wsm RTV900 Instruction manual

WORKSHOP MANUAL
UTILITY VEHICLE
RTV900
KiSC issued 03, 2008 A

TO THE READER
This Workshop Manual has been prepared to provide servicing personnel with
information on the mechanism, service and maintenance of RTV900. It is divided into
three parts, "General", "Mechanism" and "Servicing".
■General
Information on the product identification, the general precautions, maintenance
check list, check and maintenance and special tools are described.
■Mechanism
Information on the construction and function are included. This part should be
understood before proceeding with troubleshooting, disassembling and servicing.
Refer to Diesel Engine Workshop Manual (Code No. 9Y021-01872) for the one which
has not been described to this workshop manual.
■Servicing
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.
January 2004
© KUBOTA Corporation 2004
KiSC issued 03, 2008 A

1
RTV900, 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.
■IMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
■NOTE : Gives helpful information.
KiSC issued 03, 2008 A

2
RTV900, 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 03, 2008 A

3
RTV900, 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 spilled on the engine.
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 03, 2008 A

4
RTV900, 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.
KiSC issued 03, 2008 A

5
RTV900, 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 03, 2008 A

6
RTV900, WSM SAFETY INSTRUCTIONS
KiSC issued 03, 2008 A

7
RTV900, WSM SAFETY INSTRUCTIONS
KiSC issued 03, 2008 A

8
RTV900, WSM SAFETY INSTRUCTIONS
KiSC issued 03, 2008 A

9
RTV900, WSM SPECIFICATIONS
SPECIFICATIONS
NOTE: * Manufacture’s estimate
The company reserves the right to change the specifications without notice. W1028103
Model General Purpose Worksite Turf Recreational
Engine
Maker KUBOTA
Model D902-E-UV / D902-E2-UV
Type Indirect Injection. Vertical, water-cooled, 4-cycle diesel
Number of cylinders 3
Bore and stroke 72 ×73.6 mm (2.83 ×2.90 in.)
Total displacement 898 cm3(54.8 cu.in.)
Engine gross power (DIN) 16.1 kW (21.6 HP)
Rated revolution 53.3 r/s [3200 min-1 (rpm)]
Maximum torque 54.7 N·m (5.6 kgf·m, 40.5 lbf·ft) / 30.0 to 36.7 r/s [1800 to 2200 min-1 (rpm)]
Battery 12 V, CCA : 535 A, RC : 80 min.
Starting system Electric starting with cell starter, 12 V, 1.2 kW
Lubrication system Forced lubrication by trochoidal pump
Cooling system Pressurized radiator, forced circulation with water pump
Fuel Diesel fuel No. 2-D [above −10 °C (14 °F)],
Diesel fuel No. 1 [below −10 °C (14 °F)]
Capacities
Fuel tank 28 L (7.4 U.S.gals, 6.2 Imp.gals)
Engine crankcase (with filter) 3.1 L (3.3 U.S.qts, 2.7 Imp.qts)
Engine coolant (with recovery tank) 4.0 L (4.2 U.S.qts, 3.5 Imp.qts)
Transmission case 10.0 L (2.6 U.S.gals, 2.2 Imp.gals)
Front axle case 0.6 L (0.63 U.S.qts, 0.52 Imp.qts)
Knuckle case Ref. 0.1 L (0.10 U.S.qts, 0.09 Imp.qts)
Brake fluid (reservoir and lines) 0.4 L (0.42 U.S.qts, 0.35 Imp.qts)
Hydraulic lift oil
(Hydraulic dumping system model) 8.0 L (2.1 U.S.gals, 1.8 Imp.gals)
Hydraulic lift oil (Hydraulic PTO model) 7.0 L (1.8 U.S.gals, 1.5 Imp.gals)
Power steering oil 5.9 L (1.6 U.S.gals, 1.3 Imp.gals)
Travelling
system
Tires Front 25 ×10 – 12
Knobby, 6PLY 25 ×10 – 12 HDWS, 6PLY 23 ×10.5 – 12 Turf, 4PLY 25 ×10 – 12 ATV, 6PLY
Rear 25 ×10 – 12
Knobby, 6PLY 25 ×10 – 12 HKDWS, 6PLY 23 ×10.5 – 12 Turf, 4PLY 25 ×11 – 12 ATV, 6PLY
Steering Hydrostatic power
Transmission Continuously variable hydro transmission (VHT)
Wheels and drive 4 wheels, rear 2WD or 4WD
Gear selection Hi-Med-Lo range, forward, neutral, reverse
Differential lock Standard; foot operated with mechanical holder
Brake Front / Rear Wet disc type
Parking brake Rear wheel, hand lever
Turning diameter 7.5 m (24.6 feet)
Suspension Front Independent, macpherson strut-type
Rear Semi-independent, devion axle with leaf springs and shock absorber
KiSC issued 03, 2008 A

10
RTV900, WSM SPECIFICATIONS
NOTE: * Manufacture’s estimate
The company reserves the right to change the specifications without notice. W1030858
Model General Purpose Worksite Recreational Recreational
Dimensions
Overall length 2990 mm
(117.7 in.) 3030 mm (119.3 in.)
Overall width 1520 mm (59.8 in.)
Overall height 2015 mm (79.3 in.) 1989 mm
(78.3 in.) 2015 mm (79.3 in.)
Front tread center 1150 mm (45.3 in.)
Rear tread center 1180 mm (46.5 in.)
Wheel base 1965 mm (77.4 in.)
Ground
clearance Front axle 215 mm (8.5 in.) 180 mm (7.5 in.) 215 mm (8.5 in.)
Rear axle 210 mm (8.3 in.) 185 mm (7.3 in.) 210 mm (8.3 in.)
Weight 805 kg (1775 lbs) 830 kg (1830 lbs) 850 kg (1874 lbs) 820 kg (1808 lbs)
Max. rolling weight (Towing capacity) 590 kg (1300 lbs)
Payload capacity 740 kg (1630 lbs)
Cargo bed
Width 1320 mm (52.0 in.)
Length 1180 mm (46.7 in.)
Depth 290 mm (11.4 in.)
Volume 0.455 m3(16 cu.ft.)
Bed height (unload) 800 mm (31.5 in.)
Cargo bed load 500 kg (1102 lbs)
Sound level (operator ear) 87 db (A)
Front deluxe guard – Standard
Body color Orange Camo
Bed lift – Standard –
Auxiliary control valve – Standard –
Speedometer – Standard
KiSC issued 03, 2008 A

11
RTV900, WSM TRAVELLING SPEEDS
TRAVELLING SPEEDS
The company reserves the right to change the specifications without notice. W1035065
Model General Purpose Worksite Turf Recreational
Tire size (Rear) 25 ×10 – 12
Knobby 25 ×10 – 12 HDWS 25 ×10.5 – 12 Turf 25 ×10 – 12 HDWS 23 ×10.5 – 12 Turf 25 ×11 – 12 ATV
Rangegearshift
lever km/h (mph) km/h (mph) km/h (mph) km/h (mph)
Low 16 (10) 16 (10) 14 (8) 16 (10) 14 (8) 15 (9)
Medium 29 (18) 29 (18) 26 (16) 29 (18) 26 (16) 29 (18)
High 40 (25) 40 (25) 36 (22) 40 (25) 36 (22) 40 (25)
Reverse 24 (15) 24 (15) 21 (13) 24 (15) 21 (13) 22 (14)
KiSC issued 03, 2008 A

12
RTV900, WSM DIMENSIONS
DIMENSIONS
KiSC issued 03, 2008 A

G GENERAL
KiSC issued 03, 2008 A

CONTENTS
GENERAL
1. PRODUCT IDENTIFICATION......................................................................... G-1
2. GENERAL PRECAUTIONS ............................................................................ G-2
3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING.. G-3
[1] WIRING ..................................................................................................... G-3
[2] BATTERY................................................................................................... G-5
[3] FUSE.......................................................................................................... G-5
[4] CONNECTOR............................................................................................ G-5
[5] HANDLING OF CIRCUIT TESTER......................................................... G-7
4. LUBRICANTS, FUEL AND COOLANT ......................................................... G-8
5. TIGHTENING TORQUES ............................................................................. G-11
[1] GENERAL USE SCREWS, BOLTS AND NUTS................................. G-11
[2] STUD BOLTS.......................................................................................... G-11
[3] METRIC SCREWS, BOLTS AND NUTS ............................................. G-12
[4] AMERICAN STANDARD SCREWS, BOLTS AND NUTS WITH UNC
OR UNF THREADS............................................................................... G-12
[5] PLUGS..................................................................................................... G-12
6. MAINTENANCE CHECK LIST..................................................................... G-13
[1] FROM FIRST 50 HOURS TO EVERY 550 HOURS......................... G-13
[2] FROM EVERY 600 HOURS TO EVERY 4 YEARS.......................... G-15
7. CHECK AND MAINTENANCE..................................................................... G-17
[1] DAILY CHECK........................................................................................ G-17
[2] CHECK POINTS OF INITIAL 50 HOURS........................................... G-23
[3] CHECK POINTS OF EVERY 50 HOURS........................................... G-30
[4] CHECK POINTS OF EVERY 100 HOURS......................................... G-32
[5] CHECK POINTS OF EVERY 200 HOURS......................................... G-38
[6] CHECK POINT OF EVERY 300 HOURS ........................................... G-41
[7] CHECK POINTS OF EVERY 400 HOURS......................................... G-42
[8] CHECK POINT OF EVERY 500 HOURS ........................................... G-42
[9] CHECK POINT OF EVERY 800 HOURS ........................................... G-42
[10]CHECK POINT OF EVERY 1500 HOURS ......................................... G-42
[11]CHECK POINT OF EVERY 3000 HOURS ......................................... G-43
[12]CHECK POINT OF EVERY 1 YEAR................................................... G-43
[13]CHECK POINTS OF EVERY 2 YEARS.............................................. G-43
[14]CHECK POINT OF EVERY 4 YEARS................................................ G-46
[15]OTHERS.................................................................................................. G-46
8. SPECIAL TOOLS.......................................................................................... G-49
[1] SPECIAL TOOLS FOR ENGINE .......................................................... G-49
[2] SPECIAL TOOLS FOR TRACTOR....................................................... G-53
9. TIRES............................................................................................................. G-59
[1] TYPE OF TIRE....................................................................................... G-60
[2] TYPE PRESSURE.................................................................................. G-61
[3] VEHICLE LIMITATIONS ......................................................................... G-61
[4] CARGO BED........................................................................................... G-62
KiSC issued 03, 2008 A

G-1
RTV900, WSM G GENERAL
1. PRODUCT IDENTIFICATION
When contacting your local KUBOTA distributor, always specify
engine serial number, product serial number and hour meter
reading.
W1011386
(1) Vehicle Identification Plate
(2) Product Identification Number (3) Engine Serial Number D902-E-UV : up tp 4Z9999
D902-E2-UV : from 5A0001
(4) Transmission Assembly Serial
Number
KiSC issued 03, 2008 A

G-2
RTV900, 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 03, 2008 A

G-3
RTV900, 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.
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.
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 03, 2008 A

G-4
RTV900, WSM G GENERAL
• Securely clamp, being careful not to damage wiring.
W10114580
• Clamp wiring so that there is no twist, unnecessary sag, or
excessive tension, except for movable part, where sag be
required.
W10115870
• In installing a part, take care not to get wiring caught by it.
W10116700
• After installing wiring, check protection of terminals and clamped
condition of wiring, only connect battery.
W10117350
(1) Clamp
• Wind Clamp Spirally
(2) Wire Harness
(3) Clamp
(4) Welding Dent
(1) Wiring
(2) Clamp (A) Correct (B) Incorrect
(1) Wiring (A) Incorrect
(1) Cover
• Securely Install Cover
KiSC issued 03, 2008 A