Case 788 Manual

Crawler excavators

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

788/988 - 788/988 Plus Wheeled Excavators

DIVISION/SECTION

GENERAL INFORMATION

Safety, general and torque settings .................................................................1001

Specifications (Crawler excavators).................................................................1002

Specifications (Wheeled excavators)...............................................................1002

ENGINE

Engine removal and installation (788 - 988 - 988 Plus ....................................2002

Engine removal and installation (788 Plus)......................................................2002

Radiator and oil cooler .....................................................................................2003

Engine specifications .......................................................................................2401

Cylinder head and valve assembly ..................................................................2415

Engine block ....................................................................................................2425

Lubrication system ...........................................................................................2445

Cooling system ................................................................................................2455

Turbocharger....................................................................................................2465

Turbocharger failure analysis...........................................................................2565

FUEL SYSTEM

Fuel system and filter.......................................................................................3410

CAV injection pump..........................................................................................3411

BOSCH injection pump ....................................................................................3412

Fuel injector .....................................................................................................3412

BOSCH ANEROID fuel injection pump............................................................3416

ELECTRICAL SYSTEM

Electrical schematic (Crawler excavators) - (before November 1999).............4001

Electrical schematic (Wheeled excavators) - (before November 1999) ...........4001

Electrical schematic (Crawler excavators) - (November 1999 and after).........4001

Electrical schematic (Wheeled excavators) - (November 1999 and after) .......4001

Electronic system and troubleshooting (Crawler excavators) ..........................4002

Electronic system and troubleshooting (Wheeled excavators) ........................4002

Starter motor ....................................................................................................4003

Alternator .........................................................................................................4004

Powersensor diagnostic tool ............................................................................4010

UNDERCARRIAGE

Track group (Crawler excavators)....................................................................5002

DRIVE TRAIN

Travel reduction gear and brake (Crawler excavators) ....................................6002

Swing reduction gear and brake (788 - 788 Plus)............................................6003

Swing reduction gear and brake (988) .............................................................6003

Swing reduction gear and brake (988 Plus).....................................................6003

Front axle and service brake (Wheeled excavators)........................................6004

Rear axle and service brake (Wheeled excavators) ........................................6005

Gearbox and parking brake (Wheeled excavators) .........................................6008

Twin wheels (Wheeled excavators) .................................................................6020

* * Consult the engine Service Manual.

Case

788/988 - 788/988 Plus Crawler Excavators

Table of Contents

SECTION N°

Cre 7-58655GB

REFERENCE N°

7-56942GB

7-80071GB

7-80062GB

7-58681GB

7-26560GB

7-80621GB

* *

7-80040GB

7-80021GB

7-26570GB

7-26540GB

7-80031GB

7-80051GB

7-58691GB

7-58701GB

7-79991GB

7-58711GB

7-80661GB

7-80671GB

7-58731GB

7-84141GB

7-80681GB

7-80691GB

7-80701GB

7-26170GB

Printed in France

March 2000

Table of Contents

Need help?

Do you have a question about the 788 and is the answer not in the manual?

Questions and answers

Summary of Contents for Case 788

Page 1 Safety, general and torque settings ..............1001 7-56942GB Specifications (Crawler excavators)..............1002 7-80071GB Specifications (Wheeled excavators)...............1002 7-80062GB ENGINE Engine removal and installation (788 - 988 - 988 Plus ........2002 7-58681GB Engine removal and installation (788 Plus)............2002 7-26560GB Radiator and oil cooler ..................2003 7-80621GB Engine specifications ..................2401 Cylinder head and valve assembly ..............2415...
Page 2 Travel hand control block (Inching, wheeled excavators) ........8052 7-80870GB Direction of travel inverter control block (Inching, crawler excavators) ....8053 7-80290GB Travel control block (788 - 788 Plus 988 - 988 Plus wheeled excavators) ..8054 7-80301GB Brake module (wheeled excavators)..............8060 7-80882GB Parking brake electro-control valve (wheeled excavators) ......8061...
Page 3 (788 Pus crawler excavators) - (November 1999 and after).....Pocket 7-26730GB Large format hydraulic and electrical schematics (788 Plus wheeled excavators) - (November 1999 and after) ....Pocket 7-26760GB Large format hydraulic and electrical schematics (988 Plus crawler excavators) - (November 1999 and after) ....Pocket...
Page 5 Thanks very much for your reading, Want to get more information, Please click here, Then get the complete manual NOTE: If there is no response to click on the link above, please download the PDF document first, and then click on it. Have any questions please write to me: admin@servicemanualperfect.com...
Page 7: Table Of Contents
1001-2 TABLE OF CONTENTS SAFETY..................................3 TWIN WHEELS ................................. 5 Safety rules ................................5 Safety instructions..............................5 GENERAL INFORMATION ............................6 CORRECT USE OF TORQUE WRENCHES ......................7 HARDWARE TIGHTENING ORDER ........................8 STANDARD SCREW A TORQUE SPECIFICATIONS....................9 Correct screw identification ........................... 9 METAL CAP REFERENCES...........................10 PLASTIC PLUG AND CAP REFERENCE CHART ....................11 Cre 7-56942GB...
Page 8: Safety
It is your responsibility to follow applicable rules and regulations. Service and Operator’s Manuals are available from your J.I. Case Dealer. WARNING: If you wear loose clothing or if you omit to use safety equipment for your work, you risk injury. Always wear clothes that do not risk getting caught in the machine.
Page 9 1001-4 WARNING: Prior to operating the hydraulic WARNING: When performing maintenance cylinders of this machine for setting or to or repair operations on the machine, make bleed the circuit, have all people standing sure that the work shop floor, the cab and around the machine move away.
Page 10: Twin Wheels
1001-5 TWIN WHEELS Safety rules Safety instructions • Use appropriate, good quality tools to disassemble WARNING: In all cases, before removing twin the various wheel components. Never use a ham- wheels, always deflate both tyres completely. mer. Use a rubber, plastic or copper-faced mallet. IMPORTANT: Never remove the inner tyre valve WARNING: If a tyre bursts it can cause seri- extension, as this will be necessary afterwards for...
Page 11: General Information
CASE spare detect wear and pitting and subsequent changing of parts. Failures caused by the use of parts that are not parts will prevent premature failure. original CASE spare parts are not covered by the warranty. BEARINGS LUBRICATION Check that bearings rotate freely.
Page 12: Correct Use Of Torque Wrenches
1001-7 CORRECT USE OF TORQUE WRENCHES TORQUE Adjusting lever Setting pointer WRENCHES Leverage point handle Manipulator Extension SJ214, for doubling 1/2” square insert capacity of S203 wrenches Open-ended wrench PDG0315 CORRECT USE a - Hold the wrench by the handle provided.
Page 13: Hardware Tightening Order
1001-8 HARDWARE TIGHTENING ORDER TORQUE WRENCHES PDG0317 INITIAL TORQUE a - Torque wrench. - Follow the correct order of proce- dure when tightening. - Cross or diagonal pattern tightening. PDG0318 FINAL TORQUE Always tighten in clockwise order. PDG0319 Cre 7-56942GB Issued 11-99...
Page 14: Standard Screw A Torque Specifications
1001-9 STANDARD SCREW A TORQUE SPECIFICATIONS Correct screw identification Steel grade Steel grade PDG0320 Torque lb.ft Diameter x thread size Grade 8.8 Two-part hydraulic connector (to SAE J518 specifications) M5 x 0.8 M6 x 1 M8 x 1.5 22.5 22.5 16.6 16.6 M10 x 1.5...
Page 15: Metal Cap References
1001-10 METAL CAP REFERENCES To SAE J518 specifications NP 250 bar NP 400 bar Part number Ø ND Ø ND 13 mm D5327838 E5327839 19 mm F5327840 G5327841 25 mm H5327842 J5327843 32 mm K5327844 L5327845 38 mm M5327846 N5327847 13 mm U5327830 V5327831...
Page 16: Plastic Plug And Cap Reference Chart
1001-11 PLASTIC PLUG AND CAP REFERENCE CHART Dia. x pas Part number Dia. x pas Part number Tapped orifices and connectors with tighten- ing nuts = screw-type plugs M10 x 1.5 F3237416 M20 x 1.5 L3237421 M12 x 1.5 G3237417 M22 x 1.5 M3237422 M14 x 1.5...
Page 17 1001-12 Cre 7-56942GB Issued 11-99...
Page 19 WEIGHTS................................12 Machine ................................12 Attachments ...............................15 Counterweight ..............................15 Cab ..................................15 788 AND 788 "PLUS" BUCKETS ..........................16 988 AND 988 "PLUS" BUCKETS ..........................17 788 AND 788 "PLUS" CLAMSHELLS ........................18 988 AND 988 "PLUS" CLAMSHELLS ........................19 MACHINE OVERALL DIMENSIONS........................20 TRANSPORTATION OVERALL DIMENSIONS ......................22 WARNING: This symbol is used in this manual to indicate important safety messages.
Page 20 Fluid type ISO VG 46 CASE reference: CASYNTH46 This grade of fluid must be in conformity with CASE France specification P9903203B Transmission component oil Extreme pressure oil used for transmission compo- nents inside sealed housings.
Page 21 API/CG/CF. NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out on CASE lubricants. RF97F136 RB97F100...
Page 22 1002-5 Fuel Environment Use fuel that is to ASTM (American Society for Test- Before carrying out any servicing operation on this ing and Materials) D975 standard. machine and before disposing of used fluids or lubri- cants, always think of the environment. Never throw Use Grade No N°2 fuel.

This manual is also suitable for:

988 788 plus 988 plus

Case 788 Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Case 788

Summary of Contents for Case 788

This manual is also suitable for:

Table of Contents