Supplement To CLAAS JAGUAR 880 - 820 Repair Manual Spare Part No. 188 124.0

Supplement to CLAAS JAGUAR 880 – 820 Repair Manual
Spare Part No. 188 124.0

Gearbox / Reverser Gear
Supplement to Group 4 – Feed Unit and Reverser Gear
Pages 4.39 to 4.49 to be removed
Pages 4.39/2 to 4.96/2 to be added
Order No. 297 580.0
4 FEED UNIT AND FEED UNIT
REVERSER GEAR Removing the feeder housing 4. 1
Fitting the feeder housing 4. 3
Removing the gearbox for the upper rollers 4. 4
Dismantling the gearbox for the upper rollers 4. 5
Assembling the gearbox for the upper rollers 4. 8
Fitting the gearbox for the upper rollers 4. 9
Removing the pressure roller 4. 10
Dismantling the pressure roller 4. 11
Assembling the pressure roller 4. 13
Fitting the pressure roller 4. 13
Removing the compression roller 4. 15
Assembling and fitting the compression roller 4. 17
Removing the chain housing for the
feeder roller drive 4. 20
Dismantling the chain housing 4. 20
Removing the chain housing bearing rings 4. 21
Assembling and fitting the chain housing
for the feeder roller drive 4. 23
Dismantling the clutch 4. 23
Assembling the clutch 4. 25
Removing the feeder roller magnetic boxes 4. 25
Dismantling the feeder roller magnetic boxes 4. 26
Assembling the feeder roller magnetic boxes 4. 29
Fitting the feeder roller magnetic boxes 4. 30
Removing the smooth roller 4. 31
Fitting the smooth roller 4. 33
Tensioning the tension springs
for the compression/pressure roller 4. 34
GEARBOX / REVERSER GEAR

Removing the shut-off mechanism 4. 35
Fitting the shut-off mechanism 4. 37
Adjusting the solenoid 4. 38
Removing the gearbox / reverser gear 4.39/2
Removing and dismantling the drive crown 4.42/2
Assembling the drive crown 4.47/2
Dismantling the gearbox / reverser gear 4.48/2
Assembling the gearbox / reverser gear 4.63/2
Fitting the gearbox / reverser gear 4.94/2
Removing the gearbox / reverser gear

Drain the oil out of the gearbox.
A = Oil drain plug
Collect the used oil in a suitable vessel and dispose of it
correctly.
(Fig. 106)
106
Unscrew the guard for the electro-magnetic clutch.

Remove the shut-off mechanism.
(Fig. 107)
107
Unscrew the hexagon head bolt (B) with the spring and take
off the plate (C).
Unscrew the hexagon head bolt (D) on the bearing plate
and then fold it over.
Completely remove the hydraulic cylinder (E and F) on the
gearbox casing.
Unscrew the bearing plate (G) from the gearbox.
(Fig. 108)
108
Disconnect the cable from the inductive sensor (H).

Unscrew the ring bolt (S) and place the cable holder (L) with
the wiring loom on the feeder housing.
Screw the ring bolt (S) back in again.
(Fig. 109)
109
JAG 880 – 820 4.39/2

Unscrew the protective tube (R) and pull out the cable.
(Fig. 110)
110
Unscrew the clamping screw.

Open the assembly flap and pull the universal drive shaft off
the shaft end.
(Fig. 111)
111
Unscrew the plate.

(Fig. 112)
112
Unscrew the cheese head screw and take off the centering
plate over the drive crown.
(Fig. 113)
113
4.40/2 JAG 880 – 820

Unscrew the clutch guard (K) and remove the roller chain
from the chain coupling.
(Fig. 114)
114
Suspend the gearbox in a suitable lifting device using the

ring bolt.
Unscrew the three hexagon nuts (M).
Pull off the gearbox to the side.
(Fig. 115)
115
If necessary, push the machine forward or backward a little

so that the gearbox can be guided past the cleats on the
tyre.
(Fig. 116)
116
JAG 880 – 820 4.41/2

Removing and dismantling the drive crown

Unscrew and remove the drive crown casing from the
gearbox casing.
(Fig. 117)
117
Drain the oil out of the drive crown.

A = Oil drain plug
Unscrew the mounting bolts in the gearbox cover and press
the cover off using a chisel. Remove the cover.
(Fig. 118)
118
Take the flat key out of the crown wheel shaft, unscrew the
slotted nut and remove the back-up ring.
(Fig. 119)
119
Drive the crown wheel out of the gearbox cover. Remove

the taper roller bearing, spacer ring and back-up ring. Take
the O-ring off the crown wheel shaft.
(Fig. 120)
120
4.42/2 JAG 880 – 820

Use a chisel to press the taper roller bearing out far enough
to apply an extractor.
(Fig. 121)
121
Drive the shaft seal out of the gearbox cover. Press the
bearing outer ring out of the cover and remove the shims.
(Fig. 122)
122
Drive the drive shaft out of the bearing seat using a plastic
hammer.
Remove the circlip and back-up ring in front of the bevel
gear from the drive shaft. Pull the bevel gear off the shaft
together with the deep groove ball bearing.
Take the O-ring out of the bevel gear hub.
(Fig. 123)
123
Remove the circlip and shaft seal from the gearbox casing.
Drive out the shaft seal using a striking tube
(approx. 75 mm ∅).
(Fig. 124)
124
JAG 880 – 820 4.43/2

125
4.44/2 JAG 880 – 820

Drive crown, dismantled:

1 Gearbox casing
2 Oil sight glass
M 24 x 1.5
3 Screw plug
M 24 x 1.5 CN 200515
4 Screw plug with magnet
M 24 x 1.5 CN 200515
5 Shaft seal
A 50 x 80 x 8 NB
6 80 x 2.5 DIN 472 circlip
7 Bevel gear Z 15
8 Bearing seal ring 6210 AV
9 Deep groove ball bearing
6210 2RS DIN 925
10 29.75 x 3.53 NB 70 O-ring
11 Drive shaft
12 25 x 35 x 2 DIN 988 back-up disc
14 Crown wheel
15 Taper roller bearing
LM 48548 / LM 48510 2 pieces
16 Gearbox cover
17 52 x 65 x 0.5 DIN 988 shim
52 x 65 x 0.3 DIN 988 shim
52 x 65 x 0.1 DIN 988 shim
as required
18 S 35 x 45 DIN 988 back-up disc 2 pieces

19 30 x 2.5 NB 70 O-ring
20 Inner ring
LR 35 x 40 x 16.5
21 Shaft seal
AS 40 x 72 x 10 NBR
22 M 35 x 1.5 slotted nut
23 Hexagon head bolt
M 10 x 30 DIN 933-8.8 MK
A 10 DIN 128 spring washer
9 pieces
24 Cheese head screw

M 16 x 25 DIN 912-8.8,
(inserted using DELO-ML
5328 or Loctite 638)
25 Hexagon head bolt
M 16 x 40 DIN 933-8.8
Contact disc A 16
4 pieces
(Fig. 125)
JAG 880 – 820 4.45/2

126
127
4.46/2 JAG 880 – 820

Assembling the drive crown 16. Fit the crown wheel back into the gearbox
1. Clean all parts thoroughly. cover (see no. 10). Also insert the shaft
seal (21).
2. Replace defective parts, especially gaskets,
shaft seals and circlips. 17. Apply a thin coating of ”Epple 33” sealing
compound (410 219.0) to the flange surface
3. Apply oil to all gearbox parts before of the cover; fit the cover on the gearbox
assembly. casing and tighten the hexagon head bolts
4. Press the circlip (6) into the gearbox crosswise.
casing (1). 18. Tighten the slotted nut (22) so that the
5. Place the bearing seal ring (8) on the bevel turning torque of the drive crown, measured
gear (7) hub and press on the deep groove at the crown wheel shaft, is 1.5 - 2.5 Nm.
ball bearing (9). Insert the O-Ring (10) in the (Fig. 125)
bevel gear hub.
6. Press the shaft seal (5) into the gearbox
casing (1) in front of the circlip (6).
7. Drive the pre-assembled bevel gear (7 - 10)
into the bearing seat in the gearbox casing;
push the drive shaft (11) into the bevel gear
from below and fix it by means of the
back-up disc (12) and circlip (13).
8. Drive the taper roller bearing (15) onto the
crown wheel (14).
9. Press the bearing outer rings of the taper
roller bearings (15), first without the shims,
into the gearbox cover (16).
10. Insert the crown wheel (14) in the gearbox
casing and press the outer taper roller
bearing (15) onto the crown wheel shaft;
push the back-up disc (18), O-ring (19), inner
ring (20) and second back-up disc (18) onto
the shaft and tighten the slotted nut (22)
(permissible axial play of the taper roller
bearings is 0 - 0.1 mm).
11. Fix the pre-assembled gearbox cover onto
the gearbox casing (1) by means of the two
hexagon head bolts (23).
12. Measure and adjust the torsional flank
clearance.
Fit a bearing set collar (35D) (503 414.1) on
the bevel gear shaft by means of an M10 x
20 hex. head bolt (237 382.0) and apply a
dial gauge.
ATTENTION! The measuring point must lie
on the reference diameter of the bevel gear.
The torsional flank clearance should be
0.15 - 0.25 mm.
13. Measure the torsional flank clearance and
determine the number shims and their
thickness (17).
14. Then take off the gearbox cover again,
remove the crown wheel and drive the
bearing outer ring of the inner taper roller
bearing out of the cover.
15. Place the determined number of shims of the
same thickness (17) in the bearing seat in
the gearbox cover (16) and press the
bearing outer ring back into the seat.
JAG 880 – 820 4.47/2

Dismantling the gearbox / reverser gear

Unscrew the drive crown and remove it.
Screw on the shift lever (l) and fork.
Press the ”fast / slow” selector shaft right into the gearbox
casing and block it.
Remove the snap ring (M).
(Fig. 128)
128
Unscrew the screwed insert (N) in the gearbox cover.
ATTENTION! The screwed insert is under tension. Take the

shims, stop and pressure spring out of the
casing.
Unscrew the shift lever (l) and fork.

(Figs. 128 and 129)
129
Block the sprocket and unscrew the hexagon head bolt.

Pull off the sprocket.
(Fig. 130)
130
Unscrew all bolts in the gearbox cover. Remove the

gearbox cover from the gearbox casing.
(Fig. 131)
131
4.48/2 JAG 880 – 820

Shaft designations:
A = Gear shaft
B = Gear shaft
C = Clutch shaft
D = Gear shaft
E = Reverse shaft
F = Selector shaft
G = Selector shaft
H = Drive shaft / bevel pinion
(Figs. 132 and 133)
132
133
Pull the slinger disc off the gear shaft (A) together with
the taper roller bearing and disc.
(Fig. 134)
134
Drive out the gear shaft (A) cap. Remove the circlip,
back-up disc, shim and bearing shell. Make a note of the
number of shims and back-up discs and their thickness.
(Fig. 135)
135
JAG 880 – 820 4.49/2

Lift the complete gear wheel with the gear shaft (B) out of
the gearbox.
(Fig. 136)
136
Pull off the deep groove ball bearing. Take the back-up disc
and the gear wheel off the gear shaft (B).
Remove the O-ring and pull off the bearing inner ring.
(Fig. 137)
137
Drive the shaft seal out of the gear shaft (B). Take out the
circlip, back-up disc and cylindrical roller bearing.
(Fig. 138)
138
Pull the whole clutch shaft (C) out of the gearbox.

Take out the axial needle bearing, shims and back-up disc.
Pay attention to the number of shims and their thickness!
(Fig. 139)
139
4.50/2 JAG 880 – 820

Remove the circlip and back-up disc from the clutch

shaft (C).
(Fig. 140)
140
Pull off the taper roller bearing together with the back-up
disc and taper spur gear.
(Fig. 141)
141
Drive out the clutch shaft (C) cap. Remove the circlip,
back-up disc shim and bearing shell.
Pay attention to the number of shims and back-up discs and
their thickness.
(Fig. 142)
142
Take the circlip out of the gearbox cover.

Drive the bevel pinion with the deep groove ball bearing,
shims and back-up disc out of the gearbox cover from the
inside using a curved steel rod of ∅ 8 x 200.
Pay attention to the number of shims and back-up discs and
their thickness.
(Fig. 143)
143
JAG 880 – 820 4.51/2

Pull the deep groove ball bearing off the bevel pinion.
(Fig. 144)
144
Take the gear wheel, back-up disc and circlip off the clutch
shaft (C).
(Fig. 145)
145
Determine the installation depth of the selector shaft (K).

This dimension is used as a basic setting during assembly.
(Fig. 146)
146
Unscrew the self-locking slotted nut on the outside of the

gearbox.
Unscrew the selector shaft (K) out of the thread using a
special tool.
ATTENTION! Do not pull the selector shaft out of the shift

fork.
(Figs. 146 and 147)
147
4.52/2 JAG 880 – 820

Special tool:
(self-made)
R = Tube of ∅ 33 mm x ∅ 25 mm x 140 mm
O = Iron rod of ∅ 8 mm x 160 mm
X = 10 mm
Y = ∅ 6 mm
S = M 5 x 40 DIN 931 hexagon head bolt
M = M 5 DIN 934 hexagon nut
O
(Fig. 148) X
Y X
S
148 36345
Take the double gear wheel out of the gearbox casing

together with the shift fork and selector shaft (K).
(Fig. 149)
149
Pull the selector shaft out of the shift fork.
ATTENTION! The spring and ball are tensioned!
(Fig. 150)
150
JAG 880 – 820 4.53/2

Remove the circlip and back-up disc from the driving hub.
(Fig. 151)
151
Drive out the driving hub using a plastic hammer.
ATTENTION! Hold the hub.
(Fig. 152)
152
Remove the shaft seal and take the snap ring out of
the shaft groove.
Drive out the bearing bushes using a suitable tube.
(Fig. 153)
153
Drive out the bearing outer ring inwards.

Drive out the shaft seal outwards.
(Fig. 154)
154
4.54/2 JAG 880 – 820

Determine the installation depth of the selector shaft (L).

This dimension is used as a basic setting during assembly.
(Fig. 155)
155
Unscrew the self-locking slotted nut on the outside of

the gearbox.
Unscrew the selector shaft (L) out of the thread using a
special tool.
ATTENTION! Do not pull the selector shaft out of the

shift fork.
(Fig. 156)
156
Special tool:
(self-made)
X = 10 mm
Y = ∅ 6 mm
O
(Fig. 157) X
Y X
S
157 36345
JAG 880 – 820 4.55/2

Take the double gear wheel out of the gearbox casing

together with the shift fork and selector shaft (K).
(Fig. 158)
158
Pull the selector shaft out of the shift fork.
ATTENTION! The spring and ball are tensioned.
(Fig. 159)
159
Drive the complete gear shaft (A) with the gear wheel out of
the casing.
Take the bearing outer ring, shims, back-up disc and circlip
out of the gearbox casing. Pay attention to the number of
shims and their thickness.
Take the circlip, back-up disc and gear wheel off the gear
shaft (A).
(Figs. 158 and 160)
160
Pull off the taper roller bearing and the back-up disc.
(Fig. 161)
161
4.56/2 JAG 880 – 820

Lift the gear shaft (D), complete with gear wheels and shift
fork, out of the gearbox casing.
Pull the shift fork off the shifter collar.
(Fig. 162)
162
Pull the selector shaft (F) and the back-up disc out of the
gearbox casing.
Replace the O-ring in the casing.
(Fig. 163)
163
Drive the shaft seal for the gear shaft (D) out of the cover.
Take out the circlip, back-up disc and bearing outer shell.
(Fig. 164)
164
Pull the taper roller bearing, back-up disc and gear wheel
off the gear shaft (D).
Pull the needle cage, shim and shifter collar off the shaft.
(Fig. 165)
165
JAG 880 – 820 4.57/2

Turn the gear shaft (D) around. Pull off the taper roller
bearing, back-up disc, guide disc and gear wheel.
Take the needle cages and shim off the shaft.
(Fig. 166)
166
Drive out the cap.

Take out the circlip, back-up disc and shim.
Pay attention to the number of shims and their thickness.
Drive out the bearing shell.
(Fig. 167)
167
Drive the cap for the reverse shaft (E) out of the gearbox
cover. Take out the back-up disc, shim and bearing outer
shell.
(Fig. 168)
168
Take the gear wheel and the taper roller bearing off the
reverse shaft (E).
(Fig. 169)
169
4.58/2 JAG 880 – 820

Press the taper roller bearing off the gear wheel using two
mounting levers.
ATTENTION! This destroys the taper roller bearing. Use a

new bearing for re-assembly.
(Fig. 170)
170
Take the shims, axial needle bearing, reverse gear wheel

and needle cages off the reverse shaft (E).
(Fig. 171)
171
Pull the shift fork (G) complete with shifter collar off the
reverse shaft and out of the gearbox. Take the O-ring out of
the gearbox.
(Fig. 172)
172
Unscrew the set screw and drive out the selector shaft (G).
(Fig. 173)
173
JAG 880 – 820 4.59/2

Remove the cap and drive out the reverse shaft (E) using a
soft metal drift.
Take the needle cage, spacer tube, gear wheel set and
guide disc off the reverse shaft.
(Fig. 174)
174
Take out the circlip, back-up disc, shim and bearing outer
shell.
(Fig. 175)
175
Lever the cap off the bevel pinion (H). Take out the circlip,
back-up disc and shims.
(Fig. 176)
176
Turn the gearbox and drive out the bevel pinion (H) using a
soft metal drift. Take the spacer tube out of the gearbox.
(Fig. 177)
177
4.60/2 JAG 880 – 820

Press the taper roller bearing off the bevel pinion using two
mounting levers.
ATTENTION! This destroys the taper roller bearing. Use a

new bearing for re-assembly.
(Fig. 178)
178
Remove the circlip, back-up disc, bearing outer shell and

shims.
Take out the inner circlip.
(Fig. 179)
179
Drive the bearing outer shell and shims out of the casing.
(Fig. 180)
180
Lever out the cap on the drive shaft (H). Remove the circlip,
back-up disc and shims.
(Fig. 181)
181
JAG 880 – 820 4.61/2

Unscrew the guard and drive out the drive shaft (H) to
the left.
Lift out the deep groove ball bearing, spacer tube and roller
chain complete with the two sprockets.
Take out the back-up disc and shims.
(Fig. 182)
182
Remove the cylindrical roller bearing and pull off the bearing
inner ring.
Remove the circlip.
(Fig. 183)
183
Unscrew the stop bolt (R) and the inductive sensor (G).
(Fig. 184)
184
Drive out the expansion pins.

Unscrew the set screws out of the shift plates and pull off
the shift plates.
(Fig. 185)
185
4.62/2 JAG 880 – 820

Remove the circlips from the shifter pins. Remove the

shims, locking plate and O-rings.
Pull the shifter pins inwards out of the gearbox.
(Fig. 186)
186
Assembling the gearbox / reverser gear

1. Clean all gear parts thoroughly.
Replace defective parts, especially gaskets, shaft
seals and circlips.
Apply oil to individual gear parts before assembly.
2. Use grease to insert O-rings (1) in the bore holes in
the gearbox.
(Figs. 187 and 188)
187
188
JAG 880 – 820 4.63/2

3. Push the back-up disc (3) onto the shifter pins (2). Fit
the shifter pins (2) in the gearbox.
Pay attention to the installation position. Shifter pin (A)
must point to the left and shifter pin (B) to the right.
(Figs. 187 and 189)
189
4. Mount the locking plate (8). Insert the shims (4) and the
circlip (5). The shifter pins must be without axial play.
5. Mount the shift plates (6). Insert the set screws using
liquid screw fastener. Pay attention to the installation
position of the shift plates.
(Figs. 187 and 190)
190
4.64/2 JAG 880 – 820

191
Drive shaft and bevel pinion (H), dismantled: 21 S 45 x 55 DIN 988 back-up disc
1 Gearbox casing 22 45 x 55 x 0.5 DIN 988 shim
2 Cap 23 Sprocket
3 35 x 2.5 DIN 471 circlip 24 Spacer tube
4 Shim 35 x 45 x 1; 25 Deep groove ball bearing 6207 DIN 625
0.5; 0.3; 0.1 DIN 988 26 B 1SL 35 x 62 x 12 shaft seal
5 65 x 2.5 DIN 472 circlip 27 M 8 x 12 hexagon head bolt
6 Roller bearing LM 48510 / 48548 28 Guard
7 S 52 x 65 DIN 988 back-up disc 29 Output shaft
8 65 x 2.5 DIN 472 circlip (Fig. 191)
9 Spacer tube
10 Sprocket
11 Spacer tube
12 Roller chain
13 Shim 68 x 79.5 x 1;
0.5; 0.3; 0.1
14 Taper roller bearing 32010 DIN 720
15 Bevel pinion
16 Cap
18 56 x 72 x 0.5 DIN 988 shim
19 Cylindrical roller bearing NJ 207 DIN 5412
JAG 880 – 820 4.65/2

36868
192
6. Insert the deep groove ball bearing (25) in the gearbox

casing (1).
Insert the roller chain (12) complete with both
sprockets (10 and 23).
(Figs. 191, 192 and 193)
193
7. Mount the circlip (20) on the output shaft (29). Heat up

the inner ring of the cylindrical roller bearing (19) to
approx. 100 °C and press it onto the output shaft (29).
Pay attention to the installation position.
(Figs. 191, 192 and 194)
194
4.66/2 JAG 880 – 820

8. Push the back-up disc (21) and existing shims (22)

onto the output shaft (29). Insert the spacer tube (24)
and drive in the output shaft (29).
(Figs. 191, 192 and 195)
195
9. Press in the cylindrical roller bearing (19).

Insert the existing shim (18) and the circlip (17).
Insert the cap (16) using liquid screw fastener,
e.g. DELO-ML 5349.
(Figs. 191, 192 and 196)
196
10. Insert the existing shims (13) together with the bearing
outer ring (14).
(Figs. 191, 192 and 197)
197
11. Heat up the taper roller bearing (14) to approx. 100 °C

and press it on to the bevel pinion (15).
(Figs. 191, 192 and 198)
198
JAG 880 – 820 4.67/2

12. Fit the bevel pinion (15) in the casing from the inside.
Using a special tool (self-made), screw in a hexagon
head bolt (M 12) until the taper roller bearing (14) sits
without play.
(Figs. 191, 192, 199 and 200)
199
C
D
B
A O M
L
N
K
F
P
H
G
36876
200
4.68/2 JAG 880 – 820

Special tool:
(self-made)
A = 250 mm
B = 90 mm
C = 12 mm
D = 25 mm
E = 30 mm
F = 140 mm
G = 80 mm
H = 50 mm
K = 30 mm
L = M 12
M = 103 mm
N = 54 mm
P = ∅ 25 x 70 mm
Weld on steel rod (P).
(Fig. 200)
13. Insert the circlip (8) and back-up disc (7). Drive in the
bearing outer ring (6).
14. Insert the spacer tube (9), heat up the roller
bearing to approx. 100 °C and press it in.
ATTENTION! The bearing must be without play.
15. Insert the shims (4) and the circlip (3). The roller
bearing must have an axial play of 0 to 0.1 mm.
Take the special tool out of the gearbox.
(Figs. 191, 192 and 201)
201
JAG 880 – 820 4.69/2

202
Reverse shaft (E) and selector shaft (G), dismantled: 21 Cap

1 Gearbox casing 22 65 x 2.5 DIN 2.5 circlip
2 Gearbox cover 23 S 65 x 52 DIN 988 back-up disc
3 Reverse shaft Shim 65 x 52 x 0.5;
4 Shifter collar 0.3; 0.1 DIN 988
5 K 40 x 48 x 20 needle cage 24 25 x 3-N DIN 3771 O-ring
6 Spacer tube 25 Selector shaft
7 Gear wheel set 26 Shift fork
8 Guide disc LS 4060 27 Set screw
9 55 x 35 x 3 back-up disc 28 20.22 x 3.53 O-ring
10 Roller bearing LM 48510 / 48548 (Fig. 202)
11 K 40 x 48 x 20 needle cage
12 Reverse gear wheel
13 Axial disc AS 4060
14 Axial grooved ball bearing AXK 4060
15 Shim
16 Gear wheel
17 Taper roller bearing 32010 DIN 720
18 Shim 68 x 79.5 x 3;
0.5; 0.3; 0.1
20 Cap
4.70/2 JAG 880 – 820

36879
203
16. Pre-assemble the reverse shaft (3) with the needle

cage (5), spacer tube (6) and gear wheel set (7). Push
on the guide disc (8) and the back-up disc (9). Heat up
the roller bearing (10) to approx. 100 °C and press it
onto the reverse shaft.
17. Insert the pre-assembled reverse shaft in the gearbox
casing (1).
(Figs. 202, 203 and 204)
204
18. Turn the gearbox casing (1).
ATTENTION! The reverse shaft must not make

contact.
19. Insert the bearing outer ring (10) and the existing
back-up discs and shims (23). Fit the circlip (22).
(Figs. 202, 203 and 205)
205
JAG 880 – 820 4.71/2

20. Turn the gearbox casing. Position the reverse shaft (3)
without play in the bearing seat by means of a hard
blow with a plastic hammer.
(Figs. 202, 203 and 206)
206
21. Push the reverse gear wheel (12) with the needle
cage (11) and the axial grooved ball bearing (14) with
the axial discs (13) and existing shims (15) onto the
reverse shaft.
(Figs. 202, 203 and 207)
207

and press it onto the gear wheel (16).
23. Push the pre-assembled gear wheel (16) onto the
reverse shaft (3).
(Figs. 202, 203 and 208)
208
24. Mount the special tool with the socket pins on the
gearbox and screw it down.
25. Fit the bearing outer ring (17) and existing shims (18)
together with the circlip (19).
(Figs. 202, 203, 209 and 210)
209
4.72/2 JAG 880 – 820

Special tool:
1 Gearbox cover
(Fig. 210)
210 36886
26. Check that the torsional flank clearance of the gear

wheel set (7) is 0.15 mm to 0.25 mm. If necessary,
correct the torsional flank clearance by means of
shims (23).
ATTENTION! The reverse shaft may have an axial

play of 0 to 0.1 mm.
(Figs. 202, 203 and 211)
211
27. Raise the reverse gear wheel (12) and check the
torsional flank clearance of 0.15 mm to 0.25 mm.
If necessary, correct the torsional flank clearance using
shims (15).
ATTENTION! The reverse shaft may have an axial

play of 0 to 0.1 mm.
(Figs. 202, 203 and 212)
212
28. Coat the tooth faces with inking paste.

Check and optimise the contact pattern. If necessary,
alter the setting of the bevel pinion and repeat
assembly steps 10. to 27.
JAG 880 – 820 4.73/2

29. Unscrew the special gearbox cover tool. Remove the

gear wheel (16) and reverse gear wheel (12) with the
needle bearings (11).
(Figs. 202, 203 and 213)
213
30. Insert the O-ring (24) and shift fork (26) with the
selector shaft (25).
ATTENTION! The shift fork with the rectangular dog

must face downward.
(Figs. 202, 203 and 214)
214
31. Fit the needle cages (11), reverse gear wheel (12),
axial disc (13), axial grooved ball bearing (14),
shims (15) and gear wheel (16).
(Figs. 202, 203 and 215)
215
32. Let the shift fork engage in the bottom gear wheel set.
The (shift) play between the shift fork (26) and the gear
wheel set (7) may be X = 1.0-0.5 mm.
Insert and tighten the set screw (27) using liquid screw
fastener.
(Figs. 202, 203 and 216)
216
4.74/2 JAG 880 – 820

217
Gear shaft (D), dismantled:

1 Gearbox casing
2 Gearbox cover
3 Gear shaft
4 Shifter collar
5 55 x 40 x 4 shim
6 Needle cage
7 Gear wheel
8 Guide disc LS 4060
9 55 x 35 x 3 back-up disc
10 Roller bearing LM 48510 / 48548
11 Gear wheel
12 S 65 x 52 DIN 988 back-up disc
Shim 65 x 52 x 0.5;
0.3; 0.1 DIN 988
14 Cap
15 A 50 x 72 x 8 DIN 3760 shaft seal
(Fig. 217)
JAG 880 – 820 4.75/2

X X
36894
218
33. Insert the circlip (13) and existing back-up discs and
shims (12) in the gearbox casing (1).
(Figs. 217, 218 and 219)
219
4.76/2 JAG 880 – 820

34. Pre-assemble the gear shaft (3) with items (4 to 11).

Pay attention to the installation position of the shifter
collar (4). Heat up the roller bearings (10) to approx.
100 °C and press them on.
(Figs. 217, 218 and 220)
220
35. Screw in the thrust pieces using liquid screw fastener.

The thrust pieces should be adjusted to
X = 28.3-0,3 mm
Insert the gear shaft (3) and the shift fork in the
gearbox casing.
The shift play may be X = 1-0.5 mm.
(Figs. 217, 218, 221 and 222)
221
222
JAG 880 – 820 4.77/2

223
Gear shaft (A), dismantled:

1 Gearbox casing
2 Gearbox cover
3 Gear shaft
6 Gear wheel
9 Double gear wheel
10 Slinger disc
11 50 x 35 x 2 shim
Shim 65 x 50 x 0.5;
0.3; 0.1 DIN 988
14 Cap
(Fig. 223)
4.78/2 JAG 880 – 820

36899
224
36. Insert the circlip (13) and existing back-up discs and
shims (12) in the gearbox casing (1).
(Figs. 223, 224 and 225)
225
37. Pre-assemble the gear shaft (3) with items (4 to 8).

Heat up the roller bearing to approx. 100 °C and press
it on.
(Figs. 223, 224 and 226)
226
JAG 880 – 820 4.79/2

38. Pre-assemble the shift fork (S) with the pressure

spring (F), ball (K) and selector shaft (L).
(Figs. 227 and 228)
227
228
39. Insert the gear shaft (3), shift fork and double gear
wheel (9) in the gearbox casing.
Screw in the selector shaft (L) according to the
dimension measured on removing it.
Basic adjustment: The clearance between the selector
shaft and the flange surface on the gearbox casing is
71 mm.
(Figs. 223, 224 and 229)
229
4.80/2 JAG 880 – 820

230
Clutch shaft (C) and bevel gear, dismantled: 26 S 52 x 65 DIN 988 back-up disc
1 Gearbox casing Shim 52 x 65 x 0.5;
2 Gearbox cover 0.3; 0.1
3 AS 45 x 62 x 8 DIN 3760 shaft seal 27 65 x 2.5 DIN 472 circlip
4 Driving hub 28 Cap
5 AS 80 x 100 x 10 DIN 3760 shaft seal 29 Bevel gear
6 Snap ring BR 50 / SR 50 30 Deep groove ball bearing 6210-2RS
7 Bearing bush 31 S 70 x 90 DIN 988 back-up disc
8 Taper roller bearing 32014 x DIN 720 Shim 70 x 90 x 1;
9 S 70 x 90 DIN 988 back-up disc 0.5; 0.3; 0.1 DIN 988
10 70 x 2.5 DIN 471 circlip 32 90 x 3 DIN 472 circlip
11 Double gear wheel (Fig. 230)
12 Gear wheel
13 45 x 65 x 0.1 shim
15 Axial thrust washer AS 4565
16 Axial needle bearing AXK 4565
17 Clutch shaft
18 A 10 x 8 x 80 DIN 6885 flat key
19 45 x 65 x 0.3 shim
20 45 x 65 x 0.1 shim
21 Taper spur gear
JAG 880 – 820 4.81/2

36906
231
40. Press the shaft seal (5) from below right down to the
limit in the gearbox casing (1). Insert the bearing outer
ring (8).
(Figs. 230, 231 and 232)
232
41. Pre-assemble the driving hub (4) with the snap ring (6)
and new bearing bushes (7). Insert the clutch
shaft (17) and check it for easy movement. Pull out the
shaft and insert the shaft seal (3).
(Figs. 230, 231 and 233)
233
4.82/2 JAG 880 – 820

42. Insert from below the driving hub (4) into the gearbox
casing. Make sure the shaft seal (5) is not damaged.
and press it onto the driving hub (4).
ATTENTION! The driving hub and the taper roller

bearing must be fitted without play.
Fit the back-up disc (9) and the circlip (10).

(Figs. 230, 231 and 234)
234
44. Pre-assemble the shift fork (S) with the pressure

spring (F), ball (G) and selector shaft (K).
(Figs. 235 and 236)
235
236
JAG 880 – 820 4.83/2

45. Insert the double gear wheel (11) with selector shaft (K)
in the gearbox casing.
Screw in the selector shaft (K) according to the
dimension measured on removing it.
(Figs. 230, 231, 237 and 238)
237
238
46. Fit the circlip (10) and back-up disc (9). Shift through all
possible shift positions and check the gear wheels for
free travel by rotating them.
(Figs. 230, 231 and 239)
239
47. Mount the gear wheel (12). Shift through all possible
shift positions and check the gear wheels for free travel
by rotating them. If necessary, re-adjust the selector
shafts.
(Figs. 230, 231 and 240)
240
4.84/2 JAG 880 – 820

48. Support the gearbox casing and remove the gear

wheel (12) and double gear wheel (11) again. Screw
the self-locking slotted nut onto the selector shafts from
below. Use a special tool to counter-hold the selector
shafts.
(Figs. 230, 231, 241 and 242)
241
Special tool:
(self-made)
X = 10 mm
Y = ∅ 6 mm
O
(Fig. 242) X
Y X
S
242 36345
49. Refit the double gear wheel (11), circlip (10), back-up
disc (9), gear wheel (12), shims (13) and back-up
disc (14).
(Figs. 230, 231 and 243)
243
JAG 880 – 820 4.85/2

50. Push the taper spur gear (21) and back-up disc (22)
onto the clutch shaft (17). Heat up the taper roller
bearing (23) to approx. 100 °C and press it onto the
clutch shaft.
Insert the back-up disc (24) and the circlip (25).
(Figs. 230, 231 and 244)
244
51. Push the existing shims (19 and 20) and the axial
needle bearing (16) onto the shaft.
Insert the clutch shaft (17) in the driving hub (4).
(Figs. 230, 231, 244 and 245)
245
4.86/2 JAG 880 – 820

246
Gear shaft (B), dismantled:

1 Gearbox casing
2 Gearbox cover
3 Gear shaft
4 Gear wheel
5 Shim
6 Cylindrical roller bearing
7 Deep groove ball bearing 6207 DIN 625
10 AS 50 x 72 x 8 DIN 3760 shaft seal
11 30.2 x 3-N DIN 3771 O-ring
12 Sprocket
13 Centering ring
14 13 x 40 x 6 disc
15 Contact disc A 12
16 12 x 35 hex. head bolt MK DIN 933-8.8
17 BM 18 x 1.5 hexagon nut
18 Inductive sensor
(Fig. 246)
JAG 880 – 820 4.87/2

52. Push the shim (5) onto the gear shaft (3). Heat up the
inner ring of the cylindrical roller bearing (6) to approx.
X 100 °C and press it onto the gear shaft. Insert the
O-ring (11).
53. Push the second shim (5) onto the gear shaft (3).
Press the deep groove ball bearing (7) onto the gear
shaft (3).
(Figs. 246 and 247)
36922 247
54. Fit the gear shaft (3) in the gearbox casing.

(Figs. 246, 247 and 248)
248
55. Press the slinger disc (S) onto the shaft, heat up the
taper roller bearing (K) to approx.100 °C
and press it on.
(Fig. 249)
249
4.88/2 JAG 880 – 820

56. Insert the inductive sensor (18) using sealing

compound and fix it with a clearance of X = 2 mm.
Secure the adjustment by means of the hexagon
nut (17).
(Figs. 246 and 247)
57. Screw the stop bolts (R) into the locking plate.
ATTENTION! The stop bolts must engage in the centre

of the shift plates. Check all shift options.
(Fig. 250)
250
58. Clean the sealing surfaces on the gearbox.

Insert the 20.22 x 3.53 O-ring at (O).
Coat the sealing surfaces with sealing compound and
insert the centering pins (Z). Screw down the gearbox
cover evenly.
Tightening torque M 10 = 45 Nm
(Fig. 251)
251
59. Insert the bearing outer ring and the existing shims.
Insert the circlip and check the axial play
= 0 to 0.1 mm of the shaft. If necessary, correct the
number of shims.
(Fig. 252)
252
JAG 880 – 820 4.89/2

Bevel gear, dismantled:

1 Gearbox cover
2 Bevel gear
3 Deep groove ball bearing 6210 - 2RS
Shim 70 x 90 x 1; 0.5; 0.3; 0.1 DIN 988
5 90 x 3 DIN 472 circlip
(Fig. 253)
253
60. Press the deep groove ball bearing (3) onto the bevel
gear (2).
61. Insert the bevel gear, pre-assembled with the existing
back-up discs and shims, in the gearbox cover. Fit the
circlip.
(Figs. 253 and 254)
36929 254
4.90/2 JAG 880 – 820

62. Use a slightly curved steel rod of ∅ 8 x 200 mm

(self-made) to bring the bevel gear to rest on the
circlip (5) without play.
(Figs. 253, 254 and 255)
255
63. Check the torsional flank clearance of 0.15 - 0.25 mm

at the reference diameter by means of an auxiliary tool
and correct it, if necessary. Check the contact pattern.
If necessary, remove the gearbox cover and correct the
thickness of the shims on the clutch shaft.
(Fig. 256)
256
Auxiliary tool:
R = ∅ 60 x ∅ 49 x 120 mm
X = 10 mm R K
S = M 8 x 12 hexagon head bolt
K = M 8 x 20 hexagon head bolt
M 8 hexagon nut
(Fig. 257)
X S
257 36932
64. Insert the cap (C) flush using sealing compound.

(Fig. 258)
258
JAG 880 – 820 4.91/2

65. Insert the bearing outer rings at (D and E). Insert the
existing number of shims/back-up discs of the same
thickness and fit the circlips. An axial play of 0 to
0.1 mm is permissible. If necessary, correct it using
shims.
66. Insert the A 50 x 72 x 8 DIN 3760 shaft seal at (D)
using sealing compound. Fit the cap flush at (D) on the
other side and at (E) on both sides using sealing
compound.
(Fig. 259)
259
67. Insert the cylindrical roller bearing, back-up disc and

circlip at (B). Press the AS 50 x 72 x 8 DIN 3670
shaft seal right in to the limit using sealing compound.
(Fig. 260)
260
68. Mount the sprocket (12) and fit the centering

ring (13) using low-viscosity grease. Screw in the
hexagon head bolt (16) using liquid screw fastener.
M 12 = 78 Nm
(Figs. 261 and 262)
261
262
4.92/2 JAG 880 – 820

69. Insert the bearing outer ring at (A). Insert the existing
number of shims/back-up discs of the same thickness
and fit the circlip. An axial play of 0 to 0.1 mm is
permissible. If necessary, correct it using shims. Insert
the cap using sealing compound.
(Fig. 263)
263
1 Pressure spring
2 Stop
3 20 x 28 x 0.5 DIN 988 shim
4 Screwed insert
5 20.22 x 3.53 O-ring
6 A 20 DIN 7993 snap ring
(Fig. 264)
264
70. Fit a new O-ring (5) in the screwed insert (4). Fit the
pressure spring (1) and the stop (2) in the gearbox. Fit
the existing number of shims (3) of the same thickness.
Screw in the screwed insert using liquid screw
fastener.
(Fig. 265)
265
71. Screw the fork onto the selector shaft. Screw on the
shift lever (A) and secure it with a pin. Press the shift
lever (A) right into the gearbox and let it engage in the
stop bolt.
72. Press the shift lever (A) down and check that there is a
play of 1.0-0.5 mm at the shaft. If necessary, unscrew
the screwed insert and correct the play by means of
shims.
(Fig. 266)
266
JAG 880 – 820 4.93/2

73. Screw on the drive crown.

M 16 = 195 Nm
74. Install the gearbox / reverser gear.
Fitting the gearbox / reverser gear

1. Apply assembly paste (Molykote) to the three locating
bolts and toothed wheel.
(Fig. 267)
267
2. Push on the gearbox and tighten the M 16 hexagon

nuts at 195 Nm.
(Fig. 268)
268
3. Align the sprockets and fit the roller chain. Fit the
closed side of the chain-connect link spring in the
direction of rotation.
Fill the clutch guard (K) with grease and screw it on.
(Fig. 269)
269
4.94/2 JAG 880 – 820

4. Place the centering plate on the drive crown. Screw in

the cheese head screw with a new detent edged ring
and liquid screw fastener.
(Fig. 270)
270
5. Screw on the plate.

(Fig. 271)
271
6. Coat the shaft end of the drive crown with assembly

paste and push on the universal drive shaft. Tighten
the clamping screw and new detent edged ring at
78 Nm. Close and lock the assembly flap.
(Fig. 272)
272
7. Run the cable through the protective tube (R) and

screw it on.
ATTENTION! Insert the screws using liquid screw

fastener.
(Fig. 273)
273
JAG 880 – 820 4.95/2

8. Screw on the ring bolt (S) together with the cable

holder (L).
ATTENTION! Insert the ring bolt using liquid screw

fastener.
Connect the cable to the inductive sensor (H).

(Fig. 274)
274
9. Screw the bearing plate (G) onto the gearbox. Push on

the hydraulic cylinders (E and F).
Fix the bearing plate by means of the hexagon head
bolt (D). Screw on the plate (C) by means of the
hexagon head bolt (B).
(Fig. 275)
275
10. Screw on the shut-off mechanism and the guard for the
electro-magnetic clutch.
(Fig. 276)
276
11. Pour in 0.7 litres of transmission oil in accordance with

(MIL-L-2105 B) API-GL-5-90.
E = Oil filler plug and gearbox vent
K = Oil level inspection screw
ATTENTION! Lower the front attachment until it
touches the ground.
(Fig. 277)
277
4.96/2 JAG 880 – 820

CLAAS KGaA mbH 297 580.0
33426 HARSEWINKEL RHB SRG JAGUAR 880 – 820
GERMANY GB – 06.00 – 100 – BEV
Printed in Germany

Supplement To CLAAS JAGUAR 880 - 820 Repair Manual Spare Part No. 188 124.0

Uploaded by

Supplement To CLAAS JAGUAR 880 - 820 Repair Manual Spare Part No. 188 124.0

Uploaded by

Supplement to CLAAS JAGUAR 880 – 820 Repair Manual

Spare Part No. 188 124.0

GEARBOX / REVERSER GEAR

Removing the gearbox / reverser gear

Unscrew the guard for the electro-magnetic clutch.

Disconnect the cable from the inductive sensor (H).

JAG 880 – 820 4.39/2

Unscrew the clamping screw.

Unscrew the plate.

4.40/2 JAG 880 – 820

Suspend the gearbox in a suitable lifting device using the

If necessary, push the machine forward or backward a little

JAG 880 – 820 4.41/2

Removing and dismantling the drive crown

Drain the oil out of the drive crown.

Drive the crown wheel out of the gearbox cover. Remove

4.42/2 JAG 880 – 820

JAG 880 – 820 4.43/2

4.44/2 JAG 880 – 820

Drive crown, dismantled:

18 S 35 x 45 DIN 988 back-up disc 2 pieces

24 Cheese head screw

JAG 880 – 820 4.45/2

4.46/2 JAG 880 – 820

JAG 880 – 820 4.47/2

Dismantling the gearbox / reverser gear

Unscrew the screwed insert (N) in the gearbox cover.

ATTENTION! The screwed insert is under tension. Take the

Unscrew the shift lever (l) and fork.

Block the sprocket and unscrew the hexagon head bolt.

Unscrew all bolts in the gearbox cover. Remove the

4.48/2 JAG 880 – 820

JAG 880 – 820 4.49/2

Pull the whole clutch shaft (C) out of the gearbox.

4.50/2 JAG 880 – 820

Remove the circlip and back-up disc from the clutch

Take the circlip out of the gearbox cover.

JAG 880 – 820 4.51/2

Determine the installation depth of the selector shaft (K).

Unscrew the self-locking slotted nut on the outside of the

ATTENTION! Do not pull the selector shaft out of the shift

(Figs. 146 and 147)

4.52/2 JAG 880 – 820

Take the double gear wheel out of the gearbox casing

Pull the selector shaft out of the shift fork.

ATTENTION! The spring and ball are tensioned!

JAG 880 – 820 4.53/2

Drive out the driving hub using a plastic hammer.

ATTENTION! Hold the hub.

Drive out the bearing outer ring inwards.

4.54/2 JAG 880 – 820

Determine the installation depth of the selector shaft (L).

Unscrew the self-locking slotted nut on the outside of

ATTENTION! Do not pull the selector shaft out of the

JAG 880 – 820 4.55/2

Take the double gear wheel out of the gearbox casing

Pull the selector shaft out of the shift fork.

ATTENTION! The spring and ball are tensioned.

4.56/2 JAG 880 – 820

JAG 880 – 820 4.57/2

Drive out the cap.

4.58/2 JAG 880 – 820

ATTENTION! This destroys the taper roller bearing. Use a

Take the shims, axial needle bearing, reverse gear wheel

JAG 880 – 820 4.59/2

4.60/2 JAG 880 – 820

ATTENTION! This destroys the taper roller bearing. Use a

Remove the circlip, back-up disc, bearing outer shell and

JAG 880 – 820 4.61/2

Drive out the expansion pins.

4.62/2 JAG 880 – 820

Remove the circlips from the shifter pins. Remove the

Assembling the gearbox / reverser gear

JAG 880 – 820 4.63/2

4.64/2 JAG 880 – 820

JAG 880 – 820 4.65/2