Challenger 650-658 Series Combine Workshop Manual – PDF DOWNLOAD
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Challenger 650-658 Series Combine Workshop Manual – PDF DOWNLOAD
Use of the manual
General
The purpose of the manual is to help dealers and workshops start-up, service and repair AGCO’s equipment in the most appropriate and effective manner. If the specified procedures are followed and the recommended special tools are used where necessary, tasks and work can be completed within the time indicated in the manual “Repair Time Schedule”.
Pagination
Example: ” … as described in section 2.1.3 on page 73.”
This manual is divided into chapters and sections. In the example the figures show:
Use
To make it easier to look things up, there is a table of contents at the beginning of every chapter listing the various sections in the chapter.
Modifications
Modified pages have the same section numbering as their predecessors: Only the page number and version number change.
The old pages must be destroyed.
Service tools
In the case of jobs that require service tools, the number of the tool is specified at the point in the text where it is needed.
Repairs and replacement of parts
- When replacing parts, it is very important to only ever use genuine AGCO spares. Please pay particular attention to the following points with regard to repairs and fitting spare parts and other equipment. Fitting non-genuine spare parts may impair the safety of the machine.
- In some countries it is against the law to fit parts that do not conform to the manufacturer’s specifications. Torque wrenches must always be adjusted in accordance with the instructions given in the workshop manual.
- Fit locking devices where specified. If the locking device is ruined by removal, fit a new one. If non-genuine AGCO parts are fitted, the machine will no longer be covered by the right of complaint, as the manufacturer provides a warranty on all AGCO components. AGCO dealers are under the obligation to supply genuine parts only.
TABLE OF CONTENTS:
Challenger 650-658 Series Combine Workshop Manual – PDF DOWNLOAD
0: Introduction – Specifications 1
01 Use of the manual 3
02 General specifications4
03 Dimensions and weight 11
04 Safety precautions 13
041 Safety in the workshop 13
042 Safety – a word to the mechanic 13
043 Safety – danger, warning and caution 13
044 Safety decals 13
045 General 13
046 Personal safety 13
04 7 Considerations with regard to equipment 14
048 General considerations 14
049 Operational considerations 15
0410 Maintenance techniques 16
05 Practical advice 17
06 Start-up instructions 21
061 General 21
062 Pre-delivery checks 21
063 Instruction of combine operator 22
07 Conversion tables25
071 Conventional Units of Measurement 25
08 Locking and sealing agents 27
09 Torques28
091 Wheels 28
092 Screws with metric threads 29
093 Nuts with metric threads 30
1 : Cutting table 31
11 General 33
12 Knife drive – wobble box 35
121 Removal 35
122 Mounting 36
123 Reconditioning the wobble box 38
124 Fitting knife clips and crop lifters 42
13 Table auger 43
131 Removal 43
132 Mounting 43
133 Replacement of shaft on the right-hand side 44
134 Replacement of shaft on the left-hand side 45
135 Replacement of crankshaft 45
136 Replacement of feathering fingers, bearings and bushes 46
137 Adjustment of table auger and feathering fingers 47
14 Table body 48
1 41 Adjustment of cut-off strips 48
142 Adjustment and positioning of ground sensor – PowerFlow 49
143 Adjustment and positioning of ground sensor – FreeFlow 51
15 Slip clutch and chain drive 52
151 Removal 52
152 Mounting 52
153 Replacement of bearings and sprockets 53
16 Countershaft54
161 Removal 55
162 Mounting 56
17 PowerFlow table 57
171 Removal, belts 58
172 Mounting, belts 60
173 Replacement of front rollers and bearings, scraper adjustment 62
Workshop Manual Combine Challenger 650-658 Series – EN_63002106_M4 iii
Contents
174 Replacement of rear rollers and bearings, scraper adjustment 64
175 Replacement and alignment of bearing housing, rear rollers 64
176 Belt tensioning and running-in 66
2: Reel 69
21 Reel 71
211 Removal 71
21 2 Mounting 72
21 3 Replacement of reel tine bar and plastic bearings 73
214 Replacement of guide rollers, eccentric, guide ring and bearings 74
21 5 Replacement of reel plates 75
21 6 Replacement of reel tube, bearings 75
22 Oil motor and chain drive76
221 Replacement of oil motor 76
23 Hydraulic cylinders 77
231 Replacement of cylinder – reel up/down 77
232 Replacement of cylinder – reel forward/back 78
233 Reconditioning of hydraulic cylinders 78
3: Main crop elevator 83
31 General 85
32 Main crop elevator 86
321 Removal 86
322 Mounting 87
323 Bearing block on machine frame 88
324 Replacement of lifting ram 88
325 Reconditioning of hydraulic cylinder 89
326 Replacement of cutting height preset sensor 90
33 Elevator chain 91
331 Removal 91
332 Mounting 91
333 Replacement of slats 92
334 Replacement of slide rails in crop elevator 92
335 Replacement of intermediate plate 92
34 Elevator chain top shaft 93
341 Removal 93
342 Mounting 93
343 Replacement of bearings 94
344 Replacement of sprockets 95
345 Replacement of shaft protection tube 96
35 Elevator chain front shaft 97
351 Removal 97
352 Mounting 97
353 Replacement of shaft, bearings and plate wheels 98
36 Elevator countershaft 99
361 Removal 99
362 Mounting 100
363 Replacement of bearings and sprockets 100
37 Table clutch and chain drive 101
371 Removal 101
372 Mounting 101
373 Reconditioning of clutch 101
38 Adapter102
381 Removal102
382 Mounting 103
383 Replacement of cylinder/connecting rod 103
384 Reconditioning of hydraulic cylinder 104
385 Replacement of angle sensor 105
39 Hydraulic reversing 106
iV Workshop Manual, Combine Challenger 650-658 Series – EN_63002106_M4
Contents
391 Removal 106
392 Mounting 106
310 Electrical Reversing 107
31 01 Removal107
3102 Mounting 107
4: Threshing unit 109
41 General 111
42 Stone trap112
421 Removal 112
422 Mounting 112
43 Concave 113
431 Removal 113
432 Mounting 113
433 Lateral adjustment of the concave 114
434 Concave setting – initial setting 114
435 Replacement of lead-in plate 115
436 Replacement of concave extension 115
43 7 Replacement of shaft for concave setting 116
44 Threshing cylinder 117
441 Removal117
442 Mounting 118
443 Replacement of bearings 119
444 Replacement of rasp bars and backing bars 120
445 Replacement of shaft and cylinder spiders 120
45 Cylinder variator – table clutch 121
451 Removal, hydraulic variator 121
452 Mounting, hydraulic variator 121
453 Reconditioning of hydraulic variator pulley 122
454 Removal, mechanical variator 124
455 Mounting, mechanical variator 124
456 Reconditioning of mechanical variator pulley 125
457 Removal, magnetic clutch 126
458 Mounting, magnetic clutch 127
459 Reconditioning of magnetic clutch 128
46 Bracket for counter drive 130
461 Removal 130
462 Mounting and alignment 130
47 Rear beater 131
471 Removal 131
472 Mounting 132
473 Replacement of bearings 133
48 Rear beater concave 134
481 Removal134
482 Mounting 134
49 Rotary separator cylinder 135
491 Removal 135
492 Mounting 136
493 Replacement of bearings 137
494 Replacement of rasp bars 137
410 Rotary separator concave138
41 01 Removal138
4102 Mounting 139
4103 Concave setting – initial setting 139
4104 Replacement of shaft for concave setting 140
5: Straw walkers 141
51 General 143
52 Straw walkers 144
Workshop Manual Combine Challenger 650-658 Series – EN_63002106_M4 V
Contents
521 Removal 144
522 Mounting 144
53 Crank- front 145
531 Removal 145
532 Mounting 146
533 Replacement of bearings 146
54 Crank- rear 147
541 Removal 147
542 Mounting 147
543 Replacement of bearings 147
55 Straw walker transmission – chain 148
551 Removal 148
552 Mounting 148
6: Shaker shoe – Fanning mill 149
61 General 151
62 Fanning mill 152
621 Removal 152
622 Mounting 153
623 Replacement of fan blades 154
624 Replacement of fanning mill deflectors 154
625 Replacement of seals 155
63 Main grain pan156
631 Removal 156
632 Mounting 157
633 Replacement of swivel arm and bearings 157
634 Replacement of seals 158
64 Second grain pan159
641 Removal159
642 Mounting 159
643 Replacement of swivel arm and bearings 160
644 Adjustment of second grain pan 161
65 Top shaker shoe 163
651 Removal 163
652 Mounting 164
653 Replacement of swivel arm and bearings 165
654 Replacement of seals 165
655 Electric sieve setting – initial setting 166
66 Bottom shaker shoe167
661 Removal 167
662 Mounting 168
663 Replacement of swivel arm and bearings 168
664 Replacement of seals 169
665 Electric sieve setting – initial setting 169
67 Bottom augers 170
671 Removal 170
672 Mounting 170
68 Eccentric drive 171
681 Removal 171
682 Mounting 172
683 Adjustment of connecting rod/ alignment of shaker shoes 173
684 Replacement of connecting rod bearing 174
685 Replacement of bearings and eccentric shaft 175
69 Transmissions176
691 Replacement and reconditioning of fanning mill variator 176
692 Adjustment of fanning mill variator 177
693 Replacement and reconditioning of counter drive, shaker shoe 178
yj Workshop Manual, Combine Challenger 650-658 Series – EN_63002106_M4
Contents
7: Elevators 179
71 Tank filling elevator181
711 Removal 181
712 Mounting 182
7 1 3 Replacement of top shaft, bearings and sprockets182
7 1 4 Replacement of bottom sprocket 183
715 Replacement of elevator chain 183
716 Moisture sensor 184
7 1 7 Yieldmeter sensor 184
72 Returns elevator 185
721 Removal 185
722 Mounting 185
723 Replacement of top shaft, bearings and sprockets 186
724 Replacement of bottom sprocket 186
725 Replacement of elevator chain 186
726 Returns volume sensor 186
73 Returns thresher 187
731 Removal 187
732 Mounting 187
733 Replacement of sprockets 187
734 Replacement of threshing cylinder 187
735 Reconditioning of right-angle gear 188
74 Tank filling auger190
741 Removal190
742 Mounting 190
743 Replacement of top bearing 190
744 Reconditioning of right-angle gear 191
75 Transmission 192
751 Replacement of shaft, bearings and sprockets 192
8: Engine 193
81 General 195
82 Replacement of engine 196
821 Removal of engine assembly 196
822 Mounting of engine assembly 199
9: Unloading auger – Grain tank 201
91 Unloading auger 203
91 1 Removal 203
91 2 Mounting 203
91 3 Replacement of bearings and universal joints 204
92 Unloading tube 205
921 Removal 205
922 Mounting 205
923 Replacement of swivel bearing 206
924 Replacement of hydraulic cylinder 207
925 Reconditioning of hydraulic cylinder 208
93 Bottom auger and cover plate 209
931 Removal 209
932 Mounting 209
933 Replacement of bearings, safety clutch 210
94 Transmission 211
941 Replacement of unloading auger shaft, bearings 211
942 Replacement and reconditioning of magnetic clutch 211
95 Grain tank covers 213
951 Removal 213
952 Mounting 213
Workshop Manual Combine Challenger 650-658 Series – EN_63002106_M4 vii
Contents
10: Drive unit 215
101 Radiator – lntercooler217
1011 Removal 217
1012 Mounting 217
102 Oil cooler218
1021 Removal 218
1022 Mounting 218
103 Condenser – air-conditioning219
1031 Removal 219
1032 Mounting 219
104 Rotary screen 220
1041 Removal 220
1042 Mounting 221
1043 Adjustment of rotary screen and cleaning blade 222
1044 Replacement of drive shaft and clutch 223
105 Dust aspi rater226
1051 Removal 226
1052 Mounting 226
106 Hydrostatic pump227
1061 Removal 227
1062 Mounting 228
1063 Tensioning device 229
107 Auxiliary hydraulic pump 230
1071 Removal 230
1072 Mounting 230
108 Hydraulic oil tank 231
1081 Removal 231
1082 Mounting 231
109 Fueltank 232
1091 Removal 232
1092 Mounting 232
1093 Tank gauge 232
1010 Compressor – air-conditioning 234
10101 Removal 234
10102 Mounting 234
1011 Power take-off 235
10111 Removal 235
10112 Mounting 236
10113 Replacement of clutch disc 237
10114 Replacement of output shaft, bearing and hub 238
11: Transmissions 239
111 General 241
112 Countershaft242
1121 Removal 242
1122 Mounting 243
1123 Replacement of bearings 244
1124 Reconditioning of safety clutch 244
113 Replacement of belts, right-hand side245
1131 Rear beater – counter drive, cylinder variator 245
1132 Counter drive, variator – threshing cylinder 246
1133 Rear beater – rotary separator 247
1134 Fanning mill – fanning mill variator 247
1135 Rear beater – fanning mill variator 248
1136 Unloading auger shaft – unloading auger 249
1137 Unloading auger shaft – rotary screen clutch 250
1138 Unloading auger shaft – dust aspirator 251
1139 Countershaft – counter drive, elevators 252
114 Replacement of chains, right-hand side 253
yj j j Workshop Manual, Combine Challenger 650-658 Series – EN_63002106_M4
Contents
1141 Counter drive, elevators – returns elevator 253
1142 Counter drive, elevators – tank filling elevator 253
1143 Counter drive, elevators – tank filling auger 253
11 44 Returns elevator – returns thresher 254
1145 Reel drive 254
1146 Elevator chain top shaft – electrical reversing 255
115 Replacement of belts, left-hand side 256
1151 Countershaft – straw walker drive 256
1152 Countershaft – rear beater 256
1153 Countershaft – counter drive, straw chopper 257
1154 Counter drive – straw chopper 257
1155 Engine – countershaft 258
1156 Rear beater – countershaft, shaker shoe drive 259
1157 Countershaft, shaker shoe drive – eccentric shaft 260
1158 Countershaft, shaker shoe drive – straw walker crank 260
1159 Rear beater – elevator chain top shaft 261
11510 Engine – unloading auger shaft 261
11 511 Engine – hydrostatic pump 262
11512 Table countershaft – knife drive 263
11513 Countershaft – hydraulic pump, chaff spreader 263
116 Replacement of chains, left-hand side264
1161 Table countershaft – table auger 264
1162 Elevator chain top shaft – elevator countershaft 264
1163 Table auger – belt rollers (PowerFlow) 265
1164 Straw walker drive 265
1165 Hydraulic motor, reversing – elevator countershaft 266
12: Undercarriage 267
121 Auto Level final drive bracket-4 speeds 269
1211 Removal 269
1212 Mounting 270
1213 Replacement of bushing 272
1214 Replacement of hydraulic cylinder 273
1215 Reconditioning of hydraulic cylinder 274
122 Final drive – 3 gear ranges 275
1221 Removal 275
1222 Mounting 275
1223 Reconditioning of final drives 277
123 Gearbox – 4 gear ranges 280
1231 Removal 280
1232 Mounting 281
1233 Adjustment of shifter cylinders and sensor 282
1234 Adjustment of shifter cylinders and sensor 283
1235 Replacement of lubrication pump 287
1236 Replacement of shifter forks 288
1237 Reconditioning of differential 289
1238 Reconditioning of gearbox 293
124 Auto Level final drive bracket – 3 gear ranges296
125 Final drive – 3 gear ranges297
126 Gearbox – 3 gear ranges 298
1261 Removal 298
1262 Mounting 298
1263 Replacement and adjustment of shifter cables 299
1264 Replacement of shifter forks 300
1265 Reconditioning of differential 300
1266 Reconditioning of gearbox 300
127 Hydrostatic motor 301
1271 Removal 301
1272 Mounting 301
128 Brakes, machines with 4 gear ranges302
Workshop Manual Combine Challenger 650-658 Series – EN_63002106_M4 ix
Contents
1281 Replacement of brake blocks 302
1282 Replacement of brake discs 303
1283 Replacement of handbrake shoes 305
1284 Bleeding of the brakes 305
129 Rear axle 307
General 307
Removal 307
Mounting 307
Replacement of king pins and bushings 308
Replacement of steering cylinder 309
Reconditioning of hydraulic cylinder 309
Adjustment of toe-in and steering deflection 310
13: Cab 313
131 Pedals and levers 315
1311 Gear lever 315
1312 Multi-function lever 316
1313 Throttle lever and cable 318
1314 Brake pedals and main cylinder 320
1315 Handbrake lever and cable 323
132 Control panel, right-hand side324
133 Replacement of windscreen 325
134 Control panel in roof 326
135 Roof 327
Outer roof 327
Inspection doors 327
Replacement of windscreen wiper 328
Replacement of blower 328
Replacement of heating element 329
Replacement of evaporator 329
14: Hydraulics 331
141 General 333
1411 Emptying and filling the hydrostatic system 334
1412 Running-in and bleeding the hydrostatic system 336
1413 Running-in and bleeding of auxiliary hydraulics 336
142 Hydrostatic system339
1421 Hydraulic pump 339
1422 Oil motor 339
1423 Oil cooler 339
1424 Hydraulic oil filter 341
143 Auxiliary hydraulics 343
1431 Hydraulic pump 343
1432 Hydraulic oil tank and return oil filter 343
1433 Oil cooler 343
1434 Hydraulic valve – main valve 345
144 Table 347
1441 Hydraulic cylinders – table up/down 347
1442 Pressure accumulators – cutting table 347
1443 Hydraulic valve – table up/down (standard machine) 347
1444 Hydraulic valve – table up/down (Auto Level machine) 349
1445 Hydraulic cylinder – table levelling 351
1446 Pressure accumulators – levelling 351
1447 Hydraulic valve – levelling 351
145 Auto Level 353
1451 Hydraulic cylinders – machine levelling 353
1452 Hydraulic valve – machine up/down/levelling 355
146 Reel 357
1461 Hydraulic cylinders – reel up/down 357
X Workshop Manual, Combine Challenger 650-658 Series – EN_63002106_M4
Contents
1462 Hydraulic valve – reel up/down 357
1463 Hydraulic cylinders – reel fore/aft 359
1464 Hydraulic valve – reel fore/aft 359
1465 Oil motor 361
1466 Flowdivider 361
147 Gearshift 363
1471 Hydraulic cylinders – gearshift 363
1472 Hydraulic valves – gearshift 363
148 Steering365
1481 Hydraulic cylinders – steering 365
1482 Orbitrol steering valve 365
149 Cylinder variator367
1491 Cylinder variator 367
1492 Hydraulic valve – variator 367
1410 Unloading auger369
14101 Hydraulic cylinder – unloading auger 369
14102 Hydraulic valve – unloading auger 369
1411 Reversing 371
14111 Oil motor 371
1411 2 Hydraulic valve – reversing 371
15: Machine housing 373
151 General 375
16: Electrical system 377
161 General 379
162 Description of DATAVISION 380
163 Electric box 381
1631 Removal 381
1632 Mounting 381
1633 Replacement of computer 381
1634 Replacement of relay base, busbar 381
164 Key to symbols382
165 Diagrams – components 384
1651 Ignition, diagram 10-2 385
1652 Start/stop, diagram 20-0 387
1653 SISU engine, 74 ETA, EEM, diagram 25-1 395
1654 SISU engine, Citius 84 CTA-4V, EEM, diagram 25-2 399
1655 Electric transmission, diagram 30-3 403
1656 Electric transmission, diagram 30-4 407
165 7 Power, diagram 40-0 411
1658 CAN, diagram 50-0 413
1659 Terminal, diagram 60-3 415
16510 GPS/Com-Unit, diagram 70-2 419
16511 Main light flash, diagram 80-0 421
16512 Parking light, diagram 90-0 427
16513 Stoplight, diagram 110-0 431
16514 Work light, rear, diagram 120-0 435
16515 Direction flashers, diagram 130-1 439
16516 Work light, roof, diagram 150-0 447
16517 Work light, side, diagram 160-0 451
16518 Cab light, diagram 170-0 455
16519 External connectors, diagram 200-0 457
16520 Table trailer, diagram 210-1 461
16521 Blower/air-conditioning, diagram 220-0 465
16522 Wiper, diagram 230-0 469
16523 Lighter/seat adjustment, diagram 240-0 471
16524 Radio, diagram 250-2 473
16525 Horn, diagram 260-0 475
Workshop Manual Combine Challenger 650-658 Series – EN_63002106_M4 xi
Contents
16526 Electrical concave setting, diagram 270-1 4 77
16527 Electrical gearshift, diagram 280-3 481
16528 Full warning/rotating yellow beacon, diagram 300-1 483
16529 Table attachment, diagram 310-1 487
16530 Table WWHU, attachment, diagram 310-2 491
16531 Reversing, diagram 320-0 495
16532 Bottom cover/grain tank cover, diagram 330-0 499
16533 Unloading auger, diagram 340-0 503
16534 Table up/down, diagram 350-2 507
16535 Table up/down, diagram 350-3 511
16536 Variator, reel, fanning mill, diagram 360-0 515
16537 Reel, diagram 370-0 519
16538 Indicators, yield, loss, diagram 380-2 521
16539 Vertical knives, diagram 400-0 525
16540 Vertical knives, diagram 400-1 527
16541 Electrical sieves, diagram 410-0 529
16542 Electrical straw deflectors, straw chopper, diagram 420-0 531
16543 Four-wheel drive, diagram 430-0 533
16544 Revolution sensors, diagram 510-1 535
16545 Sensors, diagram 520-0 545
16546 Sensors, diagram 530-2 549
16547 Tilt sensor, diagram 540-0 553
16548 Auto Level table, diagram 550-0-1 555
16549 Auto Level table WWHU, diagram 550-1 561
16550 Auto Level machine, diagram 560-0 565
16551 Maize header, diagram 595-0 569
16552 Main switch, diagram 900-0 571
17: Straw chopper 573
17 1 General 575
18: General assembly instructions 577
181 Mounting of gib-head keys 579
182 Mounting of tightening pins580
183 Mounting of hydraulic pipes and screw connections 581
184 Mounting of flanged bearing with locking collar 583
185 Mounting of sliding bushings 584
186 Removal of revolution sensor585
187 Mounting of tightening rings 586
19: Miscellaneous data 587
191 General 589
192 Speeds – adjustment values 590
193 Maintenance591
1931 Lubrication Chart 591
1932 Lubrication points, left-hand machine side 598
1933 Lubrication points, right-hand machine side 612
1934 Recommended lubricants 626
19~5 Gear 627
1936 Air-conditioning 629
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