Kubota RTV520 Workshop Manual — 9Y111-21534

Overview

This is the Kubota Workshop Manual for the RTV520 (document code 9Y111-21534, 2024 edition). It provides service and repair procedures for Kubota RTV520 utility vehicle.

Manual Details and Coverage

Manufacturer

Kubota

Models

RTV520

Equipment type

Utility Vehicle

Manual type

Workshop Manual

Document code

9Y111-21534

Publication year

2024

Language

English

Page count

417

Format

PDF

Contents

The manual is structured as follows. Page references correspond to the original PDF pagination.

1. SAFETY

• SAFETY FIRST (1-1)
  • Preparing for emergencies (1-1)
  • Working cautions (1-1)
  • Starting machine safely (1-2)
  • Preventing fires (1-2)
  • Preventing acid burns (1-3)
  • Avoiding high pressure fluid (1-3)
  • Avoiding hot exhaust (1-3)
  • Cleaning exhaust filter (1-4)
• SAFETY LABELS (1-5)
  • Care of danger, warning and caution labels (1-11)

2. GENERAL

• GENERAL WORKING INSTRUCTIONS (2-1)
  • General working precautions (2-1)
  • Tightening bolts and nuts (2-1)
  • Applying thread-locking fluid (2-1)
  • Installing circlips (2-2)
  • Installing
  • Installing spring pins (2-2)
  • Handling split pin (2-2)
  • Handling chain joint and split pin (2-2)
  • Handling liquid gasket (2-3)
  • Replacing O-rings (2-3)
  • Replacing oil seals (2-3)
  • Replacing floating seals (2-4)
  • Connecting hydraulic hoses (2-4)
  • Wrapping thread seal tape (2-4)
  • Installing elbows with male seat (2-4)
  • Connecting and disconnecting quick hose couplings (2-5)
  • Handling the battery (2-5)
  • Handling wire harness (2-5)
  • Handling fuses (2-7)
  • Handling connectors (2-5)
  • Handling connectors (2-7)
  • Wiring color (2-8)
  • Washing the machine with a high pressure washer (2-8)
  • Dispose fluids correctly (2-9)
  • Checking hoses (2-9)
• TIGHTENING TORQUES (2-11)
  • General use screws, bolts and nuts (2-11)
  • Stud bolts (2-12)
  • Hydraulic fittings (2-13)
  • Metric screws, bolts and nuts (2-15)
  • American standard screws, bolts and nuts with UNC or UNF threads (2-15)
  • Plugs (2-15)
• PRODUCT IDENTIFICATION
• PRODUCT IDENTIFICATION (2-17)
• SPECIFICATIONS (2-19)
  • Specification table (2-19)
  • Traveling speeds (2-20)
• DIMENSIONS (2-21)
• TIRES AND WHEELS (2-23)
  • Tires (2-23)
  • Wheels (2-23)
  • Shock absorbers (2-24)
• CARGO BED (2-25)
  • General caution (2-25)
  • Max. cargo bed load (2-26)
• VEHICLE LIMITATIONS (2-27)
• SPECIAL TOOLS (2-29)
  • Special tools for machine (2-29)
  • Special tools for engine (2-39)
• Compression tester (2-39)
• Flywheel stopper (2-40)
• Engine stand (2-42)

3. MAINTENANCE

• SERVICE INTERVALS (3-1)
• LUBRICANTS, FUEL AND COOLANT (3-5)
• CHECK AND MAINTENANCE (3-7)
  • Daily check (3-7)
  • Check points every 50 hours (3-12)
  • Check points of every 100 hours (3-14)
• Checking VHT neutral spring (3-14)
• Checking wheel bolt torque (3-14)
• Cleaning air cleaner primary element (3-14)
• Cleaning pre cleaner element (3-15)
• Adjusting alternator drive belt tension (3-15)
• Checking carbon canister air filter (3-16)
• Checking battery condition (3-17)
• Adjusting toe-in (3-18)
• Cleaning spark arrester (3-18)
  • Check points of every 200 hours (3-19)
  • Check points of every 300 hours (3-25)
  • Check points of every 400 hour
  • Check points of every 400 hours (3-25)
  • Check points of every 500 hours (3-26)
  • Check points of every 1000 hours (3-26)
  • Check points of every 1000 hours or 1 year (3-27)
  • Check points of every 2000 hours or 2 years (3-27)
  • Check points of every 1 year (3-27)
  • Check points of every 1 year (3-29)
  • Check points of every 2 years (3-31)
  • Check points of every 2 years (3-31)
  • Service as required (3-32)

4. ENGINE

• MECHANISM (4-1)
  • Engine body (4-1)
  • Lubricating system (4-4)
  • Cooling system (4-6)
  • Fuel system (4-9)
• Structure of electronic fuel injection system (4-9)
• Outline of single-point injection system (4-11)
• Function of governor (4-14)
• Structure of fuel system (4-16)
• Structure of EVAPO system (If equipped) (4-17)
• Structure of intake system (4-18)
• SERVICING
• SERVICING (4-19)
  • Troubleshooting for engine (4-19)
  • Service specifications for engine (4-24)
  • Tightening torques for engine (4-28)
  • Checking and adjusting (4-31)
• Engine body (4-31)
• Lubricating system (4-32)
• Cooling system (4-32)
• Fuel system (4-34)
• Fuel system (4-35)
  • Disassembling and assembling (4-37)
  • Servicing (4-61)

5. TRANSAXLE

• MECHANISM (5-1)
  • Outline of a transaxle (5-1)
• SERVICING (5-35)
  • Troubleshooting for transaxle (5-35)
  • Service specificatio (5-35)
  • Service specifications for transaxle (5-38)
  • Tightening torques for transaxle (5-39)
  • Checking and adjusting (5-41)
  • Disassembling and assembling (5-52)
• Removing engine and transmission (5-52)
• Separating engine from transaxle (5-60)
• Disassembling HST (5-63)
• Disassembling transaxle (5-68)
  • Servicing (5-74)

6. SUSPENSION

• MECHANISM
• MECHANISM (6-1)
  • Structure of front suspension (6-1)
  • Structure of rear suspension (6-2)
• SERVICING (6-3)
  • Tightening torques for suspension (6-3)
  • Checking and adjusting (6-4)
  • Disassembling and assembling (6-4)
  • Servicing (6-10)

7. BRAKES

• MECHANISM (7-1)
  • Outline of traveling brake (7-1)
  • Structure of traveling brake (7-2)
  • Outline of master cylinder (7-4)
  • Outline of brake oil (7-5)
  • Outline of parking brake (7-6)
• SERVICING (7-7)
  • Troubleshooting for brakes (7-7)
  • Service specifications for brakes (7-9)
  • Tightening torques for brakes (7-10)
  • Checking and adjusting (7-11)
  • Disassembling and assembling (7-17)
  • Servicing (7-28)

8. FRONT AXLE

• MECHANISM (8-1)
  • Structure of front axle (8-1)
• SERVICING (8-3)
  • Troubleshooting for front axle (8-3)
  • Service specifications for front axle (8-4)
  • Tightening torques for front axle (8-5)
  • Checking and adjusting (8-6)
  • Disassembling and assembling (8-6)
  • Servicing (8-17)

9. STEERING

• MECHANISM (9-1)
  • Structure of steering linkage (9-1)
  • Structure of manual steering (9-2)
• SERVICING (9-3)
  • Troubleshooting for steering (9-3)
  • Tightening torque for steering (9-4)
  • Disassembling and assembling (9-5)
  • Servicing
  • Servicing (9-9)

10. ELECTRICAL SYSTEM

• MECHANISM (10-1)
  • Location of electrical components (10-1)
  • Starting system (10-2)
  • Charging system (10-5)
  • Lighting system (10-8)
  • Cooling system (10-8)
  • Gauge system (10-9)
• SERVICING (10-13)
  • Troubleshooting for electrical system (10-13)
  • Service specifications for electrical system (10-20)
  • Tightening torques for electrical system (10-21)
  • Checking and adjusting (10-22)
  • Disassembling and assembling (10-45)
  • Servicing (10-48)
• DANGER
• WARNING
• CAUTION
• IMPORTANT
  • Working cautions
  • Preparing for emergencies 1. SAFETY
• RTV520
  • Starting machine safely
  • Preventing fires
  • Starting machine safely
• 1-2 RTV520
  • Preventing acid burns
  • Avoiding high pressure fluid
  • Avoiding hot exhaust
  • Preventing acid burns 1. SAFETY
• RTV520
  • Cleaning exhaust filter
  • Cleaning exhaust filter
• 1-4 RTV520
• SAFETY LABELS
• RTV520
• 1-6 RTV520
• RTV520
• 1-8 RTV520
• RTV520
• 1-10 RTV520
  • Care of danger, warning and caution labels
  • Care of danger, warning and caution labels 1. SAFETY
• RTV520
• 1-12 RTV520
• GENERAL WORKING INSTRUCTIONS
  • General working precautions
  • Tightening bolts and nuts
  • Applying thread-locking fluid
  • Apply the thread-locking fluid to the tip of the bolt
  • If the threads are large, apply the thread-locking
  • General working precautions 2. GENERAL
• RTV520
  • Installing circlips
  • Installing spring pins
  • Handling split pin
  • Handling chain joint and split
  • Installing circlips
• 2-2 RTV520
  • Handling liquid gasket
  • Replacing O-rings
  • Remove the burr and clean the O-ring groove
  • Put the O-ring in the groove
  • If there are burrs, scratches, or rust on the inner
  • Clean the inner surface of the housing hole and the
  • Lubricate the seal lip and dust lip
  • With the seal lip facing the airtight side (B) of the
  • Handling liquid gasket 2. GENERAL
• RTV520
  • Replacing floating seals
  • Apply oil appropriately to both sides of the O-ring
  • Do
  • Apply oil thinly to the sliding surfaces
  • Install the floating seal in parallel to the sliding
  • After installation, rotate the floating seal for 3 times
  • Connecting hydraulic hoses
  • Clean the inside of the hose fittings
  • T ighten with the specified torque
  • Wrapping thread seal tape
  • W rap the thread seal tape around the taper threads
  • Installing elbows with male
  • Clean the male seat surface and seal
  • Loosen the lock-nut until the top end
  • Install
  • Replacing floating seals
• 2-4 RTV520

Manual Revisions

• March 2021 — Added aluminum wheel bolt torque
• April 2021 — Added condition table and updated valve operating pressure
• March 2022 — Revised T; ransaxle section "forward" to "traveling" and "reverse" to "dynamic brake". －; Added torque value for shift cable nut
• October 2024 — Replaced the chapter about adjusting parking brake lever.; Corrected the procedure and some illustraions

Delivery (Instant Download)

This manual is supplied as a digital PDF file and is available for instant download after purchase. No physical media is shipped.

References

Kubota Workshop Manual for Utility Vehicle, document code 9Y111-21534, PDF edition.