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Kubota RTV 900 Workshop Manual

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WORKSHOP MANUAL
UTILITY VEHICLE
RTV900
KiSC issued 04, 2006 A

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Summary of Contents for Kubota RTV 900

  • Page 1 WORKSHOP MANUAL UTILITY VEHICLE RTV900 KiSC issued 04, 2006 A...
  • Page 2 NEW TRANSMISSION The machine RTV900 serial numbers of the new transmission for Europe were changed into those starting with “20001” for homologation versions, and into those starting with “60001” for non-homologation version. KiSC issued 04, 2006 A...
  • Page 3 The New Transmission of RTV900. Additional information has been prepared as the WSM for 2006 Model based on the WSM for RTV900. Please use it by attaching to the end of the WSM (No. 97897-15320) of RTV900. April 2006 © KUBOTA Corporation 2006 KiSC issued 04, 2006 A...

  • Page 4: Table Of Contents

    CONTENTS TRAVELING SPEEDS..................... 1 G. GENERAL ...................... G-1 [1] LUBRICANTS, FUEL AND COOLANT..........G-1 [2] MAINTENANCE CHECK LIST..............G-3 [3] CHECK AND MAINTENANCE..............G-3 9. NEW TRANSMISSION ................9-M1 [1] MECHANISM................... 9-M1 [2] SERVICING ....................9-S1 KiSC issued 04, 2006 A...

  • Page 5: Traveling Speeds

    RTV900, WSM TRAVELING SPEEDS TRAVELING SPEEDS Model General Purpose Worksite Recreational 25 × 10 – 12 Knobby 25 × 10 – 12 HDWS 25 × 11 – 12 ATV Tire size (Rear) Range gear shift lever km/h (mph) 16 (10) Medium 29 (18) High...

  • Page 6: General

    Above 25 °C (77 °F): SAE30, 10W-30 or 10W-40 2.9 U.S.qts 2.4 Imp.qts 10.0 L Transmission case 2.6 U.S.gals KUBOTA UDT or SUPER UDT fluid* 2.2 Imp.gals 0.6 L Front axle case 0.63 U.S.qts KUBOTA UDT or SUPER UDT fluid* 0.52 Imp.qts...
  • Page 7 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.

  • Page 8: Maintenance Check List

    RTV900, WSM G GENERAL [2] MAINTENANCE CHECK LIST Period Indication on hour meter Refer- Impor- ence tant page Item Greasing Apply Period Indication on hour meter After purchase Refer- Impor- ence tant 1500 3000 1 year page years years Item Greasing Apply [3] CHECK AND MAINTENANCE...
  • Page 9 MECHANISM CONTENTS 1. STRUCTURE ....................9-M1 2. OIL FLOW ..................... 9-M3 3. BYPASS VALVE ................... 9-M4 4. CONTROL LINKAGE FOR BYPASS VALVE........... 9-M12 KiSC issued 04, 2006 A...

  • Page 10: Structure

    RTV900, WSM NEW TRANSMISSION 1. STRUCTURE (1) Input SHaft Section (2) Hydrostatic Transmission (3) Range Shift Gear Section (4) Front Wheel Drive Section Section KiSC issued 04, 2006 A 9-M1...

  • Page 11: New Transmission

    RTV900, WSM NEW TRANSMISSION (1) Input Shaft (Pump Shaft) (8) Piston (15) Variable Swashplate (Assist (21) Servo Piston (2) Feedback Lever (9) Cylinder Block (Pump) Motor) (22) Guide (3) Regulator Shaft (10) Port Block Cover (16) Piston (23) Cradle Bearing (4) Output Shaft (Motor Shaft) (11) Suction Oil Filter Cartridge (17) Cylinder Block (Assist Motor)
  • Page 12 RTV900, WSM NEW TRANSMISSION 2. OIL FLOW (1) HST Assembly (6) Oil Cooler (10) Charge Pump (15) Output Shaft (Motor Shaft) (2) Control Lever (Pedal) (7) Check and High Pressure (11) Cylinder Block (HST Pump) (16) Cylinder Block (Stationary (3) Servo Regulator Assembly Relief Valve (12) Servo Piston Motor)
  • Page 13 RTV900, WSM NEW TRANSMISSION 3. BYPASS VALVE (1) Spool A (Connects with VHT Pressure Release Knob) (2) Spool B (Connects with Brake Cam Lever) (3) Port Block Cover [A] At Running [B] At Dynamic Braking [C] When Applying the Brake and Stopping [D] When Pull the VHT Pressure Release Knob...
  • Page 14 RTV900, WSM NEW TRANSMISSION Neutral (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) Cylinder Block (Stationary Motor) (11) Check and High Pressure Relief Valve (12) Bypass Valve...
  • Page 15 RTV900, WSM NEW TRANSMISSION Pedal pressed halfway and under light load (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) Cylinder Block (Stationary Motor) (11) Check and High Pressure...
  • Page 16 RTV900, WSM NEW TRANSMISSION Pedal pressed fully and under light load (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) Cylinder Block (Stationary Motor) (11) Check and High Pressure...
  • Page 17 RTV900, WSM NEW TRANSMISSION Pedal pressed fully, under light load and assist motor startup 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) Cylinder Block...
  • Page 18 RTV900, WSM NEW TRANSMISSION Pedal pressed 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) Cylinder Block (Stationary Motor)
  • Page 19 RTV900, WSM NEW TRANSMISSION Dynamic Brake (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) Cylinder Block (Stationary Motor) (11) Check and High Pressure Relief Valve...
  • Page 20 RTV900, WSM NEW TRANSMISSION After dynamic brake, operating brake and pulling VHT pressure release knob creates a bypass circuit (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)
  • Page 21 RTV900, WSM NEW TRANSMISSION 4. CONTROL LINKAGE FOR BYPASS VALVE (1) Bypass Valve (3) Bypass Link 1 (5) VHT Pressure Release Cable (6) Brake Cam Lever (2) Bypass Link 2 (4) Spring The upper link that activates the bypass valve is operated manually (by pulling the VHT pressure release knob) and linked by a cable in order to activate the bypass link 2 (2).
  • Page 22 SERVICING CONTENTS 1. CHECKING AND ADJUSTING ..............9-S1 2. DISASSEMBLING AND ASSEMBLING ............9-S2 [1] DISMOUNTING TRANSAXLE ..............9-S2 KiSC issued 04, 2006 A...
  • Page 23 RTV900, WSM NEW TRANSMISSION 1. CHECKING AND ADJUSTING Checking Brake Rod CAUTION • When checking, park the machine on flat ground. • Work by two people when you measure pressure. 1. Remove the tension spring (5) from the bypass link 2 (6). 2.

  • Page 24: Draining Transmission Fluid/Coolant

    Transmission fluid capacity 2.6 U.S.gals 2.2 Imp.gals IMPORTANT • Use only KUBOTA SUPER UDT fluid. Use of other oils may damage the transmission. Refer to “LUBRICANTS, FUEL AND COOLANT”. (See page G-1.) • Do not mix different brands of fluid together.

  • Page 25: Battery

    RTV900, WSM NEW TRANSMISSION 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. Disconnect the negative cable (1) from the battery. 2. Disconnect the positive cable (2) from the battery. (1) Negative Cable (2) Positive Cable W1017351...
  • Page 26 RTV900, WSM NEW TRANSMISSION Muffler Cover, Muffler, Hydraulic Oil Tank, Hydraulic Cylinder and Hydraulic Control Valve 1. Remove the muffler cover (1) and muffler (2). 2. Disconnect the quick couplers from hydraulic control valve. 3. Remove the cotter pin and clevis pin, then remove the hydraulic cylinder (3).

  • Page 27: Air Cleaner/Wire Harness/Radiator Hose

    RTV900, WSM NEW TRANSMISSION Air Cleaner, Wire Harness, Radiator Hose (Upper), Cables and Brake Cylinder 1. Remove the air cleaner body and intake hose as a unit. 2. Disconnect the wire harness (1) from engine, alternator and stator motor. 3. Remove the ground cable (5) and positive cable (4). 4.
  • Page 28 RTV900, WSM NEW TRANSMISSION VHT Pressure Release Cable 1. Loosen the lock nut (2) and remove the VHT pressure release cable (1) from the bypass link 1 (3). (When reassembling) NOTE • When adjusting the cable tension, take care not to apply excessive tension.

  • Page 29: Rear Axle Bracket

    RTV900, WSM NEW TRANSMISSION Rear Axle Bracket 1. Remove the boot band (2) on both sides. 2. Place the stand under the both side of frame. 3. Remove the rear wheels. 4. Remove the leaf spring mounting bolt (1) and nut, and remove the rear axle bracket assembly (3) by use the axle support (4).

  • Page 30: Dismounting Transmission/Engine One Piece Assembly

    RTV900, WSM NEW TRANSMISSION Dismounting Transmission and Engine One Piece Assembly 1. Remove the universal joint mounting screw and disconnect the universal joint (4) from transmission. 2. Set the power train support (5) and remove the mission frame (3) mounting bolt (2) and nut. 3.
  • Page 31 EDITOR : KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD. 64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN PHONE : ( 81 ) 72-241-1129 : ( 81 ) 72-245-2484 E-mail : ksos-pub@kubota.co.jp KUBOTA Corporation Printed in Japan 2006. 04, S, EI, EI, e...

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