Challenger 648 D User manual

648 D from serial no. 553900084
652 D from serial no. 564000301
ORIGINAL
OPERATOR'S
MANUAL

TABLE OF CONTENTS
1. General Information
2. Operation
3. Controls and Instruments
4. Field Operations
5. Lubrication and Maintenance
6. Adjustments
7. Systems
8. Troubleshooting
9. Off-Season Storage
10. Optional Equipment
11. Technical Specifications
12. Alphabetical Index
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CONTENTS
Section-page
1
1. GENERAL INFORMATION
Customer information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Combine identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Ecology: information for the prevention of environmental pollution . . . . . . . . . . . . . . . . . . . . . . . .1-9
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
Machine lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-44
Towing the combine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-45
Fire resistance inside the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-45
Noise level in the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-46
Ambient noise in motion Directive 2009/63/EC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-46
Vibrations in the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-46
Statutory regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
Hydraulic systems: hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
Scrapping and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
Electromagnetic emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
Notes for road transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-49
Weight distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-51
2. OPERATION
Crop processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3. CONTROLS AND INSTRUMENTS
Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Service and parking brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Multifunction lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Gearshift lever and reversing lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Control panel (models 648 D and 652 D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
Access to combine components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-50
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Operations to be carried out before road transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
Before using the combine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-58
4. FIELD OPERATIONS
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Starting and Stopping the Combine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Cutting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Main Crop Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Cylinder Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Concave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Rear beater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
Multi Crop Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Straw walkers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
Main Grain Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
Fanning mill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
Top sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Bottom sieve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
Grain tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
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CONTENTS
Section-page
2
5. LUBRICATION AND MAINTENANCE
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Preliminary Service Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Scheduled Service Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Where and When to Carry Out Service Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Periodical maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-39
Capacities and specifications 648 D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-42
Capacities and specifications 652 D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-43
6. ADJUSTMENTS
Belt and chain adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Belts and chains (left-hand side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Belts and chains (right-hand side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Reverse drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
Slip clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Unloading tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31
7. SYSTEMS
Engine supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Engine air intake and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Hydraulics system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Hydrostatic transmission system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
8. TROUBLESHOOTING
Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Threshing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Separation and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Hydrostatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6
Hydraulics system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Levelling Hydraulics System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-16
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17
Air conditioning circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-17
Straw Chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-19
9. OFF-SEASON
9. STORAGE
10. OPTIONAL EQUIPMENT
11. TECHNICAL SPECIFICATIONS
Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1
Combine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3
Clearance between unloading auger and table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-7
Technical specifications - 648 D and 652 D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8
12. ALPHABETICAL INDEX
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Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013 1-1
1. GENERAL INFORMATION
1.1 CUSTOMER INFORMATION
INTRODUCTION
Your new self-propelled combine is manufactured
for harvesting seed and cereal crops, for threshing,
separating, cleaning and conveying the grain into
the tank and depositing the straw on the ground.
This Operator's Manual should be used as a
practical reference guide: It contains all the
necessary practical information for the operation,
adjustment and maintenance of your new machine.
Your combine was designed and built to ensure
optimum performance, comfort and
ease-of-operation in a wide variety of crops and
conditions.
The combine has been thoroughly inspected prior
to delivery both at the factory and by your Dealer,
to ensure you receive it in perfect condition.
To keep the combine in perfect condition and to
ensure trouble-free performance, the periodical
maintenance operations listed in this manual
should be carried out at the recommended
intervals.
Before operating and/or driving the combine,
read this Operator's Manual carefully, paying
particular attention to the section on safety
rules.
Always keep this manual on hand for further
reference.
The terms "left" and "right" are always used with
reference to the machine travelling direction.
Should you require further information about the
machine, please do not hesitate to contact your
authorised Dealer.
Your Dealer provides specially trained personnel,
genuine quality spare parts and the required tools
to solve any problems that may arise.
NOTE:
• This combine has been designed and built in
compliance with the Machine Directive
2006/42/EC. 
An EC Declaration of Conformity is supplied
with the machine (see facsimile on page 1-8).
• This manual is published for worldwide
distribution, and the availability of equipment
shown as standard or optional varies
according to the territory in which the combine
is to be used. 
Specifications may differ from those contained
in this Operator's Manual according to the
customer's requirements.
• In order to provide a better view of features or
adjustments, certain illustrations in this manual
may show an assembly with standard guards,
or the guards required by law in different
countries, open or removed. However, a
machine should never be operated in this
condition. For your own safety, always
ensure all safety guards are closed and
correctly fitted before operating the
machine.
• This Operator's Manual, along with the the
PTO shaft, must always be kept in the empty
compartment under the passenger seat for
storage and convenient reference.
Company policy
In accordance with the Company's policy of
continuous improvements to its products, the
Company reserves the right to modify and improve
its products whenever necessary and to the
required extent, without any obligation to apply
such modifications to previously sold products. The
information contained in this Manual refers to the
current situation at the time it was written. All the
data given may vary.
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GENERAL INFORMATION
1-2 Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013
OPTIONAL EQUIPMENT
Your machine was designed to operate in a wide
variety of crops and conditions. However, in certain
cases it may be necessary to fit additional
accessories to improve machine performance or
adapt the machine to harvesting special crops. A
list of available accessories is provided in the
section "Optional Equipment".
SPARE PARTS AND ACCESSORIES
The genuine spare parts and accessories have
been specifically designed for this type of machine.
Only genuine parts supplied by your authorised
Dealer can guarantee correct operation and
optimum performance.
Never use non-genuine spare parts or accessories:
Some accessories (e.g. PTO shafts, straw
choppers, tables) require an EC certification, which
can be provided only by the manufacturer or his
qualified and recognised sub-suppliers.
Non-genuine spare parts have not been tested and
are not authorised by the manufacturer. The fitting
and/or use of such equipment may have a
damaging effect on the design features of the
machine and jeopardise operational safety.
The manufacturer disclaims all liability in the
event of loss or damage arising as a result of
non-genuine parts, accessories or equipment
being used.
It is expressly prohibited to make any modification
to the combine without the prior written
authorisation by the manufacturer.
When ordering spare parts and/or optional
equipment, always quote combine model and serial
number (see section “Combine Identification”).
WARRANTY
Your combine is warranted in compliance with the
regulations in force in your country and the
agreements made with your Dealer.
However, the warranty becomes void in the
following situations:
a.) If the machine has been used inappropriately.
b.) If adjustments and maintenance have not been
carried out according to the instructions in this
manual.
c.) If the failures are caused by the use of
non-genuine spare parts or accessories.
d.) If damage is the result of carelessness,
negligence, inappropriate use of the machine
or operational errors.
If the safety devices are removed and/or
non-genuine spare parts are used, the
warranty becomes void automatically and the
manufacturer disclaims any liability.
The warranty applies only to repair or free
replacement of parts proving defective after a
careful inspection by the manufacturer (excluding
wear parts and tyres), as described in the Combine
Service Record Book. In the event that warranted
parts are replaced or repaired, warranty terms are
not extended. The customer can assert his
warranty rights only insofar as the warranty
conditions contained in the Service Record Book
have been observed.
LUBRICANTS
Your Dealer can provide a wide range of special
lubricants, produced according to the specific
technical specifications of the combine.
For these combines we recommend the use of the
lubricants listed on page 5-42 and on page 5-43.
Only use genuine AGCO parts.
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GENERAL INFORMATION
Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013 1-3
1.2 APPROPRIATE USE
C series combines are designed as self-propelled units with a diesel engine.
The machines are manufactured exclusively for usual agricultural purposes, i.e. for harvesting cereal, seed,
rice, maize, soya, etc. by cutting or picking-up the crop, threshing and separating the grains from the ears,
delivering the grains in the grain tank and unloading them into the grain wagon.
Machine performance may be limited by various factors such as harvesting speed, weather conditions,
ground characteristics and the type and degree of ripeness of the crop.
When operating the machine, make sure the cab doors are shut. The operator and instructor, if present, must
remain seated in their respective seats with their seatbelts fastened (the operator should not drive the
machine when standing).
The machines may be operated only by skilled personnel, who are thoroughly familiar with all the machine's
functions and harvesting techniques.
Machine stability is ensured on the following inclinations, on condition that the ground is firm and the tyres
offer sufficient grip:
• 30% (18 °) longitudinally (uphill and downhill).
•30%(18°)crosswise.
Forbidden uses
Do not use the machine for tasks or purposes other than those specified in this Manual, on the safety decals
or on other safety information provided with the machine. The following pages contain recommendations on
correct and incorrect use of the machine when travelling on public roads, during field operations and
maintenance.
Many machine functions related to safety are managed by the software.
Do not try to modify or replace the software. You risk damaging the settings and the operating logic of the
machine.
Such tampering could lead to unpredictable and abnormal behaviour, making it unsafe for the operator(s)
and the machine.
Only your Dealer is authorised to intervene on the machine software.
The machine's maximum speed on the road is limited and controlled by the software. Do not try to change it.
648 D and 652 D models
The above combine models are designed for working on level ground to ensure even distribution of the crop
inside the machine. These models HAVE NOT been developed for working on sloping ground.
TABLE TYPES (please see the specific Operator's Manual)
The above-mentioned combines may use 4.80, 5.40, 6.00, 7.00 or 7.60 m cutting tables.
NOTE: In this manual, the term “table/s” signifies both the cutting table and the maize header when used
generically. The term “cutting table” refers to the assembly consisting of reel, cutting bar, table auger, etc.
used to harvest cereal, rice, soya, etc. The term “maize header” refers to the equipment formed by stalk
grippers, stripping blades, conveyor chains, etc. used for maize harvesting.
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GENERAL INFORMATION
1-4 Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013
1.3 COMBINE IDENTIFICATION
The combine and its main components are
identified by serial numbers and/or production
codes.
The position of the different identification data is
described below.
NOTE: Always quote the combine serial number
when contacting your Dealer for spare parts or
assistance.
Combine approval and safety plates
Fig. 1 – Fig. 3
The manufacturer's type plate, statutory for all
countries (1), or (2) for France only, is positioned on
the outer right-hand side of the operator platform
and shows the following information:
• Combine type.
• Approval number.
• Combine serial number.
• Total maximum permitted weight.
• Weight (on both axles).
• Towing weight.
For further details, please refer to the type approval
certificate.
The safety plate (3) is located next to the approval
plate, and guarantees that the combine was built in
compliance with Machinery Directive 2006/42/EC
as well as Directive 2004/108/EC.
This plate shows the following information:
• Manufacturing year.
• Year of use.
•Model.
• Combine serial number.
• Crop type.
•Totalweight(normal configuration).
• Nominal engine power.
• Maximum towing weight.
• Maximum vertical load on the trailer hitch.
In certain countries (e.g. Russia) these two plates
are positioned next to an additional decal/plate
corresponding to the approval for that specific
country.
Fig. 1
Fig. 2
Fig. 3
1
2
3
1
23
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GENERAL INFORMATION
Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013 1-5
Combine identification
Fig. 4
Combine type and serial number appear on the
plate and are also punched into the rear right-hand
side of the frame (1).











Engine Identification
Fig. 5
The engine is identified by the type plate (1) in the
middle of the cylinder block.
The following information appears on the plate (1):
• Engine manufacturer
•Enginetype
• Engine power and rated speed
• Engine serial number
• Valve clearance
• Customer reference code
• Idling speed
• Compliance with Directive 97/68/EC
• Name of the engine assembler.
The engine serial number is always also stamped
on the cylinder block.
Cutting table identification
Fig. 6
The cutting table can be identified by a metal plate
affixed on the left-hand side.
Fig. 4
Fig. 5
1
1
Fig. 6
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GENERAL INFORMATION
1-6 Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013
Operator seat identification
Fig. 7
The identification plate is located on the seat
support and can be reached by moving the seat
fully forwards.
Hydrostatic pump identification
Fig. 8
Identification of the hydrostatic pump is facilitated
by means of a plate located on the pump body front
part.
Hydrostatic motor identification
Fig. 9
Identification of the hydrostatic motor is facilitated
by means of a plate located on the motor body
lower part.
Fig. 7
Fig. 8
Fig. 9
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GENERAL INFORMATION
Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013 1-7
Straw chopper identification (if fitted)
Fig. 10
The straw chopper type plate is located on the
right-hand side next to the rotor support.
Chaff spreader identification (if fitted)
Fig. 11
The type plate is located on the right-hand side
next to the chaff spreader adjustment lever.
Trailer hitch identification (if fitted)
Fig. 12
The plate is positioned on the right-hand side of the
trailer hitch.
Fig. 10
Fig. 11
Fig. 12
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GENERAL INFORMATION
1-8 Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013
Please enter the identification details of your combine for convenient reference:
Combine model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine type and serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Straw chopper serial number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting table serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Date of initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dealer's telephone number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EC DECLARATION OF CONFORMITY
The EC Declaration of Conformity, the front and reverse sides of which are shown below, certifies that the
combine was designed and built in compliance with the regulations currently applicable within the
European Community.
The cutting table has its own EC Declaration of Conformity.
Fig. 13
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GENERAL INFORMATION
Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013 1-9
1.4 ECOLOGY: INFORMATION FOR THE PREVENTION OF
ENVIRONMENTAL POLLUTION
Soil, air and water are essential to agriculture and to
all life on earth. PROTECT THEM. In areas where
no local regulations impose standards for the use
and disposal of chemicals and petrochemical
products required by modern technology, all
necessary precautions must be adopted to avoid
any risk of pollution.
The following guidelines may be helpful:
• Find out about the legal requirements in your
country and comply strictly with them.
• If no regulations are in force, ask your Dealer
about the effects of lubricants, fuels, antifreeze
mixtures, cleaning agents etc. on people and
the environment; also ask how to store, use
and dispose of such products correctly. In
most cases, agricultural advisers will be able to
answer your questions satisfactorily.
Instructions:
1.) When refuelling the machine, take all
necessary precautions to avoid fuel spillage. In
particular, avoid using pressurised containers
or fuel supply systems, as these are unsuitable.
2.) As a rule, avoid any skin contact with liquid
fuels, lubricants, acids, solvents etc. Most of
these products contain substances that are
potentially harmful.
3.) Do not dispose of lubricants by burning:
They contain substances which may be
noxious when burned.
4.) Whenever possible, use biodegradable oil for
lubricating the chains, as this oil cannot be
collected.
In many countries, biodegradable rape oil and
other vegetable lubricants are available on the
market.
5.) Avoid spillage while draining oil, brake fluid,
coolant etc. from the engine, gearbox and
hydraulic system. Collect the fluids in suitable
containers and dispose of them properly,
according to regulations in force and the
availability of suitable systems.
6.) Modern coolants and mixtures, e.g. antifreeze
and other additives, must be replaced every
two years. Never let them drain into the
ground; collect and dispose of them safely.
7.) Never open or modify the air-conditioning
system. It contains gases which must not be
released in the atmosphere. Contact your
Dealer or a specialist who has the correct
equipment for emptying and recharging the
system and for carrying out any required
maintenance or repair.
8.) Immediately repair any leaks or defects in the
engine cooling or hydraulic system to prevent
any risk of pollution.
9.) Never increase the pressure in a pressurised
system. This may cause the components to
burst.
10.) When welding, protect the hoses properly
against welding spatters that could damage or
weaken hoses and sleeves, resulting in oil and
coolant leaks.
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GENERAL INFORMATION
1-10 Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013
1.5 SAFETY
Accidents can be prevented with your help.
All accident prevention depends on the full
co-operation of the persons using or involved with
service or maintenance of the machine.
Most accidents can be avoided by observing
simple safety rules.
The best safety system is one in which the operator
observes all applicable regulations for safety or
servicing the machine.
Some of the illustrations contained in this manual
were obtained by photographing combine models
of the same series, which may be differently
equipped. This means that apparent discrepancies
may result between your combine and those
depicted in this manual.
¥
This symbol is used in this manual
whenever your safety is involved.
TAKE THE TIME TO READ AND FOLLOW THE
INSTRUCTIONS. MOST IMPORTANTLY, BE
CAREFUL!
YOU CAN NEVER BE TOO PRUDENT.
IN ORDER TO PROVIDE A BETTER VIEW,
CERTAIN PHOTOGRAPHS OR ILLUSTRATIONS
IN THIS MANUAL MAY SHOW AN ASSEMBLY
WITH THE SAFETY GUARDS OPEN OR
REMOVED.
ENSURE THAT ALL GUARDS ARE FITTED AND
CLOSED PRIOR TO MACHINE OPERATION.
WARNING SYMBOLS AND SAFETY
INSTRUCTIONS
Personal Safety
Three types of warning signs appear in this manual
and on the decals applied to the machine
(“
CAUTION”, “WARNING” and “DANGER ”),
followed by specific instructions or decals with
symbols clearly illustrating the type of hazard.
These instructions involve your safety and the
safety of people working nearby.
Pay particular attention to these warnings.
¥
CAUTION: Indicates a potentially
dangerous situation which, if not
avoided, may result in minor
injuries.
¥
WARNING: Indicates a potentially
dangerous situation which, if not
avoided, may result in serious
injuries.
¥
DANGER: Indicates a potentially
dangerous situation which, if not
avoided, may result in very
serious injuries or even death.
FAILURE TO FOLLOW THE INSTRUCTIONS
RELATED TO THE TERMS “CAUTION”,
“WARNING” AND “DANGER” MAY RESULT IN
SERIOUS INJURIES OR EVEN DEATH.
Machine safety
Other types of warnings ("
NOTE " , " IMPORTANT "
and "
ATTENTION ") are followed by special
instructions referring to the safeguarding of the
machine.
NOTE: Highlights and describes correct techniques
or procedures to be adopted by the operator.
IMPORTANT: Informs the operator of procedures
that may prevent damage to the machine.
ATTENTION: Informs the operator that unless a
special procedure is followed, severe damage
could be caused to the machine.
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GENERAL INFORMATION
Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013 1-11
GENERAL RECOMMENDATIONS
Most agricultural accidents can be avoided by
observing simple safety rules.
Before starting the machine, sound the horn several
times and make sure that there are no people,
domestic pets or obstacles nearby. During
manoeuvres remember that the reversing buzzer
might not be understood by some people (for
example children) as a danger signal.
ROAD TRANSPORT
Combine road transport
1.) The combine may be operated only by
responsible personnel, trained and authorised
to work with the machine.
Avoid operating the combine when physically
unfit: it is better to interrupt work than to risk an
accident.
¥
WARNING:Operators should not use
alcohol or drugs which may impact their
alertness or co-ordination when operating
the combine. Operators on prescription or
over-the-counter drugs need a doctor's
note to certify that they can operate the
combine properly.
2.) In many countries (e.g. Italy and France) a
driving licence is required if the combine is to
be driven on public roads.
3.) Operators should familiarise themselves with
the provisions of the Road Traffic Acts and of
the regulations thereunder in order to ensure
that, when taking the combine on public roads,
they comply with the relevant statutory
requirements. They should keep a suitable
speed for road and traffic conditions and
ensure that all the machine safety devices (if
required) are fitted and working properly. 
The grain tank must be empty and the
unloading auger must be turned in.
4.) For safety reasons, the two brake pedals must
be latched in order to be pressed
simultaneously when travelling on roads. To
hold the machine on inclined ground, the
handbrake must be used (the braking effect of
the hydrostatic drive alone is not sufficient).
5.) When travelling on roads, make sure that the
rotating beacons and the other additional
signals required to warn that the vehicle is
abnormally large and slow-moving, are
working properly.
6.) When driving on roads, turn the cab access
ladder forward. 
When entering and leaving the combine always
use the ladders, handrails and the handles
provided. It is strictly forbidden to ride on the
access ladders to the cab, engine
compartment and grain tank when the machine
is moving.
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GENERAL INFORMATION
1-12 Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013
7.) On the left-hand side of the operator seat there
is an additional seat that can be used by a
trainee during harvest. No other persons are
allowed on the machine.
¥
CAUTION: This seat is not intended for
children.
In road transport, one person employed for
agricultural jobs is allowed in the passenger
seat, provided this is permitted by local
regulations and provided that a seat for
transport of a passenger on public roads is in
accordance with the combine documentation.
Always use the seatbelts provided on the
operator seat and on the other seat, if an
instructor is present.
8.) It is advisable to keep a first-aid kit on hand.
9.) Do not brake abruptly as this could cause the
machine to swerve.
10.) In case of steep uphill or downhill slopes,
always select a low range; change gear before
reaching the sloped area.
Gradually engage the multifunction lever.
Avoid abrupt driving manoeuvres that might
cause the machine to overturn (especially
when going downhill).
11.) In countries where travelling on roads with the
table attached is allowed when circumstances
permit, the table must be secured against
lowering by engaging the safety stops on the
hydraulic cylinders and locking the main crop
elevator adapter.
12.) When driving on the road at night, the front
headlights must be dipped so that the low
beam line hits the ground no further than 10 m
in front of the vehicle.
The rotating beacons must always be
operating, even when there is no need for
visual signalling and lighting devices. Switch
off the work lights.
13.) Before driving on public roads, ensure the
machine is equipped for road transport (see
page 3-56).
¥
WARNING: The combine may be
transported on public roads only with an
empty grain tank.
14.) If it is necessary to tow the combine due to a
mechanical breakdown, strictly follow the
procedure indicated on page 1-45.
15.) When driving on public roads towing the
cutting table, ensure that the local traffic
regulations (lights, correctly fitted trailer hitch
etc.) are complied with. Ensure the cutter bar
protection shield is fitted.
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GENERAL INFORMATION
Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013 1-13
FIELD OPERATIONS
¥
DANGER:To provide a better view, certain
illustrations in this manual show the
machine with the safety guards or covers
removed.
Keep all guards in place.
Use drive shafts with adequate protection
devices.
1.) Before starting work the operator should
familiarise himself thoroughly with all machine
controls.
Ensure that the table has been properly
attached. The combine manufacturer shall
not be held liable if non-genuine tables are
used.
2.) During harvesting operations do NOT allow
anyone to come near the machine.
People nearby could be knocked, struck or
squashed by the machine or be trapped in the
harvesting parts.
3.) Always drive the combine at a speed which,
depending on ground conditions, provides the
necessary safety.
When working on rough ground, proceed with
great care to ensure machine stability.
Always use the seatbelts provided on the
operator seat and on the other seat, if an
instructor is present.
¥
DANGER: Risk of overturning.
4.) When taking the combine to work on slopes,
the operator must be thoroughly familiar with
machine controls and with working on sloping
grounds.
The combine must not be used in the following
situations (this list is not exhaustive):
• When maximum allowable inclination is
exceeded (see page 1-4)
• If correct securing of the cutting table to the
main crop elevator with the safety stops has
not been checked
• If adequate ballast has not been applied to
balance the machine on the rear axle
• If correct tyre pressures have not been
checked
• If proper operation of the levelling system
has not been verified
• If the ground is not sufficiently firm or
features sudden surface changes, or the
tyres do not have enough grip on the
ground
• If working close to the edge of ditches or
steep drops.
5.) If the machine tends to tilt forward when
working on slopes, lower the cutting table
completely.
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GENERAL INFORMATION
1-14 Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013
6.) Take bends at a moderate speed (3–4 km/h)
and halve the speed when the grain tank is full.
¥
DANGER: Risk of squeezing, cutting or
getting trapped.
7.) If any moving part becomes blocked or
jammed, release it only when the engine is
switched off and all drives have come to a
complete stop. Never push the crop into the
main crop elevator using hands, feet or any
other means. This may cause severe injury
or death.
¥
DANGER: Risk of breathing in dust.
8.) Threshing dust may cause allergic lung
diseases. The dust may also contain residues
of pesticides injurious to health. Keep the cab
doors shut when threshing. Wear a protection
mask when carrying out service work involving
exposure to dust (cab filters, rotary screen etc.)
and when working with compressed air.
9.) Keep a fire extinguisher within easy reach.
Check the extinguisher at the intervals
prescribed by national law.
Replace or recharge it whenever it has been
used, even if only partially.
The type of extinguisher approved for Europe
contains 6 kg of extinguishing agent and
belongs to fire class ABC.
We recommend checking the dimensions of a
potential new extinguisher to ensure that it can
be stored underneath the operator's seat.
¥
DANGER: Risk of electrocution.
10.) Beware of overhead lines and check that the
combine can easily pass under without
touching the lines, particularly if:
• It is equipped with an antenna
• The unloading auger is turned out
• The grain tank cover is open.
A height of 4 metres is exceeded in these cases
Make sure the machine is able to pass through
easily. In case of contact between the machine and
the power supply line, the following procedure must
be adopted:
a) Disengage all drives.
b) Switch off the engine.
c) Apply the parking brake.
d) Ensure that you can leave the operator
seat safely without touching the electrical
cables.
e) Jump from the last step, making sure there
is no contact of body parts, ground and
machine.
f) Do not touch the machine until the power
has been cut off. Anyone approaching the
machine must be informed not to touch it.
g) Ask the power station to cut off the power.
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Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013 1-15
¥
DANGER: Risk of squeezing, cutting or
getting trapped.
11.) Never leave the cutting table in raised position
when the combine is stationary.
12.) Always park the combine on level ground. In
the event of an emergency, when parking on
level ground is not possible, park the combine
across the slope, engage 1st gear and apply
the handbrake before stopping the engine.
If it is not possible to park as described above,
proceed as follows:
• Downhill parking: Engage 1st gear, switch
off the engine and apply the parking brake.
Get off the machine and place sprags (if
available) or two solid objects of a suitable
size in front of the traction wheels.
• Uphill parking: Engage 1st gear, switch off
the engine and apply the parking brake. Get
off the machine and place sprags (if
available) or two solid objects of a suitable
size behind the traction wheels.
In any case, before leaving the combine
unattended, switch off the engine, remove
the ignition key and lower the cutting table.
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GENERAL INFORMATION
1-16 Operator's Manual Combines CHALLENGER 648 C-652 C- EN - LA327318013 - 10/2013
MAINTENANCE WORK
Work on the Machine
1.) Before inspecting, cleaning, adjusting or
servicing combine and table (grain or maize),
always ensure that the engine is stopped,
the brakes are applied and all moving parts
have come to a complete stop.
¥
WARNING: Wear protective clothing
(overalls, gloves, shoes, goggles, mask,
etc.) suited to the maintenance operation
that you intend to carry out.
2.) To lift one side of the machine (for example to
remove a wheel), use lifting equipment with
suitable capacity, e.g. a column hydraulic jack
or a lift with a minimum capacity of 10,000 kg.
3.) Pay special attention while removing
preloaded parts.
¥
DANGER: Risk of shocks.
It is strictly forbidden to loosen the nut
fastening the cylinder variator pulley
without using the proper tools. This
operation may be carried out only by your
Dealer's skilled staff. The operator may
only perform adjustments/maintenance
that he is totally familiar with and for which
he has the necessary tools; otherwise, he
must consult the local Dealer.
4.) Work on tyres requires correct tools and expert
knowledge. An incorrect assembly can
seriously compromise your safety. When in
doubt, refer to specialised staff.

5.) Before fitting the wheels, ensure that the
contact surfaces of wheel rim and final drive
hub are perfectly clean and that the thread is in
perfect condition.
The front wheel fixing elements must be
torque tightened to 700 Nm (71 kgm)
crosswise and the rear wheel fixing
elements to 304 Nm (31 kgm).
Check the aforementioned tightening
torques again after the first and second
hours of work or road travel and then every
10 hours at least 5 times.
6.) Do not carry out any work (inspection or
maintenance) on the machine when the wheels
have been removed, unless the machine is
properly supported.
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