Page 1 WORKSHOP MANUAL UTILITY VEHICLE RTV900 KiSC issued 03, 2008 A...
Page 2 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.
Page 3 RTV900, WSM SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 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.
Page 4 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.
Page 5 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.
Page 6 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...
Page 7 RTV900, WSM SAFETY INSTRUCTIONS 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 parts number is listed in the parts list. KiSC issued 03, 2008 A...
Page 8 RTV900, WSM SAFETY INSTRUCTIONS KiSC issued 03, 2008 A...
Page 9 RTV900, WSM SAFETY INSTRUCTIONS KiSC issued 03, 2008 A...
Page 10 RTV900, WSM SAFETY INSTRUCTIONS KiSC issued 03, 2008 A...
Page 11 RTV900, WSM SPECIFICATIONS SPECIFICATIONS Model General Purpose Worksite Turf Recreational Maker KUBOTA Model D902-E-UV / D902-E2-UV Type Indirect Injection. Vertical, water-cooled, 4-cycle diesel Number of cylinders 72 × 73.6 mm (2.83 × 2.90 in.) Bore and stroke Total displacement 898 cm (54.8 cu.in.)
Page 12 RTV900, WSM SPECIFICATIONS Model General Purpose Worksite Recreational Recreational Overall length 2990 mm 3030 mm (119.3 in.) (117.7 in.) Overall width 1520 mm (59.8 in.) Overall height 1989 mm 2015 mm 2015 mm (79.3 in.) (78.3 in.) (79.3 in.) Dimensions Front tread center 1150 mm (45.3 in.)
Page 13 RTV900, WSM TRAVELLING SPEEDS TRAVELLING SPEEDS Model General Purpose Worksite Turf Recreational 25 × 10 – 12 25 × 10 – 12 25 × 10.5 – 25 × 10 – 12 23 × 10.5 – 25 × 11 – 12...
Page 14 RTV900, WSM DIMENSIONS DIMENSIONS KiSC issued 03, 2008 A...
Page 15 GENERAL KiSC issued 03, 2008 A...
Page 16: Table Of Contents
GENERAL CONTENTS 1. PRODUCT IDENTIFICATION ................. G-1 2. GENERAL PRECAUTIONS ................G-2 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING .. G-3 [1] WIRING ..................... G-3 [2] BATTERY....................G-5 [3] FUSE......................G-5 [4] CONNECTOR .................... G-5 [5] HANDLING OF CIRCUIT TESTER............G-7 4.
Page 17: Product Identification
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. (1) Vehicle Identification Plate (3) Engine Serial Number (2) Product Identification Number D902-E-UV : up tp 4Z9999...
Page 18: General Precautions
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.
Page 19: Handling Precautions For Electrical Parts And Wiring
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 damage loosened connection every year.
Page 20 RTV900, WSM G GENERAL • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp • Wind Clamp Spirally (4) Welding Dent (2) Wire Harness W10114580 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.
Page 21: Battery
RTV900, WSM G GENERAL [2] BATTERY • 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).
Page 22 RTV900, WSM G GENERAL • In separating connectors, do not pull wire harnesses. • Hold connector bodies to separate. (A) Correct (B) Incorrect W10122720 • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make certain there is no terminal being exposed or displaced.
Page 23: Handling Of Circuit Tester
RTV900, WSM G GENERAL [5] HANDLING OF CIRCUIT TESTER • Use tester correctly following manual provided with tester. • Check for polarity and range. W1012684 KiSC issued 03, 2008 A...
Page 24: Lubricants, Fuel And Coolant
RTV900, WSM G GENERAL 4. LUBRICANTS, FUEL AND COOLANT Place Capacity Lubricants, fuel and coolant 28.0 L No. 2-D diesel fuel No. 1-D diesel fuel if temperature is below −10 °C Fuel tank 7.4 U.S.gals 6.2 Imp.gals (14 °F) 4.0 L Cooling system 4.2 U.S.qts...
Page 25 RTV900, WSM G GENERAL Greasing Place No. of greasing point Capacity Type of grease VHT link Until grease overflows Battery terminal Cargo lift cylinder pivot Multipurpose type Cargo bed pivot grease NLGI-2 or NLGI-1 Parking brake Moderate amount (GC-LB) linkage...
Page 26 RTV900, WSM G GENERAL (Continued) • Lubricating Oil With the emission control now in effect, the CF-4 and CG-4 lubricating oils have been developed for use of a low-sulfur fuel on-road vehicle engines. When an off-road vehicle engine runs on a high-sulfur fuel, it is advisable to employ the CF, CD or CE lubricating oil with a high total base number.
Page 27: Tightening Torques
RTV900, WSM G GENERAL 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of...
Page 28: Metric Screws, Bolts And Nuts
RTV900, WSM G GENERAL [3] METRIC SCREWS, BOLTS AND NUTS Property class 8.8 Property class 10.9 Grade Unit Nominal N·m kgf·m lbf·ft N·m kgf·m lbf·ft Diameter 23.6 to 27.4 2.4 to 2.8 17.4 to 20.2 29.4 to 34.3 3.0 to 3.5 21.7 to 25.3...
Page 29: Maintenance Check List
RTV900, WSM G GENERAL 6. MAINTENANCE CHECK LIST [1] FROM FIRST 50 HOURS TO EVERY 550 HOURS IMPORTANT • The jobs indicated by must be done after the first 50 hours of operation. (To be continued) Indication on hour meter...
Page 30 RTV900, WSM G GENERAL (Continued) Indication on hour meter Refe- Period Impor- rence Item tant page Tire wear Check G-30 Front axle case oil Change G-42 Knuckle axle case oil Change G-42 Engine valve clearance Adjust – Fuel injection nozzle injection Check –...
Page 31: From Every 600 Hours To Every 4 Years
RTV900, WSM G GENERAL [2] FROM EVERY 600 HOURS TO EVERY 4 YEARS IMPORTANT • *1 : Air cleaner should be cleaned more often in dusty conditions than in normal conditions. • *2 : Every year or every 6 times of cleaning.
Page 32 RTV900, WSM G GENERAL (Continued) Service Interval After purchase Refe- Period Impor- rence Item 1500 3000 1 year 2 years 4 years tant page Check G-39 Radiator hose and clamp Replace – Check G-40 Power steering oil line Replace 6-S8...
Page 33: Check And Maintenance
RTV900, WSM G 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"...
Page 34 RTV900, WSM G 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.
Page 35 RTV900, WSM G 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.
Page 36 RTV900, WSM G 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.
Page 37 RTV900, WSM G 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.
Page 38 RTV900, WSM G GENERAL Checking Gauges, Meter and Easy Checker (TM) 1. Inspect the instrument panel for broken gauge(s), meter(s) and Easy Checker lamps. 2. Replace if broken. W1056786 Checking Head Light, Turn Signal Light etc. 1. Inspect the lights for broken bulbs and lenses.
Page 39: Check Points Of Initial 50 Hours
RTV900, WSM G 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. Tire sizes Inflation pressure 25 x 10 - 12 Knobby, Front and Rear...
Page 40 RTV900, WSM G GENERAL 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 can burn. 1. Remove the oil filter (1).
Page 41 RTV900, WSM G GENERAL Cleaning Muffler This vehicle is equipped with a spark arrester muffler approved by the U.S. Forest Service. If requires periodic maintenance to ensure it's effectiveness. CAUTION • Before touching any part of an exhaust system, be absolutely sure that it has sufficient time to cool.
Page 42 RTV900, WSM G GENERAL Changing Transmission Oil CAUTION • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. 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.
Page 43 RTV900, WSM G GENERAL Replacing Transmission Oil Filter CAUTION • Be sure to stop the engine before changing the oil filter cartridge. • Allow engine too cool down sufficiently, oil can be hot and can burn. 1. Remove the drain plug (4) at the bottom of the transmission case and drain the oil completely into the oil pan.
Page 44 RTV900, WSM G 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.
Page 45 RTV900, WSM G 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- S13.) (1) Drain Plug...
Page 46: Check Points Of Every 50 Hours
RTV900, WSM G GENERAL [3] CHECK POINTS OF EVERY 50 HOURS Checking Engine Start System CAUTION • Do not allow anyone near the vehicle while testing. • If the vehicle does not pass the test do not operate the vehicle.
Page 47 RTV900, WSM G GENERAL Greasing 1. Apply a small amount of multi-purpose grease to the following points every 50 hours. If you operated the machine in extremely wet and muddy conditions, lubricate grease fittings more often. (1) Grease Fitting (VHT Link)
Page 48: Check Points Of Every 100 Hours
RTV900, WSM G GENERAL Oiling 1. Apply a small amount of engine oil to the accelerator wire (1) every 50 hours. (1) Accelerator Wire W1063874 [4] CHECK POINTS OF EVERY 100 HOURS Changing Engine Oil 1. See page G-23. W1065099 Cleaning Muffler 1.
Page 49 RTV900, WSM G GENERAL Cleaning Spark Arrester CAUTION • After operating the engine, do not touch the muffler, exhaust pipe, or spark arrester until they have had sufficient time to cool. This screen type spark arrester was examined, tested, and qualified in accordance with the USDA Forest Service Standard 5100-1c, "Spark Arresters for Internal Combustion Engines"...
Page 50 RTV900, WSM G 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...
Page 51 RTV900, WSM G GENERAL Checking Battery Condition 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.
Page 52 RTV900, WSM G 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.
Page 53 RTV900, WSM G 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.
Page 54: Check Points Of Every 200 Hours
RTV900, WSM G GENERAL 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.
Page 55 RTV900, WSM G GENERAL Checking Front Brake Case 1. See page G-29. W1069089 Checking Brake Hose and Pipe 1. See page G-29. W1069157 Checking Radiator Hose and Clamp Check to see if radiator hoses (1) are properly fixed every 200 hours of operation or six months, whichever comes first.
Page 56 RTV900, WSM G GENERAL Changing Hydraulic Lift Oil (Hydraulic Dumping System Model) 1. Park the vehicle on a firm, flat and level surface. 2. Raise the cargo bed and mount the safety support. 3. To drain the used oil, remove the drain plug (1) and filling plug (2) and drain the oil completely into the oil pan.
Page 57: Check Point Of Every 300 Hours
RTV900, WSM G GENERAL Changing Power Steering Oil CAUTION • Be sure to stop the engine before changing the oil. • Allow engine to cool down sufficiently, oil can be hot and can burn. 1. To drain the used oil, remove the suction hose (1) on the gear pump (2).
Page 58: Check Points Of Every 400 Hours
RTV900, WSM G GENERAL [7] CHECK POINTS OF EVERY 400 HOURS Changing Knuckle Case Oil 1. Remove the tire. 2. Park the vehicle on a firm, flat and level surface. 3. To drain the used oil, remove the drain and filling plugs at the LH knuckle case and drain the oil completely into the oil pan.
Page 59: Check Point Of Every 3000 Hours
RTV900, WSM G GENERAL [11] CHECK POINT OF EVERY 3000 HOURS Checking Injection Pump 1. See page 1-S15. [12] CHECK POINT OF EVERY 1 YEAR Replacing Air Cleaner Primary Element and Secondary Element 1. Replace the both primary and secondary elements.
Page 60 RTV900, WSM G 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.
Page 61 RTV900, WSM G GENERAL Anti-Freeze CAUTION • When using antifreeze, put on some protection such as rubber gloves. (Antifreeze contains poison.) • If 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.
Page 62: Check Point Of Every 4 Years
RTV900, WSM G GENERAL 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.
Page 63 RTV900, WSM G 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.
Page 64 RTV900, WSM G GENERAL 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.
Page 65: Special Tools
RTV900, WSM G GENERAL 8. SPECIAL TOOLS [1] SPECIAL TOOLS FOR ENGINE Special Use Puller Set Code No.: 07916-09032 Application: Use exclusively for pulling out bearing, gears and other parts with ease. W1024050 Piston Ring Compressor Code No.: 07909-32111 Application: Use exclusively for pushing in the piston with piston rings into the cylinder.
Page 66 RTV900, WSM G GENERAL Diesel Engine Compression Tester (for Glow Plug) Code No.: 07909-39081 (Assembly) 07909-31301 (L) 07909-31291 (K) 07909-31311 (M) Application: Use to measure diesel engine compression and diagnostics of need for major overhaul. (1) Gauge (4) Adaptor L...
Page 67 RTV900, WSM G GENERAL Connecting Rod Alignment Tool Code No.: 07909-31661 Application: Use to check the connecting rod alignment. Applicable: Connecting rod big end I.D. range 30 to 75 mm (1.18 to 2.95 in.) dia. Connecting rod length 65 to 300 mm (2.56 to 11.81 in.)
Page 68 RTV900, WSM G GENERAL Valve Guide Replacing Tool Application: Use to press out and press fit the valve guide. 20 mm dia. (0.79 in. dia.) 9.96 to 9.98 mm dia. (0.3921 to 0.3929 in. dia.) 5.5 to 5.7 mm dia. (0.2165 to 0.2244 in. dia.) 200 mm (8.66 in.)
Page 69: Special Tools For Tractor
RTV900, WSM G GENERAL Crankshaft Bearing 1 Replacing Tool Application: Use to press out and press fit the crankshaft bearing 1. [Press Out] 135 mm (5.31 in.) 72 mm (2.83 in.) 40 mm radius (1.57 in. radius) 10 mm (0.39 in.) 22 mm (0.87 in.)
Page 70 RTV900, WSM G GENERAL Relief Valve Pressure Tester Code No.: 07916-50045 Application: This allows easy measurement of relief set pressure. (1) Gauge (07916-50322) (6) Adaptor C (PS3/8) (07916-50371) (2) Cable (07916-50331) (7) Adaptor D (PT1/8) (07916-50381) (3) Threaded Joint (07916-50401)
Page 71 RTV900, WSM G GENERAL Axle Support Application: Use for removing and installing rear axle bracket. 254.0 mm (10.0 in.) 44.5 mm (1.75 in.) 79.5 mm (3.13 in.) 12.7 mm (0.50 in.) 28.7 mm dia. (1.13 in. dia.) 69.9 mm (2.75 in.) 38.1 mm (1.50 in.)
Page 72 RTV900, WSM G GENERAL Power Train Support Application: Use for dismounting and mounting transmission and engine one piece assembly. 186.9 mm (7.36 in.) 203.2 mm (8.0 in.) 44.5 mm (1.75 in.) 69.9 mm (2.75 in.) 317.5 mm (12.5 in.) 3.3 mm (0.13 in.) 25.4 mm dia.
Page 73 RTV900, WSM G GENERAL Lower Arm Bush Tool Application: Use for removing and installing lower arm rubber bush. 256.5 mm (10.10 in.) 2.6 mm (0.102 in.) 22 mm (0.866 in.) 262.5 mm (10.33 in.) 34.65 mm dia. (1.364 in. dia.) 35 mm dia.
Page 74 RTV900, WSM G GENERAL Check and High Pressure Relief Valve Assembly Tool Application: Use for Readjusting relief valve pressure. 1.05 rad (10 °) 30 mm (1.181 in.) Chamfer 0.4 mm (0.157 in.) 21 mm (0.827 in.) Chamfer 3 mm (0.118 in.) Chamfer 0.3 mm (0.012 in.)
Page 75: Tires
RTV900, WSM G GENERAL 9. TIRES CAUTION • Do not attempt 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 below.
Page 76: Type Of Tire
RTV900, WSM G GENERAL [1] TYPE OF TIRE (1) Knobby Tire (3) Turf Tire (2) Heavy Duty Work Site Tire (HDWS) (4) All Terrain Vehicle Tire (ATV) W1092542 G-60 KiSC issued 03, 2008 A...
Page 77: Type Pressure
RTV900, WSM G GENERAL [2] TYPE PRESSURE 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. Tire sizes...
Page 78: Cargo Bed
RTV900, WSM G GENERAL [4] CARGO BED 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.) •...
Page 79 ENGINE KiSC issued 03, 2008 A...
Page 80 MECHANISM CONTENTS 1. ENGINE BODY ..................... 1-M1 [1] HALF-FLOATING HEAD COVER ............1-M1 [2] GEAR CASE ................... 1-M1 [3] OIL PAN ....................1-M2 2. LUBRICATING SYSTEM ................1-M3 3. COOLING SYSTEM ..................1-M4 4. FUEL SYSTEM ..................... 1-M5 KiSC issued 03, 2008 A...
Page 81: Engine Body
RTV900, WSM ENGINE 1. ENGINE BODY [1] HALF-FLOATING HEAD COVER The rubber packing is fitting in to maintain the head cover 0.5 mm or so off the cylinder head. This arrangement helps reduce noise coming from the cylinder head. (1) Cylinder Head Cover...
Page 82: Oil Pan
RTV900, WSM ENGINE [3] OIL PAN The oil pan is expanded under the gear case. Therefore, the height of the engine can be lowered more than so far while securing a necessary amount of oil. (1) Gear Case (3) Crankcase...
Page 83: Lubricating System
RTV900, WSM ENGINE 2. LUBRICATING SYSTEM (1) Rocker Arm (2) Oil Pressure Switch (3) Rocker Arm Shaft (4) Valve (5) Idle Gear (6) Crankshaft (7) Oil Pump (8) Oil Strainer (9) Relief Valve (10) Push Rod (11) Tappet (12) Camshaft...
Page 84: Cooling System
RTV900, WSM ENGINE 3. COOLING SYSTEM (1) Radiator (5) Thermostat A : From Transmission Oil B : To Transmission Oil Cooler (2) Fan Drive Motor (6) Cylinder Head Cooler (3) Radiator Fan (7) Cylinder Block (4) Water Pump The cooling system consists of a radiator (1), a radiator fan (3), a centrifugal water pump (4) and a thermostat (5).
Page 85: Fuel System
RTV900, WSM ENGINE 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 W1013691 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.
Page 86 SERVICING CONTENTS 1. TROUBLESHOOTING ..................1-S1 2. SERVICING SPECIFICATIONS ..............1-S4 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-S13 (3) Cooling System.................1-S13 (4) Fuel System ..................1-S16 [2] PREPARATION ..................1-S18 (1) Removing Battery ................1-S18 (2) Separating Radiator ................1-S18 (3) Separating Fuel Tank................1-S19...
Page 87: Troubleshooting
RTV900, WSM ENGINE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Engine Does Not No fuel Replenish fuel Start Air in the fuel system Bleed G-46 Water in the fuel system Change fuel and – repair or replace fuel system...
Page 88 RTV900, WSM ENGINE Reference Symptom Probable Cause Solution Page Engine Revolution Is Fuel filter clogged or dirty Replace G-37 Not Smooth Air cleaner clogged Clean or replace G-34 Fuel leak due to loose injection pipe retaining nut Tighten retaining nut...
Page 89 RTV900, WSM ENGINE Reference Symptom Probable Cause Solution Page Water Mixed into Cylinder head gasket defective Replace 1-S23 Lubricant Oil Cylinder block or cylinder head flawed Replace – Low Oil Pressure Engine oil insufficient Replenish Oil strainer clogged Clean 1-S25...
Page 90: Servicing Specifications
RTV900, WSM ENGINE 2. SERVICING SPECIFICATIONS ENGINE BODY Item Factory Specification Allowable Limit Compression Pressure 3.53 to 4.02 MPa 2.55 MPa 36.0 to 41.0 kgf/cm 26.0 kgf/cm 512 to 583 psi 370 psi Variance among Cylinder – 10 % or less Top Clearance 0.50 to 0.70 mm...
Page 91 RTV900, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.045 mm 0.15 mm 0.00063 to 0.00177 in. 0.0059 in. Rocker Arm Shaft O.D. 10.473 to 10.484 mm –...
Page 92 RTV900, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Piston Pin Bore I.D. 20.000 to 20.013 mm 20.05 mm 0.78740 to 0.78791 in. 0.7894 in. Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.038 mm 0.10 mm 0.00055 to 0.00150 in.
Page 93 RTV900, WSM ENGINE ENGINE BODY (Continued) Item Factory Specification Allowable Limit Crankpin to Crankpin Bearing Oil Clearance 0.020 to 0.051 mm 0.15 mm 0.00079 to 0.00201 in. 0.0059 in. Crankpin O.D. 33.959 to 33.975 mm – 1.33697 to 1.33760 in.
Page 94 RTV900, WSM ENGINE LUBRICATING SYSTEM Engine Oil Pressure At Idle Speed – More than 98 kPa 1.0 kgf/cm 14 psi At Rated Speed 196 to 441 kPa 147 kPa 2.0 to 4.5 kgf/cm 1.5 kgf/cm 28 to 64 psi 21 psi...
Page 95: Tightening Torques
RTV900, WSM ENGINE 3. TIGHTENING TORQUES Tightening torques of screws and nuts on the table below are especially specified. (For general use screws and nuts : See page G-11.) Item Size x Pitch N·m kgf·m lbf·ft Engine mounting screw –...
Page 96: Checking, Disassembling And Servicing
RTV900, WSM ENGINE 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING CAUTION • Be sure to check that the speed is neutrality before the following checks. • When checking, park the machine on flat ground and apply the parking brake.
Page 97 RTV900, WSM 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.
Page 98 RTV900, WSM ENGINE Valve Clearance IMPORTANT • The valve clearance must be checked and adjusted when engine is cold. 1. Remove the cylinder head cover, the glow plugs and the timing window cover. 2. Align the "1TC" mark (1) on the flywheel and center of timing window (2) so that the No.
Page 99: Lubricating System
RTV900, WSM ENGINE (2) Lubricating System Engine Oil Pressure CAUTION • Work by people when you measure pressure. 1. Remove the engine oil pressure switch, and set an oil pressure tester (Code No.: 07916-32032). 2. Start the engine. After warming up, measure the oil pressure of both idling and rated speeds.
Page 100 RTV900, WSM ENGINE Fan Belt Damage and Wear 1. Check the fan belt for damage. 2. If the fan belt is damaged, replace it. 3. Check if the fan belt is worn and sunk in the pulley groove. 4. If the fan belt is nearly worn out and deeply sunk in the pulley groove, replace it.
Page 101 RTV900, WSM ENGINE CAUTION • When removing the radiator cap, wait at least ten minutes after the engine has stopped and cooled down. Otherwise, hot water way gush out, scalding nearby people. Radiator Cap Air Leakage 1. Set a radiator tester (1) and an adaptor (2) on the radiator cap.
Page 102: Fuel System
RTV900, WSM ENGINE (4) Fuel System Injection Timing 1. Remove the injection pipes. 2. Remove the engine stop solenoid and the timing window cover. 3. Turn the flywheel counterclockwise (facing the flywheel) until fuel flows from the delivery valve holder.
Page 103 RTV900, WSM ENGINE 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.
Page 104: Preparation
RTV900, WSM ENGINE Valve Seat Tightness 1. Set the injection nozzle to a nozzle tester (Code No. 07909- 31361). 2. Raise the fuel pressure, and keep at 12.75 MPa (130 kgf/cm 1849 psi) for 10 seconds. 3. If any fuel leak is found, replace the nozzle piece.
Page 105: Separating Fuel Tank
RTV900, WSM ENGINE Seat and Center Cover 1. Tilt up the cargo bed. 2. Remove the seat back (2) and seat assembly (1). 3. Remove the center cover LH (4) and center cover RH (6). 4. Remove the seat belts (3).
Page 106: Separating Engine
RTV900, WSM ENGINE (4) Separating Engine Separate Engine and Transmission Assembly 1. Refer to "DISMOUNTING TRANSAXLE" section. (See page 2-S29.) W1024055 Engine Assembly 1. Remove the fan cover (1). 2. Disconnect the water hoses (2), (3) and accelerator wire (4).
Page 107: Disassembling And Assembling
RTV900, WSM ENGINE Hydraulic Pump, Stop Solenoid and Others 1. Drain the engine oil. 2. Remove the input flange (1). 3. Remove the hydraulic pump (2), dipstick (3) and stop solenoid. (When refilling engine oil) • Fill the engine oil up to the upper line on the dipstick (3).
Page 108 RTV900, WSM ENGINE Nozzle Holder Assembly and Glow Plug 1. Remove the overflow pipe (2). 2. Remove the nozzle holder assemblies (4). 3. Remove the copper gasket (5) and the heat seal (6). 4. Remove the lead (3) from the glow plugs (1).
Page 109 RTV900, WSM ENGINE Cylinder Head 1. Loosen the pipe clamp (2), and remove the water return pipe (1). 2. Disconnect the spring (3) from the speed control lever. 3. Remove the cylinder head screws in order of (n) to (a).
Page 110 RTV900, WSM 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).
Page 111: Oil Pan, Timing Gears, Camshaft And Fuel Camshaft
RTV900, WSM ENGINE (2) Oil Pan, Timing Gears, Camshaft and Fuel Camshaft Oil Pan and Oil Strainer 1. Remove the oil pan mounting screws (1). 2. Remove the oil pan (2) by lightly tapping the rim of the pan with a wooden hammer.
Page 112 RTV900, WSM ENGINE Injection Pump, Fuel Feed Pump and Speed Control Plate 1. Remove the socket head screws and nuts, and remove the injection pump (1). 2. Remove the screws and separate the speed control plate (2), taking care not to damage the governor spring (4).
Page 113 RTV900, WSM ENGINE Gear Case 1. Disconnect the start spring (2) from the fork lever 1 (3). 2. Remove the screw (1) of inside the gear case and outside screws. 3. Remove the gear case (4). (When reassembling) • Replace the gear case gasket with new one.
Page 114 RTV900, WSM ENGINE Camshaft 1. Remove the camshaft mounting screws (1) and draw out the camshaft with gear (2) on it. (When reassembling) • When install the camshaft, apply engine oil to the camshaft journals. • Apply engine oil to the camshaft mounting screws. And tighten them.
Page 115: Pistons And Connecting Rods
RTV900, WSM ENGINE (3) Pistons and Connecting Rods Connecting Rod 1. Remove the connecting rod caps (1) using a bihexagonal 8 mm socket. (When reassembling) • Align the marks (a) with each other. (Face the marks toward the injection pump.) •...
Page 116 RTV900, WSM 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 (13) near the gap faces the top of the piston.
Page 117: Crankshaft
RTV900, WSM ENGINE (4) Crankshaft Flywheel 1. Secure the flywheel to keep it from turning. 2. Remove all flywheel screws (1) and then remove the flywheel (2). (When reassembling) • Set the No. 1 crankpin at the top dead center (T.D.C.).
Page 118 RTV900, WSM ENGINE Crankshaft Assembly 1. Remove the main bearing case screw 2 (1). 2. Turn the crankshaft to set the crankpin of the third cylinder to the bottom dead center. Then draw out the crankshaft until the crankpin of the second cylinder comes to the center of the third cylinder.
Page 119 RTV900, WSM ENGINE Main Bearing Case Assembly 1. Remove the two main bearing case screws 1 (9), and remove the main bearing case assembly 1 (1), being careful with crankshaft bearing 3 (4) (5). 2. Remove the main bearing case assembly 2 (2) and the main bearing case assembly (3) as above.
Page 120: Water Pump
RTV900, WSM ENGINE (5) Water Pump Thermostat Assembly 1. Remove the thermostat cover mounting screws, and remove the thermostat cover (1). 2. Remove the thermostat assembly (3). (When reassembling) • Apply a liquid gasket (Three Bond 1215 or equivalent) only at the thermostat cover side of the gasket (2).
Page 121: Injection Nozzle
RTV900, WSM ENGINE (6) Injection Nozzle 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 oil. • Install the push rod (4), noting its direction.
Page 122 RTV900, WSM ENGINE Cylinder Head Flaw 1. Prepare an air spray red check (Code No. 07909-31371). 2. Clean the surface of the cylinder head with the detergent (2). 3. Spray the cylinder head surface with the red permeative liquid (1). Leave it five to ten minutes after spraying.
Page 123 RTV900, WSM ENGINE Clearance between Valve Stem and Guide 1. Remove carbon from the valve guide section. 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.
Page 124 RTV900, WSM ENGINE Valve Seating 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.
Page 125 RTV900, WSM 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.
Page 126 RTV900, WSM ENGINE Free Length and Tilt of Valve Spring 1. Measure the free length (A) 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.
Page 127 RTV900, 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. 0.25 mm Push rod alignment Allowable limit 0.0098 in.
Page 128: Oil Pan, Timing Gear And Camshaft
RTV900, WSM ENGINE (2) Oil Pan, Timing Gear and Camshaft Timing 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.
Page 129: Piston And Connecting Rod
RTV900, WSM ENGINE Cam Height 1. Measure the height of the cam at its highest point with an outside micrometer. 2. If the measurement is less than the allowable limit, replace the camshaft. 26.88 mm Factory spec. 1.0583 in. Cam height of intake and exhaust 26.83 mm...
Page 130 RTV900, WSM ENGINE 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.
Page 131 RTV900, WSM ENGINE Piston Ring Gap 1. Insert the piston ring into the lower part of the cylinder (the least worn out part) with piston. 2. Measure the ring gap with a thickness gauge. 3. If the measurement exceeds the allowable limit, replace the piston ring.
Page 132 RTV900, WSM ENGINE Connecting Rod Alignment 1. Remove the crankpin bearing, and install the connecting rod cap. 2. Install the piston pin in the connecting rod. 3. Install the connecting rod on the connecting rod alignment tool (Code No. 07909-31661).
Page 133: Crankshaft
RTV900, WSM ENGINE (4) Crankshaft 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.
Page 134 RTV900, WSM ENGINE Oil Clearance between Crankpin and Crankpin Bearing 1. Clean the crankpin and crankpin bearing. 2. Put a strip of plastigage (Code No.: 07909-30241) 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.
Page 135 RTV900, 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.
Page 136 RTV900, WSM ENGINE Replacing Crankshaft Bearing 1 (When removing) 1. Press out the used crankshaft bearing 1 using a crankshaft bearing 1 replacing tool. (See page G-55.) (When installing) 1. Clean a new crankshaft bearing 1 and crankshaft journal bore, and apply engine oil to them.
Page 137 RTV900, WSM ENGINE Oil Clearance between Crankshaft Journal and Crankshaft Bearing 2 (Crankshaft Bearing 3) (Continued) (Reference) • Undersize crankshaft bearing 2 and 3. Undersize Bearing Code Number Marking Crankshaft bearing 2 02 1G460-23930 0.2 mm 020 US 0.008 in.
Page 138: Cylinder
RTV900, WSM ENGINE (5) Cylinder 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.
Page 139: Oil Pump
RTV900, WSM ENGINE (6) Oil Pump Rotor Lobe Clearance 1. Measure the clearance between lobes of the inner rotor and the outer rotor with a thickness gauge. 2. If the clearance exceeds the factory specifications, replace the oil pump rotor assembly.
Page 140 TRANSMISSION KiSC issued 03, 2008 A...
Page 141 MECHANISM CONTENTS 1. STRUCTURE ....................2-M1 2. POWER TRAIN ..................... 2-M2 [1] HYDROSTATIC TRANSMISSION (HST) ..........2-M2 (1) Structure .................... 2-M2 (2) Oil Flow ....................2-M4 (3) Function of Components ..............2-M5 [2] RANGE GEAR SHIFT SECTION AND FRONT WHEEL DRIVE SECTION ....................
Page 142: Structure
RTV900, WSM TRANSMISSION 1. STRUCTURE (1) Input Shaft Section (2) Hydrostatic Transmission (3) Range Shift Gear Section (4) Front Wheel Drive Section Section 2-M1 KiSC issued 03, 2008 A...
Page 143: 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. [1] HYDROSTATIC TRANSMISSION (HST) (1) Structure The RTV900 has its HST built into the transmission case incorporates hydraulically operated servomechanism.
Page 144 RTV900, WSM TRANSMISSION (1) Input Shaft (Pump Shaft) (7) Oil Filter Cartridge (14) Variable Swashplate (19) Servo Piston (2) Feedback Lever (8) Piston (Assist Motor) (20) Guide (3) Regulator Shaft (9) Cylinder Block (Pump) (15) Piston (21) Cradle Bearing (4) Output Shaft (Motor Shaft)
Page 145: Oil Flow
RTV900, WSM TRANSMISSION (2) Oil Flow (1) HST Assembly (6) Oil Cooler (10) Charge Pump (15) Cylinder Block (2) Control Lever (Pedal) (7) Check and High Pressure (11) Cylinder Block (HST Pump) (Stationary Motor) (3) Servo Regulator Assembly Relief Valve...
Page 146: Function Of Components
RTV900, WSM TRANSMISSION (3) Function of Components (A) Servomechanism (1) Regulator Valve Assembly (4) Pin B (Fixed with Spool) (8) Guide (for Variable (10) Orifice (2) Regulator Spool (5) Feedback Lever Swashplate) (11) Servo Piston (3) Pin A (6) Regulator Shaft...
Page 147 RTV900, WSM TRANSMISSION Regulator and Servo Piston Operation Control Lever at Neutral (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...
Page 148 RTV900, WSM TRANSMISSION Control Lever Activated (First Step : Moving the Control Lever) (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...
Page 149 RTV900, WSM TRANSMISSION Control Lever Activated (with Control Lever at Desired Position) (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...
Page 150 RTV900, WSM TRANSMISSION Control Lever Deactivated (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...
Page 151 RTV900, WSM TRANSMISSION Motor Mechanism Neutral (1) Pedal (2) Regulator Valve Assembly (3) Regulator Spool (4) Servo Piston (5) Cylinder Block (HST Pump) (6) HST Housing (7) Control Piston (8) Variable Swashplate (Assist Motor) (9) Cylinder Block (Assist Motor) (10) Check and High Pressure...
Page 152 RTV900, WSM TRANSMISSION Pedal pressed halfway and under light load (1) Pedal (2) Regulator Valve Assembly (3) Regulator Spool (4) Servo Piston (5) Cylinder Block (HST Pump) (6) HST Housing (7) Control Piston (8) Variable Swashplate (Assist Motor) (9) Cylinder Block (Assist Motor)
Page 153 RTV900, WSM TRANSMISSION Pedal pressed fully and under light load (1) Pedal (2) Regulator Valve Assembly (3) Regulator Spool (4) Servo Piston (5) Cylinder Block (HST Pump) (6) HST Housing (7) Control Piston (8) Variable Swashplate (Assist Motor) (9) Cylinder Block (Assist Motor)
Page 154 RTV900, WSM 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 (HST Pump) (6) HST Housing (7) Control Piston...
Page 155 RTV900, WSM 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 (HST Pump) (6) HST Housing (7) Control Piston (8) Variable Swashplate (Assist...
Page 156 RTV900, WSM TRANSMISSION Dynamic Brake (1) Pedal (2) Regulator Valve Assembly (3) Regulator Spool (4) Servo Piston (5) Cylinder Block (HST Pump) (6) HST Housing (7) Control Piston (8) Variable Swashplate (Assist Motor) (9) Cylinder Block (Assist Motor) (10) Check and High Pressure...
Page 157 RTV900, WSM TRANSMISSION Charge Relief Valve 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.
Page 158 RTV900, WSM TRANSMISSION Check and High Pressure Relief Valve 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.
Page 159 RTV900, WSM TRANSMISSION Cables (1) Shift Cable (3) 4WD Shift Cable (5) 4WD Lever (7) Differential Lock Pedal (2) Select Cable (4) Main Shift Lever (6) Differential Lock Holder (8) Differential Lock Cable 2-M18 KiSC issued 03, 2008 A...
Page 160 RTV900, WSM TRANSMISSION Control Linkage (1) Damper (4) Neutral Holder (7) Neutral Spring (10) HST Regulator (2) Neutral Holder Arm (5) Engine Accelerator Wire (8) HST Control Rod (3) Ball Bearing (6) Speed Control Pedal Cable (9) HST Control Lever A : To Speed Control Pedal The speed control pedal and neutral holder arm (2) are connected with speed control pedal cable (6).
Page 161: Range Gear Shift Section And Front Wheel Drive Section
RTV900, 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 W1020797 Range Gear Shift Section First, power is transmitted to the HST at the back of the transmission case.
Page 162 SERVICING CONTENTS 1. TROUBLESHOOTING ..................2-S1 2. SERVICING SPECIFICATIONS ..............2-S4 3. TIGHTENING TORQUES ................2-S5 4. CHECKING .....................2-S6 5. DISASSEMBLING AND ASSEMBLING ............2-S17 [1] DISASSEMBLING HYDROSTATIC TRANSMISSION......2-S17 [2] DISMOUNTING TRANSAXLE ...............2-S21 (1) Front Case ..................2-S28 (2) Transmission Case ................2-S32 6. SERVICING ....................2-S38 KiSC issued 03, 2008 A...
Page 163: Troubleshooting
RTV900, WSM TRANSMISSION 1. TROUBLESHOOTING 2-S1 KiSC issued 03, 2008 A...
Page 164 RTV900, WSM TRANSMISSION 2-S2 KiSC issued 03, 2008 A...
Page 165 RTV900, WSM TRANSMISSION TRAVELLING GEAR SHIFT SECTION Reference Symptom Probable Cause Solution Page Noise from Transmission oil insufficient Refill 2-S17 Transmission Gear worn or broken Replace 2-S29 Bearings worn Replace – Gear Slip Out of Shift fork spring tension insufficient...
Page 166: Servicing Specifications
RTV900, WSM TRANSMISSION 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Charge Relief Valve Setting Pressure 0.52 to 0.72 MPa – 5.3 to 7.3 kgf/cm 75 to 104 psi Check and High Pressure Relief Valve Setting Pressure 25.5 to 26.5 MPa –...
Page 167: Tightening Torques
RTV900, WSM TRANSMISSION 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-11.) Item N·m kgf·m lbf·ft Pump base mounting screw (if equipped) 48.0 to 56.0...
Page 168: Checking
RTV900, WSM TRANSMISSION 4. CHECKING 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.
Page 169 RTV900, WSM TRANSMISSION Checking High Pressure Relief Valve Pressure (Reverse Side) (To be continued) 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.
Page 170 RTV900, WSM TRANSMISSION Checking High Pressure Relief Valve Pressure (Reverse Side) (Continued) NOTE • High pressure gauge is 29.4 MPa (300 kgf/cm , 4267 psi) full scale. (When reassembling) • Apply liquid lock (Three Bond 1324B or its equivalent) to the hex.
Page 171 RTV900, 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.
Page 172 RTV900, WSM TRANSMISSION Checking Neutral (To be continued) 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.
Page 173 RTV900, WSM TRANSMISSION Checking Neutral (Continued) 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.
Page 174 RTV900, 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.
Page 175 RTV900, WSM TRANSMISSION Checking Speed Control Pedal Stroke (Adjustment of the speed control pedal cable) CAUTION • When checking, park the machine on flat ground, apply the parking brake. • Work by two people when you checking and adjusting speed control pedal stroke.
Page 176 RTV900, 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, apply the parking brake. • Work by two people when you checking and adjusting main shift lever position.
Page 177 RTV900, WSM TRANSMISSION Checking Four Wheel Drive Lever Position (Adjustment of the 4WD shaft cable length) CAUTION • When checking, park the machine on flat ground, apply the parking brake. • Work by two people when you checking and adjusting four wheel drive lever position.
Page 178 RTV900, WSM TRANSMISSION Checking Bearing 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.
Page 179: Disassembling And Assembling
RTV900, WSM TRANSMISSION 5. DISASSEMBLING AND ASSEMBLING [1] DISASSEMBLING HYDROSTATIC 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.
Page 180 RTV900, WSM TRANSMISSION Rear Guard and Oil Filter Bracket 1. Remove the rear guard (1). 2. Remove the filter bracket (2) with oil filter cartridge and suction hoses. (When reassembling) 18.0 to 21.0 N·m Oil filter bracket mounting Tightening torque 1.8 to 2.1 kgf·m...
Page 181 RTV900, WSM TRANSMISSION Piston Case and Motor Case 1. Place oil pan underneath the motor case (3). 2. Loosen the piston case (1) with return piston, springs and stopper rod. 3. Remove the motor case (3) with variable swashplate (4).
Page 182 RTV900, 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.
Page 183: Dismounting Transaxle
RTV900, WSM TRANSMISSION [2] DISMOUNTING TRANSAXLE Draining the Transmission Fluid 1. Place oil pans underneath the transmission case. 2. Remove the drain plug (1). 3. Drain the transmission fluid. 4. Reinstall the drain plug (1). (When refilling) • Fill up from filling port after removing the filling plug (2) until reaching the upper notch on the dipstick (3).
Page 184 RTV900, WSM 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.
Page 185 RTV900, WSM 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 coupler from hydraulic control valve. 3. Remove the cotter pin and clevis pin, then remove the hydraulic cylinder (3).
Page 186 RTV900, WSM 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).
Page 187 RTV900, WSM TRANSMISSION Power Steering Hose and Radiator Hose (Lower) 1. Remove the power steering suction hose (3) and delivery hose (4). 2. Disconnect the fuel hose (2). 3. Disconnect the radiator hose (lower) (1). (1) Radiator Hose (Lower) (3) Suction Hose...
Page 188 RTV900, WSM TRANSMISSION Dismounting Transmission and Engine One Piece Assembly 1. Set the power train support (5) and remove the mission frame (3) mounting bolt (2) and nut. 2. Lift up the main frame by hoist. 3. Remove the transmission and engine one piece assembly (4).
Page 189 RTV900, WSM TRANSMISSION Separate the Transmission and Engine One Piece Assembly 1. Remove the engine mounting screw and stator motor (2) mounting screws. 2. Disconnect the oil cooler hoses (1). 3. Disconnect the accelerator wire (2). 4. Separate the engine from transmission assembly.
Page 190: Front Case
RTV900, WSM TRANSMISSION Separate the Front Case and Transmission Case 1. Remove the shift cover (1). 2. Remove the brake cylinder (2) and separate the front case (4) and transmission case (3). (When reassembling) • Replace the transmission case gasket with new one.
Page 191 RTV900, WSM TRANSMISSION Detent Ball, Interlocking Ball and Back Idle Gear Shaft 1. Remove the stopper bolt (3) from bearing holder (1). 2. With a magnet, remove the three interlock balls (6). 3. Tap out the roll pins (2) and remove the springs (8) and detent balls (7).
Page 192 RTV900, WSM TRANSMISSION Detent Ball, Interlocking Ball and Back Idle Gear Shaft (Continued) (When reassembling) • Remove the bearing (1) on 12T-14T 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.
Page 193 RTV900, WSM TRANSMISSION Shaft Assemblies 1. Remove the four wheel drive idle shaft assembly (1). 2. Draw out the 6T spiral bevel pinion shaft assembly (3) and 12T- 14T gear shaft assembly (2) with shift fork. 3. Loosen the lock bolt for four wheel drive shift arm (4).
Page 194: Transmission Case
RTV900, WSM TRANSMISSION (2) Transmission Case Propeller Shaft Assembly 1. Remove the bearing cover (2) mounting screw, and remove the propeller shaft assembly (1). (When reassembling) 18.0 to 21.0 N·m Bearing cover mounting Tightening torque 1.8 to 2.1 kgf·m screw 13.3 to 15.5 lbf·ft...
Page 195 RTV900, WSM 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.
Page 196 RTV900, WSM TRANSMISSION Motor Case 1. Stand up the transmission case (6). 2. Loosen the suction hose clamps (3). 3. Remove the oil filter bracket (1) with suction hose (2). 4. Remove the suction pipe (4). 5. Remove the motor case (5).
Page 197 RTV900, 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.
Page 198 RTV900, WSM TRANSMISSION Cylinder Block (Motor) Assembly, Motor Shaft Swashplate and Pump Shaft 1. Tap 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 the pump shaft (1) with a plastic hammer slightly, then slide out to the rear and then remove the swashplate (4) with bearing.
Page 199 RTV900, 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.
Page 200 RTV900, WSM TRANSMISSION 6. 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 kinded, replace the cable.
Page 201 RTV900, WSM TRANSMISSION 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.
Page 202 RTV900, WSM TRANSMISSION 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. W1046874 12T-14T Gear Shaft, Gear and Needle Bearing 1.
Page 203 RTV900, WSM TRANSMISSION 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 front case. At this time, install the same shim (2) to bearing holder side.
Page 204 RTV900, 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.
Page 205 RTV900, WSM TRANSMISSION Tooth Contact between 6T Spiral Bevel Pinion Shaft and 37T Spiral Bevel Gear (When checking) • Use the transmission gasket (1) of the same thickness as the origin first. • Use same number of shims as before disassembling.
Page 206 RTV900, WSM TRANSMISSION 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.
Page 207 RTV900, WSM TRANSMISSION 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 W1051512 Cylinder Block Bore and Pistons 1.
Page 208 RTV900, 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 exhaust with genuine parts.
Page 209 RTV900, 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.
Page 210: Rear Axle
REAR AXLE KiSC issued 03, 2008 A...
Page 211 MECHANISM CONTENTS 1. STRUCTURE ....................3-M1 KiSC issued 03, 2008 A...
Page 212 RTV900, WSM REAR AXLE 1. STRUCTURE (1) Shock Absorber (3) Rear Axle Bracket (5) Rear Axle (6) Propeller Shaft (2) Leaf Spring (4) Ball Bearing 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.
Page 213: Servicing
SERVICING CONTENTS 1. TROUBLESHOOTING ..................3-S1 2. TIGHTENING TORQUES ................3-S2 3. CHECKING, DISASSEMBLING AND SERVICING........3-S3 [1] DISASSEMBLING AND ASSEMBLING..........3-S3 [2] SERVICING ....................3-S6 KiSC issued 03, 2008 A...
Page 214: Troubleshooting
RTV900, WSM REAR AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Noise when Start Universal joint bearing worn (propeller shaft) Replace 3-S5 Noise while Forward Universal joint bearing worn (propeller shaft) Replace 3-S5 and Reverse Noise Bearings damaged or broken...
Page 215 RTV900, WSM REAR AXLE 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-11.) Item N·m kgf·m lbf·ft Rear wheel mounting screw 75.0 to 90.2...
Page 216: Tightening Torques
RTV900, WSM REAR AXLE 3. CHECKING, DISASSEMBLING AND SERVICING [1] DISASSEMBLING AND ASSEMBLING Rear Wheel and Rear Axle Bracket 1. Remove the cargo bed. 2. Remove the cotter pin (1) and loosen the propeller shaft slotted nut (2). 3. Remove the boot band (3) on both sides.
Page 217 RTV900, WSM 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 of rear axle bracket mounting nut. 4. Remove the leaf spring mounting bolt (4) and nut (2).
Page 218 RTV900, WSM REAR AXLE 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).
Page 219: Servicing
RTV900, WSM REAR AXLE [2] SERVICING Checking Oil Seal 1. Visually check the oil seal. 2. If the lips are misshapen, discolored, hardened, or been otherwise damaged, replace it. W1015374 Checking Bearing 1. Check the bearing seal for tears or leakage.
Page 220 RTV900, WSM REAR AXLE 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.
Page 221 BRAKES KiSC issued 03, 2008 A...
Page 222 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 03, 2008 A...
Page 223: General Outline
RTV900, WSM BRAKES 1. GENERAL OUTLINE (1) Brake Pipe (4) Brake Piston (6) Parking Brake Lever (8) Brake Cylinder (2) Parking Brake Cable (5) Brake Pedal (7) Brake Cam Lever (9) Master Cylinder (3) Brake Hose Description of the brake system with an illustration with all its component parts in place.
Page 224: Knuckle (Front Brake)
RTV900, 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.
Page 225: Rear Brake
RTV900, WSM BRAKES 3. REAR BRAKE (1) Brake Shaft (Propeller Shaft) (3) Differential Support Cover (5) Brake Disc (7) Cam Plate (Actuator) (2) Brake Cam Lever (4) Friction Plate (6) Steel Ball (8) Brake Cylinder 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).
Page 226: Master Cylinder
RTV900, WSM BRAKES 4. MASTER CYLINDER (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...
Page 227: Brake Oil
RTV900, 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.
Page 228: Parking Brake
RTV900, WSM BRAKES 6. PARKING BRAKE (1) Parking Brake Lever (3) Mechanical Equalizer (4) Parking Brake Cable (5) Brake Cam Lever (2) Plate The parking brake is mechanical type which is connected to the brake cam lever (5) by the parking brake cables (4).
Page 229 SERVICING CONTENTS 1. TROUBLESHOOTING ..................4-S1 2. SERVICING SPECIFICATIONS ..............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-S9 [3] SERVICING ....................4-S17 KiSC issued 03, 2008 A...
Page 230: Troubleshooting
RTV900, WSM BRAKES 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Poor Braking Force Brake pedal play excessive Adjust 4-S4 Brake disc worn Replace 4-S12, S16 Brake fluid insufficient or improper Replenish or change 4-S5 with specified oil Brake fluid leakage from brake pipes, bleeder,...
Page 231: Servicing Specifications
RTV900, WSM BRAKES 2. SERVICING SPECIFICATIONS TRAVELLING BRAKE Item Factory Specification Allowable Limit Brake Pedal Play 7 to 14 mm – 0.28 to 0.55 in. Stroke Less than 120 mm – 4.7 in. Brake Disc Thickness 3.3 to 3.5 mm 3.0 mm...
Page 232: Tightening Torques
RTV900, WSM BRAKES 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-11.) Item N·m kgf·m lbf·ft Front axle slotted nut 15.3 110.6...
Page 233: Checking, Disassembling And Servicing
RTV900, WSM BRAKES 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING Brake Pedal Free Play CAUTION • When checking, park the tractor on flat ground, and stop the engine. 1. Measure the free play by depressing the brake pedal (1).
Page 234 RTV900, WSM BRAKES Brake Fluid Change 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.
Page 235 RTV900, 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.
Page 236 RTV900, WSM BRAKES Parking Brake Lever Free Play 1. Release the parking brake lever (1). 2. If the number of notches is not within the factory specifications, loosen the lock nuts (2) and adjust the length of the parking brake wire (3).
Page 237 RTV900, 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. Adjust the length of the parking each brake cable (1) outer...
Page 238: Disassembling And Assembling
RTV900, WSM BRAKES [2] DISASSEMBLING AND ASSEMBLING 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 torques, install a cotter pin as shown figure left.
Page 239 RTV900, WSM BRAKES Knuckle Case (To be continued) 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.
Page 240 RTV900, WSM BRAKES Knuckle Case (Continued) (When reassembling) • When installing the strut to knuckle case, set the wedge to decide the position of strut (1) to the slit of the knuckle case (2). • 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 case mounting bolt, tighten the nut clockwise up to next alignment.
Page 241 RTV900, WSM BRAKES Brake Piston, Brake Disc and Friction Plate (To be continued) 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.
Page 242 RTV900, WSM BRAKES Brake Piston, Brake Disc and Friction Plate (Continued) (When reassembling) • Refer to front page. (4) Knuckle Case (10) Brake Seal 4 (7) Piston (11) Brake Seal 3 (8) Brake Seal 1 (12) Alignment Mark (9) Brake Seal 2...
Page 243 RTV900, WSM BRAKES Master Cylinder Assembly 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.
Page 244 RTV900, WSM BRAKES Master Cylinder Inner Parts 1. Remove the reservoir (3) from master cylinder body (1). 2. Pushing in the piston (4), remove the internal snap ring (2). 3. Remove the piston from master cylinder body. 4. Pushing in the secondary piston (8), remove the stop pin (6).
Page 245 RTV900, WSM BRAKES 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.
Page 246 RTV900, 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...
Page 247 RTV900, WSM 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. W1023933 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.
Page 248 RTV900, 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.
Page 249 FRONT AXLE KiSC issued 03, 2008 A...
Page 250 MECHANISM CONTENTS 1. STRUCTURE ....................5-M1 [1] FRONT AXLE..................5-M1 [2] FRONT SUSPENSION ................5-M2 KiSC issued 03, 2008 A...
Page 251 RTV900, WSM FRONT AXLE 1. STRUCTURE [1] FRONT AXLE (1) Bevel Gear Shaft (8T) (4) Strut (7) Ball Joint (9) Front Case (2) Bevel Gear (35T) (5) Knuckle (8) Constant Velocity (CV) Joint (10) Lower Arm (3) Side Gear (6) Front Axle The front axle consists mainly of knuckles (5) (right and left), front case (9) and CV (constant velocity) joint (8).
Page 252 RTV900, WSM FRONT AXLE [2] FRONT SUSPENSION (1) Spring (4) Knuckle (7) Bump Stopper (9) Front Case (2) Shock Absorber (5) Front Axle (8) Constant Velocity (CV) Joint (10) Lower Arm (3) Strut (6) Ball Joint (11) Rubber Bushing The 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.
Page 253: Servicing
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-S4 [3] SERVICING ....................5-S17 KiSC issued 03, 2008 A...
Page 254: Troubleshooting
RTV900, WSM FRONT AXLE 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Front Wheels Tire pressure uneven Adjust G-23 Wander to Right or Improper toe-in adjustment (improper alignment) Adjust 5-S4 Left Tie-rod end loose Tighten 5-S7 Air sucked in power steering circuit Bleed –...
Page 255: Servicing Specifications
RTV900, WSM FRONT AXLE 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Front Wheel Alignment Toe-in 1 to 10 mm 0.30 mm 0.04 to 0.39 in. 0.0118 in. Differential Case to Differential Side Gear Clearance 0.25 to 0.066 mm –...
Page 256: Tightening Torques
RTV900, WSM FRONT AXLE 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-11.) Item N·m kgf·m lbf·ft Front axle slotted nut 15.3...
Page 257: Checking, Disassembling And Servicing
RTV900, 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.
Page 258 RTV900, WSM 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 and filling plugs at the front axle case and drain the oil completely into the oil pan.
Page 259 RTV900, WSM FRONT AXLE Front Suspension (Strut Suspension) (To be continued) 1. Place the stand under the frame. 2. Remove the front wheel. 3. Remove the joint guard. 4. Loosen the lower arm mounting bolt and nut (2). 5. Remove the cotter pin and remove the tie-rod end (7) slotted nut.
Page 260 RTV900, WSM FRONT AXLE Front Suspension (Strut Suspension) (Continued) (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.
Page 261 RTV900, WSM FRONT AXLE Drive Shaft and Lower Arm 1. Remove the front case cover mounting screw (1). 2. Draw out the drive shaft assembly (4). 3. Remove the lower arm mounting bolt and nut (2). 4. Remove the lower arm (3).
Page 262 RTV900, WSM FRONT AXLE Knuckle Case (To be continued) 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.
Page 263 RTV900, WSM FRONT AXLE Knuckle Case (Continued) (When reassembling) • When installing the strut to knuckle case, set the wedge to decide the position of strut (1) to the slit of the knuckle case (2). • 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 case mounting bolt, tighten the nut clockwise up to next alignment.
Page 264 RTV900, WSM FRONT AXLE Front Differential Case 1. Remove the front differential protector (1). 2. Remove the front center cover (2). 3. Remove the front differential case mounting nut (4) and separate the front differential case (3) from main frame and propeller shaft 2 (5).
Page 265 RTV900, WSM 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 plastic hammer. 4. Remove the knuckle case mounting screw.
Page 266 RTV900, WSM FRONT AXLE 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 1208D or equivalent) to joint face of the front case cover and front case other eliminate the oil and stuck liquid gasket.
Page 267 RTV900, 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).
Page 268 RTV900, WSM FRONT AXLE Strut Damper and Spring 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).
Page 269 RTV900, WSM FRONT AXLE 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.
Page 270: Servicing
RTV900, WSM FRONT AXLE [3] SERVICING 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.
Page 271 RTV900, 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.
Page 272 RTV900, 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.
Page 273 RTV900, 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.
Page 274 RTV900, 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).
Page 275 RTV900, WSM FRONT AXLE Drive Shaft Boot (To be continued) 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.
Page 276 RTV900, WSM FRONT AXLE Drive Shaft Boot (Continued) 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.
Page 277 RTV900, WSM FRONT AXLE Drive Shaft Boot (Continued) (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.
Page 278 STEERING KiSC issued 03, 2008 A...
Page 279 MECHANISM CONTENTS 1. STRUCTURE ....................6-M1 2. HYDRAULIC CIRCUIT .................. 6-M2 3. STEERING CONTROLLER ................6-M3 4. STEERING CYLINDER................. 6-M5 KiSC issued 03, 2008 A...
Page 280: Structure
(10) Return Hose (3) Cylinder Hose (6) Hydraulic Pump The full hydrostatic type power steering is used on RTV900. This steering system is composed of steering wheel, steering controller, steering cylinder and other components shown in the figure. 6-M1 KiSC issued 03, 2008 A...
Page 281: Hydraulic Circuit
RTV900, WSM STEERING 2. HYDRAULIC CIRCUIT 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 piping. Accordingly, it does not have mechanical transmitting parts such as steering gear, pitman arm, drag link, etc.
Page 282: Steering Controller
RTV900, 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).
Page 283 RTV900, 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. 8.33 to 8.83 MPa 85 to 90 kgf/cm 1209 to 1280 psi...
Page 284: Steering Cylinder
RTV900, WSM STEERING 4. STEERING CYLINDER (1) Rod (4) Guide (7) Center Piston (10) Cylinder Tube (2) Wiper Ring (5) O-ring (8) Piston O-ring (11) Rod O-ring (3) Internal Snap Ring (6) Seal Ring (9) External Snap Ring 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.
Page 285 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-S4 (1) Separating Power Steering Controller ..........6-S4 (2) Separating Power Steering Cylinder ...........6-S6 (3) Separating Hydraulic Pump for Power Steering .........6-S7 (4) Removing Power Steering Hose............6-S8 [3] DISASSEMBLING AND ASSEMBLING..........6-S11 (1) Power Steering Cylinder ..............6-S11...
Page 286: Troubleshooting
RTV900, WSM STEERING 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Cannot Be Steered Steering controller malfunctioning Replace 6-S6 Hose broken Replace 6-S9 Hard Steering Power steering oil improper Change with G-41 specified oil Hydraulic pump malfunctioning Replace 6-S7 Steering controller malfunctioning...
Page 287: Servicing Specifications
RTV900, WSM STEERING 2. SERVICING SPECIFICATIONS POWER STEERING BODY Item Factory Specification Allowable Limit Relief Valve Operating 8.33 to 8.83 MPa – Pressure 85 to 90 kgf/cm 1209 to 1280 psi W1013874 6-S2 KiSC issued 03, 2008 A...
Page 288 RTV900, WSM STEERING 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-11.) Item N·m kgf·m lbf·ft Steering wheel mounting nut 20 to 25 2.0 to 2.6...
Page 289: Checking, Disassembling And Servicing
RTV900, 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.
Page 290 RTV900, 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).
Page 291: Separating Power Steering Cylinder
RTV900, 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.
Page 292: Separating Hydraulic Pump For Power Steering
RTV900, WSM STEERING (3) Separating Hydraulic Pump for Power Steering Hydraulic Pump 1. Remove the air cleaner assembly and inlet hose together. 2. Remove the side cover. 3. Disconnect the power steering delivery hose (3)and power steering suction hose (1).
Page 293: Removing Power Steering Hose
RTV900, WSM STEERING (4) Removing Power Steering Hose Panel 1. Refer to page 6-S4 to page 6-S6. W1017194 Center Cover (Front), Step Mat and Step (Center) 1. Remove the center cover mounting screws and remove the center cover (front) (1).
Page 294 RTV900, WSM STEERING Power Steering Hose (To be continued) 1. Disconnect the suction hose (1) from hydraulic pump (2) and then drain the power steering oil. 2. Disconnect the delivery hose (3) and return hose (5) from power steering controller.
Page 295 RTV900, WSM STEERING Power Steering Hose (Continued) (When reassembling) • Be sure to connect the power steering hoses to their original position, and tighten them to the specified torque. 28.4 to 30.0 N·m Power steering hose Tightening torque 2.9 to 3.1 kgf·m mounting nut 20.9 to 22.1 lbf·ft...
Page 296: Disassembling And Assembling
RTV900, WSM 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).
Page 297 RTV900, WSM STEERING (2) 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...
Page 298: Hydraulic System
HYDRAULIC SYSTEM KiSC issued 03, 2008 A...
Page 299 MECHANISM CONTENTS 1. STRUCTURE ....................7-M1 2. HYDRAULIC CIRCUIT .................. 7-M2 [1] HYDRAULIC CARGO BED LIFT (IF EQUIPPED) ......7-M2 3. HYDRAULIC PUMP ..................7-M3 4. HYDRAULIC CYLINDER ................7-M4 5. AUXIALIARY CONTROL VALVE ..............7-M5 [1] DOUBLE ACTING TYPE 1 ..............7-M5 (1) Floating with Detent Valve ..............
Page 300 (8) Suction Hose (12) Hydraulic Cylinder The cargo bed lifting system of RTV900 is composed of the hydraulic pump, control valve, hydraulic cylinder, oil tank and other components as shown in the figure. This hydraulic system has the hydraulic oil tank besides in the transmission case. Moreover, the control valve is defferent the adapted type of each model.
Page 301 (2) Hydraulic Pump (4) Transmission B : Out The cargo bed lifting system of RTV900 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.
Page 302: Hydraulic Pump
RTV900, WSM HYDRAULIC SYSTEM 3. HYDRAULIC PUMP The hydraulic pump is composed of the casing (3), cover (4), and two spur gears (drive gear (2) and driven gear (5)) that are in mesh. Hydraulic pump is driven by the input shaft in the transmission case.
Page 303: Hydraulic Cylinder
RTV900, WSM HYDRAULIC SYSTEM 4. HYDRAULIC CYLINDER 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.
Page 304: Auxialiary Control Valve
RTV900, WSM HYDRAULIC SYSTEM 5. AUXIALIARY CONTROL VALVE [1] DOUBLE ACTING TYPE 1 (1) Floating with Detent Valve Neutral (1) Spool (2) Check Valve (3) Detent Ball (4) Detent Sleeve A : A Port (Lift Cylinder) B : B Port (Lift Cylinder)
Page 305 RTV900, WSM HYDRAULIC SYSTEM Lift (1) Check Valve (2) Spool A : A Port (Lift Cylinder) B : B Port (Lift Cylinder) P : Pump Port T : Tank Port When 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.
Page 306 RTV900, WSM HYDRAULIC SYSTEM Down (1) Check Valve (2) Spool A : A Port (Lift Cylinder) B : B Port (Lift Cylinder) P : Pump Port T : Tank Port When 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.
Page 307 RTV900, WSM HYDRAULIC SYSTEM 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 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.
Page 308: Double Acting Type 2 (Mono Block)
RTV900, WSM HYDRAULIC SYSTEM [2] DOUBLE ACTING TYPE 2 (MONO BLOCK) (1) Floating with Detent Valve Neutral (1) Spool (2) Check Valve (3) Detent Ball (4) Detent Sleeve A : A Port (Lift Cylinder) B : B Port (Lift Cylinder)
Page 309 RTV900, WSM HYDRAULIC SYSTEM Lift (1) Check Valve (2) Spool A : A Port (Lift Cylinder) B : B Port (Lift Cylinder) P : Pump Port T : Tank Port When 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.
Page 310 RTV900, WSM HYDRAULIC SYSTEM Down (1) Check Valve (2) Spool A : A Port (Lift Cylinder) B : B Port (Lift Cylinder) P : Pump Port T : Tank Port When 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.
Page 311 RTV900, WSM HYDRAULIC SYSTEM 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 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.
Page 312: On-Off Valve
RTV900, WSM HYDRAULIC SYSTEM (2) On-Off Valve Neutral (Floating) (1) Spool (2) Check Valve (3) Detent Ball (4) Detent Sleeve A : A Port (Implement Cylinder) B : B Port (Implement Cylinder) P : Pump Port T : Tank Port Pressure-fed oil from the hydraulic pump is delivered into the P port, and flows to the oil tank through T port.
Page 313 SERVICING CONTENTS 1. TROUBLESHOOTING ..................7-S1 2. SERVICING SPECIFICATIONS ..............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] DISASSEMBLING AND ASSEMBLING..........7-S5 (1) Separating Hydraulic Pump ..............7-S5 (2) Separating Hydraulic Cylinder and Control Valve.......7-S5 (3) Disassembling Control Valve Assembly ..........7-S7 (4) Disassembling Hydraulic Cylinder ............7-S10...
Page 314 RTV900, WSM HYDRAULIC SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Implement Does Not Control valve broken Replace 7-S6 Rise (No Noise) Control valve improperly assembled Repair 7-S7 Relief valve spring damaged Replace 7-S6 Spool sticks Repair 7-S7 Piston O-ring or cylinder damaged...
Page 315: Servicing Specifications
RTV900, WSM HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Relief Valve Setting Pressure 14.7 to 15.7 MPa – 150 to 160 kgf/cm 2133 to 2276 psi W1013874 7-S2 KiSC issued 03, 2008 A...
Page 316 RTV900, WSM HYDRAULIC SYSTEM 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-11.) Item N·m kgf·m lbf·ft Hydraulic pump mounting bolt and nut 48.1 to 55.9...
Page 317: Checking, Disassembling And Servicing
RTV900, WSM HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Hydraulic Control Valve, Pump and Cylinder Relief Valve Setting Pressure 1. Set the adaptor, cable and pressure gauge. 2. Start the engine and depress the speed control pedal.
Page 318: Disassembling And Assembling
RTV900, WSM HYDRAULIC SYSTEM [2] DISASSEMBLING AND ASSEMBLING (1) Separating Hydraulic Pump Hydraulic Pump 1. Drain the hydraulic lift oil from oil tank. 2. Lift up the cargo bed (1) by hand and support it so that the hydraulic cylinder should not drop (if hydraulic cylinder equipped).
Page 319 RTV900, WSM HYDRAULIC SYSTEM Cargo Bed 1. Lift up the cargo bed (1) by hand and support it so that the hydraulic cylinder should not drop. (If hydraulic cylinder equipped.) 2. Remove the cotter pin and clevis pin (2). (If hydraulic cylinder equipped.)
Page 320: Disassembling Control Valve Assembly
RTV900, WSM HYDRAULIC SYSTEM (3) Disassembling Control Valve Assembly 3 Position Valve (To be conntinued) (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...
Page 321 RTV900, WSM HYDRAULIC SYSTEM 3 Position Valve (Conntinued) 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.
Page 322 RTV900, WSM HYDRAULIC SYSTEM 3 Position Valve and 4 Position Valve (Monoblock Type) (To be conntinued) (1) O-ring (2) Back Up Ring (3) Collar (4) Spring Holder (5) Spring (6) Spring Holder (7) Spacer (8) Detent Bolt (9) Plug (10) Detent Plug...
Page 323: Disassembling Hydraulic Cylinder
RTV900, WSM HYDRAULIC SYSTEM 3 Position Valve and 4 Position Valve (Monoblock Type) (Conntinued) 1. Loosen the plug (9) and draw out the spool (8) with other component parts from valve body (21). 2. Remove the internal snap ring (15) and detent stopper (13).
Page 324: Electrical System
ELECTRICAL SYSTEM KiSC issued 03, 2008 A...
Page 325 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 (2) Hydraulic Control Lever (Turf Model Only) ........8-M1 [4] ENGINE STOP SOLENOID ..............
Page 326: Wiring Diagram
RTV900, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM Blinker (R) Color of Wiring Blinker 2 (4W) Turn Signal W ..White B ..Black WR ..White / Red RG ..Red / Green BY ..Black / Yellow GW ..Green / White Lamp RH R ..
Page 327: Starting System
RTV900, WSM ELECTRICAL SYSTEM 2. STARTING SYSTEM (1) Slow Blow Fuse (50 A) (5) Starter Relay (9) Battery (13) Timer (2) Main Switch (6) Fuse (10) Glow Lamp (14) Engine Stop Solnoid (3) Safety Switch (7) Slow Blow Fuse (60 A)
Page 328: Starter
RTV900, WSM ELECTRICAL SYSTEM [1] STARTER (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 W1016159 The starter motor is a reduction type. The speed of the pinion gear is reduced to approximately one third of motor one.
Page 329: Glow Plug
RTV900, WSM ELECTRICAL SYSTEM [2] GLOW PLUG 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.
Page 330: Hydraulic Control Lever (Turf Model Only)
RTV900, WSM ELECTRICAL SYSTEM (2) Hydraulic Control Lever (Turf Model Only) This switch has two functions. One is a normal open type. Another is a normal close type. And, a normal open type is used to start the engine safely.
Page 331: Charging System
RTV900, WSM ELECTRICAL SYSTEM 3. CHARGING SYSTEM (1) Alternator (3) Slow Blow Fuse (50 A) (5) Slow Blow Fuse (60 A) (7) Battery (2) Battery Charge Lamp (4) Fuse (6) Main Switch The charging system supplies electric power for various electrical devices and also charges the battery while the engine runs.
Page 332: Alternator
RTV900, WSM ELECTRICAL SYSTEM [1] ALTERNATOR A compact alternator with an IC regulator is used, having the following characteristics : • Approximately 26 % lighter and 17 % smaller than a standard alternator. • Cooling performance and safety have been improved by combining the cooling fan with the rotor and incorporating the fan / rotor unit inside the alternator.
Page 333: Ic Regulator
RTV900, WSM ELECTRICAL SYSTEM [2] IC REGULATOR (1) Alternator (2) Rectifier (3) Stator Coil (4) Rotor Coil (5) IC Regulator (6) Charge Lamp (7) Main Switch (8) Battery (9) Load W1018047 An IC regulator uses solid state transistors, chips or other semiconductor elements instead of the relays in a conventional regulator.
Page 334: Lighting System
RTV900, WSM ELECTRICAL SYSTEM 4. LIGHTING SYSTEM (1) Combination Lamp (LH) (7) Light Switch (14) Slow Blow Fuse (60 A) (21) Parking Brake Switch (2) Combination Lamp (RH) (8) Brake Lamp Switch (15) Oil Pressure Switch (22) Hydraulic Outlet Warning...
Page 335: Cooling System
RTV900, WSM ELECTRICAL SYSTEM 5. COOLING SYSTEM (1) Slow Blow Fuse (50 A) (4) Slow Blow Fuse (60 A) (7) Relay (9) Fan Motor (2) Main Switch (5) Battery (8) Coolant Temperature Switch (10) Ground (3) Fuse (6) Fuse The cooling system consists of coolant temperature switch, relay, fan motor, etc.
Page 336: Fan Motor
RTV900, WSM ELECTRICAL SYSTEM [1] FAN MOTOR 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.
Page 337: Gauges
RTV900, WSM ELECTRICAL SYSTEM 6. GAUGES (1) Hour Meter (4) Fuel Sensor (7) Rotation Sensor (If equipped) (10) Fuse (2) Thermo Unit (5) Fuel Gauge (8) Slow Blow Fuse (50 A) (11) Slow Blow Fuse (60 A) (3) Coolant Temperature Gauge...
Page 338: Coolant Temperature
RTV900, WSM ELECTRICAL SYSTEM [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.
Page 339: Easy Checker
RTV900, WSM ELECTRICAL SYSTEM [4] EASY CHECKER To check the conditions of vehicle easily before and during operation, easy checker combination of lamps on the easy checker board is provided. Indication Items (1) Parking Brake Lamp When apply parking brake, this lamp illuminates.
Page 340 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-S10 (3) Starter ....................8-S12 (4) Glow Plug..................8-S13 (5) Safety Switch ..................8-S14 (6) Engine Stop Solenoid ...............8-S15 (7) Timer Relay for Stop Solenoid ............8-S15 (8) Charging System ................8-S16 (9) Lighting System ................8-S18...
Page 341 RTV900, WSM ELECTRICAL SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page All Electrical Battery discharged or defective Recharge or replace G-35 Equipments Do Not Battery positive cable disconnected or Repair or replace 8-S8 Operate improperly connected Battery negative cable disconnected or...
Page 342 RTV900, WSM ELECTRICAL SYSTEM STARTING SYSTEM Reference Symptom Probable Cause Solution Page Starter Motor Does Battery discharged or defective Recharge or replace G-35 Not Operate Slow blow fuse blown Replace G-48 Safety switch improperly adjusted or defective Repair or replace...
Page 343 RTV900, WSM ELECTRICAL SYSTEM LIGHTING SYSTEM Reference Symptom Probable Cause Solution Page Head Light Does Not Fuse blown (15 A) Replace G-47 Light Head light switch defective Replace 8-S18 Bulb blown Replace G-48 Wiring harness disconnected or improperly Repair or Replace –...
Page 344 RTV900, WSM ELECTRICAL SYSTEM Reference Symptom Probable Cause Solution Page Oil Pressure Lamp Engine oil pressure too low Repair engine – Lights Up When Engine oil insufficient Replenish Engine Is Running Oil pressure switch defective Replace 8-S19 Short circuit between oil pressure switch lead Repair –...
Page 345 RTV900, WSM ELECTRICAL SYSTEM GAUGES Reference Symptom Probable Cause Solution Page Fuel Gauge Does Not Fuel gauge defective Replace 8-S30 Function Fuel level sensor defective Replace 8-S23 Wiring harness disconnected or improperly Replace or Replace – connected (between fuel gauge and fuel level...
Page 346: Servicing Specifications
RTV900, WSM ELECTRICAL SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Battery Voltage More then 12 V – Potential Difference Less than 0.1 V – Approx. 0.9 Ω Glow Plug Resistance – Alternator No-load Voltage More then 14 V –...
Page 347 RTV900, WSM ELECTRICAL SYSTEM 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-11.) Item N·m kgf·m lbf·ft Starter (B terminal nut) 5.9 to 11.8...
Page 348: Checking, Disassembling And Servicing
RTV900, 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.
Page 349 RTV900, WSM ELECTRICAL SYSTEM Battery Specific Gravity 1. Check the specific gravity of the electrolyte in each cell with a hydrometer. 2. When the electrolyte temperature differs from that at which the hydrometer was calibrated, correct the specific gravity reading following the formula mentioned in (Reference).
Page 350: Main Switch
RTV900, WSM ELECTRICAL SYSTEM (2) Main Switch Main Switch 1. Remove the under panel (1). 2. Disconnect the 4P connector and remove the main switch (2). 3. Perform the following checks. (1) Under Panel (2) Main Switch W1023642 Connector Voltage 1.
Page 351 RTV900, 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.
Page 352: Starter
RTV900, WSM ELECTRICAL SYSTEM (3) Starter 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.
Page 353: Glow Plug
RTV900, WSM ELECTRICAL SYSTEM (4) Glow Plug 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.
Page 354: Safety Switch
RTV900, WSM ELECTRICAL SYSTEM (5) Safety Switch Brake Swtich 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.
Page 355: Engine Stop Solenoid
RTV900, WSM ELECTRICAL SYSTEM (6) Engine Stop Solenoid Engine Stop Solenoid Test 1. Disconnect the 1P connector (2) from the engine stop solenoid. 2. Remove the engine stop solenoid from the engine. 3. Connect the jumper leads from the battery positive terminal to the 1P connector, and from the battery negative terminal to the engine stop solenoid body.
Page 356: Charging System
RTV900, WSM ELECTRICAL SYSTEM Test of Timer Relay 1. Remove the timer relay from the tractor. 2. Connect jumper leads across the battery positive terminal and the timer relay terminal 3, and across the battery positive terminal and the timer relay terminal 4.
Page 357 RTV900, WSM 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 (3) 2P Connector (2) Alternator W1032752 Connector Voltage 1. Turn the main switch OFF. Measure the voltage between the B terminal (1) and the chassis.
Page 358: Lighting System
RTV900, WSM 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.
Page 359 RTV900, 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.
Page 360 RTV900, WSM ELECTRICAL SYSTEM Parking Brake Lamp 1. Disconnect the connecting lead (1) from the parking brake switch after turning the main switch OFF. 2. Turn the main switch ON and connect a jumper lead from the lead to the chassis.
Page 361: Cooling System
RTV900, WSM ELECTRICAL SYSTEM (10) Cooling System Fan Motor Wiring Harness 1. Disconnect the wiring lead (1) 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.
Page 362 RTV900, WSM ELECTRICAL SYSTEM Fan Motor Relay 1. Disconnect the connector from fan motor relay (1) after turning the main switch off. 2. Remove the fan motor relay from bracket. 3. Measure the resistance with an ohmmeter across the terminal 1 (2) to terminal 2 (3) and terminal 3 (4) to terminal 4 (5).
Page 363: Gauges
RTV900, WSM ELECTRICAL SYSTEM (11) Gauges Fuel Lever Sensor 1) 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.
Page 364: Others
RTV900, WSM ELECTRICAL SYSTEM 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 B terminal (6) and G terminal (4) of the gauge.
Page 365: Disassembling And Assembling
RTV900, WSM 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).
Page 366: Alternator
RTV900, WSM 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).
Page 367 RTV900, WSM ELECTRICAL SYSTEM Rear End Cover 1. Unscrew the three rear end cover screws and the B terminal nut, and remove the rear end cover. W1047547 Brush Holder 1. Unscrew the two screws holding the brush holder, and remove the brush holder (1).
Page 368 RTV900, WSM ELECTRICAL SYSTEM 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 W1048215 Rotor 1. Press out the rotor (1) from drive end frame (3).
Page 369: Panel
RTV900, WSM ELECTRICAL SYSTEM 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 (3) Puller (2) Bearing W1048953 (3) Panel Bonnet Upper 1.
Page 370: Servicing
RTV900, WSM ELECTRICAL SYSTEM Steering Wheel and Panel 1. Remove the steering wheel cap (7). 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).
Page 371 RTV900, WSM ELECTRICAL SYSTEM 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.
Page 372 RTV900, 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 W1049931 Armature Coil 1.
Page 373: Alternator
RTV900, WSM ELECTRICAL SYSTEM (2) Alternator Bearing 1. Check the bearing for smooth rotation. 2. If it does not rotate smoothly, replace it. W1051152 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.
Page 374 RTV900, WSM ELECTRICAL SYSTEM 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.
Page 375 HYDRAULIC UTILITY MODEL KiSC issued 03, 2008 A...
Page 376 RTV900-TS, WSM SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS 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.
Page 377 RTV900-TS, 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.
Page 378 RTV900-TS, 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.
Page 379 RTV900-TS, 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...
Page 380 RTV900-TS, WSM SAFETY INSTRUCTIONS 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. KiSC issued 03, 2008 A...
Page 381 RTV900-TS, WSM SAFETY INSTRUCTIONS KiSC issued 03, 2008 A...
Page 382 RTV900-TS, WSM SAFETY INSTRUCTIONS KiSC issued 03, 2008 A...
Page 383 RTV900-TS, WSM SAFETY INSTRUCTIONS KiSC issued 03, 2008 A...
Page 384 RTV900-TS, WSM SAFETY INSTRUCTIONS KiSC issued 03, 2008 A...
Page 385 RTV900-TS, WSM SPECIFICATIONS SPECIFICATIONS Model Worksite Utility Turf Utility Maker KUBOTA Model D902-E2-UV Type Indirect Injection. Vertical, water-cooled, 4-cycle diesel Number of cylinders 72 × 73.6 mm (2.83 × 2.90 in.) Bore and stroke Total displacement 898 cm (54.8 cu.in.) Engine gross power (DIN) 16.1 kW (21.6 HP)
Page 386 RTV900-TS, WSM SPECIFICATIONS Model Worksite Turf Overall length 3030 mm (119.3 in.) Overall width 1520 mm (59.8 in.) Overall height 2010 mm (79.1 in.) 2015 mm (79.3 in.) Front tread center 1150 mm (45.3 in.) 1180 mm (46.5 in.) Dimensions Rear tread center 1180 mm (46.5 in.)
Page 387 RTV900-TS, WSM TRAVELLING SPEEDS TRAVELLING SPEEDS Model Worksite Utility Turf Utility 25 × 10 – 12 HDWS 25 × 12 – 12 Turf Tire size (Rear) Range gear shift lever km/h (mph) km/h (mph) 16 (10) 16 (10) Medium 29 (18)
Page 388 RTV900-TS, WSM DIMENSIONS DIMENSIONS KiSC issued 03, 2008 A...
Page 389 GENERAL CONTENTS 1. TRACTOR IDENTIFICATION ...............HG-1 2. GENERAL PRECAUTIONS ................HG-2 3. HANDLING PRECAUTIONS FOR ELECTRICAL PARTS AND WIRING ......................HG-3 [1] WIRING....................HG-3 [2] BATTERY....................HG-5 [3] FUSE......................HG-5 [4] CONNECTOR ..................HG-5 [5] HANDLING OF CIRCUIT TESTER............HG-6 4. LUBRICANTS, FUEL AND COOLANT ............HG-7 5. TIGHTENING TORQUES ................HG-9 [1] GENERAL USE SCREWS, BOLTS AND NUTS.........HG-9 [2] STUD BOLTS..................HG-9 [3] METRIC SCREWS, BOLTS AND NUTS ...........HG-10...
Page 390: Tractor Identification
RTV900-TS, WSM G GENERAL 1. TRACTOR IDENTIFICATION When contacting your local KUBOTA distributor, always specify engine serial number, product serial number and hour meter reading. (1) Vehicle Identification Plate (4) Transmission Assembly Serial (2) Product Identification Number Number (3) Engine Serial Number...
Page 391: General Precautions
RTV900-TS, WSM G GENERAL 2. GENERAL PRECAUTIONS • During disassembly, carefully arrange removed parts in a clean area to prevent confusion later. Bolts and nuts should be installed in their original position to prevent reassembly errors. • When special tools are required, use KUBOTA genuine special tools.
Page 392: Handling Precautions For Electrical Parts And Wiring
RTV900-TS, 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 damage loosened connection every year.
Page 393 RTV900-TS, WSM G GENERAL • Securely clamp, being careful not to damage wiring. (1) Clamp (3) Clamp • Wind Clamp Spirally (4) Welding Dent (2) Wire Harness W10114580 • Clamp wiring so that there is no twist, unnecessary sag, or excessive tension, except for movable part, where sag be required.
Page 394: Battery
RTV900-TS, WSM G GENERAL [2] BATTERY • 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).
Page 395: Handling Of Circuit Tester
RTV900-TS, WSM G GENERAL • Use sandpaper to remove rust from terminals. • Repair deformed terminal. Make certain there is no terminal being exposed or displaced. (1) Exposed Terminal (3) Sandpaper (2) Bend Terminal (4) Rust W10123460 • Make certain that there is no female connector being too open.
Page 396: Lubricants, Fuel And Coolant
RTV900-TS, WSM G GENERAL 4. LUBRICANTS, FUEL AND COOLANT Place Capacity Lubricants, fuel and coolant 28.0 L No. 2-D diesel fuel No. 1-D diesel fuel if temperature is below −10 °C Fuel tank 7.4 U.S.gals 6.2 Imp.gals (14 °F) 4.0 L Cooling system 4.2 U.S.qts...
Page 397 RTV900-TS, WSM G GENERAL NOTE • *KUBOTA UDT or SUPER UDT fluid : KUBOTA original transmission hydraulic fluid • 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 above.
Page 398: General Use Screws, Bolts And Nuts
RTV900-TS, WSM G GENERAL 5. TIGHTENING TORQUES [1] GENERAL USE SCREWS, BOLTS AND NUTS Screws, bolts and nuts whose tightening torques are not specified in this Workshop Manual should be tightened according to the table below. Indication on top of...
Page 399: Metric Screws, Bolts And Nuts
RTV900-TS, WSM G GENERAL [3] METRIC SCREWS, BOLTS AND NUTS Grade Property class 8.8 Property class 10.9 Unit Nominal Diameter N·m kgf·m ft-lbs N·m kgf·m ft-lbs 23.6 to 27.4 2.4 to 2.8 17.4 to 20.2 29.4 to 34.3 3.0 to 3.5 21.7 to 25.3...
Page 400: Maintenance Check List
RTV900-TS, WSM G GENERAL 6. MAINTENANCE CHECK LIST [1] FROM FIRST 50 HOURS TO EVERY 550 HOURS IMPORTANT • The jobs indicated by must be done after the first 50 hours of operation. (To be continued) Period Indication on hour meter...
Page 401 RTV900-TS, WSM G GENERAL (Continued) Period Indication on hour meter Refer- Impor- ence tant page Item Tire wear Check G-30 Front axle case oil Change G-42 Knuckle axle case oil Change G-42 Engine valve clearance Adjust – Fuel injection nozzle Check –...
Page 402: From Every 600 Hours To Every 4 Years
RTV900-TS, WSM G GENERAL [2] FROM EVERY 600 HOURS TO EVERY 4 YEARS 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.
Page 403 RTV900-TS, WSM G GENERAL (Continued) Period Indication on hour meter After purchase Refer- Impor- ence tant 1500 3000 1 year page years years Item Check G-39 Radiator hose and clamp Replace – HG-18 Check Hydraulic auxiliary oil line Replace HG-18...
Page 404: Check And Maintenance
RTV900-TS, WSM G 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”...
Page 405: Check Points Of Every 50 Hours
RTV900-TS, WSM G GENERAL [2] CHECK POINTS OF EVERY 50 HOURS Oiling 1. Apply a small amount of engine oil to the accelerator wire every 50 hours. (1) Hand Throttle Wire W1043356 [3] CHECK POINTS OF EVERY 150 HOURS Cleaning Air Cleaner Primary Element 1.
Page 406: Check Points Of Every 200 Hours
RTV900-TS, WSM G GENERAL [4] CHECK POINTS OF EVERY 200 HOURS Checking Hydraulic Auxiliary Tank Oil 1. Park the vehicle on a firm, flat and level surface. 2. Raise the cargo bed and mount the safety support. 3. To drain the used oil, remove the drain plug and filling plug and drain the oil completely into the oil pan.
Page 407 RTV900-TS, WSM G GENERAL Checking Intake Air 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. (1) Hose...
Page 408: Others
RTV900-TS, WSM G GENERAL [5] OTHERS 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.
Page 409: Tires
RTV900-TS, WSM G GENERAL 8. TIRES CAUTION • Do not attempt 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 below.
Page 410: Vehicle Limitations
RTV900-TS, WSM G GENERAL [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.
Page 411 SERVICING CONTENTS 1. TIGHTENING TORQUES ................H2-S1 2. DISASSEMBLING AND ASSEMBLING ............. H2-S2 [1] DISMOUNTING TRANSAXLE .............. H2-S2 KiSC issued 03, 2008 A...
Page 412 RTV900-TS, WSM TRANSMISSION 1. 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 HG-9.) Item N·m kgf·m ft-lbs Muffler mounting nut 23.6 to 27.4 2.4 to 2.8...
Page 413 RTV900-TS, WSM TRANSMISSION 2. DISASSEMBLING AND ASSEMBLING [1] DISMOUNTING TRANSAXLE Draining the Transmission Fluid 1. Place oil pans underneath the transmission case. 2. Remove the drain plug (1). 3. Drain the transmission fluid. 4. Reinstall the drain plug (1). (When refilling) •...
Page 414 RTV900-TS, WSM 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.
Page 415 RTV900-TS, WSM TRANSMISSION Muffler Cover, Muffler, Hydraulic Cylinder and Hydraulic Control Valve 1. Remove the muffler cover (3) and muffler (4). 2. Disconnect the quick couplers (2) from hydraulic control valve (8). 3. Remove the cotter pin and clevis pin, then remove the hydraulic cylinder (1).
Page 416 RTV900-TS, WSM TRANSMISSION Oil Cooler with Fan Motor 1. Place oil pan underneath the oil cooler (3). 2. Disconnect the delivery hose (2) from oil cooler (3). 3. Disconnect the return hose (1) from oil cooler (3). 4. Remove the oil cooler with fan motor (3).
Page 417 RTV900-TS, WSM TRANSMISSION Wire Harness, Radiator Hose (Upper), Cables and Brake Hoses 1. Disconnect the wire harness (1) from engine, alternator and stator motor etc.. 2. Remove the hand accelerator wire (2). 3. Remove the ground cable (6) and positive cable (5).
Page 418 MECHANISM CONTENTS 1. STRUCTURE ....................H7-M1 2. HYDRAULIC CIRCUIT ................H7-M2 [1] HYDRAULIC CARGO BED LIFT OR HYDRAULIC OUTLET ..H7-M2 3. HYDRAULIC PUMP ................... H7-M3 4. HYDRAULIC CYLINDER ................H7-M4 5. HYDRAULIC OUTLET VALVE..............H7-M5 [1] DOUBLE ACTING TYPE 2 (MONO BLOCK TYPE) ....... H7-M5 (1) Floating with Detent Valve for Hydraulic Lift Cylinder .....
Page 419: Structure
Cylinder W1012642 The cargo bed lifting system of RTV900 is composed of the hydraulic pump, control valve, hydraulic cylinder, oil tank and other components as shown in the figure. This hydraulic system has the hydraulic oil tank besides in the transmission case.
Page 420: Hydraulic Circuit
HYDRAULIC SYSTEM 2. HYDRAULIC CIRCUIT [1] HYDRAULIC CARGO BED LIFT OR HYDRAULIC OUTLET The cargo bed lifting system of RTV900 is composed of the hydraulic pump, hydraulic outlet valve, hydraulic cylinder, oil tank and other components as shown in the figure.
Page 421: Hydraulic Pump
RTV900-TS, WSM HYDRAULIC SYSTEM 3. HYDRAULIC PUMP The hydraulic pump is composed of the casing (3), cover (4), and two spur gears (drive gear (2) and driven gear (5)) that are in mesh. Hydraulic pump is driven by the input shaft in the transmission case.
Page 422: Hydraulic Cylinder
RTV900-TS, WSM HYDRAULIC SYSTEM 4. HYDRAULIC CYLINDER 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.
Page 423: Hydraulic Outlet Valve
RTV900-TS, WSM HYDRAULIC SYSTEM 5. HYDRAULIC OUTLET VALVE [1] DOUBLE ACTING TYPE 2 (MONO BLOCK TYPE) (1) Floating with Detent Valve for Hydraulic Lift Cylinder Neutral (1) Spool (2) Check Valve (3) Detent Ball (4) Detent Sleeve A : A Port (Lift Cylinder)
Page 424 RTV900-TS, WSM HYDRAULIC SYSTEM Lift (1) Check Valve (2) Spool A : A Port (Lift Cylinder) B : B Port (LIft Cylinder) P : Pump Port T : Tank Port When 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 lift cylinder via B port.
Page 425 RTV900-TS, WSM HYDRAULIC SYSTEM Down (1) Check Valve (2) Spool A : A Port (Lift Cylinder) B : B Port (Lift Cylinder) P : Pump Port T : Tank Port When 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 lift cylinder via A port.
Page 426 RTV900-TS, WSM HYDRAULIC SYSTEM Floating (1) Check Valve (2) Spool (3) Detent Ball (4) Detent Sleeve A : A Port (Lift Cylinder) B : B Port (Lift Cylinder) P : Pump Port T : Tank Port When the spool (2) moves to extreme left, the detent ball (3) and detent sleeve (4) hold the spool (2) at the floating position as shown in the figure.
Page 427: On-Off Valve For Hydraulic Outlet
RTV900-TS, WSM HYDRAULIC SYSTEM (2) On-Off Valve for Hydraulic Outlet Neutral (Floating) (1) Check Valve (2) Spool (3) Detent Ball (4) Detent Sleeve A : A Port (Hydraulic Equipment) B : B Port (Hydraulic Equipment) P : Pump Port T : Tank Port Pressure-fed oil from the hydraulic pump is delivered into the P port, and flows to oil tank through T port.
Page 428 RTV900-TS, WSM HYDRAULIC SYSTEM Lift (1) Check Valve (2) Spool A : A Port (Hydraulic Equipment) B : B Port (Hydraulic Equipment) P : Pump Port T : Tank Port When 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 hydraulic equipment inlet via B port.
Page 429 SERVICING CONTENTS 1. TROUBLESHOOTING ................. H7-S1 2. SERVICING SPECIFICATIONS ..............H7-S2 3. TIGHTENING TORQUES ................H7-S3 4. CHECKING, DISASSEMBLING AND SERVICING........H7-S4 [1] CHECKING AND ADJUSTING ............H7-S4 (1) Hydraulic Control Valve, Pump and Cylinder ........H7-S4 [2] DISASSEMBLING AND ASSEMBLING..........H7-S5 (1) Separating Hydraulic Pump .............
Page 430 RTV900-TS, WSM HYDRAULIC SYSTEM 1. TROUBLESHOOTING Reference Symptom Probable Cause Solution Page Implement Does Not Hydraulic outlet valve broken Replace H7-S8 Rise (No Noise) Hydraulic outlet valve improperly assembled Repair H7-S9 Relief valve spring damaged Replace H7-S9 Spool sticks Repair...
Page 431: Servicing Specifications
RTV900-TS, WSM HYDRAULIC SYSTEM 2. SERVICING SPECIFICATIONS Item Factory Specification Allowable Limit Relief Valve Setting Pressure 14.7 to 15.7 MPa – 150 to 160 kgf/cm 2133 to 2276 psi W1013874 H7-S2 KiSC issued 03, 2008 A...
Page 432 RTV900-TS, WSM HYDRAULIC SYSTEM 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 HG-9.) Item N·m kgf·m ft-lbs Hydraulic pump mounting bolt and nut 48.1 to 55.9...
Page 433: Checking, Disassembling And Servicing
RTV900-TS, WSM HYDRAULIC SYSTEM 4. CHECKING, DISASSEMBLING AND SERVICING [1] CHECKING AND ADJUSTING (1) Hydraulic Control Valve, Pump and Cylinder Relief Valve Setting Pressure 1. Set the adaptor, cable and pressure gauge. 2. Start the engine and depress the speed control pedal.
Page 434: Disassembling And Assembling
RTV900-TS, WSM HYDRAULIC SYSTEM [2] DISASSEMBLING AND ASSEMBLING (1) Separating Hydraulic Pump Hydraulic Pump 1. Lift up the cargo bed (1) by hand and support it so that the hydraulic cylinder should not drop (if hydraulic cylinder equipped). 2. Disconnect the suction hose (5) and delivery hose (3) from hydraulic pump.
Page 435: Separating Hydraulic Cylinder, Hydraulic Outlet Valve And Oil Cooler
RTV900-TS, WSM HYDRAULIC SYSTEM (2) Separating Hydraulic Cylinder, Hydraulic Outlet Valve and Oil Cooler 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.
Page 436 RTV900-TS, WSM HYDRAULIC SYSTEM Oil Cooler and Fan Motor Assembly 1. Place oil pan underneath the oil cooler (4). 2. Disconnect the delivery hose (3) from oil cooler (4). 3. Disconnect the return hose (1) from oil cooler (4). 4. Remove the oil cooler bracket (2) and remove the oil cooler (4) with fan motor assembly (5).
Page 437 RTV900-TS, WSM HYDRAULIC SYSTEM Hydraulic Outlet Valve Assembly 1. Disconnect the cables (1) from hydraulic outlet valve lever (2). 2. Disconnect the delivery hose (4) from hydraulic pump. 3. Remove the hydraulic outlet valve (3). (When reassembling) • The install angle of elbow (5) is as shown in the table below.
Page 438: Disassembling Hydraulic Outlet Valve Assembly
RTV900-TS, WSM HYDRAULIC SYSTEM (3) Disassembling Hydraulic Outlet Valve Assembly 3 Position Valve and 4 Position Valve (Monoblock Type) (To be continued) (1) O-ring (2) Back Up Ring (3) Collar (4) Spring Holder (5) Spring (6) Spring Holder (7) Spacer...
Page 439: Disassembling Hydraulic Cylinder
RTV900-TS, WSM HYDRAULIC SYSTEM 3 Position Valve and 4 Position Valve (Monoblock Type) (Continued) 1. Loosen the plug (9) and draw out the spool (8) with other component parts from valve body (21). 2. Remove the internal snap ring (15) and detent stopper (13).
Page 440 MECHANISM CONTENTS 1. WIRING DIAGRAM ..................H8-M1 2. STARTING SYSTEM ................. H8-M2 [1] SAFETY SWITCH ................H8-M3 (1) Hydraulic Outlet Lever ..............H8-M3 3. HYDRAULIC OIL COOLING SYSTEM ............ H8-M4 [1] OIL COOLER FAN MOTOR............... H8-M5 [2] OIL TEMPERATURE SWITCH ............H8-M5 KiSC issued 03, 2008 A...
Page 441: Wiring Diagram
RTV900-TS, WSM ELECTRICAL SYSTEM 1. WIRING DIAGRAM Color of Wiring W ..White B ..Black WR ..White / Red RG ..Red / Green BY ..Black / Yellow GW ..Green / White R ..Red Br ..Brown WY ..
Page 442: Starting System
RTV900-TS, WSM ELECTRICAL SYSTEM 2. STARTING SYSTEM (1) Slow Blow Fuse (50 A) (5) Starter Relay (9) Battery (13) Timer (2) Main Switch (6) Fuse (10) Glow Lamp (14) Engine Stop Solenoid (3) Safety Switch (7) Slow Blow Fuse (60 A)
Page 443: Safety Switch
RTV900-TS, WSM ELECTRICAL SYSTEM [1] SAFETY SWITCH (1) Hydraulic Outlet Lever Switches are located at the hydraulic outlet lever. Switch is one of the four connectors switch. Four connector are device to two sections. It means that one switch have independent two switches in the switch.
Page 444: Hydraulic Oil Cooling System
RTV900-TS, WSM ELECTRICAL SYSTEM 3. HYDRAULIC OIL COOLING SYSTEM (1) Slow Blow Fuse (50 A) (4) Slow Blow Fuse (60 A) (7) Oil Cooler Motor Relay (9) Oil Cooler Fan Motor (2) Main Switch (5) Battery (8) Oil Temperature Switch...
Page 445: Oil Temperature Switch
RTV900-TS, WSM ELECTRICAL SYSTEM [1] OIL COOLER FAN MOTOR The oil cooler fan motor 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.
Page 446 SERVICING CONTENTS 1. CHECKING, DISASSEMBLING AND SERVICING........H8-S1 [1] CHECKING AND ADJUSTING ............H8-S1 (1) Safety Switch ................... H8-S1 (2) Hydraulic Oil Cooling System ............H8-S2 (3) Gauges .................... H8-S4 KiSC issued 03, 2008 A...
Page 447 RTV900-TS, WSM ELECTRICAL SYSTEM 1. 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.
Page 448 RTV900-TS, WSM ELECTRICAL SYSTEM (2) Hydraulic Oil Cooling System Fan Motor WIring Harness 1. Disconnect the wiring lead (1) from oil temperature switch after turning the main switch OFF. 2. Turn the main switch ON and connect terminal A connect to terminal B with a jumper lead (4).
Page 449 RTV900-TS, WSM ELECTRICAL SYSTEM Oil Cooler Fan Motor Relay 1. Disconnect the connector from oil cooler fan motor relay (1) after turning the main switch off. 2. Remove the fan motor relay from bracket. 3. Measure the resistance with an ohmmeter across the terminal 1 (2) to terminal 2 (3) and terminal 3 (4) to terminal 4 (5).
Page 450 RTV900-TS, WSM ELECTRICAL SYSTEM (3) Gauges Traveling Speed (Rotation) Sensor 1) Lead Terminal Voltage 1. Disconnect the lead from the speedometer after turning the main switch OFF. 2. Turn the main switch ON and measure the voltage with a voltmeter across the lead terminal (Red / Green) and the chassis.
Page 451 NEW TRANSMISSION The machine RTV900 serial number of the new transmission for North Armerica was changed into those starting with “50001”. KiSC issued 03, 2008 A...
Page 452 CONTENTS TRAVELING SPEEDS..................10-1 G. GENERAL ....................10-G1 [1] LUBRICANTS, FUEL AND COOLANT..........10-G1 [2] MAINTENANCE CHECK LIST............10-G3 [3] CHECK AND MAINTENANCE............10-G3 10. NEW TRANSMISSION ................10-M1 [1] MECHANISM..................10-M1 [2] SERVICING ....................10-S1 KiSC issued 03, 2008 A...
Page 453: Traveling Speeds
RTV900, WSM TRAVELING SPEEDS TRAVELING SPEEDS Worksite Turf Model General Purpose Worksite Recreational Utility Utility 25 × 10 – 25 × 10 – 25 × 12 – 25 × 10 – 25 × 10 – 25 × 10 – 25 × 10 –...
Page 454: General
RTV900, WSM G GENERAL G. GENERAL [1] LUBRICANTS, FUEL AND COOLANT Place Capacity Lubricants, fuel and coolant 28.0 L No. 2-D diesel fuel No. 1-D diesel fuel if temperature is below −10 °C Fuel tank 7.4 U.S.gals 6.2 Imp.gals (14 °F) 4.0 L...
Page 455 RTV900, WSM G GENERAL Greasing Place No. of greasing point Capacity Type of grease VHT link Until grease overflow Battery terminal Cargo lift cylinder pivot Cargo bed pivot Multipurpose type grease Parking brake NLGI-2 or NLGI-1 linkage Moderate amount (GC-LB)
Page 456: Maintenance Check List
RTV900, WSM G GENERAL [2] MAINTENANCE CHECK LIST Period Indication on hour meter Refer- Impor- ence tant page Item 10-G3 Greasing Apply Period Indication on hour meter After purchase Refer- Impor- ence tant 1500 3000 1 year page years years...
Page 457 MECHANISM CONTENTS 1. STRUCTURE ....................10-M1 2. OIL FLOW ....................10-M3 3. BYPASS VALVE ..................10-M4 4. CONTROL LINKAGE FOR BYPASS VALVE......... 10-M12 KiSC issued 03, 2008 A...
Page 458: New Transmission
RTV900, WSM NEW TRANSMISSION 1. STRUCTURE (1) Input Shaft Section (2) Hydrostatic Transmission (3) Range Shift Gear Section (4) Front Wheel Drive Section Section 10-M1 KiSC issued 03, 2008 A...
Page 459 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...
Page 460: Oil Flow
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...
Page 461: Bypass Valve
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...
Page 462 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)
Page 463 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)
Page 464 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)
Page 465 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...
Page 466 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)
Page 467 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...
Page 468 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...
Page 469: Control Linkage For Bypass Valve
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 470 SERVICING CONTENTS 1. CHECKING AND ADJUSTING ..............10-S1 2. DISASSEMBLING AND ASSEMBLING ............10-S2 [1] DISMOUNTING TRANSAXLE ...............10-S2 KiSC issued 03, 2008 A...
Page 471 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).
Page 472 RTV900, WSM NEW TRANSMISSION 2. DISASSEMBLING AND ASSEMBLING [1] DISMOUNTING TRANSAXLE Draining the Transmission Fluid 1. Place oil pans underneath the transmission case. 2. Remove the drain plug (1). 3. Drain the transmission fluid. 4. Reinstall the drain plug (1).
Page 473 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.
Page 474 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 475 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 starter motor. 3. Remove the ground cable (5) and positive cable (4).
Page 476 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 477 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 478 (3) Mission Frame (6) Power Train Support (4) Universal Joint (A) Master Spline W1015698 Power Steering Hose and Radiator Hose (Lower) Here after, refer to WSM No. 97897-15300 of RTV900, which serves as basis. W1018519 10-S8 KiSC issued 03, 2008 A...
Page 479 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 Printed in Japan 2008. 03, S, EI, EI, e Code No.9Y011-15305 KUBOTA Corporation 2004.

wsm RTV900 Workshop Manual

General

1 Product Identification

2 General Precautions

3 Handling Precautions for Electrical Parts and Wiring

4 Lubricants, Fuel and Coolant

5 Tightening Torques

6 Maintenance Check List

7 Check and Maintenance

8 Special Tools

9 Tires

Mechanism

1 Engine Body

2 Lubricating System

3 Cooling System

4 Fuel System

Servicing

Mechanism

1 Structure

2 Power Train

Servicing

1 Troubleshooting

2 Servicing Specifications

3 Tightening Torques

4 Checking

5 Disassembling and Assembling

Servicing

1 Troubleshooting

2 Tightening Torques

3 Checking, Disassembling and Servicing

Mechanism

Servicing

Servicing

Mechanism

Servicing

1 Troubleshooting

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Mechanism

3 Hydraulic Pump

4 Hydraulic Cylinder

5 Auxialiary Control Valve

Servicing

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Mechanism

1 Wiring Diagram

2 Starting System

3 Charging System

4 Lighting System

5 Cooling System

6 Gauges

Servicing

2 Servicing Specifications

4 Checking, Disassembling and Servicing

General

1 Tractor Identification

2 General Precautions

3 Handling Precautions for Electrical Parts and Wiring

4 Lubricants, Fuel and Coolant

6 Maintenance Check List

7 Check and Maintenance

8 Tires

Mechanism

1 Structure

2 Hydraulic Circuit

3 Hydraulic Pump

4 Hydraulic Cylinder

5 Hydraulic Outlet Valve

Servicing

2 Servicing Specifications

4 Checking, Disassembling and Servicing

Quick Links

Chapters

Troubleshooting

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Summary of Contents for wsm RTV900