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GROUP 1 2 3 4 5 DESCRIPTION General Information Splitting the Tractor Sheet Metal Front Axle Engine a) Cylinder Block & Liner b) Cylinder Head c) Timing Case & Gears d) Timing e) Piston & Connecting Rod f) Crank shaft g) Cam shaft h) Fly Wheel i) Intake & Exhaust System j) Lubrication system k) Fuel system l) Cooling system m) Trouble shooting Steering Clutch a) Clutch b) Trouble Shooting Front Gear Box a) Front Gear Box b) Trouble Shooting Rear Gear Box a) Rear Gear Box b) Trouble Shooting Rear Axle Power Take off Brakes a) Brakes b) Trouble Shooting Hydraulic a) Hydraulic b) Trouble Shooting Hydraulic Linkage Electricals Instruments & Gauges Controls Wheels & Tyres Conversion Table Recommended Lubricants Service & Maintenance Schedule Instruments, Gauges and Service Special Tools Adhesive & Sealants PAGE NO. 3 14 20 26 33 39 43 49 53 54 61 67 70 72 74 79 97 102 106 126 127 138 139 140 147 148 149 161 162 165 167 168 176 177 178 198 199 209 227 235 238 245 247 249 256 286
WORKSHOP SERVICE MANUAL
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10 11 12
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SAME DEUTZ - FAHR INDIA
GENERAL INFORMATION
General
This section has been compiled to enable the users to ascertain quickly the specifications, punching of chassis numbers and engine serial numbers and how it has been followed as per the standards. This service manual is divided into number of groups and each group has been explained and dealt with very briefly for the convenience of the users. Important dimensions, clearances and torque values are given besides trouble shooting for easy reference. Note : Throughout this Manual, reference Left or Right is viewed from Drivers Seat.
The Identification plate of the tractor, which is fitted at the Right hand side of the dashboard, has got the following information: A - Model B - Year of Manufacture C - Engine Serial Number D - Chassis Serial Number E - Maximum P.T.O. Power F - Specific Fuel Consumption ENGINE SERIAL No. CHASSIS SERIAL No. MAKE
B C
MAXIMUM PTO POWER Kw (hp) SPECIFIC FUEL CONSUMPTION g/Kwh(g/hph)
A
Fig. 1
A - Model - 503 B - Year of Manufacture - It comprises of year, month, date & the shift. Codification system is illustrated below with an example.
GENERAL INFORMATION
Say the year of Manufacture is Punched as 01 A 10 A >> >> >> >> 01 Stands for year 2001 A Stands for Month January
Refer Table - 1
Month of Manufacture 2001 January February March April May June July August September October November December 01A 01B 01C 01D 01E 01F 01G 01H 01J 01K 01L 01M 2002 02A 02B 02C 02D 02E 02F 02G 02H 02J 02K 02L 02M
Year of Manufacture 2003 03A 03B 03C 03D 03E 03F 03G 03H 03J 03K 03L 03M 2004 04A 04B 04C 04D 04E 04F 04G 04H 04J 04K 04L 04M 2005 05A 05B 05C 05D 05E 05F 05G 05H 05J 05K 05L 05M 2006 06A 06B 06C 06D 06E 06F 06G 06H 06J 06K 06L 06M
TABLE No. 1
With the help of Table No. 1 the users can know the year of manufacture. Similar logic can be applied for years beyond 2006 as shown in the above table. For shift of the day it can A, B or C. D - Chassis Serial Number (C - Fig. 1) is sequential number and it follows as : RPT XXXXX >> >> RPT - Stands for Ranipet Production Centre. XXXXX - is Sequential Serial Number starting from 00001.
Chassis serial number is also punched on two more places as shown in figures on Page No. 13. On the rear portion of the rear gear box (Fig - 3). On the side of the front support (Fig - 4). SAME DEUTZ - FAHR INDIA
GENERAL INFORMATION
C - Engine serial number: It comprises of 9-digit codification as shown in Table-2. Take EXAMPLE - 3A00001A1
NU
AL
NU
AL
NU
NU :: Numerical AL :: Alphabetic
XXXXX
X
YEAR MONTH SL. No. MODEL CATEGORY / TYPE
TABLE No. 2
1 - Digit (Numerical) - Category / Type-3 denotes Tractor Engine. 2 - Digit (Alpha) - Denotes Model-A stands for 3W (Three cylinder water cooled). 3rd to 7th Digit (Numerical) Serial No. of Engine Example : 00001 (Five digit number). 8th Digit (Alpha) denotes Month A-Jan., B-Feb. ...so on L-Dec. 9th Digit (Numerical) Denotes year 8-1998 and 9-1999.
GENERAL INFORMATION
SPECIFICATION
Tractor
Model
Make Type
SAME 603
SAME
Engine
Make Model Type No. of Cylinders Bore Diameter Stroke Capacity Compression Ratio Firing Order Horse Power Max. torque at rated speed Valves Valves Tip Clearance: Weight of Engine (Dry) Nm / RPM 35HP/25.74kw at 2200 RPM 1418% at 1200 RPM 42HP/30.88Kw at 2200 RPM 1608% at 1400 RPM SAME SAME 1000.3W (Four stroke water cooled, Direct injection Diesel Engine) Three 105 mm 115.5 mm 3000 CC 17:01 1,3,2 50HP/36.76Kw at 2350 rpm 1818% at 1200 RPM Overhead Valve 0.25 mm (cold) 320 Kg 60HP/44.12Kw at 2350 rpm 2088% at 1200 RPM SAME SAME
Fuel System
Fuel Lift Pump Fuel Filter Filtering Capacity Fuel Injection Pump No. of Pumps Injectors Injector Pressure Engine Speed on No Load (Low Idle) Injection Timing 95050 16 BTDC Centrifugal Pre-Cleaner with transparent dust collector Oil bath type 70050 70050 70050 Diaphragm type MICO 0.5 Lit. Dual filter with replaceable paper element 1.5 to 2 MICO PFR 1K (F002 F20 008) Mono Cylinder Three Multi Hole - MICO (F 002 C70 203) 180 + 8 bar
GENERAL INFORMATION
Model
Cooling System
Type
SAME 603
Lubrication System
Type System Pressure Oil Filter Type
Electrical System
Voltage Battery Alternator Starter Motor Safety Start Horn Lead acid maintenance free, 13 plates, 12V, 80Ah@20 hrs. discharge rate 12V, 35 amps, built-in voltage regulator Pre-engaging, Solenoid operated 12V, 2.2kW Flange mounted Gear shift neutral safety switch provided Electro magnetic, Diaphragm type
Front lights
Head lights Direction lights Parking light W W W W W W W W W 2 Fixed Axle 2 mm--6 mm 280 mm (11) Optional 280 mm (11) Optional ------280 mm (11) ------280 mm (11) 2 21 45/40 21 5 21/5 35 45/40 - Halogen 21 5 21/5 35 21 None 2 45/40 - Halogen 21 5 21/5 35 21 45/40 - Halogen 21 5 21/5 55 - Halogen 5 21 21 2
Rear lights
Brake light cum Tail light Rear Work Lamp Registration plate light Direction lights Reverse lights Panel lights
Front Axle
Type Toe-in Telescopic (Straight Axle) with variable Track adjustment
Clutch
Single Clutch (common for transmission and PTO) Double Clutch (Independent for transmission and PTO)
Gear Box
Type No. of Speed Constant mesh 8 Forward and 2 Reverse with high and low range
GENERAL INFORMATION
Model
Steering
Make Type Location Method of operation Diameter of Steering Wheel
SAME 603
Rear Axle
Type Final Drive Ratio
Differential Lock
Type Method of operation POWER TAKE OFF (PTO) Location Method of Operation
Two hand levers are provided on LHS of operators Seat 1. PTO clutch engagement lever. 2. PTO gear engagement lever.
No. of Splines Diameter of Shaft (mm) PTO Speed corresponding to rated engine speed Engine RPM at std PTO speed (540 + 10 RPM) Distance behind rear Axle Engine to PTO speed ratio Direction of Rotation Max. PTO HP
Six 35 581 RPM 2046 RPM 430 mm 3.785:1 Clockwise (Rear view) 32.2 Live, ADDC One, Single acting Mechanical (Knob on lever sector) Gear driven pump LHS of Engine & Drive through Timing Gear 2 2 2 2 39.9 45.5 54.0 621 RPM
Hydraulic System
Type No. & Type of Cylinder Type of Linkage Hydraulic Pump Location & Drive No. of Filters
GENERAL INFORMATION
Model
Type of Filters Max. output at rated RPM Relief Valve Opening Pressure bar Details of Control Lever Method of draft sensing
SAME 603
Washable metallic strainer before suction pipe & spin on paper element filter in suction line 29 litres /min. 180 + 10 a) Depth Control (green) b) Raising and lowering with position, draft, mix & float control (yellow) Through Top Link (External Linkages) Three point linkage CAT-II 1300 1400 1500 1500 31 litres /min.
Hydraulic Linkage
Type Max. Lift Capacity throughout the Range
Towing Hitch
Type & Location Height above ground level (max) (min) Type of adjustment & reversing the bracket. ( 6 positions) Clevis, Rear end of RGB 775 mm 300 mm 800 mm 325 mm 820 mm 345 mm 860 mm 385 mm
Brakes
Service Brake: Make Type No. of Discs Location Braking Area Brake lining Material Method of Operation SAME DEUTZ - FAHR S.P.A, Hydraulic operated, Oil immersed disc type Two (one each Side of the Wheel) On Rear Axle Shaft between Differential and Epicyclic reduction unit 369.06 Cm2 for each Wheel side FRENDO HDT 303 Individually or Combined foot pedal Operated SAME DEUTZ - FAHR S.p.A, Fully Independent, Oil immersed 3 disc type On high - low reduction shaft By hand lever on LHS of operators seat
Parking Brake
Make Type Location Method of Operation
GENERAL INFORMATION
Model
Wheels and Tyres Front Wheel
Size Track Width Ref. fig. no. 2 (N) Adjustment Size in step Method of changing Track Width mm mm
SAME 603
6.50 x 20 (8 Ply) 1315 1315, 1415, 1515 & 1615
By extending the Telescopic axle 2.3 Kg./Cm2 2.3 Kg. Cm2 2.3 Kg./Cm2 2.3 Kg. Cm2 660 14.9x28 1340 1340, 1350, 1460, 1636 & 1700 2.5 Kg./Cm2 2.5 Kg./Cm2 630 16.9x28 1410 1410, 1490, 1605, 1695 & 1810
Inflation Pressure
For Field work Haulage Operation Max. permissible loading capacity of each Tyre at
Rear Wheel
Tyre size Track Width Ref. fig. no. 2 (P) Adjustment Size in step
By changing the position of Disc on Rim lugs and by reversing the wheel rim 1 Kg./ Cm2 1 Kg./ Cm2 Kgs 1050 1084 1.3 Kg./ Cm2 1.3 Kg./ Cm2 1324 1.33 Kg./ Cm2 1.33 Kg./ Cm2 1665
Inflation Pressure
For Field work Haulage Operation Max. permissible loading capacity of each Tyre
Seat
Driver Seat - cushioned with mutually adjustable slots Driver Seat - cushioned with fore and aft adjustable holes Yes Optional ---Yes ---Yes ---Yes
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GENERAL INFORMATION
A B C C E F G H
Without rear 3-point hitch With rear 3-point hitch Minimum with reference tyres Maximum with reference tyres Mudguards Steering wheel Fender rail Exhaust silencer
Width
Height
Weight without ballast but with all the liquid reservoirs full front / rear / total NOTE: All dimensions are in mm.
SAME 393
(12.4 x 28 tyre)
Rated Engine RPM 2200
SAME 453
Rated Engine RPM 2200
2.58 3.96 6.57 9.23 8.32 12.76 21.18 29.76 4.44 14.32
SAME 503
Rated Engine RPM 2350
2.86 4.38 7.26 10.21 9.21 14.11 23.43 32.92 4.6 14.83
SAME 603
Rated Engine RPM 2350
3.08 4.72 7.83 11.01 9.93 15.21 25.26 35.5 4.96 15.98
1 2 3 4 1 2 3 4
SLOW SLOW SLOW SLOW FAST FAST FAST FAST SLOW FAST
2.55 3.91 6.49 9.12 8.23 12.61 20.94 29.43 4.39 14.15
2 REVERSE SPEEDS
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GENERAL INFORMATION
Fig. 2
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GENERAL INFORMATION
IDENTIFICATION MARKS
CHASSIS SERIAL NUMBER AND ENGINE SERIAL NUMBER ARE TO BE MENTIONED FOR FOLLOWING PURPOSES: 1. 2. WHENEVER PARTS ARE TO BE ORDERED FOR REPLACEMENT, FOR RAISING WARRANTY CLAIM DURING WARRANTY PERIOD, OR ANY CORRESPONDENCE IN CONNECTION WITH THE TRACTOR.
SAME DEUTZ - FAHR INDIA (P) LTD. RANIPET, TAMIL NADU, INDIA.
MAKE MODEL YEAR OF MANUFACTURE
B
ENGINE SERIAL No. CHASSIS SERIAL No.
C
MAXIMUM PTO POWER Kw (hp) SPECIFIC FUEL CONSUMPTION g/Kwh(g/hph)
13
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Fig.1
Remove the pre-Cleaner Assembly along with pipe and Silencer Assembly. Remove the Top Bonnet Assembly along with side panels. Remove the Water Hose connection and air induction hose connection. Keep the Tractor front Wheel in straight direction. Wedge the Centre Front Axle with Front Support from both ends. Remove the Drag link connection at Steering box end. Loosen 8 bolts connecting Front Engine Support and Engine Assembly. Jack front Axle with Trolley Jack of Splitting Kit. (Refer Fig. 1) Remove the Eight bolts and withdraw the front Axle Assy. completely along with Radiator, Front Support and Air Cleaner Assembly etc. (Refer Fig. 1) Hold the Front Axle Assembly with the help of Special Horse holder. Remove the trolley jack from Front Axle Assembly.
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Fig. 2
Remove the Instrument panel and its connected Parts. Remove the Dash Board. Drain and remove the Fuel tank. Remove the set screw connecting the Rear bulk head the Engine rear end (refer Fig. 2). Jack the Engine Assembly at bottom of Sump with the moving Trolley jack as shown in Fig. 3. Loosen the belt connecting the Engine Assembly and Front Gear Box (Use 18/22 mm spanner) Remove the Starter Motor.
CAUTION:
Keep both the jacks at even height for easy removal of bolts without load.
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Fig. 3
Remove all Bolts. Press the Clutch and withdraw the Engine Assy. along with the Clutch Assembly from Front Gear Box slowly with the help of Trolley jack. Keep the Engine Assembly with proper support.
Splitting the Front Gear Box from Rear Gear Box (02 - 3)
1. 2. 3. 4. 5. 6. Keep the Tractor on a level ground and apply parking brake. Also keep wedge on both sides of rear wheel. Remove the Battery (-) earth connection. Remove Wiring connection between Front and Rear gear box. Drain the Transmission oil. Remove Hydraulic oil pipe connections a) Suction pipe (Big) at front end, b) Pressure pipe (small) at front coupling end for easy handling of work. Remove Hydraulic Brake fluid pipe line connection at both ends.
Fig.4
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Remove foot throttle connection near Foot Rest. Remove Foot Step Assembly at both ends (R.H./L.H.) Remove following linkage connection (Gear Shift Lever, High/Low Gear Lever, PTO clutch/drive lever. and Hydraulic external Linkage) from Flat car Assembly. Loosen the bolts Connecting the Fender Assembly and Axle/Trumpet Housing and slide fenders for removal of set screws to Flat car. Remove Flat car Assy. by removing the set screws to Fenders. Keep the rail, part to Tractor splitting kit (Special Tool No. G.ST.001) below Front and Rear gear box. Keep trolley jack one below the Front gear box and another below the Rear gear box as shown in Fig. 4 and jack both gear box uniformly.
WARNING:
Before performing the separation of Front Gear Box & Rear Box Housings, it is also necessary to remove the drive hub which controls the reversing gear unit and the drive hub of the 4-speed control, along with the intermediate support, all placed at the right side of the rear gear casing. Loosen screw which secure the sleeves on the speed control rods.
CAUTION:
Remove the balls and the relevant rod holding springs by unscrewing the screw plugs located at the right side of the gear casing. After this proceed with the separation of two gear casings. 14. 15. 16. 17. Use 18mm size spanner and loosen twelve bolts. Remove 12 bolts. Withdraw both the Front and Rear Gear box slowly with the help of moving trolley jack refer Fig. No. 4. Support both the Assembly with help of horses or bracket support assembly.
Splitting the Rear Gear Box Assy. and Axle Housing from Tractor (02-4)
1. 2. 3. 4. 5. Split the Front gear box as mentioned in earlier operation (02-3). Support the Axle housing at both sides. Remove Rear wheel bolts with the help of 27mm spanner. Remove the Tyres from both sides. Remove L.H. Lower link Assembly.
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CAUTION:
Ensure that the trolley jack is below the gear box where crown wheel & pinion assy. is assembled. Give proper support for safe disassembly. 6. 7. 8. Remove the Fender Assy. and Oil filter assembly at L.H. side. Loosen the nuts (L.H.) connecting Rear gear box and Axle housing. Removing the L.H. side support for further dismantling.
Fig. 5
Remove L.H. Axle housing along with the axle shaft. Remove Internal Axle shaft. Remove brake fluid pipe lines at both ends. Remove the brake housing and its connected parts. Follow the same procedure for R.H. side like L.H. side. Keep all parts in a safe place.
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SHEET METAL
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SHEET METAL
Sheet Metal
This section consists of all sheet metal items in SAME Tractors. The major items are as follows: Front Grill Bonnet Assy. Foot Step Assemblies Flat Car Fender Assemblies Removal and fitment procedure of these items.
Front Grill
This grill safeguards the Battery, Radiator and Air cleaner assy. It also gives a good ventilation for Battery and protects radiator and Battery from dust in field operation.
Fig. 1
Fig. 1A
Fig. 2
Fig. 2A
Bonnet Assy. :
This covers the Engine and gives an aesthetic look to the Tractor. It is designed in such a way that it paves ways to Air induction and exhaust system of Engine assy. Side panels are provided with hinge and stay rod for easy service accessibility. It also gives good ventilation to Engine. It also has the product model monogram for identification. SAME DEUTZ - FAHR INDIA WORKSHOP SERVICE MANUAL
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SHEET METAL
MUFFLER
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Removal and fitment of side lower panel R.H. / A.H. (04 - 3) : Fig. 4A/4B
12 13. 14. Remove the two nuts connecting the front frame and lower side panel. Fig. A Remove the set screw connecting the front support and lower side panel. Fig. B Remove the side lower panel.
A
B Fig. 4
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SHEET METAL
Removal and fitment procedure along with ladder assembly (L.H.) (04 - 4): Fig. 4a
1 2 3 4 5 6 7 Keep the Tractor on plane surface and apply hand brake. Remove two set screw & nuts connecting fender assembly Fig. A Remove two set screw & nuts connecting Flat car assembly Fig. B Remove clutch PTO cable connection. Remove two set screws connecting ladder assembly and Front gear box. Fig. C Withdraw the complete foot step assembly along with ladder assembly carefully. Follow the reverse procedure for fitment.
A
CAUTION :
As the foot step assembly is very heavy, proper care to be taken while removing & fitment. Removal of foot step can be done separately. For this, follow the procedure. Remove two set screw & nuts connecting fender assembly. Remove two set screw & nuts connecting Flat car assembly. Remove four carriage bolt & nuts connecting Ladder assembly Support assembly and foot step. Remove the foot step. Follow the reverse procedure for fitment.
B
Note: The same procedure to be followed for R. H. side. The difference is that instead of Ladder assembly, it will be Support assembly.
C Fig. 4a
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SHEET METAL
FLAT CAR :
This covers all the external mechanical controls and gives a aesthetic look.
Removal & fitment procedure for Flat Car Assembly (04 - 5): Fig. 5
1 2 3 4 Remove the Drivers seat assembly by unscrewing the set screws. Remove the battery (-) earth connection for safety purpose. Remove the flat car bolts connecting to Foot step assembly at both L.H. & R.H. end. Fig. 5A Remove the following control connection for removing the Flat Car.
D Fig. 5
5 6 7 8 9
Gear shift lever: Disconnect the connection by removing the Nyloc-nut. Fig. 5B High/Low lever: Remove circlip and disconnect the lever linkage. Fig. 5C Hydraulic levers: Remove two circlip to remove the connection of hydraulic position & draft lever linkage. Fig. 5D PTO lever: Remove the split pin (cotter pin) and disconnect the PTO lever linkage by removing the pin clevis. Fig. 5E PTO clutch cable: Disconnect the PTO clutch cable connection at clutch end and now Flat Car is free from all control linkage connection. Fig. 5F
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SHEET METAL
10 11 12 13 14 15
Remove six set of screws connecting Fender assembly and Flat car at both R. H. & L. H. side. Remove wiring connection at Flat car end. Remove the L. H. Fender holding bolts and shift the position outward for easy removal of Flat car. Lift the Flat Car slowly up and remove without any damage. Keep the Flat car in safe place. Follow the reverse procedure for fitment.
Fender Assembly:
This protects the driver from dust & mud coming during field operation from rear tyre. The rear signal lights, red lights, number plate and reverse light are mounted on this. It is also having cushion on seat on both side. This also gives an aesthetic look to the Tractor.
C Fig. 6
CAUTION:
As the Fender assy. is heavy, ensure that it is lifted carefully and kept in a safe place. 7 8 Follow the same procedure for L. H. Fender assembly. Follow the reverse procedure for fitment.
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