Challenger 660B Service Manual
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Challenger 660B Service Manual

Rotary combine
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Challenger
660B / 670B
Rotary Combine
SERVICE MANUAL
79032966 A Rev.
CONTENTS
GENERAL INFORMATION ....................................................................................................................................01
SPECIFICATIONS ..................................................................................................................................................02
ENGINE WORKSHOP MANUAL ........................................................................................................................ 03A
ENGINE - DRIVES, COOLING AND FUEL......................................................................................................... 03B
MATERIAL HANDLING..........................................................................................................................................04
MATERIAL DISCHARGE .......................................................................................................................................05
REAR AXLE ...........................................................................................................................................................06
THRESHING AND SEPARATING..........................................................................................................................07
FRONT AXLE...................................................................................................................................................................... 08
HYDRAULICS..................................................................................................................................................................... 09
ELECTRICAL...................................................................................................................................................................... 10
ELECTRONICS................................................................................................................................................................... 11
CAB AND HVAC ................................................................................................................................................................. 12
GRAIN HEADER................................................................................................................................................................. 13
CORN HEADER.................................................................................................................................................................. 14
RESERVED......................................................................................................................................................................... 15
© AGCO Corporation, 2008 All rights reserved.
Part Number 79032966 A Rev. (English)
Printed in U.S.A.
August 2008

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  • Page 1 ® Challenger 660B / 670B Rotary Combine SERVICE MANUAL 79032966 A Rev. CONTENTS GENERAL INFORMATION ............................01 SPECIFICATIONS ..............................02 ENGINE WORKSHOP MANUAL ........................03A ENGINE - DRIVES, COOLING AND FUEL......................03B MATERIAL HANDLING............................04 MATERIAL DISCHARGE ............................05 REAR AXLE ................................06 THRESHING AND SEPARATING..........................07 FRONT AXLE..................................

  • Page 2: Table Of Contents

    Contents ® Challenger 660B / 670B Rotary Combine SERVICE MANUAL 79032966 A Rev. 01 - General Information Contents SAFETY Safety Alert Symbol ............................01-1 Signal Words ..............................01-1 Shields and Latches ............................01-7 Header Lift Cylinder Stop ..........................01-8 Rear Hook ..............................01-9 Travel On Public Roads ..........................
  • Page 3 Contents Brakes ................................01-41 Master Cylinder Oil Reservoir ....................... 01-41 Bleeding Brake System ......................... 01-41 Final Drive ..............................01-42 Tires and Wheels ............................01-43 Tire Pressure ............................01-43 Dual Tires .............................. 01-43 Maintenance of Tires ..........................01-43 Removing Wheel from Combine ......................01-44 Wheel Installation ..........................
  • Page 4 Contents Removing Air From Hydraulic System ....................01-98 Hydraulic Pump ............................. 01-99 Steering Priority Valve ........................... 01-99 Main Hydraulic Control Valve ......................01-100 Unloader Auger Engagement Valve ....................01-101 Pump Drive Disconnect Valve ......................01-101 Accumulator ............................01-102 Hydrostatic Drives - A66 ........................01-103 Hydrostatic Drives - A76 ........................
  • Page 5 Contents INDEX ................................01-131 01-iv 79032966 A Rev. Find manuals at https://best-manuals.com...

  • Page 6: Safety

    Safety SAFETY SAFETY ALERT SYMBOL FIG. 1: This is the safety alert symbol. This symbol stands for ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Look for this symbol, both in this manual and on safety decals on the combine. This symbol will direct you to information that includes your personal safety and the personal safety of others.
  • Page 7 Safety FIG. 3: Read and understand this manual and the manual for all attachments before operating the combine. Learn how to operate the combine and how to use the controls properly. Do not operate the combine without instruction and training. For your personal safety and the personal safety of others, follow all safety precautions and instructions found in the manual and on decals fastened to the combine and...
  • Page 8 Safety FIG. 6: Face the ladder and use the handrails when getting on or off the combine. Wc1940 FIG. 6 FIG. 7: Never operate the engine in a closed building unless exhaust is vented outside. Wc1949 FIG. 7 FIG. 8: Make sure that all shields, guards, and access doors are in location and properly closed before starting the engine.
  • Page 9 Safety FIG. 10: Never permit any person to be on any part of the combine or the attachments except in the operator seat or the instructor seat when the engine is running. Do not get on or off the combine while the combine is moving.
  • Page 10 Safety FIG. 14: Never work under the header or feeder house, unless the stop is properly engaged on the header lift cylinder, the engine is stopped, the parking brake is set, and the start key is removed from the start switch. Wc1954 FIG.
  • Page 11 Safety FIG. 18: Do not remove radiator cap if engine is hot. Only remove the cap when the cap is cool enough to touch with bare hands. Loosen cap slowly to first notch to relieve pressure, then remove cap. Wc1951 FIG.

  • Page 12: Shields And Latches

    Safety FIG. 22: Electrical storage batteries give off highly flammable hydrogen gas. Keep smoking material, open flame, or electrical sparks away from the battery. Do not lay tools or other conductive materials on the battery. Be careful when connecting booster cables to combine batteries.

  • Page 13: Header Lift Cylinder Stop

    Safety FIG. 26: The engine platform ladder shield latch (1) is located in the rear section of the shield (2). P107227 FIG. 26 HEADER LIFT CYLINDER STOP A header lift cylinder stop is provided on the left-hand header lift hydraulic cylinder. FIG.

  • Page 14: Rear Hook

    Safety REAR HOOK FIG. 29: The rear hook (1) is located in the center of the combine on the rear axle. Use the rear hook (1) as a point on the combine to fasten a suitable chain to aid in pulling the combine out of the mud when the combine is stuck and not able to drive out.
  • Page 15 Safety NOTES 01-10 79032966 A Rev.

  • Page 16: General Information

    General Information GENERAL INFORMATION MACHINE MAIN COMPONENTS D-9839 FIG. 31 Some of the main components of the combine are as 8. Engine Compartment follows: 9. Grain Tank Unloading Auger 1. Feeder 10. Straw Chopper 2. Operator Cab 11. Steering Axle 3.

  • Page 17: How A Combine Works

    General Information HOW A COMBINE WORKS D-9839 FIG. 32 FIG. 32: Four functions are done in the overall Threshing and Separating harvesting operation of a combine. These are: The rotor does four functions as the crop moves in rotary • Cutting and Feeding motion from front to rear: •...

  • Page 18: Cleaning

    General Information Grain, chaff, and unthreshed heads which penetrated the separator grates are carried to the cleaning shoe by the separator return pan (7). Cleaning The material is moved from the front of the separator return pan onto a short cascade pan (8) which in turn moves the mixture across a fingered comb and into the front of the chaffer sieve.

  • Page 19: Combine Identification

    General Information COMBINE IDENTIFICATION Your combine is identified by serial numbers which are important if you require service or repair parts. Record the serial numbers from the serial plate on your combine in the spaces provided for easy reference. Machine Model Number: ________________________ Machine Serial Number: _________________________ Engine Serial Number: __________________________ Transmission Serial Number: _____________________...

  • Page 20: Fuel Injection Pump Dataplate

    General Information Fuel Injection Pump Dataplate FIG. 35: The fuel injection pump dataplate (1) is located on the back of the injection pump. M818422 FIG. 35 ECM Dataplate FIG. 36: The Electronic Control Module (ECM) dataplate (1) shows important information about the ECM and how the ECM is programmed.

  • Page 21: Final Drive Serial Number

    General Information Final Drive Serial Number FIG. 38: The final drive serial number is stamped on the plate that is on the inner half of the final drive housing at location (1). N516643 FIG. 38 HEADERS The combine is equipped with a quick attach feeder for fast and easy hook up of headers.

  • Page 22: Lubrication And Maintenance

    General Information LUBRICATION AND MAINTENANCE For efficient and low cost operation of any machine proper lubrication and maintenance is needed. Follow the instructions in this section of the manual (and on the lubrication decals and charts located on the right and left side frames of the machine) to make sure the combine is lubricated at regular service intervals.

  • Page 23: Lubrication And Maintenance

    General Information LUBRICATION AND MAINTENANCE New Machine Lubrication and Maintenance Component Action Required General Information Bolts (attaching wheels, Check torque Refer to appropriate sections of final drives, front and rear manual. axles, feeder elevator brackets, straw chopper hammers and beater bearing housings) Brake Fluid Level Check fluid level, with combine parked on...
  • Page 24 General Information 10 Hour or Daily Maintenance Component Action Required General Information Hydrostatic Check tension and adjust as required. Especially important when operating Rotor/Propulsion Pump on hilly terrain to assure engine Drive Belt braking assistance. Radiator Coolant Check level of coolant in radiator coolant Use solution of 50% water and 50% recovery tank, with combine parked on level diesel type low silicant antifreeze.
  • Page 25 General Information 50 Hour or Weekly Lubrication Component Action Required General Information Fixed Speed Header Lubricate one fitting On the right-hand side of the feeder Drive Idler Pivot house. Standard Adjustable Rear Lubricate thirteen fittings Center pivot - Below battery Axle disconnect switch - One fitting.
  • Page 26 General Information 50 Hour or Weekly Maintenance Component Action Required General Information Hydraulic Reservoir Filler Remove and clean Use kerosene or suitable solvent. Hydraulic System Check for leaks Hydrostatic Check tension and adjust Refer to appropriate section of manual Rotor/Propulsion Pump Drive Belt Hydrostatic Propulsion Drive Check adjustment...
  • Page 27 General Information 100 Hour Lubrication Component Action Required General Information Grain Tank Unloader Joint Lubricate one fitting Below right-hand side of grain tank to the front. Grain Tank Cross Auger Lubricate two fittings On the right-hand and left-hand ends Shaft of the grain tank cross auger shaft.
  • Page 28 General Information 500 Hours or Once a Season Maintenance Component Action Required General Information Cleaning Fan Housing Clean accumulated trash from top of housing. Engine Air Cleaner Replace inner and outer air cleaner Replace elements annually or when Elements elements. indicated by monitor.

  • Page 29: Lubrication Details

    General Information LUBRICATION DETAILS 71424752 FIG. 39 FIG. 39: The efficient and economical operation of any machine depends on proper lubrication and maintenance at recommended intervals. Follow the instructions in this manual and on the lubrication charts, located on the right and left sides of the machine to assure timely lubrication.
  • Page 30 General Information 71424751 FIG. 40 FIG. 40: The efficient and economical operation of any machine depends on proper lubrication and maintenance at recommended intervals. Follow the instructions in this manual and on the lubrication charts, located on the right and left sides of the machine to assure timely lubrication. 79032966 A Rev.

  • Page 31: Front Of Combine

    General Information Front of Combine FIG. 41: Main drive axle outer coupler (1). The right-hand is shown, the left-hand coupler is on the opposite side. One fitting each coupler (100 hours). N722107 FIG. 41 FIG. 42: Front axle, inner driveshaft couplings. One fitting (1) each side of transmission (100 hours).
  • Page 32 General Information FIG. 45: Variable speed corn header drive sheave (if equipped). Two fittings (1) (10 hours or daily). LA06287 FIG. 45 FIG. 46: Left-hand side of feeder house. Pivot drive idler hub - one fitting (1) (50 hours or weekly). N722061 FIG.

  • Page 33: Left-Hand Side

    General Information Left-hand Side FIG. 49: Behind front axle. Pitman Drive Idler Pivot (1) (50 hours or weekly). N722115 FIG. 49 FIG. 50: Above cleaning fan. Shaker Shoe Shaft left-hand bearing (1) (500 hours). Clean Grain Elevator Drive Idler Pivot (2) (50 hours or weekly).
  • Page 34 General Information FIG. 53: Left-hand side of combine next to the battery tray. Rotor gear box fitting (1) (50 hours or weekly). Center Pivot (2) (50 hours or weekly). N722120 FIG. 53 FIG. 54: Left-hand side of combine next grain tank. Cross auger shaft (1) (100 hours).

  • Page 35: Right-Hand Side

    General Information Right-hand Side FIG. 55: Transmission shift linkage (1). One fitting (500 hours). LA06503 FIG. 55 FIG. 56: Grease bank in front of the clean grain elevator Straw Chopper/Spreader Secondary Drive Idler Pivot (1) (50 hours or weekly). Straw Chopper/Spreader Primary Drive Idler Pivot (2) (50 hours or weekly).
  • Page 36 General Information FIG. 59: On cleaning fan shaft. Cleaning Fan Driven Pulley Inner Sliding Sheave Hub (1) (10 hours or daily). Do not get grease on belt. N722126 FIG. 59 FIG. 60: Inside of rotary screen door. Rotary screen drive idler pivot (1) (100 hours). N718776 FIG.

  • Page 37: Rear Axle

    General Information Rear Axle FIG. 63: Standard Adjustable Steering Axle King Pins (1) two fittings, one each side (50 hours or weekly). Steering rod (2), two fittings, one each side (50 hours or weekly). N516606 FIG. 63 FIG. 64: Single Speed Rear Wheel Assist Axle King Pins (1) eight fittings, four each side (50 hours or weekly).

  • Page 38: Auto Lube

    General Information AUTO LUBE FIG. 67: The optional Auto Lube system lubricates certain components automatically. following components lubricated automatically: • Variable speed drive (If equipped) • Cleaning fan fitting • Pitman arm fitting • Inner and outer axle couplers • Transmission linkages •...

  • Page 39: Auto Lube Intervals

    General Information Auto Lube Intervals FIG. 70: The amount of time between the auto lube system lubricates and the amount of time the system lubricates can be adjusted. To adjust the time remove the sealing plug (1) from the pump housing by turning counterclockwise. Below the sealing plug is the on time rotary switch, the off time rotary switch, and the manual lube switch.
  • Page 40 General Information FIG. 72: To adjust the times, rotate either of the rotary switches (1) until the notch in the switch is over the desired time. The recommended settings for the auto lube system is two minutes of on time every 6 hours. Use the following tables to adjust the times.

  • Page 41: Auto Lube Diagnosis

    General Information Auto Lube Diagnosis FIG. 73: To check for proper operation of the auto lube system, check for movement of the plunger (1) in each of the distribution blocks (2) of the auto lube system. The plunger will slowly move in and out with each pump of the auto lube system.

  • Page 42: Engine

    General Information ENGINE WARNING: The engine and surrounding parts will be hot enough to cause burns if the engine has been run recently. Allow enough time engine surrounding parts cool prior inspecting or servicing the engine. IMPORTANT: The engine parts are of metric dimensions. Be sure that hardware from the engine is replaced in the proper locations.

  • Page 43: Checking Oil Level

    General Information Checking Oil Level FIG. 77: The dipstick (1) is located next to the engine oil filter (2). With the combine sitting on level ground, check oil level every 10 hours of operation and replenish if necessary to maintain the correct level on the dipstick (1). Check oil level before starting engine.
  • Page 44 General Information FIG. 80: Remove the centrifugal filter (1) cover by loosening the retainer on top of the cover. Remove the filter canister (2) and the seal ring (3) from the centrifugal filter head (4). Using clean engine lubricating oil, lightly oil the seal ring and install the ring on the filter head.

  • Page 45: Rotor Gearbox

    General Information ROTOR GEARBOX FIG. 83: The rotor gearbox (1) is located at the rear of the combine. Every 500 hours or annually, change gearbox oil. Drain oil using the drain plug (2). Check oil level using plug (3). N708270 FIG.

  • Page 46: Brakes

    General Information BRAKES Check fluid level every 500 hours or once a season and fill as necessary. Master Cylinder Oil Reservoir FIG. 86: Check fluid level every 500 hours or once a season and fill as necessary. The master cylinder oil reservoir (1) is located behind the washer fluid reservoir (2), behind on access door on the right-hand cab platform.

  • Page 47: Final Drive

    General Information Check and add brake fluid to reservoir. WARNING: Incomplete bleeding allowing air to remain in the system will lead to poor braking performance and possible loss of braking capability. FINAL DRIVE Combines are equipped with a heavy-duty front axle. The heavy-duty final drives use a bull gear and pinion.

  • Page 48: Tires And Wheels

    General Information TIRES AND WHEELS Tire Pressure Maintenance of Tires Tire pressures for both front and rear tires must be To reduce amount of wear, and extend the life of the tires, checked every 50 hours of operation or weekly. See the the correct pressures must be maintained and checked at Specifications section for the correct tire pressure.

  • Page 49: Removing Wheel From Combine

    General Information Removing Wheel from Combine WARNING: Before removing the wheel from the combine stop the engine, set the parking brake, remove the ignition key and take the ignition key with you. Do not remove or install tires without the proper tools.

  • Page 50: Wheel Installation

    General Information FIG. 93: Secure the tire to be removed using a tire dolly or hoist. Remove the nuts or capscrews securing the wheel to the axle or final drive. WARNING: Do not hit the tire or rim with a hammer.

  • Page 51: Tire Dimensions

    General Information Tire Dimensions Front Wheel Tread (Center to Center of Tire) Shipping Wheels - 2.74 m (108 in) Standard (800/65 R32 tires), Operating Position (Wheels IN) - 3.12 m (123 in) Standard (800/65 R32), Operating Position (Wheels OUT) - 3.76 m (148 in) NOTE: Combines can be shipped with special 16.9 x 34 shipping tires...

  • Page 52: Drive Belts

    General Information DRIVE BELTS Banded Drive Belt FIG. 96: A banded drive belt is made of two or more V-belts (of a standard cross section size) banded together at the top with a tie band (1). The seperate V-belts and the tie band are vulcanized together to form a multiple strand banded belt.

  • Page 53: Maintenance Of Belts

    General Information Maintenance of Belts FIG. 97: Cross sections of some of the belts used on the combine are shown. A drive inspection must be done every one to two weeks. Check belts frequently for excessive wear, tearing, breaking, increasing, and unraveling. Belt tensions are controlled with spring loaded idlers on most drives on the combine.

  • Page 54: Belt Changing Guides

    General Information Belt Changing Guides Removal FIG. 98: Before Removing or Installing any drive belts. Lower the header to the ground. Remove the starter key. Engage the parking brake. Disconnect the battery at battery switch. Raise or remove shields or guards and locate the guards away from the drive so that the guards do not cause problems with working on the drive.
  • Page 55 General Information FIG. 100: Replace all belts on multiple belt drives. Never replace a single belt or part of a multiple belt drive. If a new belt is used with old belts, the load will not be divided evenly between the belts. Mixing new and old belts can lead to early belt failure and not even sheave wear.

  • Page 56: Belt Sheave Alignment

    General Information Belt Sheave Alignment FIG. 102: Check the sheave and shaft alignment. Running the belts with the sheaves out of alignment will cause severe side wear. Not aligned belt drives will be noisier than properly aligned drives since interference is at the belts enter point into the sheave.

  • Page 57: Belt Troubleshooting

    General Information Belt Troubleshooting When troubleshooting a belt drive problem, stand back and watch the drive while the drive is in operation and when drive is not. Is there a warm rubber smell? Is the belt moving around the drive in a normal way? Are there chirping, squealing, or grinding noises? Is there a deposit of dust or debris under the drive which will cause problems with the belts?
  • Page 58 General Information TABLE 2 Belt Extended Beyond Idler or Sheave Take Up Symptom / Observation Possible Causes Corrections / Remedy Idler spring can not be Belt extended and worn. Properly install a new original equipment belt adjusted to properly and adjust belt tension and idler spring. tension drive belt.
  • Page 59 General Information TABLE 3 Belt Turns Over in Sheaves Symptom / Observation Possible Causes Corrections / Remedy Belt turns over in sheaves Excessive lateral belt movement. Properly adjust belt tension. and runs or can turn over and come off sheaves when no reason can be Trash or debris fell into sheave Clean trash and debris from sheave grooves.
  • Page 60 General Information TABLE 4 Drive Belt Makes Noise Symptom / Observation Possible Causes Corrections / Remedy Belt makes noise. Belt slippage. Properly adjust belt tension. Belt or sheaves contaminated with Repair cause of oil, grease, or chemicals. oil, grease, or chemicals. Clean belt and sheave grooves with a degreasing solvent that is not flammable or toxic, then wash the belts with a soap and...
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