the gear case side.

• Match the alignment numbers

(a)

on the main bearing case assembly 1

• When installing the main bearing case 1 and 2, face the mark

"FLYWHEEL"

to the flywheel.

• Install the thrust bearing (3) with its oil groove facing outward.

• Confirm that the main bearing case moves smoothly after tightening the main bearing case screw 1 to the specified torque.

Tightening torque Main bearing case screw 1

30 to 34 N·m

3.0 to 3.5 kgf·m

22 to 25 lbf·ft

(1) Main Bearing Case Assembly 1

(2) Main Bearing Case Screw 1

(3) Thrust Bearing

(a) Alignment Number

(b) Marking (A, B, C)

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[4] SERVICING

(1) Cylinder Head and Valves

ENGINE

Top Clearance

1. Remove the cylinder head. (Do not attempt to remove the cylinder head gasket.)

2. Move the piston up and stick a strip of fuse [1.5 mm dia.

(0.059 in. dia.), 5 to 7 mm long (0.197 to 0.276 in. long)] on the piston head at three positions with grease so as to avoid the intake and exhaust valves and the combustion chamber ports.

3. Lower the piston, and install the cylinder head and tighten the cylinder head screws to the specified torque.

4. Turn the flywheel until the piston passes top dead center.

5. Remove the cylinder head, and measure the thickness of the squeezed fuses.

6. If the measurement is not within the factory specifications, check the oil clearance between the crankpin and crankpin bearing and between the piston pin and small end bushing.

NOTE

• After checking the top clearance, be sure to assemble the cylinder head with a new cylinder head gasket.

Top clearance Factory specification

0.55 to 0.70 mm

0.022 to 0.027 in.

Tightening torque Cylinder head screws

64 to 68 N·m

6.5 to 7.0 kgf·m

47 to 50 lbf·ft

(1) Fuse (2) Fuse

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Cylinder Head Surface Flatness

1. Clean the cylinder head surface.

2. Place a straightedge on the cylinder head's four sides and two diagonal as shown in the figure.

3. Measure the clearance with a thickness gauge.

4. If the measurement exceeds the allowable limit, correct it with a surface grinder.

IMPORTANT

• Do not place the straightedge on the combustion chamber.

• Be sure to check the valve recessing after correcting.

Cylinder head surface flatness

Allowable limit

0.05 mm

0.002 in.

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ENGINE

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.

4. Wash away the read permeative liquid on the cylinder head surface with the detergent (2).

5. Spray the cylinder head surface with white developer (3).

6. If flawed, it can be identified as red marks.

(1) Red Permeative Liquid

(2) Detergent

(3) White Developer

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Valve Recess

1. Clean the cylinder head surface, valve face and valve seat.

2. Insert the valve into the valve guide.

3. Measure the valve recess with a depth gauge.

4. If the measurement exceeds the allowable limit, replace the valve.

5. If it still exceeds the allowable limit after replacing the valve, replace the cylinder head.

Valve recess

Factory specification

Allowable limit

0.050 (protrusion) to

0.25 (recessing) mm

0.0020 (protrusion) to

0.0098 (recessing) in.

0.40 (recessing) mm

0.016 (recessing) in.

(1) Cylinder Head Surface

(A) Recess

(B) Protrusion

9Y1210293ENS0066US0

Clearance between Valve Stem and Valve Guide

1. Remove carbon from the valve stem.

2. Measure the valve stem O.D. with an outside micrometer.

3. Measure the valve guide I.D. with a small hole gauge, and calculate the clearance.

4. If the clearance exceeds the allowable limit, replace the valves.

If it still exceeds the allowable limit, replace the valve guide.

Clearance between valve stem and valve guide

Factory specification

Allowable limit

0.035 to 0.065 mm

0.0014 to 0.0025 in.

0.10 mm

0.0039 in.

Valve stem O.D.

Valve guide I.D.

Factory specification

Factory specification

6.960 to 6.975 mm

0.2741 to 0.2746 in.

7.010 to 7.025 mm

0.2760 to 0.2765 in.

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ENGINE

Replacing Valve Guide

(When removing)

1. Press out the used valve guide using a valve guide replacing tool. (Refer to "8. SPECIAL TOOLS" in "G. GENERAL" section.)

(When installing)

1. Clean a new valve guide and valve guide bore, and apply engine oil to them.

2. Press in a new valve guide using a valve guide replacing tool.

3. Ream the I.D. of the valve guide to the specified dimension.

Valve guide I.D.

(Intake and exhaust)

Factory specification

7.010 to 7.025 mm

0.2760 to 0.2765 in.

IMPORTANT

• Do not hit the valve guide with a hammer during replacement.

(A) When Removing (B) When Installing

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Valve Seat

1. Coat the valve face lightly with prussian blue and put the valve on its seat to check the contact.

2. If the valve does not seat all the way around the valve seat or the valve contact is less than 70 %, correct the valve seating as follows.

3. If the valve contact does not comply with the reference value, replace the valve or correct the contact of valve seat.

Valve seat width Factory specification

2.12 mm

0.0835 in.

(1) Correct

(2) Incorrect

(3) Incorrect

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ENGINE

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.

1) Correcting Valve

1. Correct the valve with a valve refacer.

Valve face angle

Factory specification

IN.

EX.

1.0 rad

60 °

0.79 rad

45 °

2) Correcting Valve Seat

1. Slightly correct the seat surface with a 1.0 rad (60 °) (intake valve) or 0.79 rad (45 °) (exhaust valve) valve seat cutter.

2. Resurface the seat surface with a 0.52 rad (30 °) valve seat cutter to intake valve seat and with a 0.26 rad (15 °) valve seat cutter to exhaust valve seat so that the width is close to specified valve seat width (2.12 mm, 0.0835 in.).

3. After resurfacing the seat, inspect for even valve seating, apply a thin film of lapping compound between the valve face and valve seat, and fit them with valve lapping tool.

4. Check the valve seat with prussian blue. The valve seating surface should show good contact all the way around.

Valve seat angle

Factory specification

IN.

EX.

1.0 rad

60 °

0.79 rad

45 °

(1) Valve Seat Width

(A) Check Contact

(B) Correct Seat Width

(C) Check Contact

(a) 0.26 rad (15 °) or 0.52 rad (30 °)

(b) 0.79 rad (45 °) or 1.0 rad (60 °)

(c) 0.52 rad (30 °) or 0.26 rad (15 °)

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Valve Lapping

1. Apply compound evenly to the valve lapping surface.

2. Insert the valve into the valve guide. Lap the valve onto its seat with a valve flapper or screwdriver.

3. After lapping the valve, wash the compound away and apply oil, then repeat valve lapping with oil.

4. Apply prussian blue to the contact surface to check the seated rate. If it is less than 70 %, repeat valve lapping again.

IMPORTANT

• When valve lapping is performed, be sure to check the valve recess and adjust the valve clearance after assembling the valve.

9Y1210293ENS0071US0

1-S42

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ENGINE

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

3. Check to see if the entire side is in contact with the square.

Rotate the valve spring and measure the maximum tilt

(A)

.

If the measurement exceeds the allowable limit, replace it.

4. Check the entire surface of the valve spring for scratches.

If there is any defect, replace it.

Tilt

(A)

Allowable limit

1.0 mm

0.039 in.

Free length

(B)

Factory specification

Allowable limit

37.0 to 37.5 mm

1.46 to 1.47 in.

36.5 mm

1.44 in.

(A) Tilt (B) Free Length

9Y1210293ENS0072US0

Valve Spring Setting Load

1. Place the valve spring on a tester and compress it to the same length it is actually compressed in the engine.

2. Read the compression load on the gauge.

3. If the measurement is less than the allowable limit, replace it.

Setting load /

Setting length

Factory specification

Allowable limit

117.4 N / 31.0 mm

11.97 kgf / 31.0 mm

26.39 lbf / 1.22 in.

100.0 N / 31.0 mm

10.20 kgf / 31.0 mm

22.48 lbf / 1.22 in.

9Y1210293ENS0073US0

Oil Clearance between Rocker Arm and Rocker Arm Shaft

1. Measure the rocker arm shaft O.D. with an outside micrometer.

2. Measure the rocker arm I.D. with an inside micrometer, and then calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit, replace the rocker arm and measure the oil clearance again. If it still exceeds the allowable limit, replace also the rocker arm shaft.

Oil clearance between rocker arm and rocker arm shaft

Factory specification

Allowable limit

0.016 to 0.045 mm

0.00063 to 0.0017 in.

0.10 mm

0.0039 in.

Rocker arm shaft O.D.

Rocker arm I.D.

Factory specification

Factory specification

11.973 to 11.984 mm

0.47138 to 0.47181 in.

12.000 to 12.018 mm

0.47244 to 0.47314 in.

9Y1210293ENS0074US0

1-S43

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ENGINE

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.

Push rod alignment Allowable limit

0.25 mm

0.0098 in.

9Y1210293ENS0075US0

Oil Clearance between Tappet and Tappet Guide Bore

1. Measure the tappet O.D. with an outside micrometer.

2. Measure the I.D. of the tappet guide bore with a cylinder gauge, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit or the tappet is damaged, replace the tappet.

Oil Clearance between tappet and tappet guide bore

Factory specification

Allowable limit

0.020 to 0.062 mm

0.00079 to 0.0024 in.

0.07 mm

0.003 in.

Tappet O.D.

Tappet guide bore I.D.

Factory specification

Factory specification

19.959 to 19.980 mm

0.78579 to 0.78661 in.

20.000 to 20.021 mm

0.78740 to 0.78822 in.

9Y1210293ENS0076US0

(2) Timing Gears, Camshaft and Governor Gear

Timing Gear Backlash and Governor 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.

3. If the backlash exceeds the allowable limit, check the oil clearance of the shafts and the gear.

4. If the oil clearance is not correct, replace the gear.

Backlash between idle gear 1 and crank gear

Factory specification

Allowable limit

0.0320 to 0.115 mm

0.00126 to 0.00452 in.

0.15 mm

0.0059 in.

Backlash between idle gear 1 and cam gear

Backlash between idle gear 1 and injection pump gear

Factory specification

Allowable limit

Factory specification

Allowable limit

Backlash between injection pump gear and governor gear

Factory specification

Allowable limit

0.0360 to 0.114 mm

0.00142 to 0.00448 in.

0.15 mm

0.0059 in.

0.0340 to 0.116 mm

0.00134 to 0.00456 in.

0.15 mm

0.0059 in.

0.0300 to 0.117 mm

0.00119 to 0.00460 in.

0.15 mm

0.0059 in.

9Y1210293ENS0077US0

1-S44

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ENGINE

Idle Gear 1 Side Clearance

1. Set a dial indicator with its tip on the idle gear.

2. Measure the side clearance by moving the idle gear from the front and rear.

3. If the measurement exceeds the allowable limit, replace the idle gear collar.

Idle gear 1 side clearance

Factory specification

Allowable limit

0.20 to 0.51 mm

0.0079 to 0.020 in.

0.80 mm

0.031 in.

9Y1210293ENS0078US0

Camshaft Side Clearance

1. Set a dial indicator with its tip on the camshaft.

2. Measure the side clearance by moving the cam gear from the front to rear.

3. If the measurement exceeds the allowable limit, replace the camshaft stopper.

Camshaft side clearance

Factory specification

Allowable limit

0.070 to 0.22 mm

0.0028 to 0.0086 in.

0.30 mm

0.012 in.

9Y1210293ENS0079US0

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.

Camshaft alignment Allowable limit

0.01 mm

0.0004 in.

9Y1210293ENS0080US0

Cam Lobe Height

1. Measure the height of the cam lobe at its highest point with an outside micrometer.

2. If the measurement is less than the allowable limit, replace the camshaft.

Cam lobe height of intake

Factory specification

Allowable limit

28.80 mm

1.134 in.

28.75 mm

1.132 in.

Cam lobe height of exhaust

Factory specification

Allowable limit

29.00 mm

1.142 in.

28.95 mm

1.140 in.

9Y1210293ENS0081US0

1-S45

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ENGINE

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.

Oil clearance of camshaft journal

Factory specification

Allowable limit

0.050 to 0.091 mm

0.0020 to 0.0035 in.

0.15 mm

0.0059 in.

Camshaft journal O.D.

Camshaft bearing I.D.

(Cylinder block bore I.D.)

Factory specification

Factory specification

35.934 to 35.950 mm

1.4147 to 1.4153 in.

36.000 to 36.025 mm

1.4173 to 1.4183 in.

9Y1210293ENS0082US0

Oil Clearance between Idle Gear Shaft 1 and Idle Gear Bushing

1. Measure the idle gear shaft 1 O.D. with an outside micrometer.

2. Measure the idle gear bushing I.D. with an inside micrometer, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit, replace the bushing.

If it still exceeds the allowable limit, replace the idle gear shaft 1.

Oil clearance between idle gear shaft 1 and idle gear bushing

Factory specification

Allowable limit

0.020 to 0.054 mm

0.00079 to 0.0021 in.

0.10 mm

0.0039 in.

Idle gear shaft 1 O.D.

Idle gear bush I.D.

Factory specification

Factory specification

25.967 to 25.980 mm

1.0223 to 1.0228 in.

26.000 to 26.021 mm

1.0237 to 1.0244 in.

9Y1210293ENS0083US0

Replacing Idle Gear Bushing

(When removing)

1. Press out the used idle gear bushing using an idle gear bushing replacing tool. (Refer to "8. SPECIAL TOOLS" in "G.

GENERAL" section.)

(When installing)

1. Clean a new idle gear bushing and idle gear bore, and apply engine oil to them.

2. Press in a new bushing using an idle gear bushing replacing tool, until it is flush with the end of the idle gear.

(A) When Removing (B) When Installing

9Y1210293ENS0084US0

1-S46

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ENGINE

(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.

Piston pin bore I.D.

Factory specification

Allowable limit

22.000 to 22.013 mm

0.86615 to 0.86665 in.

22.03 mm

0.8673 in.

9Y1210293ENS0085US0

Oil Clearance between Piston Pin and Small End Bushing

1. Measure the piston pin O.D. where it contacts the bushing with an outside micrometer.

2. Measure the small end bushing I.D. with an inside micrometer, and calculate the oil clearance.

3. If the oil clearance exceeds the allowable limit, replace the bushing. If it still exceeds the allowable limit, replace the piston pin.

Oil clearance between piston pin and small end bushing

Factory specification

Allowable limit

0.014 to 0.038 mm

0.00055 to 0.0014 in.

0.15 mm

0.0059 in.

Piston pin O.D.

Small end bushing I.D.

Factory specification

Factory specification

22.002 to 22.011 mm

0.86622 to 0.86657 in.

22.025 to 22.040 mm

0.86713 to 0.86771 in.

9Y1210293ENS0086US0

Replacing Small End Bushing

(When removing)

1. Press out the used bushing using a small end bushing replacing tool. (Refer to "8. SPECIAL TOOLS" in "G. GENERAL" section.)

(When installing)

1. Clean a new small end bushing and bore, and apply engine oil to them.

2. Using a small end bushing replacing tool, press in a new bushing (service parts) taking care to see that the connecting rod oil hole matches the bushing hole.

Oil clearance between piston pin and small end bushing (Spare parts)

Factory specification

Allowable limit

0.015 to 0.038 mm

0.00059 to 0.0014 in.

0.15 mm

0.0059 in.

Small end bushing I.D.

(Spare parts)

(1) Seam

(2) Oil Hole

Factory specification

22.025 to 22.040 mm

0.86713 to 0.86771 in.

(A) When Removing

(B) When Installing

(a) 0.79 rad (45 °)

9Y1210293ENS0087US0

1-S47

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ENGINE

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.

3. Put a gauge over the piston pin, and move it against the face plate.

4. If the gauge does not fit squarely against the face plate, measure the space between the pin of the gauge and the face plate.

5. If the measurement exceeds the allowable limit, replace the connecting rod.

Connecting rod alignment

Allowable limit

0.05 mm

0.002 in.

9Y1210293ENS0088US0

Piston Ring Gap

1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with a piston.

2. Measure the ring gap with a thickness gauge.

3. If the measurement exceeds the allowable limit, replace the piston ring.

Piston ring gap

Top ring

Second ring

Oil ring

Factory specification

Allowable limit

Factory specification

Allowable limit

Factory specification

Allowable limit

0.30 to 0.45 mm

0.012 to 0.017 in.

1.25 mm

0.0492 in.

0.30 to 0.45 mm

0.012 to 0.017 in.

1.25 mm

0.0492 in.

0.25 to 0.40 mm

0.0099 to 0.015 in.

1.25 mm

0.0492 in.

9Y1210293ENS0089US0

1-S48

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(4) Crankshaft

ENGINE

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.

3. If the clearance exceeds the allowable limit, replace the piston ring.

4. If the clearance still exceeds the allowable limit with new ring, replace the piston.

Clearance between piston ring and piston ring groove

Second ring

Oil ring

Factory specification

Allowable limit

Factory specification

Allowable limit

0.0850 to 0.112 mm

0.00335 to 0.00440 in.

0.20 mm

0.008 in.

0.020 to 0.055 mm

0.00079 to 0.0021 in.

0.15 mm

0.0059 in.

Factory specification:

"a"

(A) Top Ring (Key Stone Type)

More than

0.2 mm

0.008 in.

(B) 2nd, Oil Ring

9Y1210293ENS0090US0

Crankshaft Side Clearance

1. Set a dial indicator with its tip on the end of the crankshaft.

2. Measure the side clearance by moving the crankshaft to the front and rear.

3. If the measurement exceeds the allowable limit, replace the thrust bearings.

4. If the same size bearing is still loose because of the crankshaft journal wear, replace it with an oversize one referring to the table and figure.

Crankshaft side clearance

Factory specification

Allowable limit

0.15 to 0.31 mm

0.0059 to 0.012 in.

0.50 mm

0.020 in.

(Reference)

• Oversize dimensions of crankshaft journal

Oversize

Dimension

Dimension

A

B

0.20 mm

0.0079 in.

51.50 to 51.70 mm

2.028 to 2.035 in.

28.20 to 28.25 mm

1.111 to 1.112 in.

0.40 mm

0.016 in.

51.60 to 51.80 mm

2.032 to 2.039 in.

28.40 to 28.45 mm

1.119 to 1.120 in.

Dimension

C

2.3 to 2.7 mm radius

0.091 to 0.10 in. radius

2.3 to 3.7 mm radius

0.091 to 0.10 in. radius

The crankshaft journal must be fine-finished to higher than Rmax=0.8S.

9Y1210293ENS0091US0

1-S49

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ENGINE

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.

Crankshaft alignment Allowable limit

0.02 mm

0.0008 in.

9Y1210293ENS0092US0

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.

4. Measure the amount of the flattening with the scale, and get the oil clearance.

5. If the oil clearance exceeds the allowable limit, replace the crankpin bearing.

6. If the same size bearing is still loose because of the crankpin wear, replace it with an undersize one referring to the table and figure.

NOTE

• Never insert the plastigage into the crankpin oil hole

• Be sure not to move the crankshaft while the connecting rod screws are tightened.

Oil clearance between crankpin and crankpin bearing

Factory specification

Allowable limit

0.029 to 0.091 mm

0.0011 to 0.0036 in.

0.20 mm

0.0079 in.

Crankpin O.D.

Crankpin bearing I.D.

Factory specification

Factory specification

39.959 to 39.975 mm

1.5732 to 1.5738 in.

40.040 to 40.050 mm

1.5764 to 1.5767 in.

(Reference)

• Undersize dimensions of crankpin

Undersize

Dimension

A

0.20 mm

0.0079 in.

2.8 to 3.2 mm radius

0.11 to 0.12 in. radius

0.40 mm

0.016 in.

2.8 to 3.2 mm radius

0.11 to 0.12 in. radius

*Dimension

B

1.0 to 1.5 mm relief

0.040 to 0.059 in. relief

1.0 to 1.5 mm relief

0.040 to 0.059 in. relief

Dimension

C

39.759 to 39.775 mm dia.

1.5654 to 1.5659 in. dia.

39.559 to 39.575 mm dia.

1.5575 to 1.5580 in. dia.

The crankpin must be fine-finished to higher than Rmax=0.8S.

*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm

(0.040 to 0.059 in.) relief.

9Y1210293ENS0093US0

1-S50

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ENGINE

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.

3. If the clearance exceeds the allowable limit, replace the crankshaft bearing 1.

4. If the same size bearing is still loose because of the crankshaft journal wear, replace it with an undersize one referring to the table and figure.

Oil clearance between crankshaft journal and crankshaft bearing 1

Factory specification

Allowable limit

0.0340 to 0.114 mm

0.00134 to 0.00448 in.

0.20 mm

0.0079 in.

Crankshaft journal O.D.

Factory specification

Crankshaft bearing 1 I.D.

Factory specification

47.934 to 47.950 mm

1.8872 to 1.8877 in.

47.984 to 48.048 mm

1.8892 to 1.8916 in.

(Reference)

• Undersize dimensions of crankshaft journal

Undersize

Dimension

*Dimension

Dimension

A

B

C

0.20 mm

0.0079 in.

2.3 to 2.7 mm radius

0.091 to 0.10 in. radius

1.0 to 1.5 mm relief

0.040 to 0.059 in. relief

47.734 to 47.750 mm dia.

1.8793 to 1.8799 in. dia.

0.40 mm

0.016 in.

2.3 to 2.7 mm radius

0.091 to 0.10 in. radius

1.0 to 1.5 mm relief

0.040 to 0.059 in. relief

47.534 to 47.550 mm dia.

1.8715 to 1.8720 in. dia.

The crankshaft journal must be fine-finished to higher than Rmax=0.8S.

*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm

(0.040 to 0.059 in.) relief.

9Y1210293ENS0094US0

Replacing Crankshaft Bearing 1

(When removing)

1. Press out the used crankshaft bearing 1 using a crankshaft

bearing 1 replacing tool. (See page G-47.)

(When installing)

1. Clean a new crankshaft bearing 1 and crankshaft journal bore, and apply engine oil to them.

2. Using a crankshaft bearing 1 replacing tool, press in a new bearing 1 (2) so that its seam (1) is toward the exhaust manifold side. (See figure.)

Dimension

(A)

Factory specification

0 to 0.3 mm

0 to 0.01 in.

(1) Seam

(2) Crankshaft Bearing 1

(3) Cylinder Block

9Y1210293ENS0095US0

1-S51

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ENGINE

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 bearing case screws 1 to the specified torque, and remove the bearing case again.

3. Measure the amount of the flattening with the scale and get the oil clearance.

4. If the clearance exceeds the allowable limit, replace the crankshaft bearing 2 and crankshaft bearing.

5. If the same size bearing is still loose because of the crankshaft journal wear, replace it with an undersize one referring to the table and figure.

NOTE

• Be sure not to move the crankshaft while the bearing case screws are tightened.

Oil clearance between crankshaft journal and crankshaft bearing 2

Factory specification

Allowable limit

0.034 to 0.095 mm

0.0014 to 0.0037 in.

0.20 mm

0.0079 in.

Crankshaft journal O.D.

(Intermediate)

Factory specification

Crankshaft bearing 2 I.D.

Factory specification

47.934 to 47.950 mm

1.8872 to 1.8877 in.

47.984 to 48.029 mm

1.8892 to 1.8909 in.

Oil clearance between crankshaft journal and crankshaft bearing 3

Factory specification

Allowable limit

0.0340 to 0.103 mm

0.0013 to 0.0038 in.

0.20 mm

0.0079 in.

Crankshaft journal O.D.

(Flywheel side)

Factory specification

Crankshaft bearing 3 I.D.

Factory specification

51.921 to 51.940 mm

2.0442 to 2.0448 in.

51.974 to 52.024 mm

2.0463 to 2.0481 in.

(Reference)

• Undersize dimensions of crankshaft journal

Undersize

Dimension

*Dimension

Dimension

A

B

C

0.20 mm

0.0079 in.

2.3 to 2.7 mm radius

0.091 to 0.10 in. radius

1.0 to 1.5 mm relief

0.040 to 0.059 in. relief

47.734 to 47.750 mm dia.

1.8793 to 1.8799 in. dia.

0.40 mm

0.016 in.

2.3 to 2.7 mm radius

0.091 to 0.10 in. radius

1.0 to 1.5 mm relief

0.040 to 0.059 in. relief

47.534 to 47.550 mm dia.

1.8715 to 1.8720 in. dia.

Dimension

D

51.721 to 51.740 mm dia.

2.0362 to 2.0370 in. dia.

51.521 to 51.540 mm dia.

2.0284 to 2.0291 in. dia.

The crankshaft journal must be fine-finished to higher than Rmax=0.8S.

*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm

(0.040 to 0.059 in.) relief.

9Y1210293ENS0096US0

1-S52

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(5) Cylinder

ENGINE

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.

4. Press fit the sleeve using the auxiliary socket for pushing (3).

NOTE

• Mount the sleeve with its largely chamfered surface facing outward.

• If sleeve is not hot enough, it might stop halfway, so be careful.

(1) Crankshaft Sleeve

(2) Sleeve Guide

(3) Auxiliary Socket for Pushing

(4) Crankshaft

9Y1210293ENS0097US0

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.

3. If the wear exceeds the allowable limit, bore and hone to the oversize dimension. (Refer to "Correcting Cylinder".)

4. Visually check the cylinder wall for scratches. If deep scratches are found, the cylinder should be bored. (Refer to "Correcting

Cylinder".)

Cylinder I.D.

Factory specification

Allowable limit

78.000 to 78.019 mm

3.0709 to 3.0716 in.

78.15 mm

3.077 in.

(A) Top

(B) Middle

(C) Bottom (Skirt)

(a) Right-angled to Piston Pin

(b) Piston Pin Direction

9Y1210293ENS0098US0

1-S53

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(6) Oil Pump

ENGINE

Correcting Cylinder

1. When the cylinder is worn beyond the allowable limit, bore and hone it to the specified dimension.

Oversized cylinder liner

I.D.

Factory specification

Allowable limit

78.500 to 78.519 mm

3.0906 to 3.0912 in.

78.65 mm

3.096 in.

Finishing

Horn to 1.2 to 2.0 µm Rmax.

(48 to 78 µin. Rmax.)

2. Replace the piston and piston rings with oversize ones.

Oversize: 0.5 mm (0.02 in.)

NOTE

• When the oversize cylinder is worn beyond the allowable limit, replace the cylinder block with a new one

(1) Cylinder I.D. (Before Correction) (2) Cylinder I.D. (Oversize)

9Y1210293ENS0099US0

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.

Rotor lobe clearance Factory specification

0.060 to 0.18 mm

0.0024 to 0.0071 in.

9Y1210293ENS0100US0

Clearance between Outer Rotor and Pump Body

1. Measure the clearance between the outer rotor and the pump body with a feeler gauge.

2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.

Clearance between outer rotor and pump body

Factory specification

0.100 to 0.180 mm

0.00394 to 0.00708 in.

9Y1210293ENS0101US0

Clearance between Rotor and Cover

1. Put a strip of plastigage onto the rotor face with grease.

2. Install the cover and tighten the screws.

3. Remove the cover carefully, and measure the amount of the flattening with the scale and get the clearance.

4. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.

Clearance between rotor and cover

Factory specification

0.025 to 0.075 mm

0.00099 to 0.0029 in.

9Y1210293ENS0102US0

1-S54

KiSC issued 05, 2014 A

2

TRANSMISSION

KiSC issued 05, 2014 A

MECHANISM

CONTENTS

1. STRUCTURE.............................................................................................................................. 2-M1

2. POWER TRAIN .......................................................................................................................... 2-M2

[1] HYDROSTATIC TRANSMISSION (HST)............................................................................. 2-M3

(1) Structure ......................................................................................................................... 2-M3

(2) Oil Flow........................................................................................................................... 2-M5

(3) Function of Components ................................................................................................ 2-M6

[2] RANGE GEAR SHIFT SECTION AND FRONT WHEEL DRIVE SECTION....................... 2-M23

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. STRUCTURE

TRANSMISSION

(1) Input Shaft Section (2) Hydrostatic Transmission

Section

(3) Range Shift Gear Section (4) Front Wheel Drive Section

9Y1210293TRM0001US0

2-M1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

2. POWER TRAIN

The transmission of this model consists of a series of gears and shafts as shown in previous page. The traveling system is chiefly composed of hydrostatic transmission section, range gear shift section and front wheel drive section.

9Y1210293TRM0002US0

2-M2

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

[1] HYDROSTATIC TRANSMISSION (HST)

(1) Structure

The RTV1140CPX has its HST built into the transmission case and incorporates a hydraulically operated servomechanism. The servomechanism controls the pedal operation hydraulically. As a result a smoother pedal operation can be achieved. The components of the RTV1140CPX HST (transmission case) are variable displacement piston pump, fixed displacement piston motor, variable displacement piston motor, charge pump, servo-regulator, unload valve and various valves. Refer to the next page for detailed parts in the HST.

(1) Input Shaft (Pump Shaft)

(2) Charge Pump

(3) Output Shaft (Motor Shaft)

(4) Suction Pipe

(5) HST Housing

(Transmission Case)

(6) Assist Motor Cover

(7) Servo Piston

(8) Servo Regulator

(9) Oil Filter Cartridge (HST)

(Yellow Color)

(10) Oil Cooler

(11) Filter Bracket

(12) Oil Filter Cartridge (Suction)

(Orange Color)

(13) Check and High Pressure

Relief Valve (Reverse)

(14) Suction Hose 2 (Oil Filter to

HST Change Pump)

(15) Suction Hose 1

(Transmission Case to Filter)

(16) Check and High Pressure

Relief Valve (Forward)

(17) Unload Valve

9Y1210293TRM0003US0

2-M3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

(1) Input Shaft (Pump Shaft)

(2) Feedback Lever

(3) Regulator Shaft

(4) Output Shaft (Motor Shaft)

(5) Charge Pump

(6) Variable Swashplate (Pump)

(7) HST Oil Filter Cartridge

(8) Piston

(9) Cylinder Block (Pump)

(10) Port Block Cover

(11) Suction Oil Filter Cartridge

(12) Charge Relief Valve

(13) Control Piston

(14) Assist Motor Cover

(15) Variable Swashplate

(Assist Motor)

(16) Piston

(17) Cylinder Block (Assist Motor)

(18) Unload Spool

(19) Cylinder Block (Motor)

(20) Piston

(21) Servo Piston

(22) Guide

(23) Cradle Bearing

(24) Regulator Spool

(25) Regulator Valve Assembly

(26) Check and High Pressure

Relief Valve

(27) Anti-cavitation Valve

9Y1210293TRM0004US0

2-M4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(2) Oil Flow

TRANSMISSION

(1) HST Assembly

(2) Control Lever (Pedal)

(3) Servo Regulator Assembly

(4) Regulator Valve

(5) Oil Filter Cartridge

(6) Anti-cavitation Valve

(7) Check and High Pressure

Relief Valve

(8) Control Piston

(9) Output Shaft (Motor Shaft)

(10) Cylinder Block (Assist Motor)

(11) Cylinder Block

(Stationary Motor)

(12) Charge Relief Valve

(13) Unload Valve

(14) Servo Piston

(15) Cylinder Block (HST Pump)

(16) Tank

(17) Oil Filter Cartridge

(18) Charge Pump

(19) Input Shaft (Pump Shaft)

A charge pump (18) is used to feed oil to the hydrostatic transmission (HST). The oil coming from the charge pump (18) flows through the oil filter cartridge (5) into the HST main circuit and regulator valve (4). At this time, the servo regulator valve and HST main circuit (that is closed with the control lever at neutral position) are kept at the charge relief valve (12) set pressure. Step on the pedal, and the regulator valve (4) switches its oil passage to allow the oil into the service port. Being interlocked with the servo piston (14), the swashplate now tilts to activate the variable pump (15). Pressurized oil is then forced into the stationary motor (11), which then rotates to circulate oil between the pump and motor.

The heavier the load on the output shaft (9), the higher the pressure of the oil coming from the pump (15). Now the assist motor (10) is activated to increase the output torque. When the load on the output shaft (9) decreases, the oil pressure in the main circuit also drops and the assist motor (10) returns to its neutral position and just the stationary motor (11) maintains torque to the output shaft (9). Now a closed circuit is formed by the pump (15) and stationary motor (11).

The unload valve (14) is composed of the manual operation spool and the spool that operates in synchronization with the brake.

(Reference)

• Valve Setting Pressure [Oil temperature: 45 to 55 °C (113 to 131 °F)]

– Engine Speed: 1350 min

− 1

(rpm)

Charge Relief Valve: 0.52 to 0.71 MPa (5.3 to 7.3 kgf/cm

2

, 75 to 100 psi)

– Engine Speed: 3000 min

− 1

(rpm)

Check and High Pressure Relief Valve

(Forward) 22.6 to 26.5 MPa (231 to 270 kgf/cm

(Reverse) 18.9 to 21.5 MPa (193 to 219 kgf/cm

2

2

, 3280 to 3840 psi)

, 2750 to 3110 psi)

9Y1210293TRM0005US0

2-M5

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(3) Function of Components

[A] Servomechanism

TRANSMISSION

(1) Regulator Valve Assembly

(2) Regulator Spool

(3) Pin A

(Fixed with Regulator Shaft)

(4) Pin B (Fixed with Spool)

(5) Feedback Lever

(6) Regulator Shaft

(7) Servo Piston

(8) Guide (for Variable

Swashplate)

(9) Variable Swashplate (Pump)

(10) Servo Piston

(11) Servo Spring

(12) Piston Adjusting Screw

The servomechanism is composed of the following. The regulator valve assembly (1) is connected to the pedal through cable and linkages, and controls the flow of oil to the servo piston (10) by the pedal operation.

The servo piston moved by hydraulic force, is connected to the pump cylinder variable swashplate (9). Therefore, a tilt angle of swashplate is varied by servo piston movement.

The regulator and the servo piston are connected with feedback lever (5), and the movement of the piston is restricted according to the amount of depressing of the pedal.

9Y1210293TRM0006US0

2-M6

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[B] Regulator and Servo Piston Operation

(A) Control Lever at Neutral

TRANSMISSION

(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

(9) Piston Adjusting Screw

(10) HST Housing

a: Drain to HST Housing b: From Charge Pump

(Charge Pressure)

The regulator spool (3) is preset to the neutral position by the servo adjust screw (1). In this state, both ends of the servo piston (8) are opened to the drain port.

With the feedback lever (7) is between the spool senses the servo piston position. When the spool is at the neutral position, the piston adjusting screw (9) serves to position the servo piston so that the pump's variable swashplate gets neutral.

9Y1210293TRM0007US0

2-M7

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(B) Control Lever Activated (First Step: Moving the Control Lever)

TRANSMISSION

(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

(9) Piston Adjusting Screw

(10) HST Housing

a: Drain to HST Housing b: From Charge Pump

(Charge Pressure)

When moving the control lever (step on the pedal), and the feedback lever (7) connected with the regulator spool

(3) goes against the servo piston (8). Such resistance pulls the regulator spool from the feedback lever. As a result, the hydraulic circuit is formed as shown here.

The servo piston is affected by the charge pressure and starts moving in the direction of arrow.

9Y1210293TRM0008US0

2-M8

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(C) Control Lever Activated (with Control Lever at Desired Position)

TRANSMISSION

(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

(9) Piston Adjusting Screw

(10) HST Housing

a: Drain to HST Housing b: From Charge Pump

(Charge Pressure)

A: Speed Up

B: Slow Down

When the control lever has been set to a desired position, the regulator's feedback lever (7) and the servo piston

(8) get balanced with each other. Now the regulator spool (3) goes to the neutral position. The pump's variable swashplate interlocked with the servo piston is kept in place to achieve a desired speed.

The load on the HST pump is not constant, however. A heavier load returns the servo piston toward the slow-down side. In so doing, the feedback lever works on the spool to switch the hydraulic circuit to the speed-up side.

Then the servo piston is brought back (speed-up) until it gets well balanced with the feedback lever.

A smaller load, on the other hand, moves the servo piston toward the speed-up side. The feedback lever now works on the regulator spool to switch the hydraulic circuit to the slow-down side. The servo piston's charge pressure is let out at the slow-down side and introduced at the speed-up side. Then the servo piston is brought back

(slow-down) until it gets well balanced with the feedback lever. This cycle of motions is repeated to maintain the desired position.

9Y1210293TRM0009US0

2-M9

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(D) Control Lever Deactivated

TRANSMISSION

(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

(9) Piston Adjusting Screw

(10) HST Housing

(11) Servo Spring

a: Drain to HST Housing b: From Charge Pump

(Charge Pressure)

Release the control lever (release the pedal), and the spool comes back to the neutral position. The oil at both ends of the servo piston (8) flows back to the tank. The oil from the charge pump also flows back to the HST housing.

With such circuit formed, the servo spring (11) pushes the servo piston back to the neutral position.

9Y1210293TRM0010US0

2-M10

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[C] HST Oil Flow

(A) Neutral

TRANSMISSION

(1) Pedal

(2) Regulator Valve Assembly

(3) Regulator Spool

(4) Servo Piston

(5) Cylinder Block

(6) HST Housing

(7) Control Piston

(8) Variable Swashplate

(Assist Motor)

(9) Cylinder Block (Assist Motor)

(10) Check and High Pressure

Relief Valve (Forward)

(11) Unload Valve

(12) Check and High Pressure

Relief Valve

(13) Cylinder Block

(Stationary Motor)

(14) Anti-cavitation Valve

(15) Transmission Case

(16) Output Shaft

(17) Charge Relief Valve

(18) Oil Filter Cartridge (Suction)

(19) Variable Swashplate

(HST Pump)

(20) Charge Pump

(21) Input Shaft

(22) Oil Filter Cartridge

(23) Orifice

a: To HST Housing

The oil that is drawn by the charge pump (20) from the transmission case (15) through the oil filter cartridge (18) and charge relief valve (17) into the HST hydraulic circuit and regulator valve (2). Surplus flow is returned from the charge relief valve (17) to the HST housing (6) and finally into the transmission case (15).

When the pedal (1) is released (neutral position), the regulator spool (3) is also at the neutral position. The pump variable swash plate is interlocked with the servo piston (4), will not tilt.

In this way, the HST pump (19) keeps rotating but the pump piston is stationary as no oil is being fed from the

HST pump (19). Until oil is fed back from the HST pump (19), the cylinder assembly of the stationary motor (13) and assist motor (9) are halted which keeps the output shaft from turning.

9Y1210293TRM0011US0

2-M11

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(B) Pedal Depressed Halfway and Under Light Load

TRANSMISSION

(1) Pedal

(2) Regulator Valve Assembly

(3) Regulator Spool

(4) Servo Piston

(5) Cylinder Block

(6) HST Housing

(7) Control Piston

(8) Variable Swashplate

(Assist Motor)

(9) Cylinder Block (Assist Motor)

(10) Check and High Pressure

Relief Valve (Forward)

(11) Unload Valve

(12) Check and High Pressure

Relief Valve

(13) Cylinder Block

(Stationary Motor)

(14) Anti-cavitation Valve

(15) Transmission Case

(16) Output Shaft

(17) Charge Relief Valve

(18) Oil Filter Cartridge (Suction)

(19) Variable Swashplate

(HST Pump)

(20) Charge Pump

(21) Input Shaft

(22) Oil Filter Cartridge

a: To HST Housing

The pedal (1) is depressed halfway, the control lever is activated by the pedal (1) to switch the regulator valve (2) hydraulic circuit. The servo piston (4) is then actuated to tilt the pump variable swashplate (18) (see the above illustration).

The pump cylinder block (5) is driven by the input shaft (21) to put the oil under high pressure and to feed it out of the pump port

A

. The pressure-fed oil flows into the motors port

D

along the circuit. The motor's piston is actuated by this pressurized oil to push down the stationary swashplate. Then together with the motor cylinder block (5), the output shaft (16) starts turning.

The output shaft rotation is determined by the delivery rate of the HST pump (19), varying the rotation.

Then the motor oil drops to a low pressure and returns through the motor port

C

to the pump port

B

.

9Y1210293TRM0012US0

2-M12

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(C) Pedal Depressed Fully and Under Light Load

TRANSMISSION

(1) Pedal

(2) Regulator Valve Assembly

(3) Regulator Spool

(4) Servo Piston

(5) Cylinder Block

(6) HST Housing

(7) Control Piston

(8) Variable Swashplate

(Assist Motor)

(9) Cylinder Block (Assist Motor)

(10) Check and High Pressure

Relief Valve (Forward)

(11) Unload Valve

(12) Check and High Pressure

Relief Valve

(13) Cylinder Block

(Stationary Motor)

(14) Anti-cavitation Valve

(15) Transmission Case

(16) Output Shaft

(17) Charge Relief Valve

(18) Oil Filter Cartridge (Suction)

(19) Variable Swashplate

(HST Pump)

(20) Charge Pump

(21) Input Shaft

(22) Oil Filter Cartridge

a: To HST Housing

The pedal (1) is fully depressed, the control lever is activated by the pedal (1) to switch the regulator valve (2) hydraulic circuit. The servo piston (4) is then actuated to tilt the pump variable swashplate (8) to maximum.

The pump cylinder block (5) is driven by the input shaft (21) to put the oil under high pressure and to feed it at the highest rate out of the pump port

A

. The pressure-fed oil flows into the motor port

D

along the circuit. The pressure of the oil from the HST pump (19) is not high enough to get the assist motor (8) started. In this way, the output shaft

(16) achieves the maximum rpm with the assist motor (8) off, as shown in the figure above.

Then the motor oil drops to a low pressure and returns through the motor port

C

to the pump port

B

.

9Y1210293TRM0013US0

2-M13

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

(D) Pedal Depressed Fully, Under Light Load and Assist Motor Started Up to Maximum

Capacity Level

(1) Pedal

(2) Regulator Valve Assembly

(3) Regulator Spool

(4) Servo Piston

(5) Cylinder Block

(6) HST Housing

(7) Control Piston

(8) Variable Swashplate

(Assist Motor)

(9) Cylinder Block (Assist Motor)

(10) Check and High Pressure

Relief Valve (Forward)

(11) Unload Valve

(12) Check and High Pressure

Relief Valve

(13) Cylinder Block

(Stationary Motor)

(14) Anti-cavitation Valve

(15) Transmission Case

(16) Output Shaft

(17) Charge Relief Valve

(18) Oil Filter Cartridge (Suction)

(19) Variable Swashplate

(HST Pump)

(20) Charge Pump

(21) Input Shaft

(22) Oil Filter Cartridge

a: To HST Housing

The pedal (1) is fully depressed, the control lever is activated by the pedal (1) to switch the regulator valve (2) hydraulic circuit. The servo piston (4) is then actuated to tilt the pump variable swashplate (19) to maximum (see the above illustration).

The pump cylinder block (5) is driven by the input shaft (21) to put the oil under high pressure and to feed it at the highest rate out of the pump port

A

. The pressure-fed oil flows into the motor port

D

along the circuit. The pressure of the oil from the HST pump (19) now gets high enough to start tilting the assist motor variable swashplate (8). The oil is fed to the port

F

(branch flow) and port

G

too. As a result, the output shaft (16) is driven by the stationary motor

(13) and assist motor (8). The output shaft (16) rpm drops in proportion to the tilt of the assist motor variable swashplate (8), whereas its torque increases.

Then the stationary motor oil and the assist motor's oil drops to a low pressure and return through their respective ports

C

and

E

to the pump port

B

.

9Y1210293TRM0014US0

2-M14

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

(E) Pedal Depressed Fully, Under Heavy Load and Input Horsepower Control

(1) Pedal

(2) Regulator Valve Assembly

(3) Regulator Spool

(4) Servo Piston

(5) Cylinder Block

(6) HST Housing

(7) Control Piston

(8) Variable Swashplate

(Assist Motor)

(9) Cylinder Block (Assist Motor)

(10) Check and High Pressure

Relief Valve (Forward)

(11) Unload Valve

(12) Check and High Pressure

Relief Valve

(13) Cylinder Block

(Stationary Motor)

(14) Anti-cavitation Valve

(15) Transmission Case

(16) Output Shaft

(17) Charge Relief Valve

(18) Oil Filter Cartridge (Suction)

(19) Variable Swashplate

(HST Pump)

(20) Charge Pump

(21) Input Shaft

(22) Oil Filter Cartridge

a: To HST Housing

The pedal (1) is fully depressed, the control lever is activated by the pedal (1) to switch the regulator valve (2) hydraulic circuit. The servo piston (4) is then actuated to tilt the pump variable swashplate (19) to maximum (see the above illustration).

The pump cylinder block (5) is driven by the input shaft (21) to put the oil under high pressure and to feed it at the highest rate out of the pump port

A

. The pressure-fed oil flows into the motor port

D

along the circuit. The oil from the

HST pump (19) then reaches the pressure level to tilt the assist motor variable swashplate (8) all the way. At this time, the assist motor (9) reaches its maximum capacity.

If the load becomes heavier, the variable swashplate (pump) (19) moves toward to the neutral position under the reaction of HST pump (8) itself. With the variable swashplate tilted back to neutral side, the engine load becomes lighter and the engine rpm higher again. At this time, the pump delivery rate drops, but the recovered engine rpm enables the delivery oil pressure to go up to the high-pressure relief valve (10) setting. Now the maximum torque is obtained.

9Y1210293TRM0015US0

2-M15

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(F) Dynamic Brake Operating

TRANSMISSION

(1) Pedal

(2) Regulator Valve Assembly

(3) Regulator Spool

(4) Servo Piston

(5) Cylinder Block

(6) HST Housing

(7) Control Piston

(8) Variable Swashplate

(Assist Motor)

(9) Cylinder Block (Assist Motor)

(10) Check and High Pressure

Relief Valve (Forward)

(11) Unload Valve

(12) Check and High Pressure

Relief Valve

(13) Cylinder Block

(Stationary Motor)

(14) Anti-cavitation Valve

(15) Transmission Case

(16) Output Shaft

(17) Charge Relief Valve

(18) Oil Filter Cartridge (Suction)

(19) Variable Swashplate

(HST Pump)

(20) Charge Pump

(21) Input Shaft

(22) Oil Filter Cartridge

(23) Orifice

a: To HST Housing

When releasing the pedal (1), the regulator valve (2) forces the servo piston (4) to the neutral position. The pump variable swashplate (19) also goes back to the neutral position.

Still the machine tends to keep running by inertia force, but no oil is pressure-fed because the pump variable swashplate (19) is in the neutral position. (There is no oil flow from the HST pump.)

The output shaft (16), however, is rotated in the same direction as before releasing the pedal (1).

Now the stationary motor (13) works like a pump to suck the oil from port

D

and pressure-feed it from port

C

.

The oil coming from port

C

pushing open the high pressure relief valve (12) and flows through the check valve

(10) back to port

D

.

The dynamic brake force is determined by the force that is exerted to push open the backward travel high-pressure relief valve (12).

When the dynamic brake is applied, the pressure at port

D

drops below the charge pressure level. If the oil from port

C

is not enough to make up for the shortage, the charge oil too is supplied together.

When dynamic braking is activated, the pressure in the braking circuit is always unloaded through the orifice (23).

9Y1210293TRM0016US0

2-M16

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(G) After Dynamic Brake Operated, Brake a Unload Circuit Operating

TRANSMISSION

(1) Pedal

(2) Regulator Valve Assembly

(3) Regulator Spool

(4) Servo Piston

(5) Cylinder Block

(6) HST Housing

(7) Control Piston

(8) Variable Swashplate

(Assist Motor)

(9) Cylinder Block (Assist Motor)

(10) Check and High Pressure

Relief Valve (Forward)

(11) Unload Valve

(12) Check and High Pressure

Relief Valve

(13) Cylinder Block

(Stationary Motor)

(14) Anti-cavitation Valve

(15) Transmission Case

(16) Output Shaft

(17) Charge Relief Valve

(18) Oil Filter Cartridge (Suction)

(19) Variable Swashplate

(HST Pump)

(20) Charge Pump

(21) Input Shaft

(22) Oil Filter Cartridge

(23) Orifice

a: To HST Housing b: Connects with Brake Pedal

When driving, releasing the pedal (1) to halt the vehicle places the system under the status of dynamic braking, as described in the previous section.

Immediately after halting the vehicle by pressing the brake pedal (1), or when the deviation from neutral position of variable swashplate (19) is significant, a torque will exist between HST and the transmission.

Under the conditions, shifting the gears is extremely difficult because of friction in the gear box.

When the brake pedal (1) is depressed, the unload valve (11) opens and the residual pressure in the circuit is relieved through the orifice (23).

This operation releases the torque remaining in the transmission.

As a result, smooth shifting of gears is made possible.

9Y1210293TRM0017US0

2-M17

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[D] Charge Relief Valve

TRANSMISSION

The charge pump feeds oil to the HST main circuit

(closed circuit) and the regulator assembly. Oil may leak out of the HST main circuit (in the HST housing) depending on the pressure, oil temperature and other factors. With this in mind, oil must be constantly. Charge relief valve will open when oil pressure exceeds valve operating pressure.

Oil temperature

45 to 55 °C

(113 to 131 °F)

Valve operating pressure

0.52 to 0.72 MPa

5.3 to 7.3 kgf/cm

2

75 to 104 psi

(1) Valve Poppet

(2) Spring

(3) Shim

(a) From Charge Pump

A: Close

B: Open

9Y1210293TRM0018US0

2-M18

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[E] Check and High Pressure Relief Valve

TRANSMISSION

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.

The valve is used to prevent an overload that would happen at a quick start, sudden stop or even during usual running. This valve doubles as a check valve.

The check and high-pressure relief valves are laid out facing each other as shown in the figure.

When the pressure of both main oil circuit are below the pressure of

P2

, both valves are open and charging oil enters into the main oil circuit through the valves.

At normal operation, the check valve in the high-pressure side is closed and it pushes and opens the another one. An excessive charge flow goes through the charge relief valve into HST housing.

The check and high-pressure relief valve along the high-pressure line serves as a high-pressure relief valve.

If the pressure exceeds a high-pressure limit level, the spring (3) force and opens the valve seat that is located between the check valve seat (1) and the pressure poppet (2). Now the flow goes from

P1

to

P2

and

P3

.

If the

P1

pressure drops, the relief valve spring forces the valve seat closed against the pressure. The high-pressure oil at

P1

does not flow to

P2

any longer.

As discussed above, the check and high-pressure relief valve protects engines, pumps, motors, gears and even the machine itself from overload.

Condition

• Engine speed: 3000 min

-1

(rpm)

Oil temperature

45 to 55 °C

(113 to 131 °F)

Forward

Reverse

Port

Valve operating pressure

22.6 to 26.5 MPa

231 to 270 kgf/cm

2

3280 to 3840 psi

18.9 to 21.5 MPa

193 to 219 kgf/cm

2

2750 to 3110 psi

Condition

• Engine speed: 1350 min

-1

(rpm)

Oil temperature

45 to 55 °C

(113 to 131 °F)

Charge

Port

Valve operating pressure

0.52 to 0.71 MPa

5.3 to 7.4 kgf/cm

2

76 to 100 psi

(1) Check Valve Seat

(2) Pressure Poppet

(3) Relief Valve Spring

(4) Spring Guide

(5) Check Valve Spring

(6) Valve Plug

(A) When both Check Valve

Activating

(B) When Check Valve

Activating

(C) When High Pressure Relief

Valve Activating

9Y1210293TRM0019US0

2-M19

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[F] Anti-cavitation Valve

TRANSMISSION

The anti-cavitation valve is normally closed.

When the oil level in the charging circuit becomes low, the anti-cavitation valve opens and the necessary amount of oil is provided to the travel circuit from the

HST housing due to the pressure difference between

HST housing case and travel circuit.

(1) Anti-cavitation Valve

(2) Spring

A: Anti-cavitation Valve is

Closed

B: Anti-cavitation Valve is

Opened

F: To Travel Circuit (Forward

Circuit)

T: From HST Housing Case

9Y1210293TRM0020US0

[G] 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.

This time, to eliminate this problem, an unload valve is employed in the traveling circuit.

When the brake pedal is depressed, the unload valve opens and the residual pressure in the travel circuit is relived through the orifice (1).

(1) Orifice

(2) Unload Valve

F: From Travel Circuit

(Forward Circuit)

T: To HST Housing Case a: Brake Pedal is Depressed

A: Unload Valve Close

B: Unload Valve Open

9Y1210293TRM0021US0

2-M20

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[H] Control Linkage

(A) For HST

TRANSMISSION

(1) HST Control Lever

(2) Damper

(3) HST Control Rod

(4) Neutral Holder Arm

(5) Ball Bearing

(6) Speed Control Pedal Cable

(7) Engine Accelerator Wire

(8) Neutral Holder

(9) Neutral Spring

The speed control pedal and neutral holder arm (4) are connected with speed control pedal cable (6). And the

HST control lever (1) and neutral holder arm (4) are linked with HST control rod (3).

The accelerator wire (7) connected with neutral holder arm (4) is able to be pulled by synchronizing with the speed control pedal cable.

As the HST pedal is depressed to forward, the HST control lever (1) is rotated, then the swashplate is tilted by servomechanism and forward travelling speed increases. Then the swashplate is returned to neutral with the neutral holder arm (4), when the pedal is released. The ball bearing (5) on the neutral holder (8) pulled with the neutral spring

(9) seats the detent of the neutral holder arm (4) so that the neutral holder arm returns to neutral.

The damper (2) is connected to the speed control pedal through speed control pedal cable and neutral holder arm

(4), restricts the movement of the linkage to prevent abrupt operation.

9Y1210293TRM0022US0

2-M21

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(B) Unload Valve Linkage

TRANSMISSION

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.

This time, to eliminate this problem, an unload valve is employed in the travel circuit.

When the brake pedal (1) is depressed, the unload valve opens and the residual pressure in the travel circuit is relieved the orifice.

(1) Brake Pedal

(2) Unload Cable

(3) Unload Rod

(4) Unload Link

(5) Unload Spool

9Y1210293TRM0023US0

2-M22

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

[2] RANGE GEAR SHIFT SECTION AND FRONT WHEEL DRIVE

SECTION

R: Reverse

L: Low Speed

M: Middle Speed

H: High Speed a: 4 Wheel Drive

A: 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 taken out to the front and transmitted further to the range shift section.

The speed can be changed in 3 steps forward and in single step backward. The shifting is made through the cable linkage of the shift lever at the operator's seat. The speed change system is of constant mesh type.



Front Wheel Drive Section

This section is located near the range gear shift section. The front wheel drive select lever at the operator's seat is used to switch between the two wheel and four wheel drive. The front wheel drive select lever is connected with the cable. Sliding gear system is adopted, in which the shifter gears are directly moved.

9Y1210293TRM0024US0

2-M23

KiSC issued 05, 2014 A

SERVICING

CONTENTS

1. TROUBLESHOOTING.................................................................................................................2-S1

2. SERVICING SPECIFICATIONS ..................................................................................................2-S4

3. TIGHTENING TORQUES............................................................................................................2-S5

4. CHECKING, DISASSEMBLING AND SERVICING .....................................................................2-S6

[1] CHECKING AND ADJUSTING..............................................................................................2-S6

[2] PREPARATION...................................................................................................................2-S17

(1) Removing Outer Components .......................................................................................2-S17

(2) Separating Rear Axle ....................................................................................................2-S23

(3) Separating Transmission Assembly ..............................................................................2-S24

(4) Separating Engine and Transmission............................................................................2-S26

(5) Separating Front Case and Transmission Case............................................................2-S26

[3] DISASSEMBLING AND ASSEMBLING ..............................................................................2-S27

(1) Front Case.....................................................................................................................2-S27

(2) Transmission Case........................................................................................................2-S31

(3) Hydrostatic Transmission ..............................................................................................2-S39

[4] SERVICING.........................................................................................................................2-S41

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. TROUBLESHOOTING

HYDROSTATIC TRANSMISSION

Symptom

System Will Not

Operate in Either

Direction

Vibration and Noise

Loss of Power

Oil level is low

Oil level is low move smoothly

Probable Cause

Control linkage or cable defective

Charge pressure is too low

Check and high pressure relief valve does not move smoothly

Component parts defective

Oil level is too low

Control linkage or cable defective

Charge pressure is too low

Check and high pressure relief valve does not move smoothly

Component part is defective

Control linkage or cable defective

Charge pressure is too low

Check and high pressure relief valve does not

Component parts defective

2-S1

TRANSMISSION

Solution

Check oil level or fill oil to proper level

Repair linkage

Solution order

1. Replace oil filter cartridge

2. Check charge pressure

3. Inspect or flush charge relief valve

Inspect or replace check and high pressure relief valve

Replace hydrostatic transmission assembly

Check oil level or fill oil to proper level

Repair linkage

Solution order

1. Replace oil filter cartridge

2. Check charge pressure

3. Inspect or flush charge relief valve

Inspect or replace check and high pressure relief valve

Replace hydrostatic transmission assembly

Check oil level or fill oil to proper level

Repair linkage

1. Replace oil filter cartridge

2. Check charge pressure

3. Inspect or flush charge relief valve

Inspect or replace check and high pressure relief valve

Replace hydrostatic transmission assembly

Reference

Page

G-8

2-S22

G-21

2-S9

2-S37

2-S37

2-S39

G-8

2-S22

G-21

2-S9

2-S37

2-S37

2-S39

G-8

2-S22

G-21

2-S9

2-S37

2-S37

2-S39

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Symptom

Transmission Oil

Over Heats

Low transmission oil level

Radiator net clogged

Excessive machine load

Improper charge pressure

Machine Will Not

Stop in Neutral

Position

Control linkage is out of adjustment or sticking

System Operates in

One Direction Only

Control linkage defective

Check and high pressure relief valve defective

TRAVELLING GEAR SHIFT SECTION

Symptom

Probable Cause

Probable Cause

Noise from

Transmission

Transmission oil insufficient

Gear worn or broken

Bearings worn

Gear Slip Out of Mesh

Shift fork spring tension insufficient

Shift fork or shiftier worn

Shift fork bent

TRANSMISSION

Solution

Fill transmission oil level up to proper level

Clean radiator net

Reduce machine load

1. Check high relief pressure

2. Replace transmission oil filter cartridge

3. Replace check and high pressure relief valve

4. Inspect and replace charge relief valve

Repair or replace linkage

Adjust neutral position

Repair or replace linkage

Replace check and high pressure relief valve

Reference

Page

G-8

–

–

2-S6, 2-S7

G-21

2-S37

2-S37

2-S22

2-S10

2-S22

2-S37

Solution

Refill

Replace

Replace

Replace

Replace

Replace

Reference

Page

2-S18

2-S27

–

2-S30

2-S30

2-S30

2-S2

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

DIFFERENTIAL GEAR SECTION

Symptom Probable Cause Solution

Excessive or Unusual

Nose at All Time

Noise while Turning

Differential Lock Can

Not Be Set

Differential Lock

Pedal Does Not

Return

Improper backlash between spiral bevel pinion and bevel gear

Improper backlash between differential pinion and differential side gear

Bearing worn

Insufficient or improper type of transmission fluid used

Differential pinions or differential side gears worn or damaged

Differential lock binding (does not disengage)

Bearings worn

Differential lock shift fork damaged

Differential lock shiftier mounting pin damaged

Differential lock pin damaged

Differential lock pedal return spring weaken or damaged

Differential lock fork shaft rusted

Adjust

Adjust

Replace

Replenish or change

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Repair

Reference

Page

2-S48

2-S44

–

2-S18

2-S32

2-S31

–

2-S31

2-S31

2-S31

–

2-S31

9Y1210293TRS0001US0

2-S3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

2. SERVICING SPECIFICATIONS

Item

Check and High Pressure Relief Valve

Condition

• Engine Speed

3000 min

− 1

(rpm)

• Oil Temperature

45 to 55 °C (113 to 131 °F)

Charge Relief Valve

Condition

• Engine Speed

1350 min

− 1

(rpm)

• Oil Temperature

45 to 55 °C (113 to 131 °F)

Servo Piston Operation Pressure (When

Neutral Adjusted)

Setting Pressure

Forward

Setting Pressure

Reverse (Brake)

Setting Pressure

Difference

Pressure (P1-P2)

L

Position

Factory Specification

22.6 to 26.5 MPa

231 to 270 kgf/cm

2

3280 to 3840 psi

18.9 to 21.5 MPa

193 to 219 kgf/cm

2

2750 to 3110 psi

0.52 to 0.72 MPa

5.3 to 7.3 kgf/cm

2

76 to 100 psi

− 0.15 to 0.05 MPa

− 1.5 to +0.50 kgf/cm

2

− 21 to +7.2 psi

106 to 119 min

− 1

(rpm) Traveling Speed

Condition

• Engine Speed

3000 min

− 1

(rpm)

VHT Pressure Release Cable Length

L1

14 mm

0.55 in.

Length

L2

6T Spiral Bevel Pinion Shaft

Differential Pinion to Differential Side Gear Backlash

Differential Case to Differential Side Gear

• Differential Case

• Differential Side Gear

Differential Pinion Shaft to Differential

Pinion

• Differential Pinion

• Differential Pinion Shaft

Bevel Pinion Shaft to Bevel Gear

Clearance

L3

Turning Torque

Clearance

I.D.

O.D.

Clearance

I.D.

O.D.

Backlash

50 mm

2.0 in.

10.5 to 11.0 mm

0.414 to 0.433 in.

0.98 to 1.2 N·m

0.10 to 0.13 kgf·m

0.73 to 0.94 lbf·ft

0.15 to 0.30 mm

0.0059 to 0.011 in.

0.0500 to 0.151 mm

0.00197 to 0.00594 in.

38.000 to 38.062 mm

1.4961 to 1.4985 in.

37.911 to 37.950 mm

1.4926 to 1.4940 in.

0.0800 to 0.122 mm

0.00315 to 0.00480 in.

20.060 to 20.081 mm

0.78976 to 0.79057 in.

19.959 to 19.980 mm

0.78579 to 0.78661 in.

0.20 to 0.40 mm

0.0079 to 0.015 in.

TRANSMISSION

Allowable Limit

–

–

–

–

–

–

–

–

–

–

0.30 mm

0.012 in.

–

–

0.30 mm

0.012 in.

–

–

–

9Y1210293TRS0002US0

2-S4

KiSC issued 05, 2014 A

RTV1140CPX, 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: See page G-10.)

Item

Drain plug

Rear wheel mounting screw

Leaf spring mounting bolt and nut

Lock nut

Mission frame mounting bolt and nut

Transmission case bottom set screw

Transmission case side set screw

Engine set screw

Engine mounting screw

Front case mounting screw and nut

Back idle gear shaft nut

Bearing holder mounting screw

Bearing cover mounting screw

Differential support cover mounting screw

37T spiral bevel gear mounting screw

Piston case

Motor case mounting screw

Port block cover mounting screw

Charge pump case mounting screw

Unload plug

Hex. head socket plug

Anti-cavitation valve cover

Anti-cavitation valve case

Regulator mounting hexagon socket head screw

Servo piston and cover mounting head screw

Oil filter bracket mounting screw

Hex. socket head screw

32 to 34

18 to 20

18 to 20

61 to 70

69 to 78

18 to 20

18 to 20

17 to 19

29 to 39

59 to 78

49 to 59

49 to 59

5.2 to 6.2

17 to 19

18 to 20

2.5 to 3.0

N·m

58 to 67

75 to 90

48.0 to 55.9

24.0 to 28.0

77.4 to 90.2

39.2 to 44.1

62.7 to 72.5

48.0 to 55.9

17.7 to 20.5

40 to 44

93.2 to 102

3.2 to 3.5

1.8 to 2.1

1.8 to 2.1

6.2 to 7.2

7.0 to 8.0

1.8 to 2.1

1.8 to 2.1

1.7 to 2.0

3.0 to 3.9

6.0 to 8.0

5.0 to 6.0

5.0 to 6.0

0.53 to 0.64

1.7 to 2.0

1.8 to 2.1

0.26 to 0.30

kgf·m

5.9 to 6.9

7.6 to 9.2

4.90 to 5.70

2.45 to 2.85

7.90 to 9.19

4.00 to 4.49

6.40 to 7.39

4.90 to 5.70

1.80 to 2.10

4.0 to 4.5

9.50 to 10.5

TRANSMISSION

24 to 25

13 to 15

13 to 15

45 to 52

51 to 57

13 to 15

13 to 15

13 to 14

22 to 28

44 to 57

37 to 43

37 to 43

3.9 to 4.6

13 to 14

13 to 15

1.9 to 2.2

lbf·ft

43 to 49

55.3 to 66.4

35.4 to 41.2

17.7 to 20.6

57.1 to 66.5

29.0 to 32.5

46.3 to 53.4

35.4 to 41.2

13.1 to 15.1

29 to 32

68.8 to 75.9

9Y1210293TRS0003US0

2-S5

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING

Checking High Pressure Relief Valve Pressure (Forward 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.

• When checking, park the machine on flat ground, and apply the parking brake.

• Work by two people when you measure pressure.

• Note that the allen wrench does not come off firmly because the plug is not loose hard. Otherwise, the plug (2) might be damaged, and the plug not be loosened.

1. Remove the hex. socket head plug (G3/8) from

P1

port (2). (

P1

is for forward.)

NOTE

• The hex. socket plug is securely tightened. Therefore, it is very important to use a proper-sized allen wrench and fit it securely onto the plug. Do not give a shock but put your weight on the plug slowly, paying attention not to damage its hex. socket section. If the allen wrench is fitted on the plug at a slant or an improper-sized allen wrench is used to loose the plug, the hex. socket section will be damaged and you won't be able to loose the plug.

2. Install the HST adaptor and high pressure gauge to

P1

port (2).

3. Check to see that parking brake is applied.

4. Disconnect the unload cable (1) from brake pedal side.

5. Set the 4WD lever to 2WD position.

6. Start the engine.

7. Place the range gear shift lever in

H

position.

8. Depress the speed control pedal, and measure the check and high pressure relief valve pressure. (Engine speed is set by using the tachometer.)

9. If the measurement is not within the operating pressure, replace the check and high pressure relief valve assembly with new

one. (See page 2-S37.).

High pressure relief valve

Operating pressure

22.6 to 26.5 MPa

231 to 270 kgf/cm

2

3280 to 3840 psi

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

2

, 4267 psi) full scale.

(When reassembling)

• Take care not to damage O-ring on the plug.

Condition

• Engine speed

3000 min

-1

(rpm)

• Oil temperature

45 to 55 °C

113 to 131 °F

(1) Unload Cable (2)

P1

Port

(for Forward, Plug Size G3/8)

9Y1210293TRS0005US0

2-S6

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Checking High Pressure Relief Valve Pressure (Reverse 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.

• When checking, park the machine on flat ground, and apply the parking brake.

• Work by two people when you measure pressure.

• Note that the allen wrench does not come off firmly because the plug is not loose hard. Otherwise, the plug (2) might be damaged, and the plug not be loosened.

1. Remove the hex. socket head plug (G3/8) from

P2

port (2). (

P2

is for reverse.)

NOTE

• The hex. socket plug is securely tightened. Therefore, it is very important to use a proper-sized allen wrench and fit it securely onto the plug. Do not give a shock but put your weight on the plug slowly, paying attention not to damage its hex. socket section. If the allen wrench is fitted on the plug at a slant or an improper-sized allen wrench is used to loose the plug, the hex. socket section will be damaged and you won't be able to loose the plug.

2. Install the HST adaptor and high pressure gauge to

P2

port (2).

3. Check to see that parking brake is applied.

4. Raise the cargo bed and set the safety support.

5. Disconnect the unload cable (1) from brake pedal side.

6. Remove the neutral rod (HST control rod) (3) from the HST control lever (4).

7. Set the 4WD lever to 2WD position.

8. Start the engine and depress the speed control pedal when measuring pressure. (Engine speed is set by using the tachometer.)

9. Shift the range gear shift lever in

H

position.

10. Slowly push reverse

"A"

the HST control lever by hand and measure the check and high pressure relief valve pressure.

11. If the measurement is not within the operating pressure, replace the check and high pressure relief valve assembly with new

one. (See page 2-S37.)

High pressure relief valve

Operating pressure

18.9 to 21.5 MPa

193 to 219 kgf/cm

2

2750 to 3110 psi

IMPORTANT

• Measure quickly so that the relief valve may not be in operation more than 10 seconds.

A: Reverse

(1) Unload Cable

(2)

P2

Port

(for Reverse, Plug Size G3/8)

(3) Neutral Rod

(4) HST Control Lever

(To be continued)

2-S7

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(Continued)

TRANSMISSION

NOTE

• High pressure gauge is 29.4 MPa (300 kgf/cm

2

, 4267 psi) full scale.

(When reassembling)

• Take care not to damage O-ring on plug.

Condition

• Engine speed

3000 min

− 1

(rpm)

• Oil temperature

45 to 55 °C

113 to 131 °F

9Y1210293TRS0006US0

2-S8

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

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 well-ventilated area.

• When checking, park the machine on flat ground, and apply the parking brake.

• Work by two people when you measure pressure.

• Note that the allen wrench does not come off firmly because the plug is not loose hard. Otherwise, the plug (1) might be damaged, and the plug not be loosened.

1. Remove the hex. socket head plug (G1/4) from

P3

port (1).

NOTE

• The hex. socket plug is securely tightened. Therefore, it is very important to use a proper-sized allen wrench and fit it securely onto the plug. Do not give a shock but put your weight on the plug slowly, paying attention not to damage its hex. socket section. If the allen wrench is fitted on the plug at a slant or an improper-sized allen wrench is used to loose the plug, the hex. socket section will be damaged and you won't be able to loose the plug.

2. Install the HST adaptor and high pressure gauge to

P3

port (1).

3. Place the range gear shift lever in neutral.

4. Set the 4WD lever to 2WD position.

5. Start the engine.

6. Measure the charge pressure.

7. If the measurement is not within the factory specification, check

the charge relief valve. (See page 2-S37.)

(When reassembling)

• Take care not to damage O-ring on plug.

Charge pressure Factory specification

0.52 to 0.72 MPa

5.3 to 7.3 kgf/cm

2

76 to 100 psi

NOTE

• Low pressure gauge is 2.9 MPa (30 kgf/cm

2

, 427 psi) full scale.

Condition

• Engine speed

1350 min

− 1

(rpm)

• Oil temperature

45 to 55 °C

113 to 131 °F

(1)

P3

Port (Charge, Plug Size G1/4)

9Y1210293TRS0007US0

2-S9

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Checking Neutral

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.

• Always try to work in a well-ventilated area.

• Lift up and secure with jack stands or blocking the front of machine, do not run the machine while adjusting.

• Work by two people when you checking and adjusting neutral.

NOTE

• The hex. socket plug is securely tightened. Therefore, it is very important to use a proper-sized allen wrench and fit it securely onto the plug. Do not give a shock but put your weight on the plug slowly, paying attention not to damage its hex. socket section. If the allen wrench is fitted on the plug at a slant or an improper-sized allen wrench is used to loose the plug, the hex. socket section will be damaged and you won't be able to loose the plug.

(To be continued)

2-S10

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(Continued)

TRANSMISSION

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

1. Remove the hex. socket head plug from

P1

port (3) and

P2

port

(4).

2. Install the HST adaptor and low pressure gauge in

P1

port and

P2

port.

3. Remove the HST control rod (1) from the HST control lever (2) to make situation that HST control lever move freely.

4. Set the 4WD lever to 2WD position.

5. Start the engine and shift the range gear shift lever in

L

position for 5 seconds to make sure that the HST is in neutral position.

6. At this time, check both

P1

port (3) and

P2

port (4) pressure if the wheel rotates.

7. If the measurement is not within the factory specification, adjust with hex. socket head screw (5).

(Adjusting procedure)

• Adjust to loosen the lock nut (6) on a right side of servo piston and for the adjustment hex. socket head screw (5) to make both

P1

port (3) and

P2

port (4) pressure equal while seeing the pressure gauge.

• Retighten the lock nut (6) securely.

(Reference)

• The pressure of

P2

port (4) (reverse side) rises when turning the clockwise.

• The pressure

P1

port (3) (forward side) rises when turning the counterclockwise.

8. Reinstall the HST control rod (1) to HST control lever (2) after confirming neutrality in the HST unit.

9. Adjust the rod length and much a neutral position if the wheel rotates after is stalling the HST control rod (1).

Difference pressure

P1

-

P2

Factory specification

− 0.15 to 0.05 MPa

− 1.5 to 0.50 kgf/cm

2

− 21 to 7.2 psi

Condition

• Engine speed

Idle (1350 min

-1

(rpm))

• Oil temperature

45 to 55 °C

113 to 131 °F

(1) HST Control Rod

(2) HST Control Lever

(3)

P1

Port

(for Forward, Plug Size G3/8)

(4)

P2

Port

(for Reverse, Plug Size G3/8)

(5) Hex. Socket Head Screw

(6) Lock Nut

9Y1210293TRS0008US0

2-S11

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

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.

• Always try to work in a well-ventilated area.

• Lift up and secure with jack stands or blocking the front of machine, do not run the machine while adjusting.

• Work by two people when you checking and adjusting travelling speed.

1. Set the 4WD lever to 2WD position.

2. Start the engine and shift the range shift lever in

L

position and depress the differential lock pedal.

3. Depress the speed control pedal (2), and measure the rotations of rear wheel. (Engine speed is set with tachometer.)

4. If the measurement is not within the factory specification, loosen the lock nut and adjust the length of the speed control pedal stopper bolt (1).

Rear wheel rotation

(axle) at

L

speed

Factory specification

106 to 119 min

-1

(rpm) at rated engine speed

(3000 min

-1

(rpm))

NOTE

• Confirm the position of the HST control becomes the foremost position when fully depress the speed control pedal, and the HST control rod is not pulled too much.

• And confirm whether to pull the accelerator wire too much at same time.

• Refer to the following paragraph a detailed adjustment of above-mentioned two points.

(1) Speed Control Pedal Stopper Bolt (2) Speed Control Pedal

9Y1210293TRS0009US0

2-S12

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Checking Speed Control Pedal Stroke (Adjustment of the speed control pedal cable)

CAUTION

• When checking, park the machine on flat ground, and apply the parking brake.

• Work by two people when you checking and adjusting speed control pedal stroke.

1. Check that the speed control pedal cable (1) is fixed to the lever support (2), with the cable outer section screw being positioned near the center.

2. Loosen the lock nut (3), and remove the cable from the cable stay (4).

3. Manually push the HST control lever (5) forward, and mark (6) the case when the lever is in the foremost position.

4. Put the cable through the cable stay (4) and adjust the length of the cable outer section so that the speed control pedal (7) is positioned in the upper limit (where the pedal comes into contact with the stopper). Then tighten the lock nut (3) firmly.

5. Adjust the height of the speed control pedal stopper bolt so that the control lever (5) is positioned 1 mm (0.04 in.) backward of the marking (6) at the edge of case when the speed control pedal (7) is pressed down to the lowest point.

6. After this, adjust the accelerator wire (8) so that it gives the maximum pull to the engine speed control lever (maximum revolutions) when the speed control pedal (7) is pressed all the way down.

NOTE

• Adjust the accelerator wire (8) carefully not to pull it excessively. Otherwise the cable damage may result.

(1) Speed Control Pedal Cable

(2) Lever Support

(3) Lock Nut

(4) Cable Stay

(5) HST Control Lever

(6) Mark

(7) Speed Control Pedal

(8) Accelerator Wire

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2-S13

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Checking Main 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 two people when you checking and adjusting main shift lever position.

1. Loosen the lock nut (3) of the cable outer section at the main shift arm (5) side, and remove the main shift cable (4).

2. Loosen the lock nut (7) of the cable outer section at the auxiliary shift arm (6) side, and remove the select cable (1).

3. Check that each cable is fixed to the lever support (11), with the cable outer section screw being positioned near the center.

Also check that the lock nut at the cable end and the ball joint are not loose. Check that the ball joint fitting nuts (9) (lever side and link side) are tightened.

4. Move the main shift arm (5) to right and left to confirm that it is in the neutral position. (Due to a force of the spring in the main shift arm (5), the arm is set to the left side.)

5. Fix the main shift lever (11) in the neutral position (the midpoint of

H

and

M

in the lever guide).

NOTE

• Check that both cables move smoothly.

6. Keeping this condition, put each cable through the cable stay (2) and adjust the length of the cable outer section while taking care not to move the main shift lever (11) and the auxiliary shift arm

(6).

Tighten the lock nuts (3), (7) firmly.

Also check that the lock nuts at the cable end and the ball joint are not loose. Check that the ball joint fitting nuts (8) are tightened.

(1) Select Cable

(2) Cable Stay

(3) Lock Nut

(4) Main Shift Cable

(5) Main Shift Arm

(6) Auxiliary Shift Arm

(7) Lock Nut

(8) Fitting Nut

(9) Fitting Nut

(10) Lever Support

(11) Main Shift Lever

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TRANSMISSION

Checking Four Wheel Drive Lever Position (Adjustment of the

4WD shaft cable length)

CAUTION

• When checking, park the machine on flat ground, and apply the parking brake.

• Work by two people when you checking and adjusting four wheel drive lever position.

1. Loosen the cable lock nut (2) at the sub-frame side, and remove the 4WD shift cable (1).

2. Check that the cable is fixed to the lever support (4), with the cable outer section screw being positioned near the center.

Also check that the lock nuts at the cable end and the ball joint are not loose. Check that the ball joint fitting nuts are tightened.

3. Shift the 4WD shift arm (3) to the 2WD position

"A"

.

4. Fix the 4WD lever (5) in the 2WD position.

NOTE

• Check that the cable moves smoothly.

5. Keeping this condition, put the cable through the cable stay and adjust the length of the cable outer section while taking care not to move the 4WD lever (5). Then tighten the lock nuts (2) firmly.

Also check that the lock nuts at the cable end and the ball joint are not loose. Check that the ball joint fitting nuts (lever side and arm side) are tightened.

(1) 4WD Shift Cable

(2) Lock Nut

(3) 4WD Shift Arm

(4) Lever Support

(5) 4WD Lever

A: 2WD Position

9Y1210293TRS0012US0

Checking Differential Lock Cable (Adjustment of the length of the cable for differential lock)

CAUTION

• When checking, park the machine on flat ground, and apply the parking brake.

1. Check that the cable is fixed to the main frame, with the cable outer section screw being positioned near the center.

2. Adjust the length of the cable outer section so that the differential lock spring (3) has no play, and tighten the lock nut

(2).

(1) Differential Lock Cable

(2) Lock Nut

(3) Differential Lock Spring

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KiSC issued 05, 2014 A

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TRANSMISSION

Checking VHT Pressure Release Cable (Unload Cable)

CAUTION

• When checking, park the vehicle on flat ground.

• Work by two people when adjusting.

1. Loosen the lock nut (2) of the cable outer section at the front side, and remove the unload cable (1).

2. Remove the spring (6) and loosen the lock nut (7) of the cable outer section at the rear side, and remove the unload cable (8).

3. Check the unload linkage (5) is parallel to the frame (3).

4. Set the position of the cable (1) in the length of

L1

and set the cable angle

A

.

5. Set the position of unload rod (4) in the length of

L2

.

6. Set for the unload cable (8) not to loosen.

NOTE

• Do not depress the brake pedal while measuring the clearance.

7. Adjust for the clearance between the unload linkage (5) and the plug (9) to become

L3

of length with the unload cable (8).

8. Start the engine.

NOTE

• Do not depress the brake pedal while measuring the clearance.

9. Confirm the clearance

L3

between the unload linkage (5) and the lock nut (9).

10. If the measurement is not within the factory specifications, adjust the clearance.

Length

L1

Length

L2

Clearance

L3

between plug and unload linkage

Factory specification

Factory specification

Factory specification

14 mm

0.55 in.

50 mm

2.0 in.

10.5 to 11.0 mm

0.414 to 0.433 in.

(1) Unload Cable (Front Side)

(2) Lock Nut

(3) Frame

(4) Unload Rod

(5) Unload Linkage

(6) Spring

(7) Lock Nut

(8) Unload Cable

(9) Plug

A: 0.52 rad (30 °)

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[2] PREPARATION

(1) Removing Outer Components

Battery

TRANSMISSION

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. Set the seat to 1 row.

2. Remove the battery cover (1).

3. Remove the air cleaner hose (2).

4. Disconnect the negative cable (3) from the battery (4).

(1) Battery Cover

(2) Air Cleaner Hose

(3) Negative Cable

(4) Battery

(5) Positive Cable

9Y1210293ENS0025US0

Cargo Bed

1. Lift up the cargo bed (1) by hand and support it with the safety support so that the hydraulic cylinder should not drop.

2. Remove the cotter pin and clevis pin (2).

3. Disconnect the connector (3) from main harness, then separate the harness for the tail lamps.

4. Loosen the lock nut (4) and remove the hinge bolt (5) and nut.

(1) Cargo Bed

(2) Clevis Pin

(3) Connector

(4) Lock Nut

(5) Hinge Bolt

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TRANSMISSION

Draining Transmission Oil

CAUTION

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 flat surface, raise the cargo bed, mount the safety support.

2. To drain the used oil, remove the drain plug (3) at the bottom of the transmission case and drain the oil completely into the oil pan.

3. After draining, reinstall the drain plug (3).

(When refilling)

• Fill with the new KUBOTA SUPER UDT fluid up to the upper notch on the dipstick (2).

(Refer to "LUBRICANTS, FUEL AND COOLANT" in

"MAINTENANCE".) (See page G-8.)

• After running the engine for a few minutes, stop the engine and check the oil level again; add oil to prescribed level.

IMPORTANT

• Do not operate the vehicle immediately after changing the transmission fluid.

Run the engine at medium speed for a few minutes to prevent damage to the transmission.

Transmission oil capacity

11 L

2.9 U.S.gals

2.4 Imp.gals

Tightening torque

(1) Oil Inlet

(2) Dipstick

(3) Drain Plug

Drain plug

58 to 67 N·m

5.9 to 6.9 kgf·m

43 to 49 lbf·ft

A: Oil level is acceptable within this range.

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TRANSMISSION

Draining Hydraulic Tank Oil

CAUTION

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 may cause burns.

1. Park the vehicle on a firm, flat and level surface.

2. Tilt the seat.

3. Remove the under guard.

4. To drain the used oil, remove the drain plug and filling plug and drain the oil completely into the oil pan.

5. After draining, reinstall the drain plug.

6. Install the under guard.

(When refilling)

• Fill with new KUBOTA SUPER UDT fluid up to the upper notch

on the dipstick. (See page G-8.)

How to check:

Wipe dipstick clean with a rag and screw filling plug into filling hole. Remove filling plug again to see if the oil level is between the upper and lower notch.

• After filling, reinstall the filling plug.

Oil capacity

14.5 L

15.3 U.S.qts

12.8 Imp.qts

(1) Under Guard

(2) Drain Plug

(3) Filling Plug with Dipstick

A: Oil level is acceptable within this range.

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TRANSMISSION

Draining Coolant

CAUTION

• 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.

1. Stop the engine and let cool down.

2. To drain the coolant, open the radiator drain plug (1) and remove radiator cap (3). The radiator cap must be removed to completely drain the coolant.

3. After all coolant is drained, close the drain plug.

(When refilling)

• Fill with clean water and cooling system cleaner.

• Follow directions of the cleaner instruction.

• After fill with clean water and anti-freeze until the coolant level is just below the radiator cap.

Install the radiator cap securely.

• Fill with fresh water up to the

"FULL"

mark on the recovery tank.

• Start and operate the engine for few minutes.

• Stop the engine and let cool.

• Check coolant level of recovery tank and add coolant if necessary.

Coolant Capacity

5.2 L

5.5 U.S.qts

4.6 Imp.qts

IMPORTANT

• Do not start engine without coolant.

• Use clean, fresh water and anti-freeze to fill the radiator and recovery tank.

• When the anti-freeze is mixed with water, the anti-freeze mixing ratio must be less than 50 %.

• Securely tighten radiator cap. If the cap is loose or improperly fitted, water may leak out and the engine could overheat.

(1) Drain Plug

(2) Rear Tire (L.H.)

(3) Radiator Cap

(4) Recovery Tank

A: FULL

B: LOW

9Y1210293ENS0103US0

Muffler Cover, Muffler, Transmission Rear Guard and

Hydraulic Cylinder

1. Remove the stay (1) and muffler cover (2).

2. Remove the muffler (4) and muffler pipe (7).

3. Remove the transmission rear guard (5).

4. Disconnect the quick couplers (6).

5. Remove the hydraulic cylinder (3).

(1) Stay

(2) Muffler Cover

(3) Hydraulic Cylinder

(4) Muffler

(5) Rear Guard

(6) Quick Coupler

(7) Muffler Pipe

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TRANSMISSION

Air Cleaner

1. Remove the air cleaner body (2) and intake hose (1) together.

(1) Intake Hose (2) Air Cleaner Body

9Y1210293ENS0028US0

Rear Wheel

1. Remove the rear fenders (1).

2. Remove the rear wheels (2).

(When reassembling)

Tightening torque

Rear wheel mounting screw

75 to 90 N·m

7.6 to 9.2 kgf·m

55.3 to 66.4 lbf·ft

(1) Rear Fender (2) Rear Wheel

9Y1210293ENS0029US0

Wiring Harness

1. Disconnect the wiring harness from engine, glow plug (1), coolant temperature switch (2), engine stop solenoid (3) and oil pressure switch (4).

2. Disconnect the wiring harness from transmission, safety switch

(5) and rotation sensor (6).

(1) Glow Plug

(2) Coolant Temperature Switch

(3) Engine Stop Solenoid

(4) Oil Pressure Switch

(5) Safety Switch

(6) Rotation Sensor

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TRANSMISSION

Brake Hoses and Cables

1. Disconnect the select cable (1), main shift cable (2) and engine wire (3).

2. Disconnect the speed control pedal cable (4), parking brake cable R.H. (5), brake hose R.H. (6) and differential lock cable

(7).

3. Disconnect the unload valve cable (8).

4. Disconnect the parking brake cable L.H. (9), brake hose L.H.

(10) and 4WD shift cable (11).

(When reassembling)

• Adjust the length of main shift cable (2) and select cable (1).

• Adjust the length of speed control pedal cable (4).

• Adjust the length of differential lock cable (7).

• Adjust the length of parking brake cables (5), (9).

• Adjust the length of 4WD shift cable (11).

NOTE

• See "[1] CHECKING AND ADJUSTING" on page 2-S6.

(1) Select Cable

(2) Main Shift Cable

(3) Engine Wire

(4) Speed Control Pedal Cable

(5) Parking Brake Cable R.H.

(6) Brake Hose R.H.

(7) Differential Lock Cable

(8) Unload Valve Cable

(9) Parking Brake Cable L.H.

(10) Brake Hose L.H.

(11) 4WD Shift Cable

9Y1210293ENS0031US0

Hydraulic Hoses

1. Disconnect the delivery hose 1 (1) and delivery hose 2 (2).

2. Disconnect the suction hose (3).

(1) Delivery Hose 1

(to Hydraulic Control Valve)

(2) Delivery Hose 2 (to Power Steering)

(3) Suction Hose

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TRANSMISSION

Wiring Harness from Engine

1. Disconnect the coolant temperature sensor connector (3).

2. Disconnect the wiring connector from alternator (1).

3. Disconnect the wiring connector from starter motor (2).

(1) Alternator

(2) Starter Motor

(3) Coolant Temperature Sensor

Connector

9Y1210293ENS0033US0

Radiator Hoses and Ground Cable

1. Disconnect the radiator hoses (1), (2) from engine.

2. Disconnect the ground cable (3).

(1) Radiator Upper Hose

(2) Radiator Lower Hose

(3) Ground Cable

9Y1210293ENS0034US0

Fuel Hose Line

1. Disconnect the fuel hose (1) and return hose (2).

(1) Fuel Hose (2) Return Hose

9Y1210293ENS0035US0

(2) Separating Rear Axle

Rear Axle Bracket

1. Remove the boot band (4) on both sides.

2. Place the stand under the both side of frame.

3. Remove the leaf spring mounting bolt (3) and flange nut, and remove the rear axle bracket assembly (5) by use the axle support (6).

(When reassembling)

• Align the master spline of propeller shaft and rear axle shaft.

• Replace the boot band (4) with new one.

• Apply anti-fretting grease (NISSEKI PYRONOC UNIVERSAL

N6C or its equivalents) to spline of rear axle shaft.

Tightening torque

Leaf spring mounting bolt and flange nut

Lock nut

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

24.0 to 28.0 N·m

2.45 to 2.85 kgf·m

17.7 to 20.6 lbf·ft

(1) Lock Nut

(2) Flange Nut

(3) Leaf Spring Mounting Bolt

(4) Boot Band

(5) Rear Axle Bracket Assembly

(6) Axle Support

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TRANSMISSION

(3) Separating Transmission Assembly

Dismounting Transmission and Engine One Piece Assembly

1. Remove the unload linkage (1).

2. Set the power train support (6) and remove the mission frame

(4) mounting bolt (2) and nut.

3. Lift up the main frame by hoist.

4. Remove the transmission and engine one piece assembly (5).

(When reassembling)

• The bolt can be put through the rubber bushing more easily if soap water is applied to the bolt. Never hit the bolt.

• Assemble the mission-frame in such a manner as to insert two bolts in the from and then two bolts in the rear, instead of inserting the four bolts at a time.

• When reassembling the transmission and engine one piece assembly (mission frame) into the main frame, do not forget to assemble the 4WD propeller shaft (3) as well.

• Apply anti-fretting grease (NISSEKI PYRONOC UNIVERSAL

N6C or its equivalents) to splines of 4WD propeller shaft (3).

Tightening torque

Mission frame mounting bolt and nut

77.4 to 90.2 N·m

7.90 to 9.19 kgf·m

57.1 to 66.5 lbf·ft

(1) Unload Linkage

(2) Mission Frame Mounting Bolt

(3) 4WD Propeller Shaft

(4) Mission Frame

(5) Transmission and Engine One

Piece Assembly

(6) Power Train Support

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TRANSMISSION

Mission Frame

1. Remove the mission frame (2) from engine and transaxle one piece assembly.

(When reassembling)

• Tighten the screws (7) of bottom in the first.

• When inserting the bushes (9) in mission frame (2), align the tags (8) of bushes with alignment marks (10) on the mission frame (2).

Tightening torque

Transmission case bottom set screw

Transmission case side set screw

Engine set screw

39.2 to 44.1 N·m

4.00 to 4.49 kgf·m

29.0 to 32.5 lbf·ft

62.7 to 72.5 N·m

6.40 to 7.39 kgf·m

46.3 to 53.4 lbf·ft

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

(1) Transmission and Engine One

Piece Assembly

(2) Mission Frame

(3) Engine Set Screw

(4) Washer

(5) Transmission Case Side Set Screw

(6) Washer

(7) Transmission Case Bottom Set

Screw

(8) Tag

(9) Bush

(10) Alignment Mark

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TRANSMISSION

(4) Separating Engine and Transmission

Separate the Transmission and Engine One Piece Assembly

1. Remove the engine mounting screw and starter motor (1) mounting screws.

2. Disconnect the oil cooler hoses (2).

3. Disconnect the accelerator wire (3).

4. Separate the engine from transmission assembly.

(When reassembling)

• Apply liquid gasket (Three Bond 1215E, Locktite 5699 or equivalents) to joint face of engine rear-end plate and the transmission case.

• Apply anti-fretting grease (NISSEKI PYRONOC UNIVERSAL

N6C or its equivalents) to splines of engine output shaft.

Tightening torque Engine mounting screw

17.7 to 20.5 N·m

1.80 to 2.10 kgf·m

13.1 to 15.1 lbf·ft

(1) Starter Motor

(2) Oil Cooler Hose

(3) Accelerator Wire

9Y1210293ENS0039US0

(5) Separating Front Case and Transmission Case

Removing the Outer Parts

1. Remove the neutral rod (1).

2. Remove the HST linkages (2) with damper (3).

3. Remove the holder (6).

4. Remove the brake rods (4).

5. Remove the brake cylinders (5).

(1) Neutral Rod

(2) HST Linkage

(3) Damper

(4) Brake Rod

(5) Brake Cylinder

(6) Holder

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TRANSMISSION

Separate the Front Case and Transmission Case

1. Remove the shift cover (1).

2. Separate the front case (2) and transmission case (3).

(When reassembling)

• Replace the transmission case gasket with new one.

• Replace the shift cover gasket with new one.

Tightening torque

Front case mounting screw and nut

40 to 44 N·m

4.0 to 4.5 kgf·m

29 to 32 lbf·ft

(1) Shift Cover

(2) Front Case

(3) Transmission Case

9Y1210293TRS0016US0

[3] DISASSEMBLING AND ASSEMBLING

(1) Front Case

Disassembling Front Case Assembly

1. Remove the O-ring (1) from input shaft.

(1) O-ring

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TRANSMISSION

Detent Ball, Interlocking Ball and Back Idle Gear Shaft

1. Remove the stopper bolt (3) from bearing holder (1).

2. Remove the three interlock balls (6) with a magnet.

3. Tap out the roll pins (2) and remove the springs (8) and detent balls (7).

4. Loosen the nut (4) and tap out the back idle shaft (5) to the case side.

5. Remove the bearing holder mounting screws and pull out the bearing holder (1).

(1) Bearing Holder

(2) Roll Pin

(3) Stopper Bolt

(4) Nut

(5) Back Idle Shaft

(6) Interlock Ball

(7) Detent Ball

(8) Spring

(To be continued)

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(Continued)

TRANSMISSION

(When reassembling)

• Remove the bearing (1) on 11T-12T gear shaft (2).

• Install the bearing to bearing holder (3), first.

• Install the back idle gear and shaft (4), then tighten the nut with specified torque.

• Before assembling the bearing holder, check that the back idle gear, 11T-12T gear shaft and 39T back gear are properly engaged.

While ensuring the engagement of the three gears, assemble the bearing holder into the front case by tapping the 11T-12T gear shaft bearing.

NOTE

• After inserting the detent ball, mount the spring. Push the spring inward using a screwdriver or the like, and press in the roll pin (5). If the spring is not pushed in properly in this step, the roll pin (5) may bend the spring. Use full care when pressing in the roll pin (5).

Tightening torque

Back idle gear shaft nut

Bearing holder mounting screw

93.2 to 102 N·m

9.50 to 10.5 kgf·m

68.8 to 75.9 lbf·ft

32 to 34 N·m

3.2 to 3.5 kgf·m

24 to 25 lbf·ft

(1) Bearing

(2) 11T-12T Gear Shaft

(3) Bearing Holder

(4) Idle Gear Shaft

(5) Roll Pin

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TRANSMISSION

Shaft Assemblies

1. Remove the 4WD idle shaft assembly (1).

2. Draw out the 6T spiral bevel pinion shaft assembly (3) and

11T-12T gear shaft assembly (2) with shift fork.

3. Loosen the lock bolt for 4WD shift arm (4).

4. Draw out the 4WD shaft (5) and input shaft (6).

(When reassembling)

• Use same number of shim (7) as before disassembling.

(Reference)

Thickness of shim Factory specification

0.60 mm

0.24 in.

(1) 4WD Idle Shaft Assembly

(2) 11T-12T Gear Shaft Assembly

(3) 6T Spiral Bevel Pinion Shaft

Assembly

(4) 4WD Shift Arm

(5) 4WD Shaft (Output Shaft)

(6) Input Shaft

(7) Shim

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(2) Transmission Case

TRANSMISSION

Propeller Shaft Assembly

1. Remove the oil filter cartridge (2), and remove the oil cooler (1).

2. Remove the bearing cover (4) mounting screw, and remove the propeller shaft assembly (3).

(When reassembling)

Tightening torque

Bearing cover mounting screw

18 to 20 N·m

1.8 to 2.1 kgf·m

13 to 15 lbf·ft

(1) Oil Cooler

(2) Oil Filter Cartridge

(3) Propeller Shaft Assembly

(4) Bearing Cover

9Y1210293TRS0020US0

Differential Support Cover

1. Remove the rue ring and clevis pin (4) from differential lock fork

(3).

2. Remove the differential lock fork (3) and differential lock shaft

(1).

NOTE

• Take care not to fly out the spring (2) when pulling out the differential lock shaft.

3. Remove the differential support cover mounting screws and remove the differential support cover (5).

(When reassembling)

• Apply liquid gasket (Three Bond 1215E, Locktite 5699 or equivalent) to joint face of the different support cover and the transmission case.

Tightening torque

Differential support cover mounting screw

18 to 20 N·m

1.8 to 2.1 kgf·m

13 to 15 lbf·ft

(1) Differential Lock Shaft

(2) Spring

(3) Differential Lock Fork

(4) Clevis Pin

(5) Differential Support Cover

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TRANSMISSION

Differential Gear Assembly

1. Remove the differential support cover (1), noting the number of left shims (2).

2. Take out the differential gear assembly (3), noting the number of right shims.

(When reassembling)

• Use same number of shims as before disassembling.

(Reference)

Thickness of shim (LH)

Thickness of shim (RH)

Factory specification

Factory specification

0.70 to 0.80 mm

0.028 to 0.031 in.

0.70 to 0.80 mm

0.028 to 0.031 in.

(1) Differential Support Cover

(2) Shim

(3) Differential Gear Assembly

Disassembling Differential Gear Assembly

9Y1210293TRS0022US0

1. Remove the bearing (1), 37T spiral bevel gear mounting screw

(7) and 37T spiral bevel gear (5).

2. Put parting marks on the differential pinions (11) and the differential side gears (10).

3. Tap out the differential pinion shaft (3).

4. Remove the differential pinions (8), differential pinion washers

(8), differential side gears (10) and differential side gear washers (9).

(When reassembling)

• Install the differential pinion and differential side gear, aligning the parting marks.

• Lock the differential pinion shaft (5) by setting the key (2).

Tightening torque

37T spiral bevel gear mounting screw

61 to 70 N·m

6.2 to 7.2 kgf·m

45 to 52 lbf·ft

(1) Bearing

(2) Key

(3) Differential Pinion Shaft

(4) Differential Case

(5) 37T Spiral Bevel Gear

(6) Differential Lock Shiftier

(7) 37T Spiral Bevel Gear Mounting

Screw

(8) Differential Pinion Washer

(9) Differential Side Gear Washer

(10) Differential Side Gear

(11) Differential Pinion

9Y1210293TRS0023US0

2-S32

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Piston Case

1. Remove the piston case (1), return piston (2), springs (4) and stopper rod (3).

(When reassembling)

• Take care not to damage O-ring on the piston case.

Tightening torque Piston case

69 to 78 N·m

7.0 to 8.0 kgf·m

51 to 57 lbf·ft

(1) Piston Case

(2) Return Piston

(3) Stopper Rod

(4) Spring

9Y1210293TRS0024US0

2-S33

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Motor Case

1. Stand up the transmission case (2).

2. Loosen the suction hose clamps (4).

3. Remove the oil filter bracket (6) with suction hose (5).

4. Remove the suction pipe (3).

5. Remove the motor case (1).

6. Remove the variable swashplate (7) and assist motor cylinder block (8), control piston (12) and valve plate (13).

7. Remove the charge relief valve (9) and spring (11).

(When reassembling)

• Replace the motor case gasket (14) with new one.

• Be sure to install the motor case to variable swashplate (7).

• Be careful to note the location of three long screws (15), (16).

• Wrap the teflon tape around the thread of long screw (16).

• Do not forget the charge relief valve and spring (11).

• Be sure set the valve plate (13) to port block cover (10).

• Thrust ball bearing sequence thin race inside variable swash plate (7), ball bearing (open side down), thick race outside.

• Be sure to set the direction of the groove (17) shown in figure.

IMPORTANT

• Valve plate (13) for assist motor can not be replace with valve plate for motor and valve plate for pump.

Tightening torque Motor case mounting screw

18 to 20 N·m

1.8 to 2.1 kgf·m

13 to 15 lbf·ft

(1) Motor Case

(2) Transmission Case

(3) Suction Pipe

(4) Hose Clamp

(5) Suction Hose

(6) Oil Filter Bracket

(7) Variable Swashplate

(8) Cylinder Block (Assist Motor)

(9) Charge Relief Valve

(10) Port Block Cover

(11) Spring

(12) Control Piston

(13) Valve Plate (Assist Motor)

(14) Gasket

(15) Long Screw

(16) Long Screw (with Teflon Tape)

(17) Groove

9Y1210293TRS0025US0

2-S34

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Port Block Cover

1. Remove the port block cover mounting screw.

2. Pull and remove the port block cover (1) from transmission case

(2).

(When reassembling)

• Replace the port block cover gasket (5) with new one.

• Be sure to set the direction of the groove (6) shown in figure.

IMPORTANT

• Valve plate (3), (4) may stick to the port block cover but they are not fixed. Take care not to drop them.

And these valve plate are not interchangeable.

Tightening torque

Port block cover mounting screw

18 to 20 N·m

1.8 to 2.1 kgf·m

13 to 15 lbf·ft

(1) Port Block Cover

(2) Transmission Case

(3) Valve Plate (Motor)

(4) Valve Plate (Pump)

(5) Gasket

(6) Groove

9Y1210293TRS0026US0

Cylinder Block (Pump) Assembly

1. Remove the pump cylinder block (1) with piston.

(1) Cylinder Block (Pump)

9Y1210293TRS0027US0

2-S35

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Cylinder Block (Motor) Assembly, Motor Shaft Swashplate and

Pump Shaft

1. Tap out the motor shaft (2) with a plastic hammer slightly to slide out it with motor cylinder block with piston (3) to the rear side.

2. Tap out the pump shaft (1) with a plastic hammer slightly, then slide out to the rear and then remove the swashplate (4) with bearing.

(When reassembling)

• Place the swashplate (4) into the transmission case, align the slot guide of swashplate and groove of servo piston.

(1) Pump Shaft

(2) Motor Shaft

(3) Cylinder Block (Motor)

(4) Swashplate

9Y1210293TRS0028US0

Charge Pump

1. Remove the charge pump mounting screws, and remove the charge pump cover (3).

2. Remove the rotors (1), (2).

(When reassembling)

NOTE

• Align the each alignment mark of rotors.

• Alignment mark should be front side.

Tightening torque

Charge pump case mounting screw

17 to 19 N·m

1.7 to 2.0 kgf·m

13 to 14 lbf·ft

(1) Inner Rotor

(2) Outer Rotor

(3) Charge Pump Cover

(4) Alignment Mark

9Y1210293TRS0029US0

Unload Valve

1. Remove the plug (3).

2. Pull out the spool (2).

(When reassembling)

• Take care not to damage the O-ring on the plug and spool.

Tightening torque Unload plug

29 to 39 N·m

3.0 to 3.9 kgf·m

22 to 28 lbf·ft

(1) O-ring

(2) Spool

(3) Plug

9Y1210293TRS0030US0

2-S36

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Charge Relief Valve and Check and High Pressure Relief Valve

1. Remove the shim (7), spring (6) and charge relief valve poppet

(5).

2. Remove the hex. head socket plugs (1) and remove the springs

(2), check and high pressure valve assembly (3), (4).

3. Remove the charge relief valve poppet (5), spring (6) and shim

(7).

(When reassembling)

• Take care not to damage the O-ring on the plug.

Tightening torque Hex. head socket plug

59 to 78 N·m

6.0 to 8.0 kgf·m

44 to 57 lbf·ft

(1) Hex. Head Socket Plug

(2) Spring

(3) Check and High Pressure Valve

Assembly (Forward)

(4) Check and High Pressure Valve

Assembly (Reverse)

(5) Charge Relief Valve Poppet

(6) Spring

(7) Shim

9Y1210293TRS0031US0

Anti-cavitation Valve

1. Remove the valve cover (1).

2. Remove the shims (4), spring (3) and poppet (2).

3. Remove the valve case (5).

(When reassembling)

• Take care not to damage the O-rings on the valve cover and valve case.

Tightening torque

Anti-cavitation valve cover

Anti-cavitation valve case

49 to 59 N·m

5.0 to 6.0 kgf·m

37 to 43 lbf·ft

49 to 59 N·m

5.0 to 6.0 kgf·m

37 to 43 lbf·ft

(1) Valve Cover

(2) Poppet

(3) Spring

(4) Shim

(5) Valve Case

9Y1210293TRS0032US0

2-S37

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Servo Regulator Assembly

1. Remove the servo piston cover (2).

2. Remove the regulator mounting hex. head screw.

3. Remove the servo regulator assembly (1).

(When reassembling)

• Replace the gasket with new ones.

• Install the servo regulator assembly to the housing, align the feedback lever (3) of regulator and groove of servo piston (4).

NOTE

• Since it has been factory-adjusted, do not disassemble the servo regulator assembly.

Tightening torque

Regulator mounting hex. head screw

5.2 to 6.2 N·m

0.53 to 0.64 kgf·m

3.9 to 4.6 lbf·ft

(1) Servo Regulator Assembly

(2) Servo Piston Cover

(3) Feedback Lever

(4) Groove of Servo Piston

9Y1210293TRS0033US0

Servo Piston Assembly

1. Remove the servo piston assembly mounting hex. head screw.

2. Pull out the servo piston assembly (2) slightly by the hand.

(When reassembling)

• Replace the gasket with new one.

NOTE

• Take care not to do damage the surface of servo piston.

• Do not disassemble the servo piston assembly, if the there is no problem.

Tightening torque

Servo piston and cover mounting hex. head screw

17 to 19 N·m

1.7 to 2.0 kgf·m

13 to 14 lbf·ft

(1) Servo Piston Cover (2) Servo Piston Assembly

9Y1210293TRS0034US0

2-S38

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(3) Hydrostatic Transmission

TRANSMISSION

Rear Guard and Oil Filter Bracket

1. Remove the rear guard (2).

2. Disconnect the quick couplers (1).

3. Remove the filter bracket (3) with oil filter cartridge and suction hoses.

(When reassembling)

Tightening torque

Oil filter bracket mounting screw

18 to 20 N·m

1.8 to 2.1 kgf·m

13 to 15 lbf·ft

(1) Quick Coupler

(2) Rear Guard

(3) Oil Filter Bracket

9Y1210293TRS0036US0

2-S39

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Piston Case and Motor Case

1. Place oil pan underneath the motor case (4).

2. Loosen the piston case (1) with return piston, springs and stopper rod.

3. Remove the motor case (4) with variable swashplate (5).

4. Remove the thrust ball bearing (10) and the assist motor cylinder block (7).

5. Remove the valve plate (8).

(When reassembling)

• Take care not to damage O-ring on the piston case.

• Replace the motor case gasket (11) with new one.

• Apply a thin coat of oil soluble grease to the surface of valve plate (8) and the variable swashplate (5) and thrust ball bearing

(10).

This is to hold the parts in place while assembling.

• Be sure to install the motor case (4) and variable swashplate (5) with thrust ball bearing to port block cover (9).

• Be careful not to loose the spring (6) for charge relief valve.

• Thrust ball bearing sequence thin race inside variable swashplate (5), ball bearing (open side down), thick race out side.

• Be careful to note the location of three different length screws

(2), (3).

• Wrap the teflon tape around the tread of three long screws (2).

• Check the direction of the groove (12).

Tightening torque

Piston case

Motor case mounting screw

69 to 78 N·m

7.0 to 8.0 kgf·m

51 to 57 lbf·ft

18 to 20 N·m

1.8 to 2.1 kgf·m

13 to 15 lbf·ft

(1) Piston Case

(2) Long Screw (with Teflon Tape)

(3) Long Screw

(4) Motor Case

(5) Variable Swashplate

(6) Spring (Charge Relief)

(7) Cylinder Block (Motor)

(8) Valve Plate

(9) Port Block Cover

(10) Thrust Ball Bearing

(11) Motor Case Gasket

(12) Groove

9Y1210293TRS0037US0

2-S40

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Port Block Cover

1. Remove the port block cover (1) mounting screw.

2. Remove the port block cover (1) carefully and slowly. Leave the cylinder blocks (2).

(When reassembling)

• Replace the port block cover gasket (5) with new one.

• Check the direction of the groove (6).

IMPORTANT

• Valve plate (3), (4) may stick to the port block cover but they are not fixed. Take care not to drop them.

And these valve plate are not interchangeable.

Tightening torque

Port block cover mounting screw

18 to 20 N·m

1.8 to 2.1 kgf·m

13 to 15 lbf·ft

(1) Port Block Cover

(2) Cylinder Block

(3) Valve Plate (Pump)

(4) Valve Plate (Motor)

(5) Gasket

(6) Groove

9Y1210293TRS0038US0

[4] SERVICING

Cable

1. Check that the cable move smoothly within the cable outer.

2. If the cable movement is not smooth, if the cable is frayed, or if the cable outer is kinked, replace the cable.

9Y1210293TRS0039US0

2-S41

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

HST Neutral Linkage

1. Check that the linkage move smoothly.

2. If the linkage movement is not smooth, if the inside bearing worn, replace the bearing.

9Y1210293TRS0040US0

Mission Frame and Rubber Bush

1. Visually check the mission frame (1) and rubber bushes (2).

2. If the hole is misshapen otherwise damaged, replace the mission frame.

3. If the discolored, hardened or been otherwise damaged, replace the rubber bush.

(1) Mission Frame (2) Rubber Bush

9Y1210293TRS0041US0

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.

Then, turn the outer race to check rotation.

3. If there is any defect, replace it.

9Y1210293TRS0042US0

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.

9Y1210293TRS0043US0

2-S42

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

6T Spiral Bevel Pinion Shaft, Gear and Needle Bearing

1. Remove the 33T gear by using the gear puller.

2. Check the needle bearing for abrasion, color change or other damage.

3. If there is any doubt as to the condition of a needle bearing, replace it.

4. Check both the shaft and the gear surface of the bearing contact point for abrasion, color change or other damage.

5. If there are any doubt as to the condition of shaft and gear.

9Y1210293TRS0044US0

Taper Roller Bearing

1. Check the bearing for abrasion, color change or other damage.

2. If there is any doubt as to the condition of a taper roller bearing, replace it.

9Y1210293TRS0045US0

11T-12T Gear Shaft, Gear and Needle Bearing

1. Remove the bearing.

2. Check the needle bearing for abrasion, color, change or other damage.

3. If there is any doubt as to the condition of a needle bearing, replace it.

4. Check both the shaft and the gear surface of the bearing contact point for abrasion, color change or other damage.

5. If there are any doubt as to the condition of shaft and gear.

9Y1210293TRS0046US0

2-S43

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Back Idle Gear, Shaft and Needle Bearing

1. Check the needle bearing for abrasion, color change, or other damage.

2. If there is any doubt as to the condition of a needle bearing, replace it.

3. Check both the shaft and gear bearing surface.

9Y1210293TRS0047US0

6T Spiral Bevel Pinion Shaft Turning Torque

NOTE

• It is necessary to adjust the pinion gear shaft turning torque, when replacing the 6T spiral bevel pinion shaft, taper roller bearing or other relative parts.

1. Assemble the 6T spiral bevel pinion shaft (1) to the front case.

At this time, install the same shim (2) to bearing holder side.

2. Tighten the bearing holder mounting screws to specified torque.

3. Check the turning torque by using the allen socket with torque wrench.

4. Add or reduce the thickness of shim (2) to make the specified turning torque.

6T spiral bevel pinion shaft turning torque

Factory specification

0.98 to 1.2 N·m

0.10 to 0.13 kgf·m

0.73 to 0.94 lbf·ft

(Reference)

Thickness of shim Factory specification

0.60 mm

0.0024 in.

• Thickness of shims

0.10 mm (0.0039 in.)

0.15 mm (0.0059 in.)

0.20 mm (0.0079 in.)

0.30 mm (0.012 in.)

0.50 mm (0.020 in.)

(1) 6T Spiral Bevel Pinion Shaft (2) Shim

9Y1210293TRS0048US0

Backlash between Differential Pinion and Differential Side

Gear

1. Secure the differential case with a vise.

2. Put the solder (0.50 mm (0.020 in.) thickness) on the position where the tooth of the differential side gear.

3. Temporarily install the propeller shaft assembly and rotate the propeller shaft carefully.

4. Measure the backlash by thickness of the point where solder is the thinnest.

5. If the backlash exceeds the allowable limit, adjust with differential side gear shims.

Backlash between differential pinion and differential side gear

(Reference)

• Thickness of shims

1.5 mm (0.059 in.)

1.6 mm (0.063 in.)

1.7 mm (0.067 in.)

Factory specification

0.15 to 0.30 mm

0.0059 to 0.011 in.

9Y1210293TRS0049US0

2-S44

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Clearance between Differential Case and Differential Side Gear

1. Measure the differential side gear boss O.D. with an outside micrometer.

2. Measure the differential case I.D. with a cylinder gauge and calculate the clearance.

3. If the clearance exceeds the allowable limit, replace faulty parts.

Clearance between differential case and differential side gear

Factory specification

Allowable limit

0.0500 to 0.151 mm

0.00197 to 0.00594 in.

0.30 mm

0.012 in.

Differential case I.D.

Differential side gear

O.D.

Factory specification

Factory specification

38.000 to 38.062 mm

1.4961 to 1.4985 in.

37.911 to 37.950 mm

1.4926 to 1.4940 in.

9Y1210293TRS0050US0

Clearance between Differential Pinion Shaft and Differential

Pinion

1. Measure the differential pinion shaft O.D. with an outside micrometer.

2. Measure the differential pinion I.D. with a cylinder gauge, and calculate the clearance.

3. If the clearance exceeds the allowable limit, replace faulty parts.

Clearance between differential pinion shaft and differential pinion

Factory specification

Allowable limit

0.0800 to 0.122 mm

0.00315 to 0.00480 in.

0.30 mm

0.012 in.

Differential pinion I.D.

Differential pinion shaft

O.D.

Factory specification

Factory specification

20.060 to 20.081 mm

0.78976 to 0.79057 in.

19.959 to 19.980 mm

0.78579 to 0.78661 in.

9Y1210293TRS0051US0

2-S45

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Tooth Contact between 6T Spiral Bevel Pinion Shaft and 37T

Spiral Bevel Gear

• Use the transmission gasket (1) of the same thickness as the origin first.

• Use same number of shims as before disassembling.

1. Apply red lead (or prussian blue) lightly on the teeth of spiral bevel pinion shaft.

2. Reassemble the front case and transmission case.

In this time, set the differential lock shiftier to lock position

3. Tighten the transmission case mounting screw and nut to specified torque.

4. Temporarily install the propeller shaft assembly and make the propeller shaft back and forth by 2 to 3 rotations.

5. Check the tooth contact, if not proper, adjust according to the instructions below.

(Reference)

Thickness of gasket (1)

Thickness of shim (LH)

Thickness of shim (RH)

Factory specification

Factory specification

Factory specification

0.50 mm

0.020 in.

0.70 or 0.80 mm

0.028 or 0.031 in.

0.70 or 0.80 mm

0.028 or 0.031 in.

• Thickness of gasket

0.30 mm (0.012 in.)

0.50 mm (0.020 in.)

0.80 mm (0.031 in.)

1.0 mm (0.039 in.)

• Thickness of shims (2) (LH)

0.10 mm (0.0039 in.)

0.20 mm (0.0079 in.)

0.30 mm (0.012 in.)

0.50 mm (0.020 in.)

• Thickness of shims (3) (RH)

0.10 mm (0.0039 in.)

0.20 mm (0.0079 in.)

0.30 mm (0.012 in.)

0.40 mm (0.016 in.)

0.50 mm (0.020 in.)

0.60 mm (0.024 in.)

0.70 mm (0.028 in.)

(1) Gasket

(2) Shim (LH)

(3) Shim (RH)

(To be continued)

2-S46

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(Continued)

TRANSMISSION

• More than 35 % red lead contact area on the gear tooth surface.

The center of tooth contact at 1/3 of the entire width from the small end.

• Replace the transmission gasket (1) with thinner one to move the spiral bevel pinion shaft backward.

For move the spiral bevel gear rightward, reduce right side shim

(2) and add shim (3) of the same thickness as the right side to left side.

• Replace the transmission gasket (1) with a thicker one to move the spiral bevel pinion shaft forward.

For move the spiral bevel gear leftward, reduce left side shim (3) and add shim (2) of the same thickness as the left side to right side.

Repeat above until the proper tooth contact and backlash are achieved.

(1) Gasket

(2) Shim (LH)

(3) Shim (RH)

(A) Proper Contact

(B) Shallow Contact

(C) Heel Contact

(D) Deep Contact

(E) Toe Contact

9Y1210293TRS0052US0

2-S47

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Backlash between 6T Spiral Bevel Pinion Shaft and 37T Spiral

Bevel Gear

1. Put the solder (0.5 mm (0.020 in.) thickness) (1) on the position where the tooth proper contact of spiral bevel pinon shaft.

2. Reassemble the front case and transmission case. In this time, set the differential lock shiftier to lock position.

3. Temporarily install the propeller shaft assembly and rotate the propeller shaft carefully.

4. Separate the front case and transmission case, again.

5. Measure the backlash by thickness of the point where solder is the thinnest.

6. When the backlash is too large, decrease the number of shims

(LH) in the side of the spiral bevel gear, and insert the shim (RH) of the same thickness as the removed ones to the opposite side.

7. When the backlash is too small, do the opposite way to increase backlash.

Adjust the backlash properly by repeating the above procedure.

Backlash between spiral bevel pinion shaft and spiral bevel gear

Factory specification

0.20 to 0.40 mm

0.0079 to 0.015 in.

(1) Solder

9Y1210293TRS0053US0

Return Piston, Springs and Stopper Rod

1. Check the springs (3) for breakage and wear.

2. Check the return piston (1) for free movement in the piston case

(4).

3. Check the stopper rod (2) for vend and wear.

(1) Return Piston

(2) Stopper Rod

(3) Spring

(4) Piston Case

9Y1210293TRS0054US0

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

9Y1210293TRS0055US0

Cylinder Block Bore and Pistons

1. Check the pistons (1) for their free movement in the cylinder block (2) bores.

2. If the piston or the cylinder block bore is scored, replace cylinder block assembly.

IMPORTANT

• Do not interchange pistons (1) between pump and motor cylinder block (2).

(1) Piston (2) Cylinder Block

9Y1210293TRS0056US0

2-S48

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

Pump Shaft, Motor Shaft and Bearings

1. Check bearings for abrasion, color change, or other damage.

2. If there is any doubt as to the condition of a bearing, replace it.

3. Check the shaft surface for abrasion, color change or other damage.

4. If there is any doubt as to the condition of shaft, replace it.

9Y1210293TRS0057US0

Unload Valve

1. Check the spool (2) for abrasion and damage.

2. If anything unusual, replace it.

(1) Plug (2) Spool

9Y1210293TRS0058US0

Anti-cavitation Valve

1. Check the spring (3) for scratches, breakage and damage.

2. If anything unusual, replace it.

3. Check the poppet (4) for abrasion and damage.

4. If anything unusual, replace it.

(1) Valve Case

(2) Shim

(3) Spring

(4) Poppet

(5) Valve Cover

9Y1210293TRS0059US0

Charge Relief Valve and Check and High Charge Pressure

Relief Valve

1. Check the spring (2) and charge relief valve poppet for scratches, breakage and damage.

2. If anything unusual, replace it.

3. Check the valve plug (1) and check and high pressure relief valve for scratches and damage.

4. Check the valve seat in the port block cover for damage.

5. Check the spring (2) for breakage and wear.

6. If anything unusual, replace the check and high pressure relief valve assembly (3), (4).

(1) Valve Plug

(2) Spring

(3) Check and High Pressure Relief

Valve Assembly (Forward)

(4) Check and High Pressure Relief

Valve Assembly (Reverse)

(5) Spring

(6) Charge Relief Valve Poppet

(7) Shim

9Y1210293TRS0060US0

2-S49

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

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 exhaustion with genuine parts.

• As the HST may be damaged if the pressure is set to higher by mistake, be careful when adjusting it.

NOTE

• The relief pressure is set in between (Forward: 25.5 to

26.5 MPa (260 to 270 kgf/cm

2

, 3700 to 3840 psi), Reverse:

20.5 to 21.5 MPa (209 to 219 kgf/cm

2

, 2980 to 3110 psi)) when shipped from the factory. But, for the purpose of after-sales services, as it is impossible to reset the pressure precisely as set in the factory, its setting range is defined as a slightly wider range between (Forward: 22.6 to

26.5 MPa (231 to 270 kgf/cm

2

, 3280 to 3840 psi, Reverse:

18.9 to 21.5 MPa (193 to 219 kgf/cm

2

, 2750 to 3110 psi)).

1. Measure the pre-adjustment distance

"A"

.

2. Compress the spring of the relief valve with a relief valve assembling tool (3).

3. Then, find the distance

"A"

by turning the poppet (4) with a screwdriver.

Reference: The distance

"A"

changes by about 0.5 mm

(0.0197 in.) per one turn of the poppet (4).

4. Repeat the same operation a few times to find the distance

"A"

as it is difficult to acquire at the first time.

5. After finding the distance

"A"

, hold the setscrew (6) to a vice and fasten the hexagon socket head screw (2) with specified torque.

On this occasion, use a copper plate, etc. for the vice jaws not to damage the setscrew (6).

6. Install the relief valve in the HST.

7. Check the relief pressure as indicated in checking section.

The distance

"A"

is for refresh only. Make sure to check the relief pressure after readjustment.

8. If the relief pressure does not fall within the readjustment pressure range, repeat the processes of the above item 1 onward.

Reference: The pressure changes by 1.47 MPa (15 kgf/cm

2

,

213.3 psi) per 0.1 mm (0.0039 in.) in distance

"A"

.

Tightening torque Hex. socket head screw

2.5 to 3.0 N·m

0.26 to 0.30 kgf·m

1.9 to 2.2 lbf·ft

Relief valve readjusting pressure

Forward

Reverse (Brake)

22.6 to 26.5 MPa

231 to 270 kgf/cm

2

3280 to 3840 psi

18.9 to 21.5 MPa

193 to 219 kgf/cm

2

2750 to 3110 psi

Distance

"A"

Reference valve

(1) Relief Valve Assembly

Forward

Reverse (Brake)

(2) Hexagon Socket Head Screw

(3) Relief Valve Assembling Tool

38.60 to 38.70 mm

1.520 to 1.523 in.

38.80 to 38.90 mm

1.528 to 1.531 in.

(4) Poppet

(5) Valve Seat

(6) Setscrew

9Y1210293TRS0061US0

2-S50

KiSC issued 05, 2014 A

RTV1140CPX, WSM

TRANSMISSION

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.

5. Check the valve plate for scratches, wear and erosion. (Run a finger nail across the valve plate surface. If worn, it will be defective.)

6. If worn or scored, replace it.

NOTE

• After checking, coat them with transmission oil.

• Valve plates are not interchangeable.

(1) Polished Face (2) Spring

9Y1210293TRS0062US0

Charge Pump

1. Check the charge pump housing (transmission case) (3), pump cover (4) and the rotor (1), (2) for scratches and wear.

2. If scratch or worn, replace the charge pump complete assembly.

(1) Inner Rotor

(2) Outer Rotor

(3) Pump Housing

(Transmission Case)

(4) Pump Cover

9Y1210293TRS0063US0

2-S51

KiSC issued 05, 2014 A

3

REAR AXLE

KiSC issued 05, 2014 A

MECHANISM

CONTENTS

1. STRUCTURE.............................................................................................................................. 3-M1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. STRUCTURE

REAR AXLE

(1) Shock Absorber

(2) Leaf Spring

(3) Rear Axle Bracket

(4) Ball Bearing

(5) Rear Axle (6) Propeller Shaft

The leaf spring (2) type is adopted for rear suspension.

And the shock absorber (1) is a design to consider riding comfort etc. by using the type which uses the gas together with oil.

After the final reduction, power is transmitted to a rear axle (5) through the propeller shaft (6).

9Y1210293RAM0001US0

3-M1

KiSC issued 05, 2014 A

SERVICING

CONTENTS

1. TROUBLESHOOTING.................................................................................................................3-S1

2. TIGHTENING TORQUES............................................................................................................3-S2

3. CHECKING, DISASSEMBLING AND SERVICING .....................................................................3-S3

[1] CHECKING............................................................................................................................3-S3

[2] PREPARATION.....................................................................................................................3-S3

(1) Rear Axle Bracket Assembly ...........................................................................................3-S3

(2) Leaf Spring ......................................................................................................................3-S5

[3] DISASSEMBLING AND ASSEMBLING ................................................................................3-S7

(1) Rear Axle Bracket Assembly ...........................................................................................3-S7

[4] SERVICING...........................................................................................................................3-S8

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. TROUBLESHOOTING

Symptom

Noise when Start

Noise while Forward and Reverse

Noise

Probable Cause

Universal joint bearing worn (propeller shaft)

Universal joint bearing worn (propeller shaft)

Bearings damaged or broken

REAR AXLE

Solution

Replace

Replace

Replace

Reference

Page

3-S8

3-S8

3-S8

9Y1210293RAS0001US0

3-S1

KiSC issued 05, 2014 A

RTV1140CPX, 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: See page G-10.)

Item

Rear wheel mounting screw

Slotted nut

Leaf spring mounting rod and flange nut

Lock nut

Spring reamer bolt and nut

Leaf spring rod and nut

Shock absorber mounting bolt and nut (M12) (Upper)

Shock absorber mounting bolt and nut (M10) (Lower)

N·m

75 to 90

190

48.0 to 55.9

24.0 to 28.0

29.4 to 49.0

29.4 to 49.0

77.4 to 90.2

48.0 to 55.9

kgf·m

7.6 to 9.2

19.4

4.90 to 5.70

2.45 to 2.85

3.00 to 4.99

3.00 to 4.99

7.90 to 9.19

4.90 to 5.70

REAR AXLE

lbf·ft

55.3 to 66.4

140

35.4 to 41.2

17.7 to 20.6

21.7 to 36.1

21.7 to 36.1

57.1 to 66.5

35.4 to 41.2

9Y1210293RAS0002US0

3-S2

KiSC issued 05, 2014 A

RTV1140CPX, WSM

REAR AXLE

3. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING

Checking Shock Absorber

1. Visually check the shock absorber (1) for breaks or distortion.

2. If the shock absorber is damaged in any way, replace it.

3. Check for oil leakage at the shock absorber.

4. If oil leakage is noted, replace it.

5. Push, and shorten the shock absorber, and check whether to return in former state.

6. Replace the shock absorber for the new one if it does not return to former state.

7. Visually check the rubber bush in the upper and lower mountings of the rear shock absorber.

8. If they are worn, cracked, hardened, or otherwise damaged, replace them with new one.

(1) Shock Absorber

9Y1210293RAS0003US0

[2] PREPARATION

(1) Rear Axle Bracket Assembly

Cargo Bed

1. Lift up the cargo bed (1) by hand and support it with the safety support so that the hydraulic cylinder should not drop.

2. Remove the cotter pin and clevis pin (2).

3. Disconnect the connector (3) from main harness, then separate the harness for the tail lamps.

4. Loosen the lock nut (4) and remove the hinge bolt (5) and nut.

(1) Cargo Bed

(2) Clevis Pin

(3) Connector

(4) Lock Nut

(5) Hinge Bolt

9Y1210293ENS0001US0

3-S3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

REAR AXLE

Rear Wheel

1. Remove the cotter pin (1), and loosen the slotted nut (2) for drive shaft.

2. Remove rear wheels (3).

(When reassembling)

• After tightening the slotted nut (2) with specified torque, install a cotter pin (1) as shown in the figure.

NOTE

• Tighten the slotted nut (2) to 190 N·m (19.4 kgf·m, 140 lbf·ft).

If the slot and pin hole do not meet, tighten the slotted nut

(2) until they meet, and install the cotter pin (1).

Tightening torque

Rear wheel mounting screw

Slotted nut

75 to 90 N·m

7.6 to 9.2 kgf·m

55.3 to 66.4 lbf·ft

190 N·m

19.4 kgf·m

140 lbf·ft

(1) Cotter Pin

(2) Slotted Nut

(3) Rear Wheel

9Y1210293RAS0004US0

Rear Axle Bracket

1. Remove the boot band (4) on both sides.

2. Place the stand under the both side of frame.

3. Remove the leaf spring mounting bolt (3) and flange nut, and remove the rear axle bracket assembly (5) by use the axle support (6).

(When reassembling)

• Align the master spline of propeller shaft and rear axle shaft.

• Replace the boot band (4) with new one.

• Apply anti-fretting grease (NISSEKI PYRONOC UNIVERSAL

N6C or its equivalents) to spline of rear axle shaft.

Tightening torque

Leaf spring mounting bolt and flange nut

Lock nut

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

24.0 to 28.0 N·m

2.45 to 2.85 kgf·m

17.7 to 20.6 lbf·ft

(1) Lock Nut

(2) Flange Nut

(3) Leaf Spring Mounting Bolt

(4) Boot Band

(5) Rear Axle Bracket Assembly

(6) Axle Support

9Y1210293ENS0036US0

3-S4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(2) Leaf Spring

REAR AXLE

Leaf Spring

1. Place the stand under the frame.

2. Remove the rear wheel (1) and support the rear axle bracket with jack.

3. Loosen the lock nut (3) and rear axle bracket flange nut (4).

4. Remove the leaf spring rod bolt and nut (2).

5. Remove the spring reamer bolt and nut (7).

6. Remove the leaf spring rod and nut (2), and then remove the leaf spring (6).

(When reassembling)

• Tighten the leaf spring rod bolt and nut (2), spring reamer bolt and nut with specified torque after setting up the wheel and unloading the machine on ground.

Tightening torque

Rear wheel mounting screw

Leaf spring mounting bolt and flange nut

Lock nut

Spring reamer bolt and nut

Leaf spring rod and nut

75 to 90 N·m

7.6 to 9.2 kgf·m

55.3 to 66.4 lbf·ft

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

24.0 to 28.0 N·m

2.45 to 2.85 kgf·m

17.7 to 20.6 lbf·ft

29.4 to 49.0 N·m

3.00 to 4.99 kgf·m

21.7 to 36.1 lbf·ft

29.4 to 49.0 N·m

3.00 to 4.99 kgf·m

21.7 to 36.1 lbf·ft

(1) Rear Wheel

(2) Leaf Spring Rod Bolt and Nut

(3) Lock Nut

(4) Rear Axle Bracket Flange Nut

(5) Rear Axle Bracket Bolt

(6) Leaf Spring

(7) Spring Reamer Bolt and Nut

9Y1210293RAS0005US0

Spring Rubber Bush

1. Remove the spring rubber bushes (1).

(When reassembling)

• When installing the bush in the mounts of the leaf spring, lubricate them with a soapy water.

CAUTION

• Do not use engine oil or petroleum distillates to lubricate the bushes because they will deteriorate the rubber.

(1) Spring Rubber Bush

9Y1210293RAS0006US0

3-S5

KiSC issued 05, 2014 A

RTV1140CPX, WSM

REAR AXLE

Rear Shock Absorber

1. Remove the shock absorber (1).

(When reassembling)

• Tighten the shock absorber mounting bolt and nut with specified torque after setting up the wheel and unloading the machine on ground.

Tightening torque

Shock absorber mounting bolt and nut (upper)

Shock absorber mounting bolt and nut (lower)

77.4 to 90.2 N·m

7.90 to 9.19 kgf·m

57.1 to 66.5 lbf·ft

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

(1) Shock Absorber

9Y1210293RAS0007US0

3-S6

KiSC issued 05, 2014 A

RTV1140CPX, WSM

REAR AXLE

[3] DISASSEMBLING AND ASSEMBLING

(1) Rear Axle Bracket Assembly

Rear Axle and Propeller Shaft

1. Remove the slotted nut (2) and draw out the rear axle (1).

2. Tap the outside of the propeller shaft (3) and remove the propeller shaft to the inside

"a"

.

(When reassembling)

• Prepare the pipe (4) of the same diameter as bearing inner, and tap it while keeping the bearing when you tap the propeller shaft.

• Moreover, there is no problem if the bearing is inserted in the position in which a rear axle can be tightened.

• After that, the bearing and the collar can be fixed to a correct position by tightening the propeller shaft slotted nut.

• Apply grease to splines of propeller shaft.

A

B

C

(4) Pipe Dimension

31 mm (1.22 in.)

51 mm (2.0 in.)

178 mm (7.0 in.)

(1) Rear Axle

(2) Slotted Nut

(3) Propeller Shaft

(4) Pipe

a: Inside

9Y1210293RAS0008US0

3-S7

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[4] SERVICING

REAR AXLE

Checking Oil Seal

1. Visually check the oil seal.

2. If the lips are misshapen, discolored, hardened, or been otherwise damaged, replace it.

9Y1210293RAS0009US0

Checking Bearing

1. Check the bearing seal for tears or leakage.

2. If the seal is torn or leaking, replace the bearing.

3. Hold the inner race, and push and pull the outer race in all directions to check for wear and roughness.

4. If there is any defect, replace it.

(1) Spin (2) Bearing Seal

9Y1210293RAS0010US0

Checking Propeller Shaft and Rear Axle

1. Visually check the splines of the propeller shaft and rear axle.

2. If they are twisted, badly worn, or chipped, replace the propeller shaft and / or rear axle with a new one.

3. Check that the universal joint works smoothly without rattling or sticking.

4. If it does not, the bearings of the joint are damaged. Replace the propeller shaft with a new one.

9Y1210293RAS0011US0

Checking Rubber Bush

1. Visually check the rubber bush.

2. If they are worn, cracked, hardened or been otherwise damaged, replace them with new ones.

9Y1210293RAS0012US0

3-S8

KiSC issued 05, 2014 A

4

BRAKES

KiSC issued 05, 2014 A

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 05, 2014 A

RTV1140CPX, WSM

1. GENERAL OUTLINE

BRAKES

(1) Brake Pipe

(2) Brake Hose

(3) Parking Brake Cable

(4) Brake Piston

(5) Brake Pedal

(6) Parking Brake Lever

(7) Brake Cam Lever

(8) Brake Cylinder

(9) Master Cylinder

Description of the brake system with an illustration with all its component parts in place.

All the four wheels are equipped with an enclosed, wet multi-disc type brake. The system consists of brake pedal

(5), master cylinder (9), brake hose (2), brake pipe (1), brake cylinder (8), brake piston (4) and other parts.

9Y1210293BRM0001US0

4-M1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

BRAKES

2. KNUCKLE (FRONT BRAKE)

Basically, the brake body is similar to that of the mechanical wet disc brake. It is designed to brake when the brake disc (10) rotating together with the front axle

(1) is pressed.

The knuckle (4) of the hydraulic brake serves as a master cylinder.

When brake oil pressure increases, the brake piston

(5) is forced out and presses the brake discs against the knuckle cover (2), thereby causing braking. This brake uses three brake discs to obtain big braking force.

(1) Front Axle

(2) Knuckle Cover

(3) Plate

(4) Knuckle

(5) Brake Piston

(6) Brake Seal 3

(7) Brake Seal 4

(8) Brake Seal 2

(9) Brake Seal 1

(10) Brake Disc

(11) Constant Velocity (CV) Joint

9Y1210293BRM0002US0

(1) Knuckle Case

(2) Brake Piston

(3) Brake Seal

(4) Piston Return Stroke

(A) When brake pedal is pressed

(B) When brake pedal is released



Automatic Brake Adjustment

With a mechanical brake system, when the brake pedal is released, seal returns to its original position by spring tension and cam mechanism.

With a hydraulic brake system, the seal (3) serves to return the brake piston (2) to the original position (no braking force).

When the brake pedal is pressed, pressure in the knuckle case rises and the brake piston moves in the direction of arrow and causing the brake discs to press against the knuckle case. At this time, the brake seals are deformed in the knuckle case (1), and are subjected to elastic deformation as shown in the figure above.

When the brake pedal is released, pressure in the knuckle case reduces due to the brake seals reverting back to its original form. Together, a clearance is formed between the brake disc and brake piston to prevent the brake dragging.

Worn brake discs require longer brake piston movement. When the brake piston movement exceeds the elastic limit of brake seal, sliding occurs between the seals and the brake piston. With the brake seals deformed a clearance is automatically kept constant.

9Y1210293BRM0003US0

4-M2

KiSC issued 05, 2014 A

RTV1140CPX, WSM

3. REAR BRAKE

BRAKES

(1) Brake Shaft (Propeller Shaft)

(2) Brake Cam Lever

(3) Differential Support Cover

(4) Friction Plate

(5) Brake Disc

(6) Steel Ball

(7) Cam Plate (Actuator)

(8) Brake Cylinder

(9) Bypass Link 2

(10) Bypass Valve

(11) Bypass Link 1

The brake body is incorporated in the differential support cover (3) filled with transmission oil and is designed to brake when the brake disc (5) splined with the propeller shaft (1) is pressed against the cam plate (7) by means of the cam mechanism incorporating steel balls (6).

For greater braking force, four brake discs are provided at the right and left sides respectively, and the friction plate (4) fixed to the rear axle case is arranged between the brake discs.



During Braking

When brake oil pressure increases, and the brake cylinder (8) is shortened, the linkage causes the brake cam lever (2) to turn into the direction of arrow shown in the above figure.

Therefore, the cam plate (7) also moves the direction of arrow. At this time, since the cam plate rides on the steel balls (6) set in the grooves of the differential support cover (3) to press the brake disc (5), the propeller shaft (1) is braked by the frictional force generated by the cam plate and brake disc.

9Y1210293BRM0004US0

4-M3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

4. MASTER CYLINDER

BRAKES

(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

(14) Grommet

a: Relief Port b: Supply Port c: Small Hole

The master cylinder is intended to convert the brake pedal operating force to the fluid pressure. It is composed of the reserve tank that contains the brake fluid and the cylinder proper that generates the fluid pressure. There are several different fluid pressure generating mechanisms. Kubota has picked up the tandem type cylinder out of them.

Even if a pipe has got cracked and the front or rear set of wheels have failed to get braked, this mechanism can apply the brakes on the other set of wheels.

(This is to comply with the rules and regulations stipulating that two lines must be independently controlled.).

Step on the brake pedal, and the push rod (12) drives the piston (9) the primary cup blocks the relief port

"a"

, and the path between the pressure chamber and reservoir is shut off. As the piston moves on, the brake fluid flows through the brake hose or pipe to the front wheel brake piston and the rear wheel brake cylinder, and the fluid pressure is then boosted.

When releasing the brake pedal, and the piston returns to its initial position under the force of the return spring.

But the brake fluid in the front wheel brake piston and the rear wheel brake cylinder is delayed in flowing back, which puts the pressure chamber under negative pressure.

To get rid of the negative pressure, the brake fluid in the reservoir flows through the supply port

"b"

, supply chamber and piston-end small hole

"c"

, along the back of the primary cup, into the pressure chamber.

Now the brake fluid flows back from the front wheel brake piston and the rear wheel brake cylinder.

The brake fluid in the reservoir fluctuates in volume, but there is no pressure fluctuation thanks to the reservoir cap that has a small hole open to the atmosphere.

The tandem type master cylinder works like this. Step on the brake pedal, and the push rod (12) activates the primary piston (8) first (spring force different between front and back; front one weaker), raising its pressure. The primary piston gets balanced in pressure with the secondary one (9) (fluid pressure adjustment). Now the brakes are applied.

The relief port

"a"

(at the secondary piston side) absorbs temperature dependent volumetric changes in the brake fluid. This helps prevent fluid pressure buildup when unnecessary. If this port is clogged, the braking effect may drag on. (At the primary piston side, the clearance between the needle (6) and piston, as well as the one between the pin

(7) and master cylinder body (5), serve as the relief port.)

9Y1210293BRM0005US0

4-M4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

BRAKES

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.

When keeping in mind that the UDT oil used for Kubota tractors so far cannot be applied as the brake oil.

If a coated surface gets stained with the brake oil, the paint becomes degraded. Immediately wipe off the oil just in case. Also immediately wipe the oil off the power steering hose if any.

9Y1210293BRM0006US0

4-M5

KiSC issued 05, 2014 A

RTV1140CPX, WSM

6. PARKING BRAKE

BRAKES

(1) Parking Brake Lever

(2) Plate

(3) Mechanical Equalizer (4) Parking Brake Cable (5) Brake Cam Lever

The parking brake is mechanical type which is connected to the brake cam lever (5) by the parking brake cables

(4). This parking brake is a mechanism that same brake discs as travelling brake is operated.

The parking brake consists basically of the following:

Brake cam lever, parking brake lever (1), mechanical equalizer (3) and right and left cables, etc.

When pulling the parking brake lever, and the rear wheel brakes are applied and the rear axle comes to a halt.

The mechanical equalizer (3) is installed to adjust the right-to-left balance of mechanical force and to achieve an equal force.

9Y1210293BRM0007US0

4-M6

KiSC issued 05, 2014 A

SERVICING

CONTENTS

1. TROUBLESHOOTING.................................................................................................................4-S1

2. SERVICING SPECIFICATIONS ..................................................................................................4-S2

[1] TRAVELING BRAKE .............................................................................................................4-S2

[2] PARKING BRAKE .................................................................................................................4-S2

3. TIGHTENING TORQUES............................................................................................................4-S3

4. CHECKING, DISASSEMBLING AND SERVICING .....................................................................4-S4

[1] CHECKING AND ADJUSTING..............................................................................................4-S4

[2] DISASSEMBLING AND ASSEMBLING ................................................................................4-S8

(1) Front Brake......................................................................................................................4-S8

(2) Rear Brake ....................................................................................................................4-S13

(3) Master Cylinder Assembly.............................................................................................4-S15

[3] SERVICING.........................................................................................................................4-S16

(1) Front Brake....................................................................................................................4-S16

(2) Rear Brake ....................................................................................................................4-S17

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. TROUBLESHOOTING

BRAKES

Symptom

Poor Braking Force

Probable Cause

Brake pedal travel excessive

Brake disc worn

Adjust

Solution

Replace

Reference

Page

4-S4

4-S11,

4-S13

4-S4

Brake fluid insufficient or improper Replenish or change with specified oil

Repair or replace

Uneven Braking

Force

Brake fluid leakage from brake pipes, bleeder, master cylinder

Master cylinder malfunctioning

Brake disc worn

Repair or replace

Replace

Brake Drags

Spongy Brake Pedal

Brake Oil Consumed

Excessively

Brake fluid leakage from brake pipes, bleeder or master cylinder

Master cylinder malfunctioning

Brake pedal travel too small

Master cylinder return spring weaken or broken

Master cylinder malfunctioning

Brake seal failure

Brake lines clogged

Brake pedal return spring weaken or broken

Brake fluid improper

Brake fluid insufficient or improper

Air in brake system

Brake seal failure

Brake fluid leakage in brake lines

Poor Parking Brake

Force

Parking brake lever play excessive

Parking Brake Drags

Parking brake lever play too small

Repair or replace

Repair or replace

Adjust

Replace

Repair or replace

Replace

Clean

Replace

Change with specified oil

Replenish or change with specified oil

Bleed air

Replace

Repair or replace

Adjust

Adjust

4-S15

4-S15

4-S11,

4-S13

4-S15

4-S15

4-S4

4-S15

4-S15

4-S11

–

–

4-S4

4-S4

4-S5

4-S11

–

4-S6

4-S6

9Y1210293BRS0001US0

4-S1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

2. SERVICING SPECIFICATIONS

[1] TRAVELING BRAKE

Item

Brake Pedal

Brake Disc

Friction Plate

Travel

Thickness

Thickness

Factory Specification

7 to 14 mm

0.28 to 0.55 in.

3.30 to 3.50 mm

0.130 to 0.138 in.

1.92 to 2.08 mm

0.0756 to 0.0818 in.

BRAKES

Allowable Limit

–

3.00 mm

0.118 in.

1.52 mm

0.0598 in.

9Y1210293BRS0002US0

[2] PARKING BRAKE

Item

Parking Brake Lever Lever Play

(Number of notches)

Factory Specification

1 notch

Allowable Limit

–

9Y1210293BRS0026US0

4-S2

KiSC issued 05, 2014 A

RTV1140CPX, 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: See page G-10.)

Item

Front axle slotted nut

Rear wheel mounting screw

Tie-rod end slotted nut

Ball joint mounting screw and nut

Knuckle case mounting bolt and slotted nut

Knuckle case cover mounting screw

Lower arm mounting bolt and nut

Brake pipe flare nut

N·m

150

75 to 90

50

48.0 to 55.9

50

48 to 55

103 to 107

13 to 17

kgf·m

15.3

7.6 to 9.2

5.1

4.90 to 5.70

5.1

4.9 to 5.7

10.5 to 12.0

1.4 to 1.7

BRAKES

lbf·ft

111

55.3 to 66.4

37

35.4 to 41.2

37

36 to 41

10.5 to 12.0

9.6 to 12

9Y1210293BRS0003US0

4-S3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

BRAKES

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING

Brake Pedal Free Travel

CAUTION

• When checking, park the tractor on flat ground, and stop the engine.

1. Measure the free travel by depressing the brake pedal (1).

2. If the measurement is not within the factory specifications, adjust the free travel by the push rod (2).

3. After adjustment, tighten the lock nut firmly.

Brake pedal free travel Factory specification

7 to 14 mm

0.28 to 0.55 in.

(1) Brake Pedal

(2) Push Rod

A: Free Travel

9Y1210293BRS0004US0

Checking Brake Fluid Level

CAUTION

• Never operate the vehicle, if the brake fluid is below the

"MIN" mark.

• Use only KUBOTA DOT3 GENUINE BRAKE FLUID from a sealed container. Using other type of oil ruins synthetic resin or rubber installed in brake system components, and may cause brake failure.

• Avoid contamination of the brake fluid. Thoroughly clean area around the filler cap before removing. Do not open the brake fluid reservoir cap unless absolutely necessary.

• Use extreme care when filling the reservoir. If brake fluid is spilled on power steering hose, wash off with water immediately. Brake fluid quickly ruins synthetic resin or rubber hoses.

1. Park the vehicle on level ground and open hood.

2. Check to see that the brake fluid level is between the

"MAX"

and

"MIN"

marks.

3. If it is below the

"MIN"

mark, add brake fluid to the

"MAX"

mark.

Brake fluid Tank capacity

0.87 L

0.92 U.S.qts

0.77 Imp.qts

(1) Oil Tank Cap

A: MAX

B: MIN

9Y1210293GEG0013US0

4-S4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

BRAKES

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.

• Avoid contamination of the brake fluid. Thoroughly clean area around the filler cap before removing. Do not open the brake fluid reservoir cap unless absolutely necessary.

• Use extreme care when filling the reservoir. If brake fluid is spilled on power steering hoses, wash off with water immediately. Brake fluid quickly ruins synthetic resin or rubber hoses.

NOTE

• The fluid level must be checked several times during the bleeding operation and replenished as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line.

1. Jack up the front side of machine and remove the front wheels.

2. Connect a clear plastic hose (4) to the bleeder (3), running the other end of the hose into a container.

3. Pump the brake pedal (5) until it becomes hard, and apply the brake pedal and hold it.

4. Quickly open and close the bleeder (3) while holding the brake pedal applied.

5. Release the brake pedal.

6. Check the brake fluid level and fill the reservoir (2) with new brake fluid.

7. Repeat the previous step for each wheel.

8. Repeat this operation until no more air can be seen coming out into the plastic hose.

9. When air bleeding is finished, add fluid up to the upper level in the reservoir.

10. Apply the brake forcefully for a few seconds, and check for fluid leakage around the fittings.

WARNING

• If the brake pedal has a soft or "spongy feeling" when it is applied, there might be air in the brake line or the brake may be defective. Since it is dangerous to operate the vehicle under such conditions, bleed the air from the brake line immediately.

(1) Reservoir Cap

(2) Reservoir

(3) Bleeder

(4) Clear Plastic Hose

(5) Brake Pedal

F: Front Brake

R: Rear Brake

9Y1210293BRS0006US0

4-S5

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Parking Brake Lever Free Play

1. Release the parking brake.

2. Loosen the lock nut, and adjust the cable wire length.

3. Tighten the lock nut (2), and check the free play.

Proper parking brake lever free play range

Factory specification 1 notch

BRAKES

(1) Parking Brake Lever (2) Lock Nut

9Y1210293BRS0025US0

Checking Brake Rod

CAUTION

• When checking, park the machine on flat ground.

• Work by two people when you measure pressure.

1. Remove the brake return spring (3).

2. Adjust the link length using the turnbuckle (1) so that the brake lever (2) has no play, then turnbuckle is returned by 1/4 rotation.

3. Adjust the other side.

(Reference)

• Turning torque of the rear axle at this time is 9.80 to 14.7 N·m

(1.00 to 1.49 kgf·m, 7.23 to 10.8 lbf·ft).

CAUTION

• Over-pulling due to poor turnbuckle adjustment can result in the problem of brake drag (overheating and burning).

(1) Turnbuckle (Brake Rod)

(2) Brake Lever

(3) Return Spring

9Y1210293BRS0008US0

4-S6

KiSC issued 05, 2014 A

RTV1140CPX, WSM

BRAKES

Checking Parking Brake Lever (Adjustment of the Parking

Brake Cable)

CAUTION

• When checking, park the machine on flat ground.

• Work by two people when you measure pressure.

1. Remove the cover (1).

2. Adjust the length of the parking each brake cable (2) outer section so that the cable does not pull the brake cam lever (4),

(5) (not activate the brake) when the parking brake lever (3) is not pulled, and pulls the brake lever (activates the brake) when the parking brake lever is pulled up by one notch.

3. Adjust both right and left brakes so that they are equally conditioned.

(1) Cover

(2) Parking Brake Cable

(3) Parking Brake Lever

(4) Brake Cam Lever (RH)

(5) Brake Cam Lever (LH)

9Y1210293BRS0009US0

4-S7

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[2] DISASSEMBLING AND ASSEMBLING

(1) Front Brake

Brake Fluid

BRAKES

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.

• Avoid contamination of the brake fluid. Thoroughly clean area around the filler cap before removing. Do not open the brake fluid reservoir cap unless absolutely necessary.

• Use extreme care when filling the reservoir. If brake fluid is spilled on power steering hoses, wash off with water immediately. Brake fluid quickly ruins synthetic resin or rubber hoses.

NOTE

• The fluid level must be checked several times during the fluid change and replenished as necessary. If the fluid in the reservoir runs completely out any time during fluid changing, air bleeding must be done since air will have entered the line.

• Start with the rear either side and finish with the front either side.

1. Jack up the front side of machine and remove the front wheels.

2. Connect a clear plastic hose (4) to the bleeder (3), running the other end of the hose into a container.

3. Remove the brake fluid reservoir cap (1).

4. Fill the reservoir (2) with new brake fluid.

5. Temporarily install the reservoir cap.

6. Open the bleeder.

7. Then, pump brake pedal (5) and hold it.

8. Close the bleeder and release the brake pedal.

9. Repeat the previous step for each wheel.

10. When brake fluid changing is finished, add the fluid to the upper level in the reservoir.

11. After changing the fluid, check the brake for good braking power, no brake drag, and no fluid leakage.

12. If necessary, bleed the air from the brake lines.

WARNING

• If the brake pedal has a soft or "spongy feeling" when it is applied, there might be air in the brake line or the brake may be defective. Since it is dangerous to operate the vehicle under such conditions, bleed the air from the brake line immediately.

(1) Reservoir Cap

(2) Reservoir

(3) Bleeder

(4) Clear Plastic Hose

(5) Brake Pedal

F: Front Brake

R: Rear Brake

9Y1210293BRS0005US0

4-S8

KiSC issued 05, 2014 A

RTV1140CPX, WSM

BRAKES

Front Wheel and Front Axle Nut

1. Remove the cotter pin and just loosen the slotted nut (1) for drive shaft.

2. Loosen the front wheel mounting screw.

(When reassembling)

• After tightening the this slotted nut to specified tightening torques, install a cotter pin as shown figure left.

NOTE

• Tighten the slotted nut to 150 N·m (15.3 kgf·m, 110 lbf·ft). If the slot and pin hole do not meet, tighten the nut until they do meet, and install cotter pin.

• Be sure to split the cotter pin like an anchor.

Tightening torque

Front axle slotted nut

Front wheel mounting screw

150 N·m

15.3 kgf·m

111 lbf·ft

75 to 90 N·m

7.6 to 9.2 kgf·m

55.3 to 66.4 lbf·ft

(1) Slotted Nut

9Y1210293BRS0010US0

Knuckle Case

CAUTION

• When the brake hose is removed, the brake fluid comes out. Take care not to stain other hoses or rubber boot with the brake fluid.

Brake fluid stains should be washed and wiped off immediately. Likewise, the brake fluid on the tools should be wiped off immediately.

1. Place the stand under the frame front.

2. Remove the front wheel.

3. Remove the joint guard (4).

4. Remove the eye joint bolt for brake hose (1) and drain the brake fluid.

5. Remove the cotter pin and remove the slotted nut (7) for tie-rod end (6).

6. Loosen the lower arm mounting bolt and nut (3), and then remove the ball joint (5) mounting screw and nut.

7. Remove the cotter pin and remove the slotted nut (2) for knuckle case mounting bolt (9).

8. Remove the knuckle case mounting bolt (9) and remove the front axle slotted nut (10).

9. Remove the knuckle case assembly (12).

(1) Brake Hose

(2) Slotted Nut (for Knuckle Case

Mounting Bolt)

(3) Lower Arm Mounting Bolt and Nut

(4) Joint Guard

(5) Ball Joint

(6) Tie-rod End

(7) Slotted Nut (for Tie-Rod End)

(8) Lower Arm

(9) Knuckle Case Mounting Bolt

(10) Front Axle Slotted Nut

(11) Strut

(12) Knuckle Case Assembly

(13) Drive Shaft

(To be continued)

4-S9

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(Continued)

BRAKES

(When reassembling)

• When installing the strut to knuckle case, set the wedge to decide the position of strut (11) to the slit of the knuckle case assembly (12).

• When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the tie-rod end, ball joint and knuckle case mounting bolt, tighten the nut clockwise up to next alignment.

• It should be within 30 degree.

• Loosen once and tighten again when the slit goes past the nearest hole.

• After tightening the these slotted nut to the specified tightening torque, install a cotter pin as shown in the figure.

NOTE

• Tighten the lower arm mounting bolt and nut (3) with the specified torque after setting up the wheel and unloading the machine on ground.

Tightening torque

Front axle slotted nut

Tie-rod end slotted nut

Ball joint mounting screw and nut

Knuckle case mounting bolt and slotted nut

Lower arm mounting bolt and nut

150 N·m

15.3 kgf·m

111 lbf·ft

50 N·m

5.1 kgf·m

37 lbf·ft

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

50 N·m

5.1 kgf·m

37 lbf·ft

103 to 117 N·m

10.5 to 12.0 kgf·m

76.0 to 86.7 lbf·ft

(3) Lower Arm Mounting Bolt and Nut

(11) Strut

(12) Knuckle Case Assembly

(14) Slit

9Y1210293BRS0011US0

4-S10

KiSC issued 05, 2014 A

RTV1140CPX, WSM

BRAKES

Brake Piston, Brake Disc and Friction Plate

IMPORTANT

• It is recommended to replace the brake seal with a new one every four years.

• Therefore, do not remove the piston unnecessarily from the knuckle case.

• If the piston should be removed, replace the seal ring with a new one.

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 hummer.

4. Remove the knuckle case (4) mounting screw.

5. Separate the knuckle case and knuckle case cover (6).

6. Remove the brake piston (7) by compressed air.

(When reassembling)

• Be sure install the external snap ring.

• Replace the oil seal (1) with new one.

• Take care not to damage the O-ring.

• Replace the brake seal 1 (8), 2 (9), and brake seal 3 (11), 4 (10).

• Insert the bearing and oil seal first to the knuckle cover (6), and install the knuckle case cover to front axle (5).

CAUTION

• The brake seal 1 (8), 2 (9) are used for brake fluid only.

• The brake seal 3 (11), 4 (10) are used for transmission fluid only.

• Degrease both the piston (7) and the knuckle case (4) before installing each brake seal.

• Before inserting the piston (7), apply a thin coat of the special grease (KLUBER LUBRICATION: SEALUB-L-101 or equivalent) to the brake seal surface. The special grease is a dual use type that can be applied to the oil seals and the

O-rings for both of the brake fluid and the transmission fluid.

• When servicing the brake, pay due attention to any oil adhered to your hands.

• Exert full care when handling the mineral oil (transmission fluid) and the brake fluid.

NOTE

• Align the each alignment mark (12) of piston and knuckle case.

• Assemble the bearing and oil seal of rear axle into the knuckle case cover side, and then assemble the rear axle.

Tightening torque

Knuckle case cover mounting screw

48 to 55 N·m

4.9 to 5.7 kgf·m

36 to 41 lbf·ft

(1) Oil Seal

(2) Snap Ring Roller

(3) External Snap Ring

(4) Knuckle Case

(5) Front Axle

(6) Knuckle Case Cover

(7) Piston

(8) Brake Seal 1

(9) Brake Seal 2

(10) Brake Seal 4

(11) Brake Seal 3

(12) Alignment Mark

(To be continued)

4-S11

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(Continued)

BRAKES

(When reassembling)

• Refer to the front page.

(4) Knuckle Case

(7) Piston

(8) Brake Seal 1

(9) Brake Seal 2

(10) Brake Seal 4

(11) Brake Seal 3

(12) Alignment Mark

9Y1210293BRS0012US0

4-S12

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(2) Rear Brake

BRAKES

Separating Differential Support Cover

1. Refer to "Transmission" section. (See page 2-S31.)

9Y1210293BRS0013US0

Bearing Support, Brake Disk and Friction Plate

1. Remove the internal snap ring (3).

2. Remove the bearing holder (1).

3. Remove the brake disk and friction plate.

(When reassembling)

• When installing the internal snap ring to differential support cover (2) as shown in the left photo.

• When installing the bearing holder (1) to differential support cover (2), do not forget to install the straight pin (4).

(1) Bearing Holder

(2) Differential Support Cover

(3) Internal Snap Ring

(4) Straight Pin

A: Installation Position

9Y1210293BRS0014US0

4-S13

KiSC issued 05, 2014 A

RTV1140CPX, WSM

BRAKES

Actuator, Ball and Cam Lever

1. Remove the actuator (1) and balls (2).

2. Remove the external snap ring (3) and remove the cam lever

(4).

(When reassembling)

• Take care not to damage the O-ring.

(1) Actuator

(2) Ball

(3) External Snap Ring

(4) Cam Lever

9Y1210293BRS0015US0

4-S14

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(3) Master Cylinder Assembly

BRAKES

Master Cylinder Assembly

CAUTION

• Use only DOT-3 brake fluid from a sealed container.

Conform 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.

• Avoid contamination of the brake fluid. Thoroughly clean area around the filler cap before removing. Do not open the brake fluid reservoir cap unless absolutely necessary.

• Use extreme care when filling the reservoir. If brake fluid is spilled on power steering hoses, wash off with water immediately. Brake fluid quickly ruins synthetic resin or rubber hoses.

NOTE

• Do not transform, and do not damage the brake pipe.

• Do not reuse the drained brake fluid.

• Do not mix the brake fluid of the other brand to prevent chemical change from occurring.

1. Remove the brake fluid reservoir cap (1).

2. Suck the brake fluid.

3. Disconnect the brake pipes (4) from master cylinder (3).

4. Remove the master cylinder (3).

(When reassembling)

• Air bleed the brake line after master cylinder reassembled. (See

page 4-S5.).

• Check and adjust the brake pedal free travel. (See page 4-S4.).

Tightening torque Brake pipe flare nut

13 to 17 N·m

1.4 to 1.7 kgf·m

9.6 to 12 lbf·ft

(1) Reservoir Cap

(2) Reservoir

(3) Master Cylinder

(4) Brake Pipe

9Y1210293BRS0016US0

4-S15

KiSC issued 05, 2014 A

RTV1140CPX, WSM

BRAKES

Master Cylinder Inner Parts

1. Remove the reservoir (2) from master cylinder body (3).

2. Pushing in the piston (8), remove the internal snap ring (7).

3. Remove the piston from master cylinder body (3).

4. Pushing in the secondary piston (9), remove the stop pin (10).

5. Remove the secondary piston (9) from master cylinder body.

NOTE

• Keep the disassembled parts in order and prevent them from being contaminated with dust or dirt.

(When reassembling)

• Wash the disassembled parts with the brake fluid and clean each port with the compressed air.

• Install the new grommet (15) in the reservoir tank.

• Apply the brake fluid to the piston cup (13) and (12).

• Do not reuse the removed piston (8) and secondary piston (9).

• Before installation, tap the valve stem (14) through the slot (11) of the piston and check that the valve stem moves smoothly.

• Push in the secondary piston, match the slot of the piston with the stop pin (10) installation hole and insert the stop pin (10).

• Apply a thin coat of special grease (COSMO RUBBER

GREASE BY COSMO OIL CO. or equivalent) to surface of piston cup (12) and hole of rod seal (4).

(1) Cap

(2) Reservoir

(3) Master Cylinder Body

(4) Rod Seal

(5) Push Rod

(6) Filter

(7) Internal Snap Ring

(8) Piston

(9) Secondary Piston

(10) Stop Pin

(11) Slot

(12) Piston Cup

(13) Piston Cup

(14) Valve Stem

(15) Grommet

9Y1210293BRS0017US0

[3] SERVICING

(1) Front Brake

Brake Disc and Friction Plate Wear (Front)

1. Measure the brake disc thickness and the friction plate thickness with an outside micrometer.

2. If the thickness is less than the allowable limit, replace it.

Brake disc thickness

Factory specification

Allowable limit

3.30 to 3.50 mm

0.130 to 0.138 in.

3.00 mm

0.118 in.

Friction plate thickness

Factory specification

Allowable limit

1.92 to 2.08 mm

0.0756 to 0.0818 in.

1.52 mm

0.0598 in.

9Y1210293BRS0018US0

4-S16

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(2) Rear Brake

BRAKES

Brake Cam Lever Movement

1. Move the brake cam lever by hand to check the movement.

2. If the movement is heavy, refine the brake cam with emery paper.

9Y1210293BRS0019US0

Flatness of Actuator and Bearing Holder

1. Place a straightedge of 200 mm (7.87 in.) or more in length on the contacting surface of the actuator and the bearing holder.

2. Inspect the friction surface of the actuator and the bearing holder with the straightedge, and determine if a 0.30 mm

(0.0118 in.) feeler gauge will fit on the part of wear.

3. If it will fit, resurface.

Flatness of actuator and bearing holder

Allowable limit

0.30 mm

0.012 in.

9Y1210293BRS0020US0

Height of Cam Plate and Ball

1. Measure the height of the cam plate with the ball 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.

4. If the uneven wear is found, replace it.

Height of cam plate and ball

Factory specification

Allowable limit

22.89 to 22.99 mm

0.9012 to 0.9051 in.

22.40 mm

0.8819 in.

9Y1210293BRS0021US0

Brake Disc and Friction Plate Wear (Rear)

1. Measure the brake disc thickness and the friction plate thickness with an outside micrometer.

2. If the thickness is less than the allowable limit, replace it.

Brake disc thickness

Factory specification

Allowable limit

3.30 to 3.50 mm

0.130 to 0.137 in.

3.00 mm

0.118 in.

Friction plate thickness

Factory specification

Allowable limit

1.92 to 2.08 mm

0.0756 to 0.0819 in.

1.52 mm

0.0598 in.

9Y1210293BRS0022US0

4-S17

KiSC issued 05, 2014 A

RTV1140CPX, WSM

BRAKES

Brake Cylinder

1. Push the brake piston from brake rod connecting side, and pull out the brake piston (1).

2. Check the brake piston and brake cylinder for signs of scoring or other damage.

3. If there is any doubt as to the condition of a piston and cylinder, replace it.

NOTE

• Apply a thin coat of the brake fluid to the piston before inserting it. Never use mineral oil, grease or the like.

(1) Brake Piston

9Y1210293BRS0023US0

Dust Seal and O-ring

1. If oil leaks from dust seal.

2. Remove the internal circlip (2) and remove the dust seal (1) and

O-ring and replace the new one.

NOTE

• These O-ring and dust seal are designed specifically for brake fluid application. Use only Kubota genuine parts (for brake fluid use) for replacement. During replacement, take care to avoid adherence of other oil or grease.

(1) Dust Seal (2) Internal Circlip

9Y1210293BRS0024US0

4-S18

KiSC issued 05, 2014 A

5

FRONT AXLE

KiSC issued 05, 2014 A

MECHANISM

CONTENTS

1. STRUCTURE.............................................................................................................................. 5-M1

[1] FRONT AXLE ....................................................................................................................... 5-M1

[2] FRONT SUSPENSION......................................................................................................... 5-M2

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. STRUCTURE

[1] FRONT AXLE

FRONT AXLE

(1) Bevel Gear Shaft (8T)

(2) Bevel Gear (35T)

(3) Side Gear

(4) Strut

(5) Knuckle

(6) Front Axle

(7) Ball Joint

(8) Constant Velocity (CV) Joint

(9) Front Case

(10) Lower Arm

The front axle consists mainly of knuckles (5) (right and left), front case (9) and CV (constant velocity) joint (8).

(See the above illustration.)

Power is transmitted from the transmission output shaft through the propeller shaft to the bevel gear shaft (1). The power is further transmitted through the differential bevel gear (2) and differential side gear (3) to the CV joint (8), and finally reaches the front axle (6) in the knuckles. The knuckles and the front case are partitioned from each other.

Which means each of the cases must be separately lubricated.

9Y1210293FAM0001US0

5-M1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[2] FRONT SUSPENSION

FRONT AXLE

(1) Spring

(2) Shock Absorber

(3) Strut

(4) Knuckle

(5) Front Axle

(6) Ball Joint

(7) Bump Stopper

(8) Constant Velocity (CV) Joint

(9) Front Case

(10) Lower Arm

(11) Rubber Bushing

The MacPherson strut type suspension has the shock absorber (2) as a strut (3) for positioning the front wheels.

The top of the strut is fixed to the machine body. Its bottom is rigid-coupled with the knuckle (4). The knuckle case is coupled through the ball joint (6) that is located at the end of the lower arm (10). This lower arm, on the other hand, is connected at two points via the rubber bushings (11) with the machine body.

(Function)

The MacPherson strut type suspension is a sort of independent suspension. Impacts from the ground are conveyed through the front tires and knuckles (4) and absorbed by the strut (3). The strut does not just serve to absorb the shock but withstands the sideway forces. The lower arm (10) regulates the to-and-fro as well as sideway movements of the front tires, which maintains a predetermined alignment. This lower arm is constructed with rubber bushings (11) in place, thereby cutting down on vibrations.

9Y1210293FAM0002US0

5-M2

KiSC issued 05, 2014 A

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-S5

(1) Front Suspension ............................................................................................................5-S6

(2) Knuckle Case ................................................................................................................5-S10

(3) Front Differential Case...................................................................................................5-S11

[3] DISASSEMBLING AND ASSEMBLING ..............................................................................5-S13

(1) Strut ...............................................................................................................................5-S13

(2) Front Axle ......................................................................................................................5-S14

(3) Front Differential Assembly ...........................................................................................5-S15

[4] SERVICING.........................................................................................................................5-S17

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. TROUBLESHOOTING

FRONT AXLE

Front Wheels Can

Not Be Driven

Noise

Symptom

Front Wheels Wander to Right or Left

Probable Cause Solution

Tire pressure uneven Adjust

Improper toe-in adjustment (improper alignment) Adjust

Tie-rod end loose

Air sucked in power steering circuit

Tighten

Bleed

Drive shaft joint broken

Front wheel drive gears in transmission broken

Front differential gear broken

Gear backlash excessive

Oil insufficient

Bearings damaged or broken

Gears damaged or broken

Bevel pinion shaft turning torque improper

Replace

Replace

Replace

Adjust or replace

Replenish

Replace

Replace

Adjust

9Y1210293FAS0001US0

Reference

Page

G-54

5-S4

5-S7

–

5-S10

2-S30

5-S15

5-S20

5-S5

–

2-S30

5-S18

5-S1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

2. SERVICING SPECIFICATIONS

Front Wheel Alignment

Item

Differential Pinion to Differential Side Gear Backlash

Differential Case to Differential Side Gear

Toe-in

Clearance

Factory Specification

0 to 20 mm

0 to 0.79 in.

0.10 to 0.30 mm

0.0040 to 0.011 in.

0.25 to 0.066 mm

0.00099 to 0.0025 in.

• Differential Case I.D.

• Spiral Bevel Gear

• Differential Side Gear

Differential Pinion Shaft to Differential

Pinion

• Differential Pinion

• Differential Pinion Shaft

Bevel Pinion Shaft

Bevel Pinion Shaft to Spiral Bevel Gear

I.D.

O.D.

Clearance

I.D.

O.D.

Turning Torque

Backlash

32.000 to 32.025 mm

1.2599 to 1.2608 in.

32.000 to 32.025 mm

1.2599 to 1.2608 in.

31.959 to 31.975 mm

1.2583 to 1.2589 in.

0.016 to 0.045 mm

0.00063 to 0.0017 in.

16.000 to 16.018 mm

0.62993 to 0.63062 in.

15.973 to 15.984 mm

0.62986 to 0.62929 in.

0.79 to 0.98 N·m

0.080 to 0.10 kgf·m

0.58 to 0.72 lbf·ft

0.15 to 0.3 mm

0.0059 to 0.011 in.

FRONT AXLE

Allowable Limit

–

–

0.30 mm

0.012 in.

–

–

–

0.3 mm

0.01 in.

–

–

–

–

9Y1210293FAS0002US0

5-S2

KiSC issued 05, 2014 A

RTV1140CPX, 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: See page G-10.)

Item

Front wheel mounting screw

Tie-rod end slotted nut

Ball joint mounting and nut

Front axle slotted nut

Knuckle case mounting bolt and slotted nut

Strut mounting nut

Lower arm mounting bolt and nut

Front differential case mounting nut

Knuckle case cover mounting screw

Bevel gear UBS screw

N·m

75 to 90

50

48.0 to 55.9

150

50

48.0 to 55.9

103 to 117

36.0 to 40.0

48 to 55

30 to 34

kgf·m

7.6 to 9.2

5.1

4.90 to 5.70

15.3

5.1

4.90 to 5.70

10.5 to 12.0

3.07 to 4.07

4.9 to 5.7

3.0 to 3.5

FRONT AXLE

lbf·ft

55.3 to 66.5

37

35.4 to 41.2

111

37

35.4 to 41.2

76.0 to 86.7

26.6 to 29.5

36 to 41

22 to 25

9Y1210293FAS0003US0

5-S3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

FRONT AXLE

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING

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.

4. Measure distance between tire beads at front of tire, at hub height (

A

-

B

).

5. Measure distance between tire beads at rear of tire, at hub height.

Toe-in (

A

-

B

) Factory specification

0 to 20 mm

0 to 0.79 in.

A: Wheel to Wheel Distance at Rear

B: Wheel to Wheel Distance at Front

C: Front

9Y1210293FAS0005US0

Toe-in Adjusting

1. Loosen the lock nuts (1).

2. Turn the tie-rod (2) until to be factory specification.

3. Tighten the lock nuts (1).

(1) Lock Nut (2) Tie-rod

9Y1210293FAS0006US0

5-S4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[2] PREPARATION

FRONT AXLE

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. Set the seat to 1 row.

2. Remove the battery cover (1).

3. Remove the air cleaner hose (2).

4. Disconnect the negative cable (3) from the battery (4).

(1) Battery Cover

(2) Air Cleaner Hose

(3) Negative Cable

(4) Battery

(5) Positive Cable

9Y1210293ENS0025US0

Draining Knuckle Case Oil

1. Park the vehicle on a firm, flat and level surface.

2. 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.

3. After draining, reinstall the drain plug.

4. Use the same procedure to change the RH knuckle case oil.

Knuckle case oil

Reference capacity

(one side)

0.15 L

0.16 U.S.qts

0.13 Imp.qts

(1) Drain Plug (2) Filling Plug

9Y1210293FAS0007US0

5-S5

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(1) Front Suspension

FRONT AXLE

Changing Front Axle Case Oil

1. Park the vehicle on a firm, flat and level surface.

2. To drain the used oil, remove the drain plug and filling plugs at the front axle case and drain the oil completely into the oil pan.

3. After draining, reinstall the drain plug.

(When reassembling)

• Use KUBOTA UDT or KUBOTA SUPER UDT fluid. Refer to

"LUBRICANTS, FUEL AND COOLANT". (See page G-8.)

Front axle case oil Capacity

0.6 L

0.63 U.S.qts

0.52 Imp.qts

(1) Drain Plug

(2) Filling Plug with Dipstick

A: Oil level is acceptable within this range.

9Y1210293FAS0008US0

Front Wheel and Front Axle Nut

1. Loosen the front wheel mounting screw (1).

(When reassembling)

Tightening torque

Front wheel mounting screw

75 to 90 N·m

7.6 to 9.2 kgf·m

55.3 to 66.4 lbf·ft

(1) Front Wheel Mounting Screw

9Y1210293FAS0031US0

5-S6

KiSC issued 05, 2014 A

RTV1140CPX, WSM

FRONT AXLE

Front Suspension (Strut Suspension)

1. Place the stand under the frame.

2. Remove the joint guard (4).

3. Loosen the lower arm mounting bolt and nut (3).

4. Remove the cotter pin and remove the tie-rod end slotted nut.

(7)

5. Remove the ball joint (5) mounting bolt and nuts.

6. Remove the front axle slotted nut (10).

7. Remove the cotter pin and remove the knuckle case mounting bolt and nut (9).

8. Separate the strut (1) and knuckle case assembly (4) from lower arm (8).

9. Remove the strut mounting nut (12) and then remove the strut

(1).

(1) Strut

(2) Slotted Nut (for Knuckle Case

Mounting Bolt)

(3) Lower Arm Mounting Bolt and Nut

(4) Joint Guard

(5) Ball Joint

(6) Tie-rod End

(7) Slotted Nut

(8) Lower Arm

(9) Knuckle Case Mounting Bolt and

Nut

(10) Front Axle Slotted Nut

(11) Knuckle Case Assembly

(12) Strut Mounting Nut

(To be continued)

5-S7

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(Continued)

FRONT AXLE

(When reassembling)

• When installing the strut (1) to knuckle case, set the wedge to decide the position of strut to the slit of the knuckle case.

• When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the tie-rod end and case mounting bolt, tighten the nut clockwise up to next alignment.

• If should be within 30 degree.

• Loosen once and tighten again when the slit goes past the nearest hole.

• After tightening the these slotted nut to specified torques, install a cotter pin as shown figure left.

NOTE

• Tighten the lower arm mounting bolt and nut (3) with the specified torque after setting up the wheel and unloading the machine on ground.

• Tighten the slotted nut to 150 N·m (15.3 kgf·m, 110 lbf·ft). If the slot and pin hole do not meet, tighten the nut until they do meet, and install cotter pin.

• Be sure to split the cotter pin like an anchor.

Tightening torque

Tie-rod end slotted nut

Ball joint mounting screw and nut

Front axle slotted nut

Knuckle case mounting bolt and slotted nut

Strut mounting nut

Lower arm mounting bolt and nut

50 N·m

5.1 kgf·m

37 lbf·ft

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

150 N·m

15.3 kgf·m

111 lbf·ft

50 N·m

5.1 kgf·m

37 lbf·ft

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

103 to 117 N·m

10.5 to 12.0 kgf·m

763.0 to 86.7 lbf·ft

(1) Strut

(3) Lower Arm Mounting Bolt and Nut

(13) Slit

9Y1210293FAS0009US0

5-S8

KiSC issued 05, 2014 A

RTV1140CPX, WSM

FRONT AXLE

Lower Arm

1. Remove the lower arm mounting bolt and nut (1).

2. Remove the lower arm (2).

(When reassembling)

NOTE

• Tighten the lower arm mounting bolt and nut (1) with the specified tightening torque after setting up the wheel and unloading the machine on ground.

Tightening torque

Lower arm mounting bolt and nut

103 to 117 N·m

10.5 to 12.0 kgf·m

76.0 to 86.7 lbf·ft

(1) Lower Arm Mounting Screw and Nut (2) Lower Arm

9Y1210293FAS0010US0

5-S9

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(2) Knuckle Case

FRONT AXLE

Knuckle Case

CAUTION

• When the brake hose is removed, the brake fluid comes out. Take care not to stain other hoses or rubber boot with the brake fluid.

Brake fluid stains should be washed and wiped off immediately. Likewise, the brake fluid on the tools should be wiped off immediately.

1. Remove the joint guard (4).

2. Remove the eye joint bolt for brake hose (1) and drain the brake fluid.

3. Remove the cotter pin and remove the slotted nut (7) for tie-rod end (6).

4. Loosen the lower arm mounting bolt and nut (3), and then remove the ball joint (5) mounting screw and nut.

5. Remove the cotter pin and remove the slotted nut (2) for knuckle case mounting bolt (9).

6. Remove the knuckle case mounting bolt (9) and remove the front axle slotted nut (10).

7. Remove the knuckle case assembly (12).

(When reassembling)

• When installing the strut to knuckle case, set the wedge to decide the position of strut (11) to the slit of the knuckle case assembly (12).

• When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the tie-rod end, ball joint and knuckle case mounting bolt, tighten the nut clockwise up to next alignment.

• It should be within 30 degree.

• Loosen once and tighten again when the slit goes past the nearest hole.

• After tightening the these slotted nut to specified torques, install a cotter pin as shown in the figure.

NOTE

• Tighten the lower arm mounting bolt and nut (3) with the specified torque after setting up the wheel and unloading the machine on ground.

Tightening torque

Tie-rod end slotted nut

Ball joint mounting screw and nut

Knuckle case mounting bolt and slotted nut

Lower arm mounting bolt and nut

50 N·m

5.1 kgf·m

37 lbf·ft

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

103 to 117 N·m

10.5 to 12.0 kgf·m

76.0 to 86.7 lbf·ft

(1) Brake Hose

(2) Slotted Nut (for Knuckle Case

Mounting Bolt)

(3) Lower Arm Mounting Bolt and Nut

(4) Joint Guard

(5) Ball Joint

(6) Tie-rod End

(7) Slotted Nut (for Tie-Rod End)

(8) Lower Arm

(9) Knuckle Case Mounting Bolt

(10) Front Axle Slotted Nut

(11) Strut

(12) Knuckle Case Assembly

(13) Drive Shaft

(14) Slit

9Y1210293FAS0011US0

5-S10

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(3) Front Differential Case

FRONT AXLE

Front Differential Assembly

1. Place the stand under the frame.

2. Remove the front wheel.

3. Remove the joint guard (5).

4. Loosen the lower arm mounting bolt and nut (3).

5. Remove the cotter pin, and remove the slotted nut (7) for tie-rod end (6).

6. Remove the ball joint (5) mounting bolt and nuts.

7. Remove the cotter pin, and remove the slotted nut (2) for knuckle case mounting bolt (9).

8. Remove the knuckle case mounting bolt (9) and front axle slotted nut (10).

9. Separate the knuckle case assembly (12) from lower arm (8) and strut (1).

10. Remove the drive shaft assembly (11) from front differential case (16).

11. Remove the differential side cover (13).

12. Disconnect the propeller shaft (14) from pinion shaft.

13. Remove the differential protector (16).

14. Remove the front differential assembly (17).

(1) Strut

(2) Slotted Nut (for Knuckle Case

Mounting Bolt)

(3) Lower Arm Mounting Bolt and Nut

(4) Joint Guard

(5) Ball Joint

(6) Tie-Rod End

(7) Slotted Nut (for Tie-Rod End)

(8) Lower Arm

(9) Knuckle Case Mounting Bolt

(10) Front Axle Slotted Nut

(11) Drive Shaft Assembly

(12) Knuckle Case Assembly

(13) Differential Side Cover

(14) Propeller Shaft

(15) Differential Protector Mounting Bolt

(16) Differential Protector

(17) Front Differential Assembly

(To be continued)

5-S11

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(Continued)

FRONT AXLE

(When reassembling)

• When installing the strut (1) to knuckle case assembly (12), set the wedge to decide the position of strut to the slit of the knuckle case assembly.

• When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in the tie-rod end or knuckle case mounting bolt, tighten the nut clockwise up to next alignment. It should be within 30 degree.

• Loosen once and tighten again, when the slit goes past the nearest hole.

• After tightening the these slotted nut to the specified tightening torque, install a cotter pin as shown in the figure.

• Apply anti-fretting grease (NISSEKI PYRONOC UNIVERSAL

N6C or its equivalents) to spline of propeller shaft (14) and pinion shaft.

NOTE

• Tighten the lower arm mounting bolt and nut (3) with the specified tightening torque after setting up the wheel and unloading the machine on ground.

Tightening torque

Tie-rod end slotted nut

Ball joint mounting screw and nut

Knuckle case mounting bolt and slotted nut

Front differential case mounting nut

50 N·m

5.1 kgf·m

37 lbf·ft

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

36.0 to 40.0 N·m

3.07 to 4.07 kgf·m

26.6 to 29.5 lbf·ft

(1) Strut

(12) Knuckle Case Assembly

(14) Propeller Shaft

(17) Front Differential Assembly

(18) Front Differential Case Mounting

Nut

(19) Slit

9Y1210293FAS0012US0

5-S12

KiSC issued 05, 2014 A

RTV1140CPX, WSM

FRONT AXLE

[3] DISASSEMBLING AND ASSEMBLING

(1) Strut

Strut

1. Cramp the strut in a vise.

2. Shorten spring with a spring compressor (3).

3. Remove the strut mount bracket mounting nut (6).

4. Remove the strut mount bracket (1), spring (4), plates, spacer, spring upper support (2) and stopper (5).

(When reassembling)

• Set the spring end to the bulge (8) in the lower spring seat the strut damper.

• Set the spring end to the bulge in the spring upper support (2).

(1) Strut Mount Bracket

(2) Spring Upper Support

(3) Spring Compressor

(4) Spring

(5) Stopper

(6) Nut

(7) Long Deep Socket Wrench

(17 mm)

(8) Bulge

9Y1210293FAS0013US0

5-S13

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(2) Front Axle

FRONT AXLE

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 a plastic hammer.

4. Remove the knuckle case mounting screw.

5. Separate the knuckle case (4) and knuckle case cover (6).

(When reassembling)

• Be sure insert the external snap ring.

• Replace the oil seal with new one.

• Take care not to damage the O-ring.

• Insert the bearing (7) and oil seal (8) first to the knuckle cover, and then install the knuckle case cover.

Tightening torque

Knuckle case cover mounting screw

48 to 55 N·m

4.9 to 5.7 kgf·m

36 to 41 lbf·ft

(1) Oil Seal

(2) Snap Ring Collar

(3) External Snap Ring

(4) Knuckle Case

(5) Front Axle

(6) Knuckle Case Cover

(7) Bearing

(8) Oil Seal

9Y1210293FAS0014US0

5-S14

KiSC issued 05, 2014 A

RTV1140CPX, WSM

FRONT AXLE

(3) Front Differential Assembly

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)

• Apply liquid gasket (Three Bond 1215E, Locktite 5699 or equivalent) to joint face of the front case cover and front case other eliminate the oil and stuck liquid gasket.

• Use same number of shims as before disassembling.

(Reference)

Thickness of shim (RH)

(Case side)

Thickness of shim (LH)

(Cover side)

Factory specification

Factory specification

0.50 mm

0.020 in.

0.90 mm

0.035 in.

(1) Front Differential Case Cover

(2) Differential Gear Assembly

(3) Front Differential Case

9Y1210293FAS0015US0

Bearings

1. Remove the right and left bearings (1) from the differential case.

(1) Bearing

9Y1210293FAS0016US0

Bevel Gear

1. Remove the bevel gear UBS screws (1).

2. Remove the bevel gear (2) from differential case (3).

(When reassembling)

• Apply liquid lock (Three Bond 1324B or its equivalent) to the spiral bevel gear UBS screws.

Tightening torque Bevel gear UBS screw

30 to 34 N·m

3.0 to 3.5 kgf·m

22 to 25 lbf·ft

(1) Bevel Gear UBS Screw

(2) Bevel Gear

(3) Differential Case

9Y1210293FAS0017US0

5-S15

KiSC issued 05, 2014 A

RTV1140CPX, WSM

FRONT AXLE

Differential Side Gear and Differential Pinion

1. Put parting marks on the differential pinion (2) and the differential side gear (1).

2. Tap out the dowel pin (3).

3. Remove the differential pinion shaft.

4. Remove the differential pinion (4), differential side gear (1) and shim (5).

(When reassembling)

• Install the differential pinion and differential side gear, aligning the parting marks.

(1) Differential Side Gear

(2) Differential Pinion

(3) Dowel Pin

(4) Differential Pinion

(5) Shim

9Y1210293FAS0018US0

Bevel Pinion Gear Assembly

1. Remove the oil seal (8) and sleeve (9).

2. Remove the internal snap ring (4) and tap out the bevel pinion shaft (3) from front.

3. Cramp the bevel pinion shaft assembly in a vise.

4. Remove the stake of lock nut (2), and then remove the lock nut.

(When reassembling)

• Apply gear oil to the taper roller bearings (10) and install them correctly, noting their direction.

• Replace the lock nut (2) and oil seal (8) with new ones.

• After tighten the lock nut (2) to the turning torque, stake it firmly.

• Install the adjusting collars (5), (7) to their original position.

• Use same thickness of collars as before disassembling.

(Reference)

Combination 1

Thickness of collar (5)

(Front)

Factory specification

4.4 mm

0.17 in.

Thickness of collar (7)

(Rear)

Factory specification

3.6 mm

0.14 in.

Combination 2

Thickness of collar (5)

(Front)

Thickness of collar (7)

(Rear)

Factory specification

Factory specification

4.6 mm

0.18 in.

3.4 mm

0.13 in.

(1) Front Differential Case

(2) Staking Lock Nut

(3) Pinion Shaft

(4) Internal Snap Ring

(5) Adjusting Collar

(6) Collar

(7) Adjusting Collar

(8) Oil Seal

(9) Sleeve

(10) Taper Roller Bearing

9Y1210293FAS0019US0

5-S16

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[4] SERVICING

FRONT AXLE

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.

Then, turn the outer race to check rotation.

3. If there is any defect, replace it.

9Y1210293TRS0042US0

Backlash between Differential Pinion and Differential Side

Gear

1. Secure the differential case with a vise.

2. Put the solder (0.5 mm (0.020 in.) thickness) on the tooth of the differential pinion.

3. Temporarily install the drive shaft assembly and rotate the drive shaft carefully to measure the backlash.

4. If the measurement exceeds the factory specifications, adjust with the differential side gears shims.

Backlash between differential pinion and differential side gear

Factory specification

0.10 to 0.30 mm

0.0040 to 0.011 in.

9Y1210293FAS0020US0

Clearance between Differential Case (Spiral Bevel Gear) and

Differential Side Gear

1. Measure the differential side gear boss O.D. with an outside micrometer.

2. Measure the differential case I.D. and the spiral bevel gear I.D.

with an inside micrometer, and calculate the clearance.

3. If the clearance exceeds the allowable limit, replace faulty parts.

Clearance between differential case (spiral bevel gear) and differential side gear

Factory specification

Allowable limit

0.025 to 0.066 mm

0.00099 to 0.0025 in.

0.30 mm

0.012 in.

Differential case I.D.

Spiral bevel gear I.D.

Differential side gear

O.D.

Factory specification

Factory specification

Factory specification

32.000 to 32.025 mm

1.2599 to 1.2608 in.

32.000 to 32.025 mm

1.2599 to 1.2608 in.

31.959 to 31.975 mm

1.2583 to 1.2589 in.

9Y1210293FAS0021US0

5-S17

KiSC issued 05, 2014 A

RTV1140CPX, WSM

FRONT AXLE

Clearance between Differential Pinion Shaft and Differential

Pinion

1. Measure the differential pinion shaft O.D. with an outside micrometer.

2. Measure the differential pinion I.D. with an inside micrometer, and calculate the clearance.

3. If the clearance exceeds the allowable limit, replace faulty parts.

Clearance between differential pinion shaft and differential pinion

Factory specification

Allowable limit

0.016 to 0.045 mm

0.00063 to 0.0017 in.

0.3 mm

0.01 in.

Differential pinion I.D.

Differential pinion shaft

O.D.

Factory specification

Factory specification

16.000 to 16.018 mm

0.62993 to 0.63062 in.

15.973 to 15.984 mm

0.62886 to 0.62929 in.

9Y1210293FAS0022US0

Turning Torque of Bevel Pinion Shaft

1. Clamp the spiral bevel pinion shaft assembly to the vise and tighten the staking nut.

2. Measure the turning torque of bevel pinion shaft.

3. If the turning torque is not within the factory specifications, adjust with the lock nut.

Turning torque Factory specification

0.79 to 0.98 N·m

0.080 to 0.10 kgf·m

0.58 to 0.72 lbf·ft

NOTE

• After turning force adjustment, be sure to stake the lock nut.

(1) Pinion Shaft (2) Staking Lock Nut

9Y1210293FAS0023US0

5-S18

KiSC issued 05, 2014 A

RTV1140CPX, WSM

FRONT AXLE

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.

2. Reassemble the front differential case and front differential case cover.

3. Tighten the front differential case cover mounting screws to specified torque.

4. Turn the bevel pinion shaft to the clockwise by 5 to 6 rotations and 5 to 6 rotations to the counterclockwise.

5. Check the tooth contact. If not proper, adjust with shims and collars according to the instructions below.

(1) Front Differential Case Cover

(2) Adjusting Shim

(3) Front Differential Gear Assembly

(4) Adjusting Shim

(5) Bevel Pinion Shaft Assembly

(6) Front Differential Case

(7) Adjusting Collar

(8) Adjusting Collar

(9) Internal Snap Ring

9Y1210293FAS0024US0

More than 35 % red lead contact area on the gear tooth surface.

The center of tooth contact at 1/3 of the entire width from the small end.

(A) Proper Contact

9Y1210293FAS0025US0

Change the adjusting collar to smaller size, and change the adjusting collar to larger size.

For move the spiral bevel gear rightward, reduce right side shim

(2) and add shim (3) of the same thickness as the right side to left side.

(B) Shallow Contact (C) Heel Contact

9Y1210293FAS0026US0

Change the adjusting collar to larger size, and change the adjusting collar to smaller size.

For move the spiral bevel gear leftward, reduce left side shim (3) and add shim (2) of the same thickness as the left side to right side.

Repeat above until the proper tooth contact and backlash are achieved.

(D) Deep Contact (E) Toe Contact

9Y1210293FAS0027US0

5-S19

KiSC issued 05, 2014 A

RTV1140CPX, WSM

FRONT AXLE

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.

3. Separate the front differential case cover and remove the differential assembly, again.

4. Measure the backlash by thickness of the point where solder is the thinnest.

5. When the backlash is too large, decrease the number of shims

(LH) in the side of the bevel gear, and insert the shim (RH) of the same thickness as the removed ones to the opposite side.

6. When the backlash is too small, do the opposite way to increase backlash.

Adjust the backlash properly by repeating the above procedure.

Backlash between bevel pinion shaft and bevel gear

Factory specification

0.15 to 0.30 mm

0.0059 to 0.011 in.

(Reference)

• Thickness of shims (1) (LH)

0.2 mm (0.008 in.)

0.3 mm (0.012 in.)

0.5 mm (0.020 in.)

• Thickness of shims (2) (RH)

0.1 mm (0.004 in.)

0.2 mm (0.008 in.)

0.3 mm (0.012 in.)

0.5 mm (0.020 in.)

• Thickness of adjusting collars (3), (4)

3.4 mm (0.134 in.)

3.6 mm (0.142 in.)

3.8 mm (0.150 in.)

3.9 mm (0.154 in.)

4.0 mm (0.157 in.)

4.1 mm (0.161 in.)

4.2 mm (0.165 in.)

4.4 mm (0.173 in.)

4.5 mm (0.177 in.)

4.6 mm (0.181 in.)

Thickness of shim LH (1)

(Cover side)

Thickness of shim RH (2)

(Case side)

Combination 1

Thickness of collar (3)

(Front)

Thickness of collar (4)

(Rear)

Factory specification

Factory specification

Factory specification

Factory specification

0.50 mm

0.020 in.

0.90 mm

0.035 in.

4.4 mm

0.17 in.

4.4 mm

0.17 in.

Combination 2

Thickness of collar (3)

(Front)

Thickness of collar (4)

(Rear)

Factory specification

Factory specification

4.6 mm

0.18 in.

3.4 mm

0.13 in.

(1) Adjusting Shim

(2) Adjusting Shim

(3) Adjusting Collar

(4) Adjusting Collar

(5) Bevel Pinion Shaft

(6) Front Differential Case Cover

9Y1210293FAS0028US0

5-S20

KiSC issued 05, 2014 A

RTV1140CPX, WSM

FRONT AXLE

Lower Arm, and Rubber Bush

1. Replace any bushing that are worn, cracked, hardened, or otherwise damaged.

2. Remove the lower arm rubber bush (5) with press machine and lower arm bush tool 1 (1), 2 (2), 3 (3).

3. Visually inspect the lower arm for breaks or distortion.

4. If the lower arm is damaged is any way, replace it.

(When reassembling)

• Install the lower arm rubber bush with press machine and lower arm bush tool 1 (1), 2 (2), 4 (4).

NOTE

• Use soapy water when you install the bush. Never use neither oil nor grease, etc..

• Bush must install it to go out right and left and evenly (see photo).

(1) Lower Bush Tool 1

(2) Lower Bush Tool 2

(3) Lower Bush Tool 3

(4) Lower Bush Tool 4

(5) Rubber Bush

9Y1210293FAS0029US0

5-S21

KiSC issued 05, 2014 A

RTV1140CPX, WSM

FRONT AXLE

Drive Shaft Boot

1. Remove the external snap ring (1), bearing (2) and bearing holder (3).

2. Unlock the both boot bands (5), (6) and slide the boot DOJ (4).

3. Remove the internal circlip (7) and wipe the old grease.

4. Separate the joint outer and drive shaft assembly.

5. Remove the external snap ring (8) and, then remove the steel ball (9), steel ball retainer (11) and steel ball base (10).

6. Remove the boot DOJ (4) of front case side.

(1) External Snap Ring

(2) Bearing

(3) Bearing Holder

(4) Boot DOJ

(5) Boot Band

(6) Boot Band

(7) Internal Circlip

(8) External Snap Ring

(9) Steel Ball

(10) Steel Ball Base

(11) Steel Ball Retainer

(To be continued)

5-S22

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(Continued)

FRONT AXLE

1. Unlock the both boot bands (2), (3) and remove the boot BJ (1) of knuckle case side.

2. Wipe the old grease.

NOTE

• The knuckle case side (wheel side) joint can not be disassembled.

(1) Boot BJ

(2) Boot Band

(3) Boot Band

(To be continued)

5-S23

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(Continued)

FRONT AXLE

(When reassembling)

• Check the each joints, if any joint does not work smoothly without rattling or sticking, the joint bearing is damaged.

Replace the drive shaft with new one.

• Visually check the splines on the each shafts, if they are badly worn or chipped, replace the drive shaft with new one.

• Replace the internal circlip, boot and boot band with new ones.

• Be sure to use the special grease is the boot kit.

• When install the internal circlip (2) so that the opening (1) is aligned with one of the projections (3) as shown in the figure left.

• Install the steel ball retainer (5) as shown in the figure left.

• Install the steel ball base (7), face the chamfered side (8) of the steel ball base (7) to the boot as shown in the figure left.

• Clamp the boot bands and bend the tangs (10) securely to hold down the end of the band (9).

(1) Opening

(2) Internal Circlip

(3) Projection Part

(4) Steel Ball

(5) Steel Ball Retainer

(6) Drive Shaft

(7) Steel Ball Base

(8) Chamfered Side

(9) Boot Band

(10) Tang

9Y1210293FAS0030US0

5-S24

KiSC issued 05, 2014 A

6

STEERING

KiSC issued 05, 2014 A

MECHANISM

CONTENTS

1. STRUCTURE.............................................................................................................................. 6-M1

2. HYDRAULIC CIRCUIT ............................................................................................................... 6-M2

3. STEERING CONTROLLER........................................................................................................ 6-M3

4. STEERING CYLINDER .............................................................................................................. 6-M5

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. STRUCTURE

STEERING

(1) Steering Wheel

(2) Steering Controller

(3) Power Steering Oil Tank

(4) Return Hose

(5) Delivery Hose

(6) Suction Pipe

(7) Suction Hose

(8) Hydraulic Pump

(9) Cylinder Hose

(10) Tie-rod

(11) Steering Cylinder

The full hydrostatic type power steering is used on RTV1140CPX. This steering system is composed of steering wheel, steering controller, steering cylinder and other components shown in the figure.

9Y1210293STM0001US0

6-M1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

2. HYDRAULIC CIRCUIT

STEERING

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 hoses. Accordingly, it does not have mechanical transmitting parts such as steering gear, pitman arm, drag link, etc. Therefore, it is simple in construction. This steering system consists of the power steering oil tank (3), hydraulic pump (4), steering controller (2), steering cylinder, etc..

An oil tank dedicated for power steering is located below the operator's seat. The oil in this tank is fed by the hydraulic pump driven by engine to the steering controller (3.5 to 8.4 L/min., 0.93 to 2.2 U.S.gals/min.,

0.77 to 1.8 Imp.gals/min.). With the steering wheel at neutral, the oil returns through the controller to the oil tank. Turn the steering wheel, and just a required amount of oil is sent to the steering cylinder. The oil at the side opposite to the cylinder flows back to the tank.

This power steering controller is of non-load reaction type.

(1) Steering Cylinder

(2) Steering Controller

(3) Oil Tank

(4) Hydraulic Pump

9Y1210293STM0002US0

6-M2

KiSC issued 05, 2014 A

RTV1140CPX, WSM

STEERING

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). This causes the forming of a

"Neutral" oil circuit.

When the steering wheel is turned either clockwise or counterclockwise, the position of the spool and sleeve changes in relation to the centering spring. This allows the forming of a "Right Turning" or "Left Turning" oil circuit. At the same time, the gear pump (Metering device) rotates with the spool and sends the oil to the cylinder corresponding to the rotation of the steering wheel.



Metering Device

An oil, sent from the hydraulic pump to the steering cylinder, passes through the metering device (2).

Namely, when the rotor is driven, two chambers suck in oil due to volumetric change in the pup chambers formed between the rotor (11) and the stator (12), while oil is discharged from other two chambers. On the other hand, rotation of the steering wheel is directly transmitted to the rotor through the spool (6), drive shaft

(9), etc.

Accordingly, the metering device serves to supply the steering cylinder with oil, amount of which corresponds to the rotation of the steering wheel. The wheels are thus turned by the angle corresponding to the rotation of the steering wheel.

When the engine stops or the hydraulic pump malfunctions, the metering device functions as a manual trochoid pump, which makes manual steering possible.

(1) Steering Controller

(2) Metering Device

(3) Control Valve

(4) Steering Cylinder

(5) Check Valve

(6) Spool

(7) Centering Spring

(8) Sleeve

(9) Drive Shaft

(10) Distributor Plate

(11) Rotor

(12) Stator

P: P Port

(From Hydraulic Pump)

T: T Port (To Power Steering

Oil Tank)

9Y1210293STM0003US0

6-M3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

STEERING

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.

8.0 to 9.0 MPa

82 to 91 kgf/cm

2

1200 to 1300 psi

(1) Relief Valve

9Y1210293STM0004US0

6-M4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

4. STEERING CYLINDER

STEERING

(1) Piston Rod

(2) Internal Snap Ring

(3) Washer

(4) Wiper Ring

(5) Internal Snap Ring

(6) Cylinder Head

(7) Cap Bolt

(8) O-ring

(9) Seal Ring

(10) Center Piston

(11) Cylinder Tube

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.

The tie-rods connected to both knuckle arm guarantees equal steering movement to both front wheels.

The steering cylinder provide force in both directions. Depending upon direction the steering wheel is turned pressure oil enters at one end of the cylinder to extend, or the other end to retract it, thereby turning front wheel of the machine.

9Y1210293STM0005US0

6-M5

KiSC issued 05, 2014 A

SERVICING

CONTENTS

1. TROUBLESHOOTING.................................................................................................................6-S1

2. SERVICING SPECIFICATIONS ..................................................................................................6-S2

3. TIGHTENING TORQUES............................................................................................................6-S3

4. CHECKING, DISASSEMBLING AND SERVICING .....................................................................6-S4

[1] CHECKING............................................................................................................................6-S4

[2] PREPARATION.....................................................................................................................6-S5

(1) Separating Power Steering Controller .............................................................................6-S5

(2) Separating Power Steering Cylinder ...............................................................................6-S7

(3) Separating Hydraulic Pump.............................................................................................6-S8

(4) Removing Power Steering Hose ...................................................................................6-S10

[3] DISASSEMBLING AND ASSEMBLING ..............................................................................6-S14

(1) Power Steering Cylinder................................................................................................6-S14

(2) Hydraulic Pump .............................................................................................................6-S15

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. TROUBLESHOOTING

Symptom

Cannot Be Steered

Hard Steering

Probable Cause

Steering controller malfunctioning

Hose broken

Power steering oil improper

Steering Force

Fluctuates

Hydraulic pump malfunctioning

Steering controller malfunctioning

Steering controller malfunctioning

Air sucked in pump due to lack of oil

Air sucked in pump from suction circuit

Steering controller malfunctioning

Steering Wheel Turns

Spontaneously When

Released

Front Wheels Wander to Right and Left

Oil Temperature

Increases Rapidly

Steering controller malfunctioning

Air sucked in pump due to lack of oil

Air sucked in pump from suction circuit

Insufficient bleeding

Cylinder malfunctioning

Improper toe-in adjustment

Tire pressure uneven

Cylinder hoses connected in reverse

Wheels Are Turned to a Direction Opposite to Steering Direction

Steering Wheel Turns

Idle in Manual

Steering

Noise

Insufficient bleeding

Air sucked in due to lack of oil

Air sucked in pump due to lack of oil

Air sucked in pump from suction circuit

Steering controller (relief valve) malfunctioning

Solution

Replace

Replace

Change with specified oil

Replace

Replace

Replace

Replenish

Repair

Replace

Reference

Page

6-S5

6-S10

G-8

6-S8

6-S5

6-S5

G-8

6-S10

6-S5

Replace

Replenish

Repair

Bleed

Repair or replace

Adjust

Inflate

Repair

Bleed

Replenish

Replenish

Repair

Replace

STEERING

6-S5

G-8

6-S10

–

6-S7

5-S4

G-54

6-S13

–

G-8

G-8

6-S10

6-S4

9Y1210293STS0001US0

6-S1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

2. SERVICING SPECIFICATIONS

POWER STEERING BODY

Item Factory Specification

Relief Valve Operating

Pressure

8.0 to 9.0 MPa

82 to 91 kgf/cm

2

1200 to 1300 psi

STEERING

Allowable Limit

–

9Y1210293STS0002US0

6-S2

KiSC issued 05, 2014 A

RTV1140CPX, 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: See page G-10.)

Item

ROPS pipe mounting bolt and nut

ROPS (front) mounting screw

Steering wheel mounting nut

Power steering hose retaining nut

Steering controller mounting screw

Tie-rod end slotted nut

Steering cylinder bracket mounting screw

Power steering delivery hose retaining nut

Hydraulic control valve delivery hose retaining nut

Drain plug

Seat belt inside mounting nut

Seat belt outside mounting nut

Tie-rod screw

Cylinder tube cap bolt

N·m

48.0 to 55.8

77.5 to 90.2

30 to 49

21.6 to 25.7

23.5 to 27.4

50

103 to 117

21.6 to 25.7

21.6 to 25.7

58 to 67

48.0 to 55.9

13.0 to 17.0

74 to 84

9.80 to 12.7

kgf·m

4.90 to 5.69

7.91 to 9.19

3.0 to 5.0

2.21 to 2.62

2.40 to 2.79

5.1

10.5 to 12.0

2.21 to 2.62

2.21 to 2.62

5.9 to 6.9

4.90 to 5.70

1.33 to 1.73

7.6 to 8.6

1.00 to 1.29

STEERING

lbf·ft

35.4 to 41.1

57.2 to 66.5

22 to 36

16.0 to 18.9

17.4 to 20.2

37

76.0 to 86.7

16.0 to 18.9

16.0 to 18.9

43 to 49

35.4 to 41.2

9.59 to 12.5

55 to 61

7.23 to 9.36

9Y1210293STS0003US0

6-S3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

STEERING

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING

Relief Valve Operating Pressure

CAUTION

• When checking, park the machine on flat ground, apply the parking brake.

1. Disconnect the power steering hose (1) L (or R) from steering cylinder, and set a pressure gauge.

2. Start the engine and set at rated speed.

3. Fully turn the steering wheel to the left (or right) to check the feeling which the steering wheel lightly locks. Read the relief valve operating pressure when the steering wheel to the above-mentioned lock position.

NOTE

• After set a pressure gauge, be sure to bleed air.

• Note that the pressure value changes by the pump action of the power steering controller when the steering operation is continued after the steering wheel is lightly locked and accurate relief valve pressure cannot be measured.

(Reference)

• Hose and adaptor Tee, swivel (9/16-18).

• Replace the hydraulic pump if pressure does not rise in 7.8 MPa

(80 kgf/cm

2

, 1100 psi).

Relief valve operating pressure

Factory specification

8.0 to 9.0 MPa

82 to 91 kgf/cm

2

1200 to 1300 psi

Condition

• Engine speed: 3000 rpm

− 1

(rpm)

• Oil temperature: 45 to 55 °C (113 to 131 °F)

(1) Power Steering Hose (2) Power Steering Cylinder

9Y1210293STS0011US0

6-S4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[2] PREPARATION

(1) Separating Power Steering Controller

Battery

STEERING

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. Set the seat to 1 row.

2. Remove the battery cover (1).

3. Remove the air cleaner hose (2).

4. Disconnect the negative cable (3) from the battery (4).

(1) Battery Cover

(2) Air Cleaner Hose

(3) Negative Cable

(4) Battery

(5) Positive Cable

9Y1210293ENS0025US0

Bonnet Upper

1. Remove the snap pin and remove the bonnet upper (3).

2. Remove the ROPS pipes (1).

3. Lift ROPS boots and remove the three screws on both sides.

4. Remove the ROPS pipe (front) (2).

Tightening torque

ROPS pipe mounting bolt and nut

ROPS (front) mounting screw

48.0 to 55.8 N·m

4.90 to 5.69 kgf·m

35.4 to 41.1 lbf·ft

77.5 to 90.2 N·m

7.91 to 9.19 kgf·m

57.2 to 66.5 lbf·ft

(1) ROPS Pipe

(2) ROPS Pipe, Front

(3) Bonnet Upper

9Y1210293STS0004US0

6-S5

KiSC issued 05, 2014 A

RTV1140CPX, WSM

STEERING

Bonnet Lower

1. Remove the four screw (2).

2. Remove the screws (3) from underneath the bonnet lower.

3. Remove the bonnet lower (1).

(1) Bonnet Lower

(2) Screw (4 pcs)

(3) Screw (2 pcs)

9Y1210293STS0005US0

Steering Wheel and Panel

1. Remove the steering wheel cap.

2. Remove the steering wheel mounting nut (1) and remove the steering wheel (2).

3. Remove the shift lever grip (3) and four wheel drive lever grip

(6).

4. Disconnect the connector for main switch, horn switch and head light switch.

5. Remove the panel mounting screws (5) and the panel support.

6. Disconnect the all connectors from panel and remove the panel

(4).

(When reassembling)

Tightening torque

Steering wheel mounting nut

30 to 49 N·m

3.0 to 5.0 kgf·m

22 to 36 lbf·ft

(1) Steering Wheel Mounting Nut

(2) Steering Wheel

(3) Shift Lever Grip

(4) Panel

(5) Screw (2pcs)

(6) 4WD Lever Grip

9Y1210293STS0006US0

6-S6

KiSC issued 05, 2014 A

RTV1140CPX, WSM

STEERING

Steering Controller

1. Disconnect the power steering hoses (2), (3), (4), (5).

2. Remove the steering controller mounting screws and remove the steering controller (1).

(When reassembling)

• Be sure to connect the power steering hoses to their original position, and tighten them to the specified torque.

• If the oil leaks from power steering controller, replace it with a new one.

Tightening torque

Power steering hose retaining nut

Steering controller mounting screw

21.6 to 25.7 N·m

2.21 to 2.62 kgf·m

16.0 to 18.9 lbf·ft

23.5 to 27.4 N·m

2.40 to 2.79 kgf·m

17.4 to 20.2 lbf·ft

(1) Steering Controller

(2) Return Hose (Tank Port)

(3) Cylinder Hose RH (L Port)

(4) Delivery Hose (Pump Port)

(5) Cylinder Hose LH (R Port)

9Y1210293STS0008US0

(2) Separating Power Steering Cylinder

Power Steering Cylinder

1. Place the stand under the frame.

2. Remove the front wheels.

3. Remove the cotter pin and remove the slotted nut (2) for tie-rod end (1).

4. Disconnect the power steering cylinder hoses (3), (4).

5. Cut the cords clamp.

6. Remove the power steering cylinder bracket (5), (7) mounting screws and remove the power steering cylinder (6) with tie-rod.

(When reassembling)

• When inserting the cotter pin, if the slots in the nut do not align with the cotter pin hole in tie-rod end, tighten the nut clockwise up to next alignment.

• If should be within 30 degree.

• Loosen once and tighten again when the slit goes past the nearest hole.

• After tightening the these slotted nut to specified torques, install a cotter pin as shown in the figure left.

Tightening torque

Tie-rod slotted nut

Power steering cylinder hose retaining nut

Steering cylinder bracket mounting screw

50 N·m

5.1 kgf·m

37 lbf·ft

21.6 to 25.7N·m

2.21 to 2.62 kgf·m

16.0 to 18.9 lbf·ft

103 to 117 N·m

10.5 to 12.0 kgf·m

76.0 to 86.7 lbf·ft

(1) Tie-rod End RH

(2) Slotted Nut

(3) Power Steering Hose (RH)

(4) Power Steering Hose (LH)

(5) Steering Cylinder Bracket RH

(6) Power Steering Cylinder

(7) Steering Cylinder Bracket LH

9Y1210293STS0009US0

6-S7

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(3) Separating Hydraulic Pump

Draining Hydraulic Tank Oil

STEERING

CAUTION

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 may cause burns.

1. Park the vehicle on a firm, flat and level surface.

2. Tilt the seat.

3. Remove the under guard.

4. To drain the used oil, remove the drain plug and filling plug and drain the oil completely into the oil pan.

5. After draining, reinstall the drain plug.

6. Install the under guard.

(When refilling)

• Fill with new KUBOTA SUPER UDT fluid up to the upper notch

on the dipstick. (See page G-8.)

How to check:

Wipe dipstick clean with a rag and screw filling plug into filling hole. Remove filling plug again to see if the oil level is between the upper and lower notch.

• After filling, reinstall the filling plug.

Oil capacity

14.5 L

15.3 U.S.qts

12.8 Imp.qts

(1) Under Guard

(2) Drain Plug

(3) Filling Plug with Dipstick

A: Oil level is acceptable within this range.

9Y1210293STS0007US0

6-S8

KiSC issued 05, 2014 A

RTV1140CPX, WSM

STEERING

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. Set the seat to 1 row.

2. Remove the battery cover (1).

3. Remove the air cleaner hose (2).

4. Disconnect the negative cable (3) from the battery (4).

(1) Battery Cover

(2) Air Cleaner Hose

(3) Negative Cable

(4) Battery

(5) Positive Cable

9Y1210293ENS0025US0

Air Cleaner

1. Remove the air cleaner body (2) and intake hose (1) together.

(1) Intake Hose (2) Air Cleaner Body

9Y1210293ENS0028US0

6-S9

KiSC issued 05, 2014 A

RTV1140CPX, WSM

STEERING

Hydraulic Pump

1. Disconnect the main shift cable (2), select cable (3), accelerator wire (1) and foot throttle cable (4) from cable stay (5).

2. Remove the cable stay (5).

3. Disconnect the suction hose (7), power steering delivery hose

(8) and hydraulic control valve delivery hose (9).

4. Remove the hydraulic pump (6) from engine.

(When reassembling)

• Before disconnecting the cables, be sure to note their original position.

Tightening torque

Power steering delivery hose retaining nut

Hydraulic control valve delivery hose retaining nut

21.6 to 25.7 N·m

2.21 to 2.62 kgf·m

16.0 to 18.9 lbf·ft

21.6 to 25.7 N·m

2.21 to 2.62 kgf·m

16.0 to 18.9 lbf·ft

(1) Accelerator Wire

(2) Main Shift Cable

(3) Select Cable

(4) Foot Throttle Cable

(5) Cable Stay

(6) Hydraulic Pump

(7) Suction Hose

(8) Power Steering Delivery Hose

(9) Hydraulic Control Valve Delivery

Hose

9Y1210293STS0010US0

(4) Removing Power Steering Hose

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. Set the seat to 1 row.

2. Remove the battery cover (1).

3. Remove the air cleaner hose (2).

4. Disconnect the negative cable (3) from the battery (4).

(1) Battery Cover

(2) Air Cleaner Hose

(3) Negative Cable

(4) Battery

(5) Positive Cable

9Y1210293ENS0025US0

6-S10

KiSC issued 05, 2014 A

RTV1140CPX, WSM

STEERING

Bonnet Upper

1. Remove the snap pin and remove the bonnet upper (3).

2. Remove the ROPS pipes (1).

3. Lift ROPS boots and remove the three screws on both sides.

4. Remove the ROPS pipe (front) (2).

Tightening torque

ROPS pipe mounting bolt and nut

ROPS (front) mounting screw

48.0 to 55.8 N·m

4.90 to 5.69 kgf·m

35.4 to 41.1 lbf·ft

77.5 to 90.2 N·m

7.91 to 9.19 kgf·m

57.2 to 66.5 lbf·ft

(1) ROPS Pipe

(2) ROPS Pipe, Front

(3) Bonnet Upper

9Y1210293STS0004US0

Bonnet Lower

1. Remove the four screw (2).

2. Remove the screws (3) from underneath the bonnet lower.

3. Remove the bonnet lower (1).

(1) Bonnet Lower

(2) Screw (4 pcs)

(3) Screw (2 pcs)

9Y1210293STS0005US0

Steering Wheel and Panel

1. Remove the steering wheel cap.

2. Remove the steering wheel mounting nut (1) and remove the steering wheel (2).

3. Remove the shift lever grip (3) and four wheel drive lever grip

(6).

4. Disconnect the connector for main switch, horn switch and head light switch.

5. Remove the panel mounting screws (5) and the panel support.

6. Disconnect the all connectors from panel and remove the panel

(4).

(When reassembling)

Tightening torque

Steering wheel mounting nut

30 to 49 N·m

3.0 to 5.0 kgf·m

22 to 36 lbf·ft

(1) Steering Wheel Mounting Nut

(2) Steering Wheel

(3) Shift Lever Grip

(4) Panel

(5) Screw (2pcs)

(6) 4WD Lever Grip

9Y1210293STS0006US0

6-S11

KiSC issued 05, 2014 A

RTV1140CPX, WSM

STEERING

Seat and Center Cover

1. Remove the seat belts (1), (2).

2. Remove the seat (3).

3. Remove the side cover RH (4) and LH (5).

4. Remove the center cover (6).

5. Remove the step mat (7) and center step (8).

(When reassembling)

Tightening torque

Seat belt inside mounting nut

Seat belt outside mounting nut

48.0 to 55.9 N·m

4.90 to 5.70 kgf·m

35.4 to 41.2 lbf·ft

13.0 to 17.0 N·m

1.33 to 1.73 kgf·m

9.59 to 12.5 lbf·ft

(1) Seat Belt Outside

(2) Seat Belt Inside

(3) Seat

(4) Side Cover RH

(5) Side Cover LH

(6) Center Cover

(7) Step Mat

(8) Center Step

9Y1210293STS0012US0

6-S12

KiSC issued 05, 2014 A

RTV1140CPX, WSM

STEERING

Power Steering Hoses

1. Disconnect the steering hoses (2), (3), (4), (5) from steering controller (1).

2. Disconnect the cylinder hose RH (3) and LH (5) from power steering cylinder (6), and remove the cylinder hose RH (3) and

LH (5).

3. Remove the return hose (2).

4. Remove the delivery hose (4).

(When reassembling)

• Be sure to connect the power steering hoses to their original position, and tighten them to the specified torque.

• Fill new oil from filing port after removing the filling plug up to the upper notch on the dipstick.

• After running the engine for few minutes, stop it and check the oil level again, if low, add oil to prescribed level.

• Use KUBOTA UDT fluid or SUPER UDT fluid.

Refer to "LUBRICANTS, FUEL AND COOLANT". (See page

G-8.)

• Never work the vehicle immediately after changing the power steering oil. Keeping the engine at medium speed for a few minutes to prevents damage to the hydraulic pump etc..

• Do not mix different brands oil together.

Tightening torque

Power steering hose retaining nut

21.6 to 25.7 N·m

2.21 to 2.62 kgf·m

16.0 to 18.9 lbf·ft

(1) Steering Controller

(2) Return Hose

(3) Cylinder Hose RH

(4) Delivery Hose

(5) Cylinder Hose LH

(6) Power Steering Cylinder

9Y1210293STS0013US0

6-S13

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Tightening torque Tie-rod screw

STEERING

[3] DISASSEMBLING AND ASSEMBLING

(1) Power Steering Cylinder

Power Steering Cylinder and Tie-rod

1. Remove the cylinder hose adaptors (2), (3).

2. Remove the tie-rods (1), (4) from piston rod (5).

3. Remove the cylinder holders (6).

(When reassembling)

• Be sure to install the hose adaptors (2), (3) as shown figure left.

• After reassembling the tie-rod, be sure to adjust the toe-in.

(Refer to 5-S4.)

• Apply liquid lock to the thread of piston rod (5).

74 to 84 N·m

7.6 to 8.6 kgf·m

55 to 61 lbf·ft

(1) Tie-rod LH

(2) Hose Adaptor LH

(3) Hose Adaptor RH

(4) Tie-rod RH

(5) Piston Rod

(6) Cylinder Holder

(7) Cylinder

A: Front

9Y1210293STS0014US0

Steering Cylinder

1. Remove the cap bolt (3).

2. Remove the internal circlip (4).

3. Remove the washer (5).

4. Push the cylinder head (6) to the inside of the cylinder tube (2).

5. Remove the internal circlip (8).

6. Remove the cylinder head (6) from the cylinder tube (2).

7. Remove the piston rod (1).

(When reassembling)

NOTE

• Seals must be exchanged after disassembling.

• Apply transmission fluid to the exchanged seals.

• Enter the piston rod and block the guide assemblies with the snap rings.

• Apply bonding agent "Loctite No242" to the threaded portion of the cap bolt.

Tightening torque Cylinder tube cap bolt

9.80 to 12.7 N·m

1.00 to 1.29 kgf·m

7.23 to 9.36 lbf·ft

(1) Piston Rod

(2) Cylinder Tube

(3) Cap Bolt

(4) Internal Circlip

(5) Washer

(6) Cylinder Head

(7) O-ring

(8) Internal Circlip

(9) Dust Seal

(10) Bushing

(11) Seal Ring

9Y1210293STS0017US0

6-S14

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(2) Hydraulic Pump

STEERING

Oil Seal

1. Remove the internal snap ring (2), and remove the oil seal (1).

(When reassembling)

• If the oil seal is defective, worn or scratched, replace it.

(1) Oil Seal (2) Internal Snap Ring

9Y1210293STS0016US0

6-S15

KiSC issued 05, 2014 A

7

HYDRAULIC SYSTEM

KiSC issued 05, 2014 A

MECHANISM

CONTENTS

1. STRUCTURE.............................................................................................................................. 7-M1

2. HYDRAULIC CIRCUIT ............................................................................................................... 7-M2

[1] HYDRAULIC CARGO BED LIFT.......................................................................................... 7-M2

3. HYDRAULIC PUMP.................................................................................................................... 7-M3

4. HYDRAULIC CONTROL VALVE................................................................................................ 7-M4

[1] RELIEF VALVE .................................................................................................................... 7-M4

[2] FLOATING WITH DETENT VALVE ..................................................................................... 7-M5

5. HYDRAULIC CYLINDER............................................................................................................ 7-M7

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. STRUCTURE

HYDRAULIC SYSTEM

(1) Hydraulic Oil Tank

(2) Delivery Hose

(3) Hydraulic Pump

(4) Return Hose

(5) Hydraulic Lift Cylinder Lever

(6) Oil Filter Cartridge

(7) Hydraulic Control Valve

(8) Hydraulic Cylinder

(9) Quick Coupler

(10) Hydraulic Cylinder Hose

(11) Suction Hose

(12) Suction Pipe

The cargo bed lifting system of RTV1140CPX is composed of the hydraulic pump, control valve, hydraulic cylinder, oil tank and other components as shown in the figure.

9Y1210293HYM0001US0

7-M1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

2. HYDRAULIC CIRCUIT

[1] HYDRAULIC CARGO BED LIFT

HYDRAULIC SYSTEM

(1) Hydraulic Control Valve

(2) Hydraulic Pump

(3) Oil Tank

(4) Engine

(5) Oil Filter Cartridge

(6) Hydraulic Cylinder

(7) Power Steering Controller

A: A Port

B: B Port

P: Pump Port

T: Tank Port

The cargo bed lifting system of RTV1140CPX is composed of the hydraulic pump, control valve, hydraulic cylinder, oil tank and other components as shown in the figure.

This system has the following functions.

1. Oil is supplied by hydraulic pump which is driven by the governor shaft in the engine. Therefore, hydraulic pump starts running when engine is started.

2. The hydraulic pump forces out the oil to hydraulic control valve for cargo bed lift system.

9Y1210293HYM0002US0

7-M2

KiSC issued 05, 2014 A

RTV1140CPX, WSM

3. HYDRAULIC PUMP

HYDRAULIC SYSTEM

The hydraulic pump has the front pump and the rear pump. The front pump supplies the oil to the cargo bed lift system. The rear pump supplies the oil to the power steering system.

The hydraulic pump is composed of the casings (2)

(3), cover (1) and four spur gears (drive gears (4), (7) and driven gears (5), (6)).

Hydraulic pump is driven by the governor shaft in the engine.

Maximum displacement is as follows.

Factory specification

Front Pump

Rear Pump

Displacement

20.5 L/min

5.42 U.S.gals/min

4.51 Imp.gals/min

12.1 L/min

3.20 U.S.gals/min

2.66 Imp.gals/min

(1) Cover

(2) Casing (for Rear Pump)

(3) Casing (for Front Pump)

(4) Drive Gear (for Front Pump)

(5) Driven Gear (for Front Pump)

(6) Driven Gear (for Rear Pump)

(7) Drive Gear (for Rear Pump)

9Y1210293HYM0003US0

7-M3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

HYDRAULIC SYSTEM

4. HYDRAULIC CONTROL VALVE

[1] RELIEF VALVE

The hydraulic raising and lowering circuit is fitted with a relief valve to control the maximum pressure.

This is a guide piston relief valve with damper, a direct acting relief valve suitable for relatively high pressure and capacity, and constructed so as to prevent chattering and other unstableness associated with direct acting relief valves. As shown in the diagram, poppet (5) has a guide, and there is a valve chamber called a damping chamber (6) in the base of this guide piston.

The valve inlet is connected to this chamber through the clearance between the guide surface and the seat so that the chamber provides a damping effect, controlling valve vibration.

When the pressure in the circuit rises, the pressure in the damping chamber also rises, and when it exceeds the relief pressure setting the spring is compressed, making a clearance between the poppet and the seat.

The hydraulic oil can escape to the transmission case through this clearance, controlling the pressure rise.

• Relief valve setting pressure

14.5 to 15.5 MPa

148 to 158 kgf/cm

2

2110 to 2240 psi

Condition

• Engine speed

3000 min

− 1

(rpm)

• Oil temperature

45 to 55 °C (113 to 131 °F)

(1) Relief Valve

(2) Shim

(3) Plug

(4) Seat

(5) Poppet

(6) Damping Chamber

(a) Normal State

(b) Active State

T: T Port

(To Transmission Case)

P: P Port (From Pump)

9Y1210293HYM0009US0

7-M4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[2] FLOATING WITH DETENT VALVE

Neutral

HYDRAULIC SYSTEM

(1) Spool

(2) Check Valve

(3) Detent Ball

(4) Detent Sleeve

A: A Port (Lift Cylinder)

B: B Port (Lift Cylinder)

P: From Hydraulic Pump

T: To Oil Tank

Lift

Pressure-fed oil from the hydraulic pump is delivered into the

P

port, and flows to the oil tank through

T

port.

9Y1210293HYM0005US0

(1) Check Valve

(2) Spool

A: A Port (Lift Cylinder)

B: B Port (Lift Cylinder)

P: Pump Port

T: Tank Port

When the hydraulic control lever is set to

"LIFT"

position, the spool (2) is moved in the direction of the arrow, the pressure-fed oil in the

P

port opens the check valve (1) and flows to the implement cylinder via

B

port.

Return oil from the implement cylinder flows from the

A

port to the transmission case through

T

port.

9Y1210293HYM0006US0

7-M5

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Down

HYDRAULIC SYSTEM

(1) Check Valve

(2) Spool

A: A Port (Lift Cylinder)

B: B Port (Lift Cylinder)

P: Pump Port

T: Tank Port

When the hydraulic control lever is set to

"DOWN"

position, the spool (2) is moved in the direction of the arrow, the pressure-fed oil in the

P

port opens the check valve (1) and flows to the implement cylinder via

A

port.

Return oil from the implement cylinder flows from the

B

port to the oil tank through

T

port.

9Y1210293HYM0007US0

Floating

(1) Spool

(2) Check Valve

(3) Detent Ball

(4) Detent Sleeve

A: A Port (Lift Cylinder)

B: B Port (Lift Cylinder)

P: Pump Port

T: Tank Port

When the hydraulic control lever is set to

"FLOATING"

position, the spool (2) moves to extreme right, the detent ball (3) and detent sleeve (4) holds the spool (1) at the floating position as shown in the figure. The pressure-fed oil from the hydraulic pump flows to oil tank through

T

port. And, the

A

port and

B

port lead to the

T

port along the notched sections of the spool (2). This result in the attached implement to follow the power from implement.

9Y1210293HYM0008US0

7-M6

KiSC issued 05, 2014 A

RTV1140CPX, WSM

5. HYDRAULIC CYLINDER

HYDRAULIC SYSTEM

The external type hydraulic cylinders are used for three point linkage system. This hydraulic cylinder is single double type, and it is installed directly between main frame arm cargo bed.

The main components of the hydraulic cylinder are shown in the figure.

(1) Piston Nut

(2) Piston Seal

(3) Piston O-ring

(4) Piston

(5) Cylinder Tube

(6) Rod

(7) End Cap

(8) End Seal

(9) End O-ring

(10) Backup Ring

(11) Internal Snap Ring

(12) Wiper Seal

9Y1210293HYM0004US0

7-M7

KiSC issued 05, 2014 A

SERVICING

CONTENTS

1. TROUBLESHOOTING.................................................................................................................7-S1

2. SERVICING SPECIFICATIONS ..................................................................................................7-S2

[1] RELIEF VALVE .....................................................................................................................7-S2

[2] HYDRAULIC PUMP ..............................................................................................................7-S2

3. TIGHTENING TORQUES............................................................................................................7-S3

4. CHECKING, DISASSEMBLING AND SERVICING .....................................................................7-S4

[1] CHECKING AND ADJUSTING..............................................................................................7-S4

(1) Hydraulic Control Valve, Pump and Cylinder ..................................................................7-S4

[2] PREPARATION.....................................................................................................................7-S5

(1) Separating Hydraulic Pump.............................................................................................7-S5

(2) Separating Hydraulic Cylinder .........................................................................................7-S7

(3) Hydraulic Control Valve ...................................................................................................7-S8

[3] DISASSEMBLING AND ASSEMBLING ................................................................................7-S9

(1) Hydraulic Pump ...............................................................................................................7-S9

(2) Disassembling Hydraulic Cylinder .................................................................................7-S10

(3) Disassembling Control Valve Assembly ........................................................................7-S11

[4] SERVICING.........................................................................................................................7-S12

(1) Hydraulic Pump .............................................................................................................7-S12

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. TROUBLESHOOTING

Symptom

Implement Does Not

Rise (No Noise)

(Noise)

Probable Cause

Control valve broken

Control valve improperly assembled

Relief valve spring damaged

Spool sticks

Piston O-ring or cylinder damaged

Suction hose loosen or broken

Insufficient hydraulic lift oil

Relief valve setting pressure too low

Hydraulic pump broken

Control valve malfunctioning

Implement Does Not

Lower

Implement Drops by

Its Weight

Hydraulic lift cylinder worn or damaged

Piston O-ring worn or damaged

Control valve malfunctioning

HYDRAULIC SYSTEM

Solution

Replace

Repair

Replace

Repair

Replace

Repair or replace

Refill

Adjust or replace

Replace

Repair or replace

Replace

Replace

Replace

Reference

Page

7-S8

7-S11

7-S11

7-S11

7-S10

7-S7

7-S5

7-S4

7-S5

7-S11

7-S8

7-S10

7-S8

9Y1210293HYS0001US0

7-S1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

2. SERVICING SPECIFICATIONS

[1] RELIEF VALVE

Relief Valve

• Engine Speed

3000 min

− 1

(rpm)

• Oil Temperature

45 to 55 °C (113 to 131 °F)

Item

Setting Pressure

Factory Specification

14.5 to 15.5 MPa

148 to 158 kgf/cm

2

2110 to 2240 psi

HYDRAULIC SYSTEM

Allowable Limit

–

9Y1210293HYS0002US0

[2] HYDRAULIC PUMP

Item

Tip of Gear Tooth and Casing

Bush and Shaft

Bush

Side Plate

Clearance

Clearance

I.D.

Thickness

Factory Specification

–

0.020 to 0.091 mm

0.00079 to 0.0035 in.

15.000 to 15.061 mm

0.59056 to 0.59295 in.

2.48 to 2.50 mm

0.977 to 0.0984 in.

Allowable Limit

0.15 mm

0.0059 in.

0.12 mm

0.0047 in.

–

2.40 mm

0.0945 in.

9Y1210293HYS0010US0

7-S2

KiSC issued 05, 2014 A

RTV1140CPX, 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: See page G-10.)

HYDRAULIC SYSTEM

Item

Power steering delivery hose retaining nut

Hydraulic control valve delivery hose retaining nut

Hydraulic cylinder hose retaining nut

Hydraulic cylinder tube retaining nut

Delivery hose retaining nut

Adaptor (for hydraulic cylinder tube)

Adaptor (for delivery hose)

Cylinder head

Cargo lift hydraulic cylinder piston mounting nut

Relief valve plug

Load check valve plug

Check valve seat

Check valve plug

N·m

21.6 to 25.7

21.6 to 25.7

22 to 25

22 to 25

35 to 41

47 to 54

47 to 54

200 to 230

150 to 180

30 to 34

20 to 24

35 to 40

25 to 29

kgf·m

2.21 to 2.62

2.21 to 2.62

2.3 to 2.5

2.3 to 2.5

3.6 to 4.1

4.8 to 5.5

4.8 to 5.5

20.4 to 23.4

15.3 to 18.3

3.0 to 3.5

2.0 to 2.5

3.5 to 4.0

2.5 to 3.0

lbf·ft

16.0 to 18.9

16.0 to 18.9

17 to 18

17 to 18

26 to 30

35 to 39

35 to 39

148 to 169

111 to 132

22 to 25

15 to 18

26 to 28

18 to 21

9Y1210293HYS0003US0

7-S3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

HYDRAULIC SYSTEM

4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING

(1) Hydraulic Control Valve, Pump and Cylinder

Relief Valve Setting Pressure

1. Disconnect the quick coupler 2 (2).

2. Set the adaptor, cable and pressure gauge.

3. Place the range gear shift lever in neutral.

4. Start the engine and depress the speed control pedal.

5. Move the hydraulic lift cylinder lever position up to operate the relief valve and read the gauge.

6. If the pressure is not within the factory specifications, adjust with the adjusting shims (4).

Relief valve setting pressure

Factory specification

14.5 to 15.5 MPa

148 to 158 kgf/cm

2

2110 to 2240 psi

Condition

• Engine speed

3000 min

− 1

(rpm)

• Oil temperature

45 to 55 °C (113 to 131 °F)

(Reference)

• Replace the hydraulic pump if pressure does not rise in

13.2 MPa (135 kgf/cm

2

, 1920 psi) or more.

• Thickness of shims (3)

0.10 mm (0.0039 in.)

0.20 mm (0.0079 in.)

0.40 mm (0.016 in.)

• 269 MPa (2.74 kgf/cm

2

, 39.0 psi) pressure is increased whenever the thickness of adjusting shim is increased by

0.10 mm (0.0039 in.).

(1) Quick Coupler 1 (for Down)

(2) Quick Coupler 2 (for Lift)

(3) Hydraulic Control Valve Assembly

(4) Shim

(5) Plug

9Y1210293HYS0005US0

7-S4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[2] PREPARATION

(1) Separating Hydraulic Pump

Draining Hydraulic Tank Oil

HYDRAULIC SYSTEM

CAUTION

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 may cause burns.

1. Park the vehicle on a firm, flat and level surface.

2. Tilt the seat.

3. Remove the under guard.

4. To drain the used oil, remove the drain plug and filling plug and drain the oil completely into the oil pan.

5. After draining, reinstall the drain plug.

6. Install the under guard.

(When refilling)

• Fill with new KUBOTA SUPER UDT fluid up to the upper notch

on the dipstick. (See page G-8.)

How to check:

Wipe dipstick clean with a rag and screw filling plug into filling hole. Remove filling plug again to see if the oil level is between the upper and lower notch.

• After filling, reinstall the filling plug.

Oil capacity

14.5 L

15.3 U.S.qts

12.8 Imp.qts

(1) Under Guard

(2) Drain Plug

(3) Filling Plug with Dipstick

A: Oil level is acceptable within this range.

9Y1210293STS0007US0

7-S5

KiSC issued 05, 2014 A

RTV1140CPX, WSM

HYDRAULIC SYSTEM

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. Set the seat to 1 row.

2. Remove the battery cover (1).

3. Remove the air cleaner hose (2).

4. Disconnect the negative cable (3) from the battery (4).

(1) Battery Cover

(2) Air Cleaner Hose

(3) Negative Cable

(4) Battery

(5) Positive Cable

9Y1210293ENS0025US0

Air Cleaner

1. Remove the air cleaner body (2) and intake hose (1) together.

(1) Intake Hose (2) Air Cleaner Body

9Y1210293ENS0028US0

7-S6

KiSC issued 05, 2014 A

RTV1140CPX, WSM

HYDRAULIC SYSTEM

Hydraulic Pump

1. Disconnect the main shift cable (2), select cable (3), accelerator wire (1) and foot throttle cable (4) from cable stay (5).

2. Remove the cable stay (5).

3. Disconnect the suction hose (7), power steering delivery hose

(8) and hydraulic control valve delivery hose (9).

4. Remove the hydraulic pump (6) from engine.

(When reassembling)

• Before disconnecting the cables, be sure to note their original position.

Tightening torque

Power steering delivery hose retaining nut

Hydraulic control valve delivery hose retaining nut

21.6 to 25.7 N·m

2.21 to 2.62 kgf·m

16.0 to 18.9 lbf·ft

21.6 to 25.7 N·m

2.21 to 2.62 kgf·m

16.0 to 18.9 lbf·ft

(1) Accelerator Wire

(2) Main Shift Cable

(3) Select Cable

(4) Foot Throttle Cable

(5) Cable Stay

(6) Hydraulic Pump

(7) Suction Hose

(8) Power Steering Delivery Hose

(9) Hydraulic Control Valve Delivery

Hose

9Y1210293STS0010US0

(2) Separating Hydraulic Cylinder

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. Set the seat to 1 row.

2. Remove the battery cover (1).

3. Remove the air cleaner hose (2).

4. Disconnect the negative cable (3) from the battery (4).

(1) Battery Cover

(2) Air Cleaner Hose

(3) Negative Cable

(4) Battery

(5) Positive Cable

9Y1210293ENS0025US0

7-S7

KiSC issued 05, 2014 A

RTV1140CPX, WSM

HYDRAULIC SYSTEM

Cargo Bed

1. Lift up the cargo bed (1) by hand and support it with the safety support so that the hydraulic cylinder should not drop.

2. Remove the cotter pin and clevis pin (2).

3. Disconnect the connector (3) from main harness, then separate the harness for the tail lamps.

4. Loosen the lock nut (4) and remove the hinge bolt (5) and nut.

(1) Cargo Bed

(2) Clevis Pin

(3) Connector

(4) Lock Nut

(5) Hinge Bolt

9Y1210293ENS0001US0

Hydraulic Cylinder

1. Disconnect the hydraulic hoses (2).

2. Remove the hydraulic cylinder (1).

Tightening torque

(1) Hydraulic Cylinder

Hydraulic cylinder hose retaining nut

22 to 25 N·m

2.3 to 2.5 kgf·m

17 to 18 lbf·ft

(2) Hydraulic Hose

9Y1210293HYS0004US0

(3) Hydraulic Control Valve

Side Cover

1. Remove the side cover (1).

(1) Side Cover

9Y1210293HYS0008US0

7-S8

KiSC issued 05, 2014 A

RTV1140CPX, WSM

HYDRAULIC SYSTEM

Hydraulic Control Valve Assembly

1. Remove the valve arm (1).

2. Disconnect the hydraulic cylinder tubes (4) (5) from hydraulic control valve (3).

3. Disconnect the delivery hose (6) and return hose (2) from hydraulic control valve (3).

4. Remove the hydraulic control valve assembly (3).

5. Remove the three adaptors (7) (8) and joint pipe (9).

(When reassembling)

Tightening torque

Hydraulic cylinder tube retaining nut

Delivery hose retaining nut

Adaptor (for hydraulic cylinder tube)

Adaptor (for delivery hose)

22 to 25 N·m

2.3 to 2.5 kgf·m

17 to 18 lbf·ft

35 to 41 N·m

3.6 to 4.1 kgf·m

26 to 30 lbf·ft

47 to 54 N·m

4.8 to 5.5 kgf·m

35 to 39 lbf·ft

47 to 54 N·m

4.8 to 5.5 kgf·m

35 to 39 lbf·ft

(1) Valve Arm

(2) Return Hose

(3) Hydraulic Control Valve Assembly

(4) Hydraulic Cylinder Tube 1

(For Down)

(5) Hydraulic Cylinder Tube 2

(For Lift)

(6) Delivery Hose

(7) Adaptor

(for Hydraulic Cylinder Tube)

(8) Adaptor (for Delivery Hose)

(9) Joint Pipe

9Y1210293HYS0009US0

[3] DISASSEMBLING AND ASSEMBLING

(1) Hydraulic Pump

Oil Seal

1. Remove the internal snap ring (2), and remove the oil seal (1).

(When reassembling)

• If the oil seal is defective, worn or scratched, replace it.

(1) Oil Seal (2) Internal Snap Ring

9Y1210293STS0016US0

7-S9

KiSC issued 05, 2014 A

RTV1140CPX, WSM

HYDRAULIC SYSTEM

(2) Disassembling Hydraulic Cylinder

Cylinder Rod Assembly

1. Drain hydraulic oil from the cylinder, and secure the tube end of the cylinder in a vise.

2. Unscrew the cylinder head (1) with the adjustable gland nut wrench (4).

3. Pull out the piston rod assembly (2) from the cylinder tube (3).

(When reassembling)

• Visually inspect the cylinder tube for signs of scoring or damage.

• Insert the piston rod assembly to the cylinder tube, using care not to damage the piston seal on the piston.

• Install the cylinder head to the cylinder tube, using care not to damage the O-ring on the cylinder head.

Tightening torque Cylinder head

200 to 230 N·m

20.4 to 23.4 kgf·m

148 to 169 lbf·ft

(1) Cylinder Head

(2) Piston Rod Assembly

(3) Cylinder Tube

(4) Adjustable Gland Nut Wrench

9Y1210293HYS0006US0

Cylinder Head, Piston and Nut

1. Secure the rod end in a vise.

2. Unscrew the nut (4), and remove the piston (3) and cylinder head (2) from the piston rod (1).

(When reassembling)

• Visually inspect all parts for signs of scoring or damage.

• Insert the piston rod to the cylinder head, using care not to damage the wiper seal (5) and oil seal (6).

Tightening torque Piston mounting nut

150 to 180 N·m

15.3 to 18.3 kgf·m

111 to 132 lbf·ft

(1) Piston Rod

(2) Cylinder Head

(3) Piston

(4) Nut

(5) Wiper Seal

(6) Oil Seal

(7) O-ring

9Y1210293HYS0011US0

7-S10

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(3) Disassembling Control Valve Assembly

Hydraulic Control Valve Assembly

HYDRAULIC SYSTEM

(1) O-ring

(2) Back Up Ring

(3) Collar

(4) Spring Holder

(5) Spring

(6) Spring Holder

(7) Detent Bolt

(8) Plug

(9) Detent Plug

(10) Spring

(11) Ball

(12) Detent Stopper

(13) O-ring

(14) Internal Snap Ring

(15) Dust Seal

(16) Spool

(17) Hex. Head Socket Screw

(18) Bracket

(19) Body

(20) Poppet

(21) Spring

(22) O-ring

(23) Plug

(24) Back Up Ring

(25) O-ring

(26) O-ring

(27) Check Valve Seat

(28) Ball

(29) Spring

(30) O-ring

(31) Plug

(32) Plug

(33) Seat

(34) Poppet

(35) Spring

(36) Shim

(37) O-ring

(38) Plug

1. Loosen the plug (8) and draw out the spool (16) with other component parts from valve body (19).

2. Remove the internal snap ring (14) and detent stopper (12).

3. Loosen the detent bolt (7) from spool (16) and then separate the spool and the detent bolt.

4. Remove the plug (23) and take out the spring (21) and poppet (20).

5. Remove the check valve seat (27) assembly.

6. Remove the plug (38) and take out the shim (36), spring (35) poppet (34) and seat (33).

(When reassembling)

• Clean all parts with a suitable solvent, and dry with a lint-free cloth or air.

• Visually inspect all parts for signs of scoring of damage.

• Install the spool and spacer to the valve housing, using care not to damage the O-ring.

Tightening torque

Relief valve plug

Load check valve plug

Check valve seat

Check valve plug

30 to 34 N·m

3.0 to 3.5 kgf·m

22 to 25 lbf·ft

20 to 24 N·m

2.0 to 2.5 kgf·m

15 to 18 lbf·ft

35 to 40 N·m

3.5 to 4.0 kgf·m

26 to 28 lbf·ft

25 to 29 N·m

2.5 to 3.0 kgf·m

18 to 21 lbf·ft

9Y1210293HYS0007US0

7-S11

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[4] SERVICING

(1) Hydraulic Pump

HYDRAULIC SYSTEM

Clearance between Tip of Gear Tooth and Casing

1. Measure the clearance between gear and casing at several points with feeler gauge.

2. If the clearance exceeds the allowable limit, replace the assembly.

Clearance between tip of gear tooth and casing

Allowable limit

0.15 mm

0.0059 in.

9Y1210293HYS0012US0

Clearance between Bushing and Gear Shaft

1. Measure the gear shaft O.D. with an outside micrometer.

2. Measure the bushing I.D. with a cylinder gauge.

3. If the clearance exceeds the allowable limit, replace it.

Clearance between bushing and shaft

Factory specification

Allowable limit

0.020 to 0.091 mm

0.00079 to 0.0035 in.

0.12 mm

0.0047 in.

Bushing I.D.

Factory specification

15.000 to 15.061 mm

0.59056 to 0.59295 in.

9Y1210293HYS0013US0

Side Plate Thickness

1. Measure the side plate thickness with an outside micrometer.

2. If the thickness is less than the allowable limit, replace it.

Side plate thickness

Factory specification

Allowable limit

2.48 to 2.50 mm

0.0977 to 0.0984 in.

2.40 mm

0.0945 in.

9Y1210293HYS0014US0

7-S12

KiSC issued 05, 2014 A

8

ELECTRICAL SYSTEM

KiSC issued 05, 2014 A

MECHANISM

CONTENTS

1. WIRING DIAGRAM..................................................................................................................... 8-M1

2. STARTING SYSTEM.................................................................................................................. 8-M2

[1] STARTER............................................................................................................................. 8-M3

[2] GLOW PLUG........................................................................................................................ 8-M4

[3] SAFETY SWITCH ................................................................................................................ 8-M4

(1) Main Shift Arm ................................................................................................................ 8-M4

[4] ENGINE STOP SOLENOID ................................................................................................. 8-M5

3. CHARGING SYSTEM................................................................................................................. 8-M6

[1] ALTERNATOR ..................................................................................................................... 8-M7

[2] IC REGULATOR................................................................................................................... 8-M7

4. LIGHTING SYSTEM ................................................................................................................... 8-M8

5. COOLING SYSTEM ................................................................................................................... 8-M9

[1] FAN MOTOR ...................................................................................................................... 8-M10

[2] COOLANT TEMPERATURE SWITCH............................................................................... 8-M10

6. GAUGES .................................................................................................................................. 8-M11

[1] FUEL QUANTITY ............................................................................................................... 8-M12

[2] COOLANT TEMPERATURE .............................................................................................. 8-M12

[3] TRAVELING SPEED SENSOR.......................................................................................... 8-M13

[4] EASY CHECKER™............................................................................................................ 8-M13

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. WIRING DIAGRAM

8-M1

ELECTRICAL SYSTEM

KiSC issued 05, 2014 A

RTV1140CPX, WSM

2. STARTING SYSTEM

ELECTRICAL SYSTEM

(1) Battery

(2) Main Switch

(3) Slow Blow Fuse (60 A)

(4) Slow Blow Fuse (50 A)

(5) Fuse (20 A)

(6) Fuse (5 A)

(7) Fuse (5 A)

(8) Neutral Safety Switch

(9) Starter Relay

(10) Solenoid Relay

(11) Engine Stop Solenoid

(12) Glow Plug

(13) Starter

(14) Ground

A: To Combination Meter

(Glow Lamp)

When the main switch is turned to the

PREHEAT

position, the terminal

BAT

is connected to the terminals

GLOW

and

ON

. The glow plugs become red-hot, and the preheat indicator lamp also lights on while preheating.

When the main switch is then turned to the

START

position with the safety switches on, the terminal

BAT

is connected to the terminals

ST

and

ON

. Consequently, battery current flows to the starter motor and start the engine.

The main switch automatically returns to the

ON

position, the terminal

BAT

is connected only to the terminal

ON

, thereby causing the starting circuit to be opened, stopping the starter motor.

When the main switch turned from the

ON

position to the

OFF

position, the fuel cut-off solenoid moves the fuel injection pump control rack to the

"No Fuel Injection"

position and stop the engine.

9Y1210293ELM0001US0

8-M2

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[1] STARTER

ELECTRICAL SYSTEM

(1) Armature

(2) Yoke

(3) Brush Holder

(4) End Frame

(5) Gear

(6) Drive End Frame

(7) Pinion

(8) Roller Clutch

(9) Ball

(10) Spring

(11) Magnet Switch one.

The starter motor is a reduction type. The speed of the pinion gear is reduced to approximately one third of motor

9Y1210293ELM0002US0

8-M3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[2] GLOW PLUG

[3] SAFETY SWITCH

(1) Main Shift Arm

ELECTRICAL SYSTEM

This plug is a two-material type QGS (Quick Glow

System) for quick temperature rise, and has self-controlling function as well as excellent durability.

The heater (4) connected in series to the heater (3), which also functions as the resistor, is incorporated in the sheath tube (1) of the super glow plug.

The resistance of this heater (3) cum resistor is small when the temperature is low, while the resistance becomes large when the temperature rises.

Therefore, because sufficient current is flown to the heater (4) during the initial period of energization, the temperature rises quickly and the resistance grows with the rise in the temperature of the resistor, the flowing current is reduces to prevent the heater (4) from being heated.

The ignition point is in the area of 2 to 3 mm (0.079

to 0.118 in.) from the tip of the plug in order to reduce its projection into the combustion chamber.

(1) Sheath Tube

(2) Insulation Powdor

(3) Heater also functioning as a

Resistor

(4) Heater

(5) Super Glow Plug

(6) Conventional Quick-heating type Glow Plug

(7) Glow Plug Current

(a) Glow Plug Temperature

(°C)

(b) Current (A)

(c) Time (Sec.)

9Y1210293ELM0003US0

The safety switch prevents current from flowing to the starter when the safety switches are released. This is to ensure safe starting.

The location of the safety switch is in the main shift arm (on the top of transmission case).

(1) Safety Switch

A: When Shifted

B: When Neutral

C: From Main Switch

D: To Starter

9Y1210293ELM0004US0

8-M4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[4] ENGINE STOP SOLENOID

ELECTRICAL SYSTEM

Flowing of the battery current into the stop solenoid

(1), the plunger (2) move to left side so that the movement of control rack becomes free, when the battery current stops, the plunger (2) is returned to the original position by the spring to keep the control rack (3) in

"No fuel injection"

position.

(1) Stop Solenoid

(2) Plunger

(3) Control Rack

9Y1210293ELM0005US0

8-M5

KiSC issued 05, 2014 A

RTV1140CPX, WSM

3. CHARGING SYSTEM

ELECTRICAL SYSTEM

(1) Battery

(2) Main Switch

(3) Slow Blow Fuse (50 A)

(4) Slow Blow Fuse (60 A)

(5) Fuse (10 A)

(6) Alternator

A: To Combination Meter

(Charge Lamp)

The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs.

This alternator has IC regulator.

9Y1210293ELM0006US0

8-M6

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[1] ALTERNATOR

[2] IC REGULATOR

ELECTRICAL SYSTEM

A compact alternator with an IC regulator is used, having the following characteristics:

• Cooling performance and safety have been improved by combining the cooling fan with the rotor and incorporating the fan / rotor unit inside the alternator.

• IC regulator is fitted inside the alternator.

• The rectifier, IC regulator and similar components are easy to remove, making it easier to service the alternator.

(1) Stator

(2) Rotor

(3) Rectifier

(4) IC Regulator

(5) Brush Holder

9Y1210293ELM0007US0

(1) Alternator

(2) Rectifier

(3) Stator Coil

(4) Rotor Coil

(5) IC Regulator

(6) Charge Lamp

(7) Main 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. Stable characteristics are achieved by cutting off the field current.

IC regulators have the following characteristics.

• The control voltage does not change over time, so the need for readjustment is eliminated. Since there are no moving parts, IC regulators are extremely durable and resistant to vibration.

• The overheat compensation characteristics ensure that the control voltage is reduced as the temperature rises, so the battery is charged at just the right level.

The internal circuitry of the IC regulator is shown in the diagram. It consists of a hybrid IC incorporating a monolithic IC. (The internal circuitry of the monolithic IC is extremely complex, so it is shown as simply

"M.IC circuit"

.)

Tr1

acts as the contacts controlling the field current, and

Tr2

acts as the charge lamp relay controlling the flashing of the charge lamp.

The

M.IC

circuit controls

Tr1

and

Tr2

, and monitors the alternator output voltage, and detects any drop in

L

terminal voltage or breaks in the rotor coil.

9Y1210293ELM0008US0

8-M7

KiSC issued 05, 2014 A

RTV1140CPX, WSM

4. LIGHTING SYSTEM

ELECTRICAL SYSTEM

(1) Battery

(2) Main Switch

(3) Slow Blow Fuse (60 A)

(4) Slow Blow Fuse (50 A)

(5) Fuse (15 A)

(6) Fuse (15 A)

(7) Combination Switch

(8) Head Light Switch

(9) Blinker Switch

(10) Horn Switch

(11) Flasher Unit (Option)

(12) Brake Lamp Switch

(13) Head Light RH

The lighting system consists of main switch, light switch, head lights, tail lights, etc.

(14) Head Light LH

(15) Tail Light RH

(16) Tail Light LH

(17) Ground

9Y1210293ELM0009US0

8-M8

KiSC issued 05, 2014 A

RTV1140CPX, WSM

5. COOLING SYSTEM

ELECTRICAL SYSTEM

(1) Battery

(2) Main Switch

(3) Slow Blow Fuse (60 A)

(4) Slow Blow Fuse (50 A)

(5) Fuse (30 A)

(6) Fuse (10 A)

(7) Radiator Fan Relay

(8) Coolant Temperature Switch

The cooling system consists of coolant temperature switch, relay, fan motor, etc..

(9) Radiator Fan Motor

(10) Ground

9Y1210293ELM0010US0

8-M9

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[1] FAN MOTOR

ELECTRICAL SYSTEM

The cooling fan of this vehicle is not driven by the engine drive but an electric motor.

An electric fan can be installed by separating from the engine.

And, it can be operated when it is necessary.

9Y1210293ELM0011US0

[2] COOLANT TEMPERATURE SWITCH

The coolant temperature switch is installed to the water flange of engine, and its tip is in touch with the coolant.

The fan motor rotates when the coolant temperature goes up more than the specified value.

When the coolant temperature falls below the specified value, the fan motor stops.

Characteristics of Coolant Temperature Switch

Type

Normally open

Operation Temperature

Fan motor rotate Fan motor stop

87 to 93 °C

(189 to 199 °F)

83 °C

(181 °F)

9Y1210293ELM0012US0

8-M10

KiSC issued 05, 2014 A

RTV1140CPX, WSM

6. GAUGES

ELECTRICAL SYSTEM

(1) Battery

(2) Main Switch

(3) Slow Blow Fuse (60 A)

(4) Slow Blow Fuse (50 A)

(5) Fuse (10 A)

(6) Fuse (5 A)

(7) Fuse (15 A)

(8) Fuse (5 A)

(9) Combination Meter

(10) Speed Meter

(11) Coolant Temperature Gauge

(12) Fuel Gauge

(13) Hour Meter

(14) Parking Brake Lamp

(15) Charge Lamp

(16) Oil Pressure Lamp

(17) Glow Lamp

(18) Rotation Sensor

(Traveling Speed Sensor)

(19) Thermo Unit

(20) Fuel Lever Sensor

(21) Brake Fluid Switch

(22) Parking Brake Switch

(23) Oil Pressure Switch

(24) Ground

A: To Alternator (L Terminal)

The combination meter (9) has a speed meter (10), coolant temperature gauge (11), fuel gauge (12), easy checker, etc..

The fuel quantity and coolant temperature are indicated by the ammeters. The ammeters indicate each amperage flowing through the fuel level sensor for the fuel quantity detection and through the coolant temperature sensor for the coolant temperature detection.

9Y1210293ELM0013US0

8-M11

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[1] FUEL QUANTITY

ELECTRICAL SYSTEM

Fuel Level Sensor

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.

As the float lowers, the resistance of the variable resistor varies. The relation between the amount of fuel and the resistance is as follows.

F

1 to 5 Ω

1/2

32.5 Ω

E

103 to 117 Ω

9Y1210293ELM0014US0

[2] COOLANT TEMPERATURE

Coolant Temperature Sensor (Thermo Unit)

The coolant temperature sensor is installed to the cylinder head of engine, and its tip is in touch with the coolant. It contains a thermistor (4) whose electrical resistance decreases as the temperature increases.

Current varies with changes in the coolant temperature, and the increases or decreases in the current move the pointer of gauge.

Temperature

Characteristics of Thermistor

Resistance of VR:



50 °C (122 °F) 153.9 Ω

80 °C (176 °F)

100 °C (212 °F)

120 °C (248 °F)

51.9 Ω

27.4 Ω

16.1 Ω

Condition

(A)



When galvarnometer shows 0 (Zero).

Condition

(A)

Setting Value

R1: 54.945 to 55.055 Ω

V: DC 6.9 to 7.1 V

(1) Terminal

(2) Insulator

(3) Body

(4) Thermistor

C: Coolant or Silicon Oil

G: Galvanometer

VR: Variable Resistor

F: Flow Velocity

(0.14 to 0.15 m/s)

9Y1210293ELM0015US0

8-M12

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[3] TRAVELING SPEED SENSOR

ELECTRICAL SYSTEM

Measure the traveling speed with the rotation sensor at the right side of the front case.

This sensor is the electromagnetic picking up type and is wound with coil (1) around a permanent magnet

(2).

When a gear is rotated, a magnetic field is charged and AC voltage is generated in the coil.

As its frequency is in proportion to the gear revolution, it is input to the speed meter as revolution of the bevel gear shaft.

(1) Coil (2) Permanent Magnet

9Y1210293ELM0016US0

[4] EASY CHECKER™

To check the conditions of vehicle easily before and during operation, combination of lamps on the board is provided.

9Y1210293ELM0017US0

Indication Items

(1) Parking Brake / Brake Fluid Lamp

When apply parking brake or brake fluid low level, this lamp illuminates.

(2) Charge Lamp

When the charging system is not functioning properly, this lamp illuminates.

(3) Oil Pressure Lamp

When the engine oil pressure is low, this lamp illuminates.

(4) Pre-heat Indicator Lamp

When the key switch is in the

Pre-heat

position, the pre-heat indicator lamp illuminates.

(1) Parking Brake / Brake Fluid

(2) Electrical Charge

(3) Engine Oil Pressure

(4) Glow Plug

9Y1210293ELM0018US0

Oil Pressure Switch

While oil pressure is high and the force applied to the diaphragm (2) is larger than the spring tension, the terminal contact (1) is open separated from the body contact (3). If the pressure drops below approx. 49 kPa

(0.5 kgf/cm

2

, 7.1 psi), the contact closes.

(1) Terminal Contact

(2) Diaphragm

(3) Body Contact

9Y1210293ELM0019US0

8-M13

KiSC issued 05, 2014 A

SERVICING

CONTENTS

1. TROUBLESHOOTING.................................................................................................................8-S1

2. SERVICING SPECIFICATIONS ..................................................................................................8-S6

3. TIGHTENING TORQUES............................................................................................................8-S7

4. CHECKING, DISASSEMBLING AND SERVICING .....................................................................8-S8

[1] CHECKING AND ADJUSTING..............................................................................................8-S8

(1) Battery .............................................................................................................................8-S8

(2) Main Switch .....................................................................................................................8-S9

(3) Starter............................................................................................................................8-S11

(4) Glow Plug ......................................................................................................................8-S12

(5) Safety Switch.................................................................................................................8-S13

(6) Engine Stop Solenoid ....................................................................................................8-S13

(7) Alternator .......................................................................................................................8-S14

(8) Lighting System .............................................................................................................8-S15

(9) Cooling System .............................................................................................................8-S18

(10)Gauges..........................................................................................................................8-S21

(11)Relays ...........................................................................................................................8-S24

(12)Others ...........................................................................................................................8-S25

[2] DISASSEMBLING AND ASSEMBLING ..............................................................................8-S26

(1) Starter............................................................................................................................8-S26

(2) Alternator .......................................................................................................................8-S27

(3) Panel .............................................................................................................................8-S30

[3] SERVICING.........................................................................................................................8-S32

(1) Starter............................................................................................................................8-S32

(2) Alternator .......................................................................................................................8-S34

KiSC issued 05, 2014 A

RTV1140CPX, WSM

1. TROUBLESHOOTING

Symptom

All Electrical

Equipments Do Not

Operate

ELECTRICAL SYSTEM

Probable Cause Solution

Battery discharged or defective

Battery positive cable disconnected or improperly connected

Battery negative cable disconnected or improperly connected

Slow blow fuse blown

Short-circuited

Recharge or replace

Repair or replace

Repair or replace

Replace

Repair or replace

Reference

Page

G-28

8-S8

8-S8

G-41

–

Fuse Blown

Frequently

BATTERY

Symptom

Battery Discharges

Too Quickly

Probable Cause Solution

Battery defective

IC Regulator defective

Wiring harness disconnected or improperly connected (between battery positive terminal and regulator

B

terminal)

Alternator belt slipping

Replace

Replace

Repair or replace

Adjust tension

Reference

Page

8-S8

8-S28

–

G-29

8-S1

KiSC issued 05, 2014 A

RTV1140CPX, WSM

STARTING SYSTEM

Symptom Probable Cause

ELECTRICAL SYSTEM

Solution

Starter Motor Does

Not Operate

Engine Does Not

Stop When Main

Switch is Turned OFF

Engine Does Not

Start

Battery discharged or defective

Slow blow fuse blown

Safety switch improperly adjusted or defective

Wiring harness disconnected or improperly connected (between main switch

ST

terminal and safety switches, between safety switches and starter motor, between battery positive terminal and starter motor)

Starter motor defective

Main switch defective

Fuse blown (20 A)

Wiring harness disconnected or improperly connected (between main switch

ACC

terminal and engine stop solenoid)

Engine stop solenoid defective

Stop solenoid relay defective

Engine stop solenoid defective

Stop solenoid relay defective

Recharge or replace

Replace

Repair or replace

Repair or replace

Repair or replace

Replace

Replace

Repair or replace

Replace

Replace

Replace

Replace

CHARGING SYSTEM

Symptom Probable Cause

Charging Lamp Does

Not Light when Main

Switch is Turned ON

Charging Lamp Does

Not Go Off When

Engine is Running

Fuse blown (5 A)

Wiring harness disconnected or improperly connected (between main switch

ACC

terminal and panel board, between panel board and alternator)

Alternator defective

Wiring harness disconnected or improperly connected (between main switch

B

terminal and alternator, between panel board and alternator)

Alternator defective

Solution

Replace

Repair or Replace

Repair or Replace

Repair or Replace

Repair or Replace

Reference

Page

G-28

G-41

8-S13

–

8-S26

8-S9

G-41

–

8-S13

8-S24

8-S13

8-S24

Reference

Page

G-41

–

8-S27

–

8-S27

8-S2

KiSC issued 05, 2014 A

RTV1140CPX, WSM

LIGHTING SYSTEM

Symptom

ELECTRICAL SYSTEM

Probable Cause Solution

Head Light Does Not

Light

Tail Light Does Not

Light

Hazard Light Does

Not Light

(If Equipped)

Fuse blown (15 A)

Combination switch defective

Bulb blown

Wiring harness disconnected or improperly connected (between main switch

ACC

terminal and head light switch, between head light switch and head light)

Fuse blown (15 A)

Bulb blown

Wiring harness disconnected or improperly connected (between main switch

ACC

terminal and head light switch, between head light switch and tail light)

Fuse blown (15 A)

Bulb blown

Wiring harness disconnected or improperly connected

Flasher unit defective

Hazard switch defective

Bulb blown

Wiring harness disconnected or improperly connected

Flasher unit defective

Hazard Indicator

Lamp Does Not Light

(If Equipped)

Hazard Light Does

Not Flicker (If

Equipped)

Turn Signal Light

Does Not Light

(If Equipped)

Fuse blown (15 A)

Bulb blown

Wiring harness disconnected or improperly connected

Flasher unit defective

Blinker switch defective

Bulb blown

Wiring harness disconnected or improperly connected (blinker switch and indicator lamp)

Turn Signal Light

Indicator Lamp Does

Not Light

(If Equipped)

Turn Signal Light

Does Not Flicker

(If Equipped)

Pre-heat Indicator

Lamp Does Not Light

When Main Switch Is in Pre-heat Position

Flasher unit defective

Blinker switch defective

Battery discharged or defective

Slow blow fuse blown

Wiring harness disconnected or improperly connected (between main switch

G

terminal and pre-heat indicator, between pre-heat indicator and glow plugs)

Main switch defective

Pre-heat indicator defective

Replace

Replace

Replace

Repair or Replace

Replace

Replace

Repair or Replace

Replace

Replace

Repair or Replace

Replace

Replace

Replace

Repair or Replace

Replace

Replace

Replace

Repair or Replace

Replace

Replace

Replace

Repair or Replace

Replace

Repair or Replace

Recharge or Replace

Replace

Repair or Replace

Replace

Replace

Reference

Page

G-41

8-S15

G-42

–

G-41

G-42

–

G-41

G-42

–

–

–

G-42

–

–

G-41

G-42

–

–

–

G-42

–

–

–

G-28

G-41

–

8-S9

8-S30

8-S3

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Symptom Probable Cause

Oil Pressure Lamp

Lights Up When

Engine Is Running

Oil Pressure Lamp

Does Not Light When

Main Switch Is

Turned ON and

Engine Is Not

Running

Parking (Position)

Light Does Not Light

Engine oil pressure too low

Engine oil insufficient

Oil pressure switch defective

Short circuit between oil pressure switch lead and chassis

Bulb blown

Oil pressure switch defective

Wiring harness disconnected or improperly connected (between panel board and oil pressure switch)

Fuse blown (5 A)

Bulb blown

Parking light switch defective

Wiring harness disconnected (between parking light switch and parking light)

COOLING SYSTEM

Symptom Probable Cause

Fan Motor Does Not

Rotate When Engine

Overheats

Fan Motor Rotates

Always (When Main

Switch Is ON

Position)

Coolant temperature gauge defective

Fuse blown (30 A)

Fan motor relay defective

Wiring harness disconnected or improperly connected

Fan motor defective

Battery discharged or defective

Coolant temperature gauge defective

Fan motor relay defective

Solution

Repair engine

Replenish

Replace

Repair

ELECTRICAL SYSTEM

Replace

Replace

Repair or Replace

Replace

Replace

Repair or Replace

Repair or Replace

Solution

Replace

Replace

Replace

Repair or Replace

Replace

Recharge or Replace

Replace

Replace

Reference

Page

–

G-8

8-S16

–

G-42

8-S16

–

G-41

G-42

8-S17

–

Reference

Page

8-S23

G-41

8-S24

–

8-S20

G-28

8-S23

8-S24

8-S4

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

GAUGES

Symptom Probable Cause

Fuel Gauge Does Not

Function

Coolant Temperature

Gauge Does Not

Function

Fuel gauge defective

Fuel level sensor defective

Wiring harness disconnected or improperly connected (between fuel gauge and fuel level sensor)

Coolant temperature gauge defective

Coolant temperature sensor defective

Wiring harness disconnected or improperly connected (between coolant temperature gauge and coolant temperature sensor)

HORN

Symptom Probable Cause

Solution

Replace

Replace

Replace or Replace

Replace

Replace

Repair or Replace

Reference

Page

8-S23

8-S21

–

8-S23

8-S22

–

Solution

Horn Does Not Sound

When Horn Button Is

Pushes

Fuse blown (10 A)

Horn switch defective

Horn defective

Wiring harness disconnected or improperly connected (between combination switch terminal and horn)

Replace

Replace

Replace

Repair or Replace

Reference

Page

G-41

8-S25

8-S25

–

9Y1210293ELS0001US0

8-S5

KiSC issued 05, 2014 A

RTV1140CPX, WSM

2. SERVICING SPECIFICATIONS

Battery

Item

Voltage

Potential

Difference

Resistance

Factory Specification

More then 12 V

Less than 0.1 V

Approx. 0.9 Ω

ELECTRICAL SYSTEM

Allowable Limit

–

–

– Glow Plug

Starter

• Commutator O.D.

30.0 mm

1.18 in.

29.0 mm

1.14 in.

• Commutator

• Mica

• Brush

Combination Switch (for Head Light)

Alternator

• Stator

• Rotor

• Slip Ring

• Brush

Difference of

O.D.'s

Undercut

Length

Resistance

OFF

Resistance

ON

No-load Voltage

Resistance

Resistance

O.D.

Length

Less than 0.02 mm

0.0008 in.

0.50 to 0.80 mm

0.020 to 0.031in.

14.0 mm

0.551 in.

Infinity

0 Ω

More then 14 V

Less than 0.1 Ω

2.9 Ω

14.4 mm

0.567 in.

10.5 mm

0.413 in.

0.05 mm

0.002 in.

0.20 mm

0.0079 in.

9.0 mm

0.35 in.

–

–

–

–

–

14.0 mm

0.551 in.

8.4 mm

0.331 in.

9Y1210293ELS0002US0

8-S6

KiSC issued 05, 2014 A

RTV1140CPX, 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: See page G-10.)

ELECTRICAL SYSTEM

Item

Starter (

B

terminal nut)

Alternator (Pulley nut)

ROPS pipe mounting bolt and nut

ROPS (front) mounting screw

Steering wheel mounting nut

N·m

5.9 to 11

58.4 to 78.9

48.0 to 55.8

77.5 to 90.2

30 to 49

kgf·m

0.60 to 1.2

5.95 to 8.05

4.90 to 5.69

7.91 to 9.19

3.0 to 5.0

lbf·ft

4.4 to 8.6

43.1 to 58.2

35.4 to 41.1

57.2 to 66.5

22 to 36

9Y1210293ELS0003US0

8-S7

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

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.

• Never remove the battery cap while the engine is running.

• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, wash it away completely with water immediately.

• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen becomes very explosive.

IMPORTANT

• If the machine is to be operated for a short time without battery (using a slave battery for starting), use additional current (lights) while engine is running and insulate terminal of battery. If this advice is disregarded, damage to alternator and regulator may result.

9Y1210293ELS0004US0

(1) Battery

Battery Voltage

1. Stop the engine and turn the main switch off.

2. Connect the COM ( − ) lead of the voltmeter to the battery's negative terminal post and the (+) lead to the positive terminal post, and measure the battery voltage.

3. If the battery voltage is less than the factory specification, check the battery specific gravity and recharge the battery.

Battery voltage Factory specification More than 12 V

9Y1210293ELS0005US0

Battery Terminal Connection

1. Turn the main switch on, and turn on the head light.

2. Measure the voltage with a voltmeter across the battery's positive terminal post and the cable terminal, and the voltage across the battery's negative terminal post and the chassis.

3. If the measurement exceeds the factory specification, clean the battery terminal posts and cable clamps, and tighten them firmly.

Potential difference Factory specification Less than 0.1 V

9Y1210293ELS0006US0

8-S8

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(2) Main Switch

ELECTRICAL SYSTEM

Main Switch

1. Disconnect the

4P

connector and remove the main switch (1).

2. Perform the following checks

(1) Main Switch

9Y1210293ELS0007US0

Connector Voltage

1. Measure the voltage with a voltmeter across the connector

B

(red) terminal and chassis.

2. If the voltage differs from the battery voltage (11 to 14 V), the wiring harness is faulty.

Voltage

Connector

B

(Red) terminal – Chassis

Approx. battery voltage

(1) Main Switch (2) Connector

9Y1210293ELS0008US0

8-S9

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

Main Switch Continuity

1) Main Switch Key at OFF Position

1. Set the main switch

OFF

position.

2. Measure the resistance with an ohmmeter across the

B

terminal and the

ACC

terminal,

B

terminal and ST terminal,

B

terminal and

G

terminal.

3. If infinity is not indicated, the contacts of the main switch are faulty.

Resistance

B

terminal –

ACC

terminal

B

terminal –

ST

terminal

B

terminal –

G

terminal

Infinity

2) Main Switch Key at ON Position

1. Set the main switch

ON

position.

2. Measure the resistance with an ohmmeter across the

B

terminal and the

ACC

terminal.

3. If 0 ohm is not indicated, the

B

-

ACC

contact of the main switch are faulty.

Resistance

B

terminal –

ACC

terminal

0 Ω

3) Main Switch Key at PREHEAT Position

1. Set and hold the main switch key at the

PREHEAT

position.

2. Measure the resistance with an ohmmeter across the

B

terminal and the

G

terminal, and measure the resistance across the

B

terminal and the

ACC

terminal.

3. If 0 ohm is not indicated, these contacts of the main switch are faulty.

Resistance

B

terminal –

G

terminal

B

terminal –

ACC

terminal

0 Ω

4) Main Switch Key at START Position

1. Set and hold the main switch key at the

START

position.

2. Measure the resistance with an ohmmeter across the

B

terminal and the

G

terminal, across the

B

terminal and the

ST

terminal, and across the

B

terminal and the

ACC

terminal.

3. If 0 ohm is not indicated, these contacts of the main switch are faulty.

Resistance

B

terminal –

G

terminal

B

terminal –

ST

terminal

B

terminal –

ACC

terminal

0 Ω

(1)

G

Terminal

(2)

ACC

Terminal

(3)

ST

Terminal

(4)

B

Terminal

9Y1210293ELS0009US0

8-S10

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(3) Starter

ELECTRICAL SYSTEM

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 and the leads from the starter.

3. Remove the starter from the engine.

4. Disconnect the connecting lead (2) from the starter

C

terminal

(1).

5. Connect a jumper lead from the connecting lead (2) to the battery positive terminal post.

6. Connect a jumper lead momentarily between the starter motor housing and the battery negative terminal post.

7. If the motor does not run, check the motor.

(1)

C

Terminal (2) Connecting Lead

Magnet Switch Test (Pull-in, Holding Coils)

9Y1210293ELS0010US0

1. Remove the motor from the starter housing.

2. Preparate a 6 V battery for the test.

3. Connect jumper leads from the battery negative terminal to the housing and the starter

C

terminal.

4. The plunger should be attracted and the pinion gear should pop out when a jumper lead is connected from the battery positive terminal to the

S

terminal. It's a correct.

5. Disconnect the jumper lead to the starter

C

terminal. Then the pinion gear should remain popped out. It's a correct.

IMPORTANT

• Testing time must be 3 to 5 sec..

C: C Terminal

S: S Terminal

(a) To Negative Terminal

(b) To Positive Terminal

9Y1210293ELS0011US0

8-S11

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(4) Glow Plug

ELECTRICAL SYSTEM

Lead Terminal Voltage

1. Disconnect the wiring lead (1) from the glow plug (2) after turning the main switch off.

2. Turn the main switch key to the

"PREHEAT"

position, and measure the voltage between the lead terminal and the chassis.

3. Turn the main switch key to the

"START"

position, and measure the voltage with a voltmeter between the lead terminal and the chassis.

4. If the voltage at either position differs from the battery voltage, the wiring harness or main switch is faulty.

Voltage

(Lead terminal - Chassis)

Main switch key at

"PREHEAT"

Main switch key at

"START"

Approx. battery voltage

Approx. battery voltage

(1) Wiring Lead (Positive) (2) Glow Plug

9Y1210293ELS0012US0

Glow Plug Continuity

1. Disconnect the lead from the glow plugs.

2. Measure the resistance with an ohmmeter between the glow plug terminal and the chassis.

3. If 0 ohm is indicated, the screw at the tip of the glow plug and the housing are short-circuited.

4. If the factory specification is not indicated, the glow plug is faulty.

Glow plug resistance Factory specification Approx. 0.9 Ω

9Y1210293ELS0013US0

8-S12

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(5) Safety Switch

ELECTRICAL SYSTEM

Safety Switch Continuity

1. Remove the safety switch leads.

2. Connect the circuit tester to the safety switch leads.

3. Measure the resistance between leads.

4. If the safety switch is defective, replace it.

Resistance (Across switch terminal)

When you move the gear shift lever

When you return the gear shift lever

Infinity

0 Ω

(1) Safety Switch for Main Shift Lever

9Y1210293ELS0015US0

(6) Engine Stop Solenoid

Engine Stop Solenoid

1. Disconnect the

2P

connector (1) from the engine stop solenoid

(2).

2. Remove the engine stop solenoid (2) from the engine.

3. Connect the jumper leads from the pulling coil

P

terminal to the switch (5), and from switch (5) to the battery positive terminal.

4. Connect the jumper leads from the holding coil

H

terminal to the switch (6), and from switch (6) to the battery positive terminal.

5. Connect the jumper leads from the engine stop solenoid body to the battery negative terminal.

6. When switch (6) is turn on, the plunger pulls into the solenoid body and then turn off the switch (6), the plunger comes out.

7. Turn on the switch (5) then turn on the switch (6), the plunger pulls into the solenoid body and it keeps in holding position after turning off the switch (6).

8. If the plunger is not attracted, the engine stop solenoid is faulty.

IMPORTANT

• Never apply the current for pulling coil more than two seconds when inspecting.

(1)

2P

Connector

(2) Engine Stop Solenoid

(3) Connector (of Engine Stop

Solenoid)

(4) Battery

(5) Switch for Holding Coil

(6) Switch for Pulling Coil

P: Terminal for Pulling Coil

H: Terminal for Holding Coil

9Y1210293ELS0016US0

8-S13

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(7) Alternator

ELECTRICAL SYSTEM

Alternator

1. Disconnect the

2P

connector (3) from alternator after turning the main switch

OFF

.

2. Perform the following checkings.

(1)

B

Terminal

(2) Alternator

(3)

2P

Connector

9Y1210293ELS0017US0

Connector Voltage

1. Turn the main switch

OFF

. Measure the voltage between the

B

terminal (1) and the chassis.

2. Turn the main switch

ON

. Measure the voltage between the

IG

terminal (3) and the chassis.

Voltage

(Main switch at

OFF

)

Voltage

(Main switch at

ON

)

B

terminal – Chassis

IG

terminal – Chassis

Approx. battery voltage

Approx. battery voltage

(1)

B

Terminal

(2) Alternator

(3)

IG

Terminal

(4)

L

Terminal

9Y1210293ELS0018US0

8-S14

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(8) Lighting System

ELECTRICAL SYSTEM

No-Load Test

1. Connect the

2P

connector (6) to previous positions of the alternator after turning the main switch

OFF

.

2. Connect the jumper lead (3) between

IG

terminal (4) and

B

terminal (2).

3. Start the engine and then set at idling speed.

4. Disconnect the negative cable from the battery.

5. Measure the voltage between the

B

terminal (2) and the chassis.

6. If the measurement is less than the factory specification, disassemble the alternator and check the IC regulator.

Voltage Factory specification More than 14 V

(Reference)

• Once the engine has started, the alternator temperature rises quickly up to an ambient temperature of 70 to 90 °C (158 to

194 °F). As the temperature goes higher than 50 °C (122 °F), the alternator voltage slowly drops; at higher than 100 °C

(212 °F), it drops by about 1 V.

(1) Voltmeter

(2)

B

Terminal

(3) Jumper Lead

(4)

IG

Terminal

(5)

L

Terminal

(6)

2P

Connector

(7) Alternator

9Y1210293ELS0019US0

Combination Switch (for Head Light)

1) Connector Terminal Voltage

1. Disconnect the connector from the combination switch (1) after turning the main switch

OFF

.

2. Turn the main switch

ON

and measure the voltage with a voltmeter across the connector terminal

B1

(4) to the chassis.

3. If the voltage differs from the battery voltage, the wiring harness or head light relay is faulty.

Voltage

Connector terminal

B1

– Chassis

Approx. battery voltage

2) Switch Continuity

1. Disconnect the connector from the combination switch (1) and remove it.

2. Measure the resistance with an ohmmeter across the switch terminal

B1

(5) to terminal

I

(6).

3. If the resistance differs from the factory specifications, the combination switch is faulty.

Resistance

Factory specification

OFF

ON

Infinity

0 Ω

(1) Combination Switch

(2) Connector (Switch Side)

(3) Connector (Harness Side)

(4) Connector Terminal

B1

(5) Switch Terminal

B1

(6) Switch Terminal

I

9Y1210293ELS0020US0

8-S15

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

Engine Oil Pressure Lamp

1. Disconnect the wiring lead (2) from the engine oil pressure switch after turning the main switch

OFF

.

2. Turn the main switch

ON

and connect a jumper lead from the lead to the chassis.

3. If the engine oil pressure indicator lamp does not light, the wiring harness is faulty.

(1) Engine Oil Pressure Switch

(2) Wiring Lead

(a) From Oil Pressure Lamp

9Y1210293ELS0021US0

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 4.9 kPa (0.5 kgf/cm

2

,

7 psi), the switch is faulty.

0 Ω

Resistance (Switch terminal – Chassis)

In normal state

At pressure over approx. 49 kPa

(0.50 kgf/cm

2

, 7.1 psi)

Infinity

(1) Engine Oil Pressure Switch

9Y1210293ELS0022US0

8-S16

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

Parking Brake Lamp

1. Disconnect the connecting lead from the parking brake switch

(1) after turning the main switch

OFF

.

2. Turn the main switch

ON

and connect a jumper lead from the lead to the chassis.

3. If the parking brake indicator lamp does not light, the wiring harness is faulty.

(1) Parking Brake Switch

(a) From Parking Brake Lamp

9Y1210293ELS0023US0

Parking Brake 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 state of parking brake

ON

, the switch is faulty.

4. If the safety switch is defective, replace it.

0 Ω

Resistance

(Switch terminal –

Chassis)

In normal state

When switch push is released

Infinity

(1) Parking Brake Switch

9Y1210293ELS0024US0

8-S17

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

Brake Switch Continuity

1. Open the bonnet.

2. Remove the safety switch leads.

3. Connect the circuit tester to the safety switch leads.

4. Measure the resistance between leads.

5. If the safety switch is defective, replace it.

Resistance (Across switch terminal)

When switch is pushed

When switch is released

0 Ω

Infinity

(1) Safety Switch for Brake

9Y1210293ELS0014US0

(9) Cooling System

Fan Motor Wiring Harness

1. Disconnect the

2P

connector (1) from the coolant temperature switch (2) after turning the main switch

OFF

.

2. Turn the main switch

ON

and connect a jumper lead (5) from the connector terminal

1

(3) to the connector terminal

2

(4).

3. If the fan motor does not rotate, wiring harness or fan motor relay is faulty.

(1)

2P

Connector

(2) Coolant Temperature Switch

(3) Connector Terminal

1

(to Fan Motor

Relay)

(4) Connector Terminal

2

(to Ground)

(5) Jumper Lead

9Y1210293ELS0025US0

8-S18

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

Coolant Temperature 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.

3. If 0 ohms is not indicated when the coolant temperature is higher than 87 to 93 °C (189 to 199 °F), the switch is faulty.

Resistance

At coolant temperature lower than 83 °C

(181 °F)

At coolant temperature more than 87 to 93 °C

(189 to 199 °F)

Infinity

0 Ω

(1) Coolant Temperature Switch

(2) Coolant

(A) ON

(B) OFF

(C) 87 to 93 °C (189 to 199 °F)

(D) 83 °C (181 °F)

9Y1210293ELS0026US0

8-S19

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

Fan Motor

1. Disconnect the

2P

connector (1) of fan motor after turning the main switch

OFF

.

2. Connect a jumper lead from the 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.

4. If the fan motor does not run, replace it.

(1)

2P

Connector

(2) Frame

(3)

1

Terminal (Positive Side)

(4)

2

Terminal (Negative Side)

9Y1210293ELS0027US0

8-S20

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(10) Gauges

ELECTRICAL SYSTEM

Fuel Lever Sensor

1) Connector Terminal Voltage

1. Disconnect the

1P

connector (2) from the fuel level sensor (1) after turning the main switch

OFF

.

2. Turn the main switch

ON

and measure the voltage with a voltmeter across the connector terminal and the chassis.

3. If the voltage differs from the battery voltage, the wiring harness or meter panel is faulty.

Voltage

Connector terminal –

Chassis

Approx. battery voltage

2) Sensor Continuity

1. Remove the fuel level sensor from the fuel tank.

2. Measure the resistance with an ohmmeter across the sensor terminal and its body.

3. If the reference value are not indicated, the sensor is faulty.

Resistance (Sensor terminal – its body)

Reference value

Float at uppermost position

Float at lowermost position

1 to 5 Ω

103 to 117 Ω

(1) Fuel Level Sensor

(2)

1P

Connector

E: Empty

F: Full

9Y1210293ELS0028US0

8-S21

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

Coolant Temperature Sensor

1) Connector Terminal Voltage

1. Disconnect the

1P

connector (2) from the coolant temperature sensor after turning the main switch

OFF

.

2. Turn the main switch

ON

and measure the voltage with a voltmeter across the connector terminal and the chassis.

3. If the voltage differs from the battery voltage, the wiring harness or meter panel is faulty.

Voltage

Connector terminal –

Chassis

Approx. battery voltage

2) Sensor Continuity

1. Measure the resistances with an ohmmeter across the sensor terminal and the chassis.

2. If the reference value is not indicated, the sensor is faulty.

Resistance

(Sensor terminal –

Chassis)

Reference value

Approx. 16.1 Ω at 120 °C (248 °F)

Approx. 27.4 Ω at 100 °C (212 °F)

Approx. 51.9 Ω at 80 °C (176 °F)

Approx. 153.9 Ω at 50 °C (122 °F)

(1) Coolant Temperature Sensor

(2)

1P

Connector

(a) From Temperature Gauge

9Y1210293ELS0029US0

8-S22

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

Traveling Speed (Rotation) Sensor

1) Connector Terminal Voltage

1. Disconnect the

2P

connector (2) from the traveling speed sensor (1) after turning the main switch

OFF

.

2. Turn the main switch

ON

and measure the voltage with a voltmeter across the connector terminal

2

(3) and the chassis.

3. If the voltage differs from the battery voltage, the wiring harness or meter panel is faulty.

Voltage

Connector terminal

2

–

Chassis

Approx. battery voltage

2) Output Voltage

1. Lift up the machine, and support it with disassembling jacks.

2. Set the 4WD lever to

4WD

position.

3. Start the engine and shift the range shift lever in

L

position.

4. Depress the speed control pedal fully, and measure the output voltage with a voltmeter across the sensor terminal

2

(6) and the chassis.

5. If the reference value is not indicated, the sensor is faulty.

Voltage of alternating current

Reference value Approx. 3.6 V

(1) Traveling Speed Sensor

(2)

2P

Connector (Harness Side)

(3) Connector Terminal

2

(4) Connector Terminal

1

(5) Sensor Terminal

1

(6) Sensor Terminal

2

(7) Gear

9Y1210293ELS0030US0

Fuel Gauge and Coolant Temperature Gauge Operation

1. Remove the under panel.

2. Turn the main switch to

ON

position. Measure the voltage with a voltmeter across the

I

terminal (5) and

G

terminal (3) of the gauge.

3. If approx. battery voltage is indicated, the ignition and ground lead connections are good.

4. Turn the main switch to

OFF

position. Connect a jumper lead between

S

terminal (4) and

G

terminal (3) of the gauge.

5. Turn the main switch to

ON

position. If the gauge resisters a full scale reading under those conditions, the gauge is good. If less than full scale reading is indicated, the gauge is defective and should be replaced.

(1) Fuel Gauge

(2) Temperature Gauge

(3)

G

(Ground) Terminal

(4)

S

(Signal) Terminal

(5)

I

(Battery) Terminal

9Y1210293ELS0031US0

8-S23

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(11) Relays

ELECTRICAL SYSTEM

Relay

1. Turn the main switch

OFF

.

2. Remove the side cover (1).

3. Remove the relay which should be checked.

4. Connect the jumper load across the battery positive terminal to relay terminal

1

, and the battery negative terminal to relay terminal

2

.

5. Check the continuity with an ohmmeter between the relay terminal

5

and terminal

3

.

6. If the continuity is 0 ohms, the relay is proper.

(1) Side Cover

(2) Relay for Radiator Fan Motor

(3) Relay for Starter Motor

(4) Relay for Engine Stop Solenoid

(5) Relay for Work Light

a: Terminal 1 b: Terminal 2 c: Terminal 5 d: Terminal 3

9Y1210293ELS0032US0

8-S24

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(12) Others

ELECTRICAL SYSTEM

Combination Switch (for Horn)

1) Connector Terminal Voltage

1. Disconnect the connector from the combination switch (1) after turning the main switch

OFF

.

2. Turn the main switch

ON

and measure the voltage with a voltmeter across the connector terminal

B3

(4) to the chassis.

3. If the voltage differs from the battery voltage, the wiring harness or fuse is faulty.

Voltage

Connector terminal

B3

– Chassis

Approx. battery voltage

2) Switch Continuity

1. Disconnect the connector from the combination switch (1) and remove it.

2. Measure the resistance with an ohmmeter across the switch terminal

B3

(5) to terminal

H

(6).

3. If the resistance differs from the factory specifications, the combination switch is faulty.

Resistance

Factory specification

OFF

ON

Infinity

0 Ω

(1) Combination Switch

(2) Connector (Switch Side)

(3) Connector (Harness Side)

(4) Connector Terminal

B3

(5) Switch Terminal

B3

(6) Switch Terminal

H

(7) Horn

9Y1210293ELS0033US0

8-S25

KiSC issued 05, 2014 A

RTV1140CPX, WSM

Tightening torque Nut (1)

ELECTRICAL SYSTEM

[2] DISASSEMBLING AND ASSEMBLING

(1) Starter

Motor

1. Remove the 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).

3. Remove the end frame screws (6) and then remove the end frame (5).

4. Separate the armature (7), the brush holder (8) from the yoke

(4).

(When reassembling)

• Apply grease to the spline teeth

"C"

of the armature (7).

• Fit the projection

"B"

on the yoke into the notch

"A"

in the magnet switch.

5.9 to 11 N·m

0.60 to 1.2 kgf·m

4.4 to 8.6 lbf·ft

(1) Nut

(2) Connecting Lead

(3) Motor Through Screw

(4) Yoke

(5) End Frame

(6) End Frame Screw

(7) Armature

(8) Brush Holder

A: Notch

B: Projection

C: Spline Teeth

9Y1210293ELS0034US0

8-S26

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(2) Alternator

ELECTRICAL SYSTEM

Magnet Switch

1. Remove the drive end frame mounting screws (1).

2. Take out 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).

(1) Drive End Frame Mounting Screw

(2) Overrunning Clutch

(3) Steel Ball

(4) Spring

(5) Roller

(6) Retainer

(7) Idle Gear

9Y1210293ELS0035US0

Plunger

1. Remove the end cover (1).

2. Take out the plunger (2).

(1) End Cover (2) Plunger

9Y1210293ELS0036US0

Pulley

1. Secure the hexagonal end of the pulley shaft with a double-ended ratchet wrench as shown in the figure, loosen the pulley nut with a socket wrench and remove it.

(When reassembling)

Tightening torque Pulley nut

58.4 to 78.9 N·m

5.95 to 8.05 kgf·m

43.1 to 58.2 lbf·ft

9Y1210293ELS0037US0

Rear End Cover

1. Unscrew the three rear end cover screws and the

B

terminal nut, and remove the rear end cover.

9Y1210293ELS0038US0

8-S27

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

Brush Holder

1. Unscrew the two screws holding the brush holder, and remove the brush holder (1).

(1) Brush Holder

9Y1210293ELS0039US0

IC Regulator

1. Unscrew the three screws holding the IC regulator, and remove the IC regulator (1).

(1) IC Regulator

9Y1210293ELS0040US0

Rectifier

1. Remove the four screws holding the rectifier and the stator lead wires

2. Remove the rectifier (1).

(1) Rectifier

9Y1210293ELS0041US0

Rear End Frame

1. Unscrew 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

9Y1210293ELS0042US0

Rotor

1. Press out the rotor (1) from drive end frame (3).

IMPORTANT

• Take special care not to drop the rotor and damage the slip ring or fan, etc..

(1) Rotor

(2) Block

(3) Drive End Frame

9Y1210293ELS0043US0

8-S28

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

Retainer Plate

1. Unscrew the four screws holding the retainer plate, and remove the retainer plate (1).

(1) Retainer Plate

9Y1210293ELS0044US0

Bearing on Drive End Side

1. Press out the bearing from drive end frame (3) with a press and jig (1).

(1) Jig

(2) Block

(3) Drive End Frame

9Y1210293ELS0045US0

Bearing at Slip Ring Side

1. Lightly secure the rotor (1) with a vise to prevent damage, and remove the bearing (2) with a puller (3).

(1) Rotor

(2) Bearing

(3) Puller

9Y1210293ELS0046US0

8-S29

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(3) Panel

ELECTRICAL SYSTEM

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. Set the seat to 1 row.

2. Remove the battery cover (1).

3. Remove the air cleaner hose (2).

4. Disconnect the negative cable (3) from the battery (4).

(1) Battery Cover

(2) Air Cleaner Hose

(3) Negative Cable

(4) Battery

(5) Positive Cable

9Y1210293ENS0025US0

Bonnet Upper

1. Remove the snap pin and remove the bonnet upper (3).

2. Remove the ROPS pipes (1).

3. Lift ROPS boots and remove the three screws on both sides.

4. Remove the ROPS pipe (front) (2).

Tightening torque

ROPS pipe mounting bolt and nut

ROPS (front) mounting screw

48.0 to 55.8 N·m

4.90 to 5.69 kgf·m

35.4 to 41.1 lbf·ft

77.5 to 90.2 N·m

7.91 to 9.19 kgf·m

57.2 to 66.5 lbf·ft

(1) ROPS Pipe

(2) ROPS Pipe, Front

(3) Bonnet Upper

9Y1210293STS0004US0

8-S30

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

Bonnet Lower

1. Remove the four screw (2).

2. Remove the screws (3) from underneath the bonnet lower.

3. Remove the bonnet lower (1).

(1) Bonnet Lower

(2) Screw (4 pcs)

(3) Screw (2 pcs)

9Y1210293STS0005US0

Steering Wheel and Panel

1. Remove the steering wheel cap.

2. Remove the steering wheel mounting nut (1) and remove the steering wheel (2).

3. Remove the shift lever grip (3) and four wheel drive lever grip

(6).

4. Disconnect the connector for main switch, horn switch and head light switch.

5. Remove the panel mounting screws (5) and the panel support.

6. Disconnect the all connectors from panel and remove the panel

(4).

(When reassembling)

Tightening torque

Steering wheel mounting nut

30 to 49 N·m

3.0 to 5.0 kgf·m

22 to 36 lbf·ft

(1) Steering Wheel Mounting Nut

(2) Steering Wheel

(3) Shift Lever Grip

(4) Panel

(5) Screw (2pcs)

(6) 4WD Lever Grip

9Y1210293STS0006US0

8-S31

KiSC issued 05, 2014 A

RTV1140CPX, WSM

[3] SERVICING

(1) Starter

ELECTRICAL SYSTEM

Overrunning Clutch

1. Inspect the pinion for wear or damage.

2. If there is any defect, 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.

4. If the pinion slips or does not rotate in the both directions, replace the overrunning clutch assembly.

9Y1210293ELS0047US0

Commutator and Mica

1. Check the contact face of the commutator for wear, and grind the commutator with emery paper if it is slightly worn.

2. Measure the commutator O.D. with an outside micrometer at several points.

3. If the minimum O.D. is less than the allowable limit, replace the armature.

4. If the difference of the O.D.'s exceeds the allowable limit, correct the commutator on a lathe to the factory specification.

5. Measure the mica undercut.

6. If the undercut is less than the allowable limit, correct it with a saw blade and chamfer the segment edges.

Commutator O.D.

Factory specification

Allowable limit

30.0 mm

1.18 in.

29.0 mm

1.14 in.

Difference of O.D.'s

Factory specification

Allowable limit

Less than

0.02 mm

0.0008 in.

0.05 mm

0.002 in.

Mica undercut

(1) Segment

(2) Undercut

(3) Mica

Factory specification

Allowable limit

(a) Correct

(b) Incorrect

0.50 to 0.80 mm

0.020 to 0.031 in.

0.20 mm

0.0079 in.

9Y1210293ELS0048US0

Brush Wear

1. If the contact face of the brush is dirty or dusty, clean it with emery paper.

2. Measure the brush length

(A)

with vernier calipers.

3. If the length is less than the allowable limit, replace the yoke assembly and brush holder.

Brush length

(A)

Factory specification

Allowable limit

14.0 mm

0.551 in.

9.0 mm

0.35 in.

9Y1210293ELS0049US0

8-S32

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

Brush Holder

1. Check the continuity across the brush holder (1) and the holder support (2) with an ohmmeter.

2. If it conducts, replace the brush holder.

(1) Brush Holder (2) Holder Support

9Y1210293ELS0050US0

Armature Coil

1. Check the continuity across the commutator (2) and armature coil core (1) with an ohmmeter.

[A]

2. If it conducts, replace the armature.

3. Check the continuity across the segments of the commutator (2) with an ohmmeter.

[B]

4. If it does not conduct, replace the armature.

(1) Armature Coil Core (2) Commutator

9Y1210293ELS0051US0

Field Coil

1. Check the continuity across the lead (1) and brush (2) with an ohmmeter.

[A]

2. If it does not conduct, replace the yoke assembly.

3. Check the continuity across the brush (2) and yoke (3) with an ohmmeter.

[B]

4. If it conducts, replace the yoke assembly.

(1) Lead

(2) Brush

(3) Yoke

9Y1210293ELS0052US0

8-S33

KiSC issued 05, 2014 A

RTV1140CPX, WSM

(2) Alternator

ELECTRICAL SYSTEM

Bearing

1. Check the bearing for smooth rotation.

2. If it does not rotate smoothly, replace it.

9Y1210293ELS0053US0

Stator

1. Measure the resistance across each lead of the stator coil with an ohmmeter.

2. If the measurement is not within factory specification, replace it.

3. Check the continuity across each stator coil lead and core with an ohmmeter.

4. If infinity is not indicated, replace it.

Resistance Factory specification Less than 1.0 Ω

9Y1210293ELS0054US0

Rotor

1. Measure the resistance across the slip rings with an ohmmeter.

2. If the resistance is not the factory specification, replace it.

3. Check the continuity across the slip ring and core with an ohmmeter.

4. If infinity is not indicated, replace it.

Resistance Factory specification 2.9 Ω

9Y1210293ELS0055US0

Slip Ring

1. Check the slip ring for score.

2. If scored, correct with an emery paper or on a lathe.

3. Measure the O.D. of slip ring with vernier calipers.

4. If the measurement is less than the allowable limit, replace it.

Slip ring O.D.

Factory specification

Allowable limit

14.4 mm

0.567 in.

14.0 mm

0.551 in.

9Y1210293ELS0056US0

Brush Wear

1. Measure the brush length with vernier calipers.

2. If the measurement is less than allowable limit, replace it.

3. Make sure that the brush moves smoothly.

4. If the brush is defective, replace it.

Brush length

Factory specification

Allowable limit

10.5 mm

0.413 in.

8.4 mm

0.331 in.

9Y1210293ELS0057US0

8-S34

KiSC issued 05, 2014 A

RTV1140CPX, WSM

ELECTRICAL SYSTEM

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.

IMPORTANT

• Do not use a 500 V megohmmeter for measuring because it will destroy the rectifier.

NOTE

• Do not use an auto digital multimeter. Because it's very hard to check the continuity of rectifier by using it.

9Y1210293ELS0058US0

IC Regulator

1. Check the continuity across the

B

terminal and the

F

terminal of

IC regulator with an analog ohmmeter. Conduct the test in the

(R x 1) setting.

2. The IC regulator is normal if the IC regulator conducts in one direction and does not conduct in the reverse direction.

IMPORTANT

• Do not use a 500 V megohmmeter for measuring because it will destroy the IC regulator.

NOTE

• Do not use an auto digital multimeter. Because it's very hard to check the continuity of IC regulator by using it.

9Y1210293ELS0059US0

8-S35

KiSC issued 05, 2014 A

EDITOR:

KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.

64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN

PHONE : (81)72-241-1129

FAX : (81)72-245-2484

E-mail : [email protected]

KUBOTA Corporation

Printed in Japan 2014. 05, S, EI, EI, engusa Code No.9Y111-02932

2009. 06, S, EI, EI, engusa

Code No.9Y121-00000