The new Challenger® 500C Series combines.

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The reason grain futures are looking up.

As farms have grown, so have the demands on the grower and their machines. It’s not enough to just get the job done. In this multi-billion dollar industry, it’s all about getting the job done faster and more efficiently.

Well, there’s good news on that front.

We designed the Challenger 500C Series combines to conquer the most demanding ag environments on earth. Delivering more capacity and more productivity per acre. Our newly redesigned processor helps you tackle the toughest, tightest havest conditions. Giving you longer days and more out of them.

4 The 540C and 560C Series

6 Processor

8 Engine Power

10 e3™ SCR Emissions & V-Cool™ System

12 Drive Technology

14 Cab Comfort

16 Data Management & Technology

18 Grain Cleaning & Unloading

20 DynaFlex® Header

22 Parts and Service

23 Specifications

Contents

There’s a lot that goes into these Challenger 500C Series combines, but you might not notice it all at first glance. You wanted straightforward machines that put more clean grain in the grain tank. You wanted workhorses up to the challenge of starting earlier, ending later and operating when conditions are the toughest. Well, everything you wanted, we give you in the Challenger 540C and 560C combines.

Our combines are smarter now with our new processor intelligently boosting throughput while enhancing grain quality. They’re cleaner, too, with e3™ SCR emissions technology for cleaner air and a new multi-stage cleaning system that uses forced air to clean the grain, then clean it some more. And we keep everything cool with our exclusive V-Cool™ System that prevents plugging and keeps the cooling system running at optimum efficiency using less power.

Open up the large side panels and you will clearly see where sense meets sensibility with easily accessible drives for inspection and maintenance. It’s easy. Just climb on in.

4 540C & 560C Combines

5540C & 560C Combines

6 Processor

Introducing Challenger’s New Processor.

Inside the Challenger 500C Series combines, our new processor design is a complete threshing and separating system always working to ultimately increase capacity, yet reduce power consumption thereby improving fuel efficiency.

You’ll find the new design gives you the advantage with benefits that include:

• Increased and smoother crop flow from a larger feeder and header drive that delivers up to 55% more horsepower. As a bonus, the feederhouse is longer for improved header visibility.

• Thekeytoperformanceistoevenlyfeedtherotor.Thanks to the new segmented feed drum design and multi-zone rotor inlet, the rotor receives material nearly 360 degrees to reduce the bottleneck found on other designs.

• Controlcropflowmoreefficientlywithitssegmented- element axial rotor. This rotor features four overlapping helical rows of segmented replaceable threshing elements, plus two additional and interchangeable rows of both narrow and wide separation paddles.

• Changingconcavesisoftenoverlookedasanoptionfor improving performance. With the unique split design, any one of the 12 concaves can be easily changed by a single person. The various concave types may be combined side-to-side or front–to-rear to deliver the ultimate sample and performance.

• Thenew“H”framedesignoftheconcavesupportnotonly keeps the concaves concentric with the rotor throughout the range of adjustment but it also offers a level of protection withitsuniquesuspensionsystemtopass“slugs”of material or reduce the damage from foreign objects.

7TriEdge Processor

Bring more muscle to the field with the Challenger 500C Series combines. Powered by AGCO POWER 9.8-liter 7-cylinder inline engines, the 500C Series packs more horsepower and capacity than ever before. Respected throughout the world for their robust construction, each engine is built by hand and tested to the highest standards in the industry. Rest assured, you’ll always have all the power you need, whenever you need it, with our e3™ SCR technology that provides compliance without compromise.

Even at maximum power, this engine serves up peak performance, and runs smooth and surprisingly quiet for such a powerhouse. During assembly of all AGCO POWER engines, rotating components are balanced right down to the nearest gram and each engine is dyno-tested before ever leaving the line. It’s built exclusively to excel in the toughest harvest conditions.

The AGCO POWER 9.8L 7-cyl. engine also features:

• Highinjectionpressureand effective charge air cooling to help control emissions. • Increasedpowerdensityandtorque to maximize fuel economy. • Aproprietarysoftware,Electronic Engine Management 4 (EEM4), powering our most advanced fuel injection system yet.

8 Engine

9Engine

10 V-Cool System

Cut heat buildup and help keep the cooling system running at optimum efficiency with our self-cleaning V-Cool System. It’s designed to keep itself clear of chaff and debris so you don’t have to do the dirty work.

Because the engine radiator and intercooler along with two hydraulic coolers are arranged in a unique V-shape, airflow makes a single pass through each element rather than passing through multiple elements on a typical stacked design. This V-Cool design is not only more efficient but it also eliminates the common issue of chaff trapped between multiple coolers.

The hydraulic-driven cooling fan automatically adjusts its speed to maintain optimum engine and hydraulic temperatures. This reduces the

power required for the fan, especially during fall harvest. Additionally, the hydraulic drive automatically reverses the fan every 15 minutes, or sooner if required to forcefully clean the intake screen while you work eliminating the need for rotary screens or brushes.

You can’t make power without air and the engineers made sure the 9.8L engine had all it wanted. The extra large engine air intake is smartly placed inside the V-Cool System to bring in cool air from above the combine. The large two-stage air filter is conveniently serviced on the right side of the combine for easy service but thanks to the new belt-driven aspirator design, you will spend more time harvesting and less time messing with a dirty filter.

A breath of fresh air regarding emissions control.

Our e3 SCR system technology helps our AGCO POWER diesel engines perform more efficiently, stay cooler and last longer, all while meeting the EPA’s Tier 4i standards. This technology is a treatment on the downstream exhaust side with Diesel Exhaust Fluid (DEF) and it’s simple, effective and powerful. Just like our engines.

11V-Cool System

12 Drive Technology

The drives inside our combines are designed for the most direct and efficient transfer of power to all their major components. Using a minimalist approach reduces power requirements but also means fewer components to wear or replace over time.

Here’s how: • Theengineispositioned in line with the rotor to deliver the maximum horsepower to the rotor using only two belts without going through power–robbing gear boxes.

• Avariablespeedrotordrivefeaturingahydraulic speed variator controlled from your C2100 Terminal gives you full control of the rotor speeds within two ranges.

• In the unlikely event of a plugged rotor, the 500C features a reversing system that not only reverses the rotor but also the feed drum, elevators and augers slowly but with high torque to save you time. All from the comfort of the cab.

• Secondarydrivesliketheheader,feeder,cleaningfan, elevators drive, and the straw chopper drive, are all directed though the distribution gearbox.

• Thestandard2-speedhydrostaticpropulsiondrive gives you more choices in the field and smoother acceleration in transport with on-the-go shifting between high and low. Combine with the constant mesh four-speed transmission you will always be in control.

13Drive Technology

14 Cab

When you’re comfortable, every control is within easy reach, seats have a little more cushion and the temperature inside is always just right. And that’s exactly how we designed our ComforTech™ II cabs. They’re roomier, quieter and offer more visibility than ever before. See, it’s always easier to be more productive when you’re more comfortable.

Command performance.

The Challenger 500C Series combines surround you with convenience. The C2100 Virtual Terminal is easily adjusted to the preferred height and angle using a new sliding mount. The right hand console keeps multiple functions at your fingertips and the pivoting multi-function joystick control is comfortable throughout the full range of travel.

Relax and take in the view.

Your day isn’t set by a clock but instead by the job that needs to be done. The deluxe seat option with leather bolsters features heat and cooling to add a new level of luxury to shorten your long days of harvest. The standard cloth and deluxe seats both feature high-back design, air suspension and multiple adjustments for your comfort.

And when the sun goes down, you will take comfort in the increased visibility of the optional NightBreaker™light package.

With four HID (high-intensity discharge) lights in the cab roof replacing the standard halogen bulbs and two additional super-bright LED (light-emitting diode) extremity lights below the cab, you have a package deserving of the name. NightBreaker™ light package

15Cab

Today, technology makes all the difference. So it makes sense that we’ve loaded the Challenger 500C Series combines with the most advanced technology available. That way you can maximize yield, and enhance your financial return. So we started with the standard FIELDSTAR® II yield monitoring system. Monitor more harvest and combine functions, store more field data and make more informed decisions about your field than ever before. Insert a jump drive and take all the information from the terminal back to your PC at the end of the day. And it’s all right there in the numbers.

Transfer of information.

The C2100 Virtual Terminal lets you view critical gauges like tachometer, engine oil pressure, fuel level, coolant temperature and grain loss monitor in analog or digital formats. Crop settings are present, plus you can create and store your own settings for unique crop conditions.

Technology that keeps everyone on the same screen.

Your first smart decision is going with a Challenger combine. The second? Adding the technology that helps you make every pass count. The Challenger 540C and 560C are standard with guidance ready equipment allowing the easy installation of auto-steering technology that will help you maintain a full cut day or night. And precision always spells profitability.

Take command with AGCOMMAND®.

AGCOMMAND is a telemetry system designed to help you track a single or multiple combines and operators. It’s invaluable for farm managers because itmonitorseachcombine’s“health”andlocation all at the same time, so you can better manage your fleet’s performance, productivity and maintenance. Upgrade to AGCOMMAND Advanced and you will have the ability to view up to 25 functions including yield data, machine settings and grain loss. You have power even when you are miles away.

16 Technology

17Technology

18 Grain Cleaning

These combines use a multi-stage stratified cleaning process to clean grain. Anchored by a dual-outlet fan, youtakeadvantageofthe140”(355.6cm)rotorbyusing full-length cleaning below it. This reduces the amount of material other than grain (MOG) landing on the chaffer for more capacity and less sensitivity to field slopes. We also increased the size of our clean grain cross auger—delivering up to 60% more grain flow to match the capacity of the new processor.

• The13”(330mm)MaxFlow™fandelivers more air than ever before with the additional upper air duct. In addition to the new upper air duct, air is directed in multiple zones to the adjustable pre-cleaner, chaffer and sieve from front to back.

• Thenewstratifiedupperairflowcleaning performs the full length of the processor and the shorter grain pan only prevents losses from late separation. The position of the rotor directly above the cleaning system eliminates the need for auger beds and discharge beaters.

Fill it faster.

The less time you spend unloading, the more time you can spend harvesting. Enter the 540C and 560C. No other unloading system is faster or more efficient then our direct high-volume design. Intuitively built to transport the grain directly inline reducing the potential for crop damage and high wear with direction changes. With the addition of a new mid-mount bearing and direct drive, our unequalled unloading system is even smoother and quieter. Opt for our new 24-foot unloading auger option, which gives you more reach when using larger headers including our 40-foot DynaFlex® header.

Manage the residue.

You have a choice of dual straw spreaders or the new maximum air velocity (MAV) straw chopper to deliver an extraordinarily fine cut. The chopper allows full width spread with authority thanks to the unique air blade design. Simple adjustments for tailboard and stationary knives allow you to fine tune the output. A diverter door adds the capability for chopping the chaff from the cleaning shoe area. Creating a windrow is easy by simply rolling the chopper rearward and using the optional windrow attachment. And lastly, chopper speed changes are a snap without switching pulleys or adjusting idlers.

19Grain Cleaning

Whatever your crop, you’ll meet it head on with a header that can finally keep up with your combine. Our DynaFlex flexible cutterbar draper header brings the flexibility of an auger-style flex header with the gentle and fluid material handling of a draper header.

Plus, it conveniently connects directly to the 500C Series combines — no adapter needed. Faster cutterbar speeds, smooth crop flow, reduced vibration and virtual elimination of bottlenecks at the feederhouse. And with the 500C Series standard Smartrac® lateral tilt system, your header will follow the contours when harvesting over rolling terrain with up to six cutterbar sensors (35’ & 40’ models) monitoring the entire header width to prevent skips and scalping.

Other advantages of the DynaFlex include: • Foursizestomeetyourneedsincluding25’, 30’, 35’ and 40’ width options. (7.6, 9.1, 10.7 and 12.2 m) • Preciseadjustmentofthecuttinganglewith 12º of range from the cab-controlled fore-aft pitch control. • Independenthydraulictiltarmslocated every 30 inches (76.2 cm) across the header width for precise fingertip adjustment of the cutterbar float allowing up to eight inches (203 mm) of vertical travel for ground-hugging harvesting. • Theshaft-drivenSCH(Schumacher) epicyclical sickle drives provide up to 400% more torque than conventional drives to assure clean cuts even in the toughest conditions. Knife and sickle serration options let you customize for your crops and preferences.

20 DynaFlex Header

Corn Heads (CHCH series)The low feed angle plus the low-profile poly snouts of our corn heads will make harvesting your down and tangled crop easier. The electrically adjusted stripper plates let you minimize header loss and maximize performance on the go. Reversible stalk roll flutes and individual row units are slip clutch-protected to reduce maintenance costs and downtime.

PiCk-UP Heads (CHPU series)Designedforthe500CSeries,our“Swathmaster”Pick-Up Heads all provide excellent crop feeding by positioning the header cross auger close to the feed conveyor chain. In addition, a slip clutch is integrated into the header drive shaft. This helps protect the header and its drive system, reducing repair and maintenance costs down the road.

rigid & Flex Heads (CHrHB/CHFHB)Our rigid and flex straight-cut heads are tough, durable performers loaded up with features for high-yield conditions. Both heads have a fully welded main frame. And with the SCH epicyclical sickle drive, you’re assured of smooth, inline, high-torque cutting action for a high-speed harvest.

21DynaFlex Header

Better parts. Better service. Better peace of mind. It’s what you expect from a better combine.

Challenger replacement parts are manufactured to the same high standards of quality and dependability as the original part used on the assembly line. Using original equipment parts will help keep your Challenger combine running like new.

From advice and support to operation and maintenance, our network of dealers understands the investment you make in our combine. We’re focused on minimizing your downtime — especially during harvest - and we know that the availability of parts and competent, well-trained mechanics is critical.

Simple and easy to understand, our Header to Spreader warranty covers you for two years/2,000 hours and applies to all new Challenger 500C Series combines and related attachments. Full details are available at your Challenger dealer.

About AGCO AGCO, Your Agriculture Company, is a premier manufacturer of agricultural equipment, providing high-tech solutions for professional farmers feeding the world. The company is dedicated to delivering superior customer service, innovation and quality. AGCO products are distributed in more than 140 countries worldwide.

At AGCO, customer care isn’t just a department. It’s a commitment. Contact us with your questions. We’ll do our best to answer them promptly or put you in touch with someone who can.

22 Parts & Service

MoDEl 540C 560C

FEEDinG SySTEM

Chain size 4-strand HD #557 4-strand HD #557

Variable-speed header drive Optional Optional

Feed reverser Electro-hydraulic Electro-hydraulic

Housing width in. (mm) 55.4 (1,408) 55.4 (1,408)

Lateral tilt Standard Standard

Rock protection Standard stone trap Standard stone trap

THrESHinG / SEParaTion

System Rotary Rotary

Concave type Grain: Small wire / Corn: Round bar

Grain: Small wire / Corn: Round bar

Concave overload protection Spring-dampened Spring-dampened

Concave / grate area in.2 (m2) 2,115 (1.36) 2,115 (1.36)

Separating area in.2 (m2) 3,420 (2.2) 3,420 (2.2)

Rotor type Segmented element Segmented element

Rotor diameter in. (mm) 31.5 (800) 31.5 (800)

Rotor length in. (mm) 140 (3,556) 140 (3,556)

Drive type Variable belt / 2-speed Variable belt / 2-speed

Drive speed (rpm) Low Range: 264-709 / High Range: 460-1235

Low Range: 264-709 / High Range: 460-1235

Processor reverser Electro-hydraulic ring and pinion Electro-hydraulic ring and pinion

ClEaninG SySTEM

Cleaning stages 3 3

Pre-cleaner area in.2 (m2) 992 (0.64) 992 (0.64)

Chaffer area in.2 (m2) 4,588 (2.96) 4,588 (2.96)

Sieve area in.2 (m2) 3,875 (2.50) 3,875 (2.50)

Total area in.2 (m2) 9,455 (6.10) 9,455 (6.10)

Cleaning fan type and diameter in. (mm) Transverse, 13 (330.0) Transverse, 13 (330.0)

Grain HanDlinG SySTEM

Grain bin bu. (L) 350 (12,334) 350 (12,334)

Unloading auger diameter in. (mm) 15 (381) 15 (381)

Average unload rate bu/sec (L / sec) 4.0 (141) 4.0 (141)

Unloading auger length from center line in. (m)

Std. 292.6 (7.4) Opt. 328.0 (8.3) Std. 292.6 (7.4) Opt. 328.0 (8.3)

Unloading auger discharge height in. (m) Std. 171.2 (4.34) Opt. 179.8 (4.6) Std. 171.2 (4.34) Opt. 179.8 (4.6)

CroP rESiDuE DiSPoSal

Straw chopper (optional) 2-speed MAV™ 2-speed MAV™

Straw spreader 2-speed 2-speed

Hydraulic chaff spreader Optional Optional

Adjustable Windrow Attachment Optional Optional

MoDEl 540C 560C

EnGinE

Engine model AGCO Power 98 ATI AGCO Power 98 ATI

Displacement in3 (L) 598 (9.8) 598 (9.8)

Number of cylinders 7 / inline 7 / inline

Horsepower @ 2,100 rpm SAE (kW) Rated 370 (276) Unload Boost 426 (318)

Rated 460 (343) Unload Boost 502 (374)

Fuel tank capacity gal (L) 230 (870) 230 (870)

DriVE / ProPulSion SySTEM

Transmission (variable / manual) 2-speed hydrostatic / 4-speed 2-speed hydrostatic / 4-speed

Steering axle options Std. Adjustable Opt. 2-Speed RWA Std. Adjustable Opt. 2-Speed RWA

HyDrauliC SySTEM

Hydraulic pump Piston / variable disp. Piston / variable disp.

Hydraulic reservoir capacity gal (L) 22.5 (85.2) 22.5 (85.2)

Cab anD ConTrolS

Standard seat High-back cloth, Pneumatic Suspension

High-back cloth, Pneumatic Suspension

Optional seat Deluxe Seat, Fabric with Leather Side Bolsters, Heating and Cooling, Pneumatic Suspension

Deluxe Seat, Fabric with Leather Side Bolsters, Heating and Cooling, Pneumatic Suspension

Interior volume ft³ (m³) 121 (3.4) 121 (3.4)

23Specifications

500C Series Combines 540C | 560C

Challenger® is a worldwide brand of AGCO Corporation.

© 2012 AGCO Corporation. AGCO, DynaFlex, AGCOMMAND, and FIELDSTAR are registered trademarks of AGCO. Challenger is a registered trademark of Caterpillar Inc. and used under license by AGCO. Nightbreaker is a trademark of Caterpillar Inc. and used under license by AGCO. All rights reserved. AGCO, 4205 River Green Parkway, Duluth, GA 30096. CH12B002DS (08) PD