Kubota WSM RTV500 Instruction manual

WORKSHOP MANUAL
UTILITY VEHICLE
RTV500
KiSC issued 09, 2008 B

TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of RTV500. It is divided into
three parts, "General", "Mechanism" and "Servicing".
QGeneral
Information on the product identification, the general precautions, maintenance
check list, check and maintenance and special tools are described.
QMechanism
Information on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.
RefertoDieselEngineWorkshop Manual(CodeNo.9Y021-01872)fortheonewhich
has not been described to this workshop manual.
QServicing
Information on the troubleshooting, servicing specification lists, tightening torque,
checking and adjusting, disassembling and assembling, and servicing which cover
procedures, precautions, factory specifications and allowable limits.
All information illustrations and specifications contained in this manual are based on
the latest product information available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
Due to covering many models of this manual, information or picture being used have
not been specified as one model.
September 2008
© KUBOTA Corporation 2008
KiSC issued 09, 2008 B
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1
RTV500, WSM SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
BEFORE SERVICING AND REPAIRING
• 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 firm and level ground, and set
the parking brake.
• Lower the implement to the ground.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “DO NOT OPERATE” tag in operator
station.
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 attempt 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.
QIMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
QNOTE : Gives helpful information.
KiSC issued 09, 2008 B
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2
RTV500, WSM SAFETY INSTRUCTIONS
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Do not alter or remove any part of machine safety
system.
• Before starting the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
• Never start the engine while standing on ground.
Start the engine only from operator’s seat.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not work under the machine that is supported
solely by a jack. Always support the machine by
safety stands.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
• Do not open high-pressure fuel system.
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt repair
fuel lines, sensors, or any other components between
the high-pressure fuel pump and injectors on engines
with high pressure common rail fuel system.
• High voltage exceeding 100 V is generated in the
ECU, and is applied to the injector.
Pay sufficient caution to electric shock when
performing work activities.
KiSC issued 09, 2008 B
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3
RTV500, WSM SAFETY INSTRUCTIONS
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilledon theengine.
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
PREVENT ACID BURNS
• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
DISPOSE OF FLUIDS PROPERLY
• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when disposing
of oil, fuel, coolant, electrolyte and other harmful
waste.
KiSC issued 09, 2008 B
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4
RTV500, WSM SAFETY INSTRUCTIONS
PREPARE FOR EMERGENCIES
• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
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5
RTV500, WSM SAFETY INSTRUCTIONS
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 parts number is listed
in the parts list.
SAFETY DECALS
KiSC issued 09, 2008 B
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6
RTV500, WSM SAFETY INSTRUCTIONS
KiSC issued 09, 2008 B
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7
RTV500, WSM SAFETY INSTRUCTIONS
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8
RTV500, WSM SAFETY INSTRUCTIONS
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9
RTV500, WSM SPECIFICATIONS
SPECIFICATIONS
NOTE: The company reserves the right to change the specifications without notice.
The values in “Ground clearance” and “Weight” are those of the machine equipped with the tires in the table above. W1028103
Model RTV500
Engine
Maker KUBOTA GZ460F-E3-UV
Type 2 cylinders, 4-cycle, Gasoline, OHV
Displacement 0.456 L (27.8 cu.in.)
Horsepower 11.8 kW (15.8 HP) /3600 min-1 (rpm)
Fuel capacity 20 L (5.3 U.S.gals, 4.4 Imp.gals)
Transmission Continuously variable hydro transmission (VHT)
Wheels, drive system 4 wheels, rear 2WD or 4WD
Differential lock Standard; hand operated with mechanical holder
Gear selection Hi-Lo range, forward, neutral, reverse
Brake Front / Rear Dry disc brake
Parking brake Rear wheel, hand lever
Steering Rack & pinion
Suspension Front Independent, MacPherson strut-type
Rear Semi-independent, multi-link
Dimensions
Length 2690 mm (105.9 in.)
Width 1390 mm (54.7 in.)
Overall height 1829 mm (72 in.)
Front tread center 1016 mm (40 in.)
Rear tread center 1041 mm (41 in.)
Wheel base 1800 mm (70.9 in.)
Ground
clearance Front axle 205 mm (8.1 in.)
Rear axle 175 mm (6.9 in.)
Overall height 7 m (22.9 ft)
Max. rolling weight
(Towing capacity) Front 250 kg (551 lbs)
Rear 500 kg (1102 lbs)
Payload capacity 430 kg (949 lbs)
Weight ATV tire 615 kg (1358 lbs)
HDWS tire 620 kg (1369 lbs)
Cargo bed
Width 1032 mm (40.6 in.)
Length 856 mm (33.7 in.)
Depth 290 mm (11.4 in.)
Volume 0.25 m3(9 cu.ft.)
Bed height (unloaded) 810 mm (31.9 in.)
Cargo bed load 200 kg (441 lbs)
Sound level (operator ear) 83 dB (A)
Tires Front 24 ×9 – 12
HDWS, 6PLY 24 ×9 – 12 ATV, 6PLY
Rear 24 ×11 – 12
HDWS, 6PLY 24 ×11 – 12 ATV, 6PLY
Front deluxe guard Opt.
Body color Orange / Camo
Speedometer Opt.
Rear net Opt.
KiSC issued 09, 2008 B

10
RTV500, WSM TRAVELLING SPEEDS
TRAVELLING SPEEDS
W1035065
Model RTV500
Rangegearshift
lever km/h (mph)
Low 16 (10)
High 40 (25)
Reverse 23 (14.3)
KiSC issued 09, 2008 B

11
RTV500, WSM DIMENSIONS
DIMENSIONS
KiSC issued 09, 2008 B

G GENERAL
KiSC issued 09, 2008 B

CONTENTS
GENERAL
1. PRODUCT IDENTIFICATION......................................................................... G-1
[1] ENGINE INDENTIFICATION .................................................................... G-1
(1) Engine Model Name and Engine Serial Number ................................. G-1
(2) Emission Label..................................................................................... G-2
(3) Cylinder Number.................................................................................. G-2
[2] Model Name and Serial Numbers.............................................................. G-3
2. GENERAL PRECAUTIONS............................................................................ G-4
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING.. G-5
[1] WIRING ..................................................................................................... G-5
[2] BATTERY................................................................................................... G-7
[3] FUSE.......................................................................................................... G-7
[4] CONNECTOR............................................................................................ G-7
[5] HANDLING OF CIRCUIT TESTER......................................................... G-9
4. LUBRICANTS, FUEL AND COOLANT ....................................................... G-10
5. TIGHTENING TORQUES ............................................................................. G-12
[1] GENERAL USE SCREWS, BOLTS AND NUTS................................. G-12
[2] STUD BOLTS.......................................................................................... G-12
[3] METRIC SCREWS, BOLTS AND NUTS ............................................. G-13
[4] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC
OR UNF THREADS ............................................................................... G-13
[5] PLUGS..................................................................................................... G-13
6. MAINTENANCE CHECK LIST..................................................................... G-14
7. CHECK AND MAINTENANCE..................................................................... G-16
[1] DAILY CHECK........................................................................................ G-16
[2] CHECK POINTS OF INITIAL 50 HOURS........................................... G-22
[3] CHECK POINTS OF EVERY 50 HOURS........................................... G-28
[4] CHECK POINTS OF EVERY 100 HOURS......................................... G-30
[5] CHECK POINTS OF EVERY 200 HOURS......................................... G-37
[6] CHECK POINT OF EVERY 300 HOURS ........................................... G-39
[7] CHECK POINT OF EVERY 400 HOURS ........................................... G-40
[8] CHECK POINTS OF EVERY 500 HOURS......................................... G-40
[9] CHECK POINT OF EVERY 1000 HOURS ......................................... G-41
[10]CHECK POINT OF EVERY 1 YEAR................................................... G-41
[11]CHECK POINTS OF EVERY 2 YEARS.............................................. G-42
[12]CHECK POINT OF EVERY 4 YEARS................................................ G-43
[13]OTHERS .................................................................................................. G-43
8. SPECIAL TOOLS.......................................................................................... G-46
[1] SPECIAL TOOLS FOR ENGINE .......................................................... G-46
[2] SPECIAL TOOLS FOR MACHINE........................................................G-47
9. TIRES............................................................................................................. G-53
[1] TYPE OF TIRE....................................................................................... G-53
[2] TIRE PRESSURE................................................................................... G-53
[3] VEHICLE LIMITATIONS ......................................................................... G-54
[4] CARGO BED........................................................................................... G-54
[5] SHOCK ABSORBERS............................................................................ G-55
KiSC issued 09, 2008 B

G-1
RTV500, WSM G GENERAL
1. PRODUCT IDENTIFICATION
[1] ENGINE INDENTIFICATION
(1) Engine Model Name and Engine Serial Number
When contacting the manufacture, always specify your engine
model name and serial number.
The engine model and its serial number need to be identified
before the engine can be serviced or parts replaced.
QEngine Serial Number
The engine serial number is an identified number for the engine.
It is marked after the engine model number.
It indicates month and year of manufacture as follows.
•Year of manufacture
W1010649
Alphabet or
Number Year Alphabet or Number Year
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014
(1) Engine Model Name
and Serial Number
KiSC issued 09, 2008 B

G-2
RTV500, WSM G GENERAL
•Month of manufacture
* Alphabetical letters “I” and “O” are not used.
e.g. GZ460F - 8 B A001
(a) (b)(c) (d)
W1011076
(2) Emission Label This label is attached on the cylinder head cover of the engine
certified to the requirements of EPA / CARB Emission regulations.
The content of the label is approved officially by EPA / CARB.
W1042484
(3) 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 and No.2
starting from the gear case side. W1011077
Month Engine Lot Number
January A0001 ~ A9999 B0001 ~ BZ999
February C0001 ~ C9999 D0001 ~ DZ999
March E0001 ~ E9999 F0001 ~ FZ999
April G0001 ~ G9999 H0001 ~ HZ999
May J0001 ~ J9999 K0001 ~ KZ999
June L0001 ~ L9999 M0001 ~ MZ999
July N0001 ~ N9999 P0001 ~ PZ999
August Q0001 ~ Q9999 R0001 ~ RZ999
September S0001 ~ S9999 T0001 ~ TZ999
October U0001 ~ U9999 V0001 ~ VZ999
November W0001 ~ W9999 X0001 ~ XZ999
December Y0001 ~ Y9999 Z0001 ~ ZZ999
(a) Engine Model Name : GZ460F
(b) Year : 8indicates 2008
(c) Month : Aor Bindicates January
(d) Lot number : (0001 ~ 9999 or A001 ~ Z999)
KiSC issued 09, 2008 B

G-3
RTV500, WSM G GENERAL
[2] Model Name and Serial Numbers
When contacting your local KUBOTA distributor, always specify
engine serial number, product serial number and hour meter
reading.
W1011386
(1) ROPS Serial Number
(2) Vehicle Serial Number
(3) Vehicle Identification Number
(4) Engine Serial Number
(5) Transmission Assembly Serial
Number
KiSC issued 09, 2008 B

G-4
RTV500, WSM G 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.
W1010794
(1) Grease
(2) Force
(3) Sharp Edge
(4) Axial Force
(5) Rotating Movement
(A) External Snap Ring
(B) Internal Snap Ring
KiSC issued 09, 2008 B

G-5
RTV500, WSM G 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.
IMPORTANTQ
• 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.
W10111140
[1] WIRING
• Securely tighten wiring terminals.
W10112160
• Do not let wiring contact dangerous part.
W10113130
• Securely insert grommet.
W10113880
(1) Negative Terminal (2) Positive Terminal
(1) Correct
(Securely Tighten) (2) Incorrect (Loosening Leads to Faulty Contact)
(1) Dangerous Part
(2) Wiring (Incorrect) (3) Wiring (Correct) (4) Dangerous Part
(1) Grommet (A) Correct
(B) Incorrect
KiSC issued 09, 2008 B