FOREWORD

DO IT RIGHT, THE FIRST TIME & EVERY TIME

This publication is intended for use by trained technicians who can work on SAME Tractors to provide complete satisfaction to our valued customers. It contains general information related to SAME Tractors and, in particular, highlights the inspection, overhauling and adjustment procedures as well as instructions for dismantling and reassembling operations. The Workshop Service Manual provides a summary of various operations to mechanics, who have attended our service training programmes, to assist them in performing a precise and quality repair job on the SAME Tractor. The contents of this Manual provide exhaustive information for experienced mechanics and is a refresher dossier on the sequence of the operations performed. It is, therefore, a good practice for every authorised dealer / authorised service center to have this publication, for a quick reference and for constantly improving the knowledge and skills of their personnel. In accordance with our policy and commitment to the process of continuous improvement, the specifications, data and procedures mentioned in this Manual are subject to change. The holders of this Manual are, therefore, requested to constantly update the same with the periodic notifications on changes which are issued by us. For any further information or clarifications, please write to: Service Department Marketing Headquarters SAME DEUTZ-FAHR INDIA 72, Sipcot Industrial Complex Ranipet - 632 403. Tamil Nadu, India. Telephone: 91-4172-247156 to 247163 (Ext. 213) Fax: 91-4172-246330 Emergency: 91-98431 96070 E-mail: service@samedeutz-fahrindia.com

Date of Publication: January 2004

SAME DEUTZ - FAHR INDIA

WORKSHOP SERVICE MANUAL

CONTENTS
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
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6 7

10 11 12

13

14 15 16 17 18 19 20 21 22 23
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.

Caution and Warning Symbols

It means: Caution! Attention! Stay alert! Your safety is involved. It means: Warning! Necessary for your safety.

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

SAME DEUTZ - FAHR INDIA (P) LTD.

RANIPET, TAMIL NADU, INDIA.
MODEL YEAR OF MANUFACTURE

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.

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WORKSHOP SERVICE MANUAL

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

10 Stands for date (i.e. 10th January) A Stands for A Shift

Following is the table for years & months : Table No. 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

WORKSHOP SERVICE MANUAL

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.

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WORKSHOP SERVICE MANUAL

GENERAL INFORMATION

SPECIFICATION
Tractor

Model
Make Type

SAME 393 SAME 453 SAME 503

SAME SAME SAME Four Wheeled, two wheel drive unit construction General purpose Agricultural Tractor.

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

Air Induction System

Pre Cleaner Air Cleaner

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GENERAL INFORMATION

Model
Cooling System
Type

SAME 393 SAME 453 SAME 503

Forced liquid coolant circulation with expansion tank. Forced feed type, Gear pump, Driven by camshaft Max. 4.5 - 5.9 Kg/cm2 Min. - 0.5 Kg/cm2 Full flow, spin-on, Paper Element 12 V

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

Inbuilt with tail lamp

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

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WORKSHOP SERVICE MANUAL

GENERAL INFORMATION

Model
Steering
Make Type Location Method of operation Diameter of Steering Wheel

SAME 393 SAME 453 SAME 503

RANE Worm screw & Nut with recirculating balls Heavy duty single drop arm Steering Above the gear box Manual, through steering wheel. 430 mm Crown Wheel bevel pinion with differential & Epicyclic Planetary final reduction. 6.75 : 1 Mechanical, Multipin type RHS foot operated Rear Single clutch One hand lever is provided on LHS of operators Seat for engaging PTO gear Double clutch

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

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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 393 SAME 453 SAME 503

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

By shifting the position of the hitch in holes on mounting bracket

Distance of hitch point

- From Rear Axle Centre - From Power Take-off shaft end - Diameter of Pin hole - Width of clevis 553 mm 120 mm 29.2 mm 70 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

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WORKSHOP SERVICE MANUAL

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 393 SAME 453 SAME 503

6.00 x 16 (inches), 6 (Ply) rating 1240 1240 1240, 1340, 1440 & 1540 None 2.3 Kg. Cm2 2.3 Kg. Cm2 Kgs 435 12.4x28 mm mm 1305 1305, 1395, 1510 13.6x28 7.50x16 (8 Ply) 1315 1315, 1415, 1515 & 1615

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

Method of changing Track Width

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

Filling Capacity (Lits.)

Engine Air Cleaner Steering Gear Box Cum Hydraulic Service Brake Coolant in cooling system 7.50 1.00 0.75 35.00 0.40 8.00 7.50 1.00 0.75 35.00 0.40 11.00 7.50 1.00 0.75 35.00 0.40 11.00 7.50 1.00 0.75 35.00 0.40 11.00

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GENERAL INFORMATION

TECHNICAL DATA DIMENSIONS AND WEIGHT

Description
Tyres size Length Front Rear

SAME 393 SAME 453 SAME 503 SAME 603

6.0x16 6PR. 3140 3395 1615 2020 1340 1510 1590 2300 340 2045 770 / 1110 / 1880 6.0x16 6PR. 3160 3395 1655 2060 1370 1520 1620 2320 370 2045 780 / 1205 / 1985 7.5x16 8PR. 3185 3395 1760 2100 1455 1530 1705 2330 380 2045 785 / 1230 / 2015 6.5X20 8PR. 3290 3395 1860 2250 1500 1580 1720 2365 420 2045 790 / 1300 / 2090 12.4x28 12PR. 13.6x28 12PR. 14.9x28 12PR. 16.9X28 12PR.

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

Ground clearance Wheel base

Weight without ballast but with all the liquid reservoirs full front / rear / total NOTE: All dimensions are in mm.

TRACTOR PERFORMANCE - GROUND SPEED

8 FORWARD SPEED
Nominal speed at rated Engine speed (Kmph)

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

(13.6 x 28 tyre) (14.9 x 28 tyre) (16.9 x 28 tyre)

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.

Fig. 3 Tractor chassis serial number

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)

Data Plate of Frame and Engine

Fig. 4 Tractor chassis serial number

Fig. 5 Engine Serial Number

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WORKSHOP SERVICE MANUAL

SPLITTING THE TRACTOR

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SPLITTING THE TRACTOR

Splitting the Front Axle Assembly From the Tractor (02 - 1)

1. 2. 3. 4. 5. 6. 7. Keep the Tractor on a level ground and apply parking brake. Also wedge the Rear Wheels at both ends. Remove the Weights and Front ballast frame (if Fitted). Remove wiring connection of Head lamp, and Battery earth connection from the side panel end. Remove Front Grill Assy. by unscrewing the screws by star screwdriver. Disconnect the cable connection and remove the Battery. Drain Water from the Radiator and no loss tank. Jack the Tractor with the help of Tractor Splitting Kit at the bottom of the Engine (Special Tool No. G. ST.001.0) as shown in the Fig. 1

Fig.1

8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

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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SPLITTING THE TRACTOR

Splitting the Engine Assembly From the Tractor (02 -2)

1. 2. 3. 4. 5. 6. Split the Front Axle Assembly as per the procedure given operation No. 02-1. Remove the hydraulic pipe line connection at the Engine end. (Note: Keep a tray below the oil pump assy. while removing pipe line as oil will leak). Drain the Engine Oil from Sump. (Note: While draining, keep the oil filler cap open for fast and complete draining up). Remove all fuel pipe line connection to Fuel Tank. Remove Wiring harness connected to Engine (i.e. Water sensing. Oil pressure sensing unit, Starter motor, Alternator). Keep the trolly jack below the Front Gear Box and nip the FGB.

Fig. 2

7. 8. 9. 10. 11. 12. 13.

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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SPLITTING THE TRACTOR

Fig. 3

14. 15. 16.

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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SPLITTING THE TRACTOR

7. 8. 9. 10. 11. 12. 13.

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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SPLITTING THE TRACTOR

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

9. 10. 11. 12. 13. 14.

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.

Removal & Fitment Procedure: (04 - 1)

1. 2. 3. 4. 5. Lift the Side panel and remove the Battery (-) earth connection for safety purpose. Fig. 1 Remove the wiring connection from Head lights from back side. Fig. 1A Unscrew Front show mounting bolts. Fig. 2 Remove the grill Assy. with head lamps. Fig. 2A Follow the reverse procedure for fitment.

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

21

SHEET METAL

Removal and Fitment procedure (04 - 2) : Fig. 3A/3B

1 2 3 4 5 6 7 8 9 10 Remove the front grill assembly-follow procedure (04-1). Remove the Silencer assembly by unscrewing the clamp. Remove the Pre-cleaner assembly along with the pipe. Loosen the two nuts connecting bonnet assembly and front frame at top end. Fig. A Remove the nuts. Loosen the two nuts connecting bonnet assy. and rear bulk head assy. at top end. Fig. B Remove the nuts. Lift the complete bonnet assy. along with the side panel and keep it in a safe place. Follow the reverse procedure for fitment. The complete Bonnet assy. can be dismantled further by removing the side panel L.H. & R.H. Remove the four nuts connecting hinge and side panel. Remove the side panel.
B Fig. 3 A

MUFFLER

11

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

Foot step Assembly L.H / R.H. :

This is provided with ladder assembly for easy entry to drivers seat. It is fixed to front gear box and supported by flat car plates, and fender assembly. So, it is very rigid. It can be removed separately and also along with ladder assembly depending on requirement.

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.

Removal & Fitment Procedure of Fender Assembly R. H. (04 - 6) Fig. 6

1 2 3 4 5 6 Remove the Battery (-) earth connection for safety purpose. Remove the wiring connection from the rear Junction. Fig. 6A Remove six set screws connecting Fender assembly and Flat car assembly Fig. 6B Remove the two set screw and nuts connecting the fender and foot step assembly Fig. 6C Remove four bolt and nuts connecting the fender assembly and bracket assembly Fig. 6D Lift the Fender R. H. assembly slowly after ensuring that it is free in all respects.

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.

SAME DEUTZ - FAHR INDIA

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WORKSHOP SERVICE MANUAL