Case 788 “Plus” & 788 Compact “Plus” Operator’s Manual 6-9290 – PDF DOWNLOAD

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Case 788 “Plus” & 788 Compact “Plus” Operator’s Manual 6-9290 – PDF DOWNLOAD

TO THE OWNER:

Your machine has been designed and built to the highest standards of quality and conforms to current safety regulations. See “Official documents”. However, the risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions.

• Read this manual carefully, paying particular attention to the instructions concerning safety, operation and maintenance so as to avoid the risk of injury while operating or servicing the machine. Use this manual as a guide. Your machine will remain a reliable working tool provided it is kept in good working condition and serviced properly.
• The standard attachments and equipment available for use with this machine are intended for general earthmoving purposes, material rehandling, boring, ditch cleaning, etc. If the machine is to be used for handling loads (tubing, concrete pipe sections, shoring material, etc.), make sure it is suitably equipped for this type of work.
• For this type of application, the machine must be equipped with safety valves, an overload indicator, a load handling chart corresponding to the type of machine and its attachment and a load fixing point. All legal requirements must also be strictly observed. Do not use this machine for any application or purpose other than those described in this manual.
• If the machine is to be used for work involving the use of special attachments, accessories or equipment, consult your CASE Dealer in order to make sure that any adaptations or modifications made are in keeping with the machine’s technical specifications and with prevailing safety requirements. Any modification or adaptation which is not approved by the manufacturer may invalidate the machine’s initial conformity with safety requirements.

TABLE OF CONTENTS:

Case 788 “Plus” & 788 Compact “Plus” Operator’s Manual 6-9290 – PDF DOWNLOAD

TO THE OWNER ………………………………………………………………………………. 7 – 11
TO THE OWNER ………………………………………………………………………………… 8
RIGHT, LEFT, FRONT AND REAR OF THE MACHINE …………………………. 11
IDENTIFICATION NUMBERS/MACHINE COMPONENTS ……………………. 12 – 17
TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE
OF THE MACHINE ………………………………………………………………………… 12
MACHINE COMPONENTS (788 Series, P2AL Version) …………………………. 14
MACHINE COMPONENTS (788 Compact Series, P2AL Version) ……………. 16
SAFETY/DECALS/HAND SIGNALS ………………………………………………….. 18 – 42
SAFETY INSTRUCTIONS ………………………………………………………………… 18
DECALS …………………………………………………………………………………………… 30
HAND SIGNALS ……………………………………………………………………………….. 39
CONTROLS/INSTRUMENTS/ACCESSORIES …………………………………. 43 – 116
CAB DOOR ………………………………………………………………………………………. 43
ACCESS GATE ………………………………………………………………………………… 44
STEPS AND ACCESS HANDLES ……………………………………………………….. 45
TILTING THE STEERING COLUMN ……………………………………………………. 47
INSTRUMENT PANEL ……………………………………………………………………….. 48
CONTROL PANEL …………………………………………………………………………….. 60
CAB CONTROLS ………………………………………………………………………………. 62
OPERATOR’S SEAT …………………………………………………………………………. 83
WINDSHIELD …………………………………………………………………………………… 86
FRONT LOWER WINDOW …………………………………………………………………. 88
HEATING AND VENTILATION ……………………………………………………………. 89
FORWARD VIEW MIRROR AND REAR VIEW MIRRORS ……………………… 90
ELECTRONIC CONTROL BOX …………………………………………………………… 91
ELECTRICAL CABINET …………………………………………………………………….. 91
TOWING EYE …………………………………………………………………………………… 92
FUEL TANK ……………………………………………………………………………………… 93
TOOL BOXES …………………………………………………………………………………… 94
TOOLS …………………………………………………………………………………………….. 94
STABILIZERS/DOZER BLADE SELECTOR VALVE ………………………………. 95
ENGINE HOODS ………………………………………………………………………………. 97
ACCESS PANELS …………………………………………………………………………….. 99
RIGHT-HAND SIDE DOOR ………………………………………………………………. 100
ELECTRICAL SOCKET ……………………………………………………………………. 101
STABILIZER PADS ………………………………………………………………………….. 102
FOLDING STABILIZERS ………………………………………………………………….. 103
HYDRAULIC RESERVOIR SHUT-OFF VALVE …………………………………… 105
BATTERY MASTER SWITCH …………………………………………………………… 105
LOAD FIXING POINT ………………………………………………………………………. 106
LOAD HANDLING EYE ON THE QUICK COUPLER ……………………………. 106
BACKHOE BUCKET MAXIMUM OPENING RANGE
AND MAXIMUM FORCE POSITIONS ……………………………………………. 107
Controls/Instruments/Accessories (continued)
QUICK COUPLER MAXIMUM OPENING RANGE
AND MAXIMUM FORCE POSITIONS ……………………………………………. 107
REFLECTORS ………………………………………………………………………………… 108
VALVE BANK PARTITION HOOD …………………………………………………….. 109
ENGINE COMPARTMENT LIGHT ……………………………………………………… 109
WHEEL BLOCKS ……………………………………………………………………………. 109
BOOM LOCKING VALVES ……………………………………………………………….. 110
DIPPER LOCKING VALVES ………………………………………………………………. 111
BUCKET/CLAMSHELL SELECTOR VALVE ……………………………………….. 111
SAFETY VALVES …………………………………………………………………………….. 112
FUEL TANK FILLER PUMP ……………………………………………………………….. 113
ROTARY BEACON …………………………………………………………………………… 115
OPERATING INSTRUCTIONS ……………………………………………………… 117 – 160
BEFORE OPERATING THE MACHINE ……………………………………………… 117
MACHINE OPERATION …………………………………………………………………… 118
RUN-IN PERIOD …………………………………………………………………………….. 120
STARTING THE ENGINE …………………………………………………………………. 121
STARTING THE ENGINE IN COLD WEATHER ………………………………….. 124
STOPPING THE ENGINE ………………………………………………………………… 125
OPERATING THE MACHINE IN COLD WEATHER …………………………….. 126
INSTALLING THE FUEL TANK CAP …………………………………………………. 127
LOAD HANDLING …………………………………………………………………………… 128
LOAD HANDLING LIMITS ………………………………………………………………… 130
HANDLING THE HYDRAULIC BREAKER ………………………………………….. 131
BREAKING TECHNIQUES WITH THE HYDRAULIC BREAKER …………… 131
CHOICE OF TOOLS FOR THE HYDRAULIC BREAKER ……………………… 132
SPECIAL CONDITIONS OF USE FOR THE HYDRAULIC BREAKER ……. 133
TRANSPORTING THE MACHINE …………………………………………………….. 134
HANDLING THE MACHINE ……………………………………………………………… 140
CAB REMOVAL AND INSTALLATION ……………………………………………….. 142
TOWING THE MACHINE …………………………………………………………………. 146
TOWING THE MACHINE IN AN EMERGENCY ………………………………….. 149
OPERATING THE MACHINE IN WATER …………………………………………… 150
TOOL INSTALLATION AND REMOVAL USING THE QUICK COUPLER .. 151
ELECTRIC TRAVEL ………………………………………………………………………… 155
OPERATING THE DOZER BLADE/STABILIZERS FROM THE OPERATOR’S
COMPARTMENT (Version with independent dozer blade/stabilizers) …. 157
PARKING THE MACHINE ………………………………………………………………… 160
JOB SITE AND ROAD OPERATION …………………………………………….. 161 – 188
OPERATING INSTRUCTIONS ………………………………………………………….. 161
ROAD TRAVEL ……………………………………………………………………………….. 163
ATTACHING THE CASE CLAMSHELL FOR ROAD TRAVEL ……………….. 174
JOB SITE TRAVEL ………………………………………………………………………….. 179
WORKING INSTRUCTIONS …………………………………………………………….. 181
LOAD HANDLING ……………………………………………………………………………. 188
SERVICE INTERVALS ………………………………………………………………… 189 – 194
SERVICE INSTRUCTIONS ………………………………………………………………. 189
HOURMETER …………………………………………………………………………………. 190
SERVICE INTERVALS CHART …………………………………………………………. 191
HYDRAULIC BREAKER SERVICING INTERVALS ……………………………… 194
LUBRICATION/FILTERS/FLUIDS ………………………………………………… 195 – 273
FLUIDS AND LUBRICANTS ……………………………………………………………… 195
ENVIRONMENT ……………………………………………………………………………… 198
PLASTIC AND RESIN COMPONENTS ………………………………………………. 198
CAPACITIES AND SPECIFICATIONS OF FLUIDS AND LUBRICANTS …. 199
GREASE POINTS ……………………………………………………………………………. 200
GREASING THE HYDRAULIC BREAKER ………………………………………….. 228
FLUID LEVELS ……………………………………………………………………………….. 230
ENGINE …………………………………………………………………………………………. 233
COOLING SYSTEM …………………………………………………………………………. 237
FUEL SYSTEM ……………………………………………………………………………….. 241
RELEASING PRESSURE IN THE HYDRAULIC SYSTEM ……………………. 248
HYDRAULIC SYSTEM …………………………………………………………………….. 249
AIR FILTER …………………………………………………………………………………….. 261
SWING REDUCTION GEAR …………………………………………………………….. 266
AXLES AND REDUCTION GEARS ……………………………………………………. 268
GEARBOX ……………………………………………………………………………………… 272
MAINTENANCE/ADJUSTMENTS …………………………………………………. 274 – 327
FUEL TANK FILTER ………………………………………………………………………… 274
FRONT AXLE LOCKING CYLINDERS ……………………………………………….. 274
WHEELS AND TYRES …………………………………………………………………….. 275
REPLACING TWIN WHEELS ……………………………………………………………. 277
HEATING UNIT FILTER …………………………………………………………………… 284
RADIATOR AND OIL COOLER …………………………………………………………. 285
ENGINE ALTERNATOR BELT AND FAN …………………………………………… 286
ADJUSTING ROCKER ARM CLEARANCE ………………………………………… 287
INSPECTING AND CLEANING THE MACHINE ………………………………….. 287
ACCUMULATORS …………………………………………………………………………… 288
QUICK COUPLER INSPECTION AND MAINTENANCE ………………………. 289
REPLACING A BACKHOE BUCKET TOOTH TIP ……………………………….. 290
TEETH AND TOOTH TIP WEAR LIMITS ……………………………………………. 291
REPLACING A BACKHOE BUCKET SIDE CUTTER ……………………………. 292
REPLACING A BACKHOE BUCKET ………………………………………………….. 293
Maintenance/Adjustments (continued)
REPLACING A CLAMSHELL TOOTH ………………………………………………… 296
REPLACING A CLAMSHELL AND ITS UNIVERSAL COUPLING ………….. 296
REPLACING A BACKHOE BUCKET BY A CLAMSHELL (or vice-versa) … 299
REPLACING AN EJECTOR BUCKET ………………………………………………… 302
REPLACING A TOOL ON A HYDRAULIC BREAKER ………………………….. 306
REPLACING A TOOL BUSHING ON A HYDRAULIC BREAKER …………… 308
REPLACING A HYDRAULIC BREAKER …………………………………………….. 310
WEAR LIMITS FOR THE HYDRAULIC BREAKER……………………………….. 312
SLEEVES FOR THREADED PINS …………………………………………………….. 313
REPLACING A HOSE ……………………………………………………………………… 314
REPLACING STANDARD PINS WITH “EXPANDER” PINS ………………….. 315
CHECKING FOR CYLINDER LEAKAGE ……………………………………………. 316
INSPECTING THE TURNTABLE BEARING ……………………………………….. 316
SHIMMING OF ATTACHMENTS ………………………………………………………. 317
AIR CONDITIONING (only 788 Series) ………………………………………………. 320
ENGINE TROUBLESHOOTING ………………………………………………………… 323
ELECTRICAL SYSTEM ……………………………………………………………….. 328 – 346
FUSES AND RELAYS ……………………………………………………………………… 328
BATTERIES ……………………………………………………………………………………. 331
BOOSTER BATTERIES …………………………………………………………………… 334
ALTERNATOR ………………………………………………………………………………… 335
STARTER MOTOR ………………………………………………………………………….. 335
ELECTRONIC CONTROL BOX ………………………………………………………… 336
TEMPERATURE SENDER ……………………………………………………………….. 338
BULBS …………………………………………………………………………………………… 338
REPLACING A BULB ………………………………………………………………………. 339
ADJUSTING THE UPPERSTRUCTURE HEADLIGHTS ……………………….. 346
STORAGE …………………………………………………………………………………. 347 – 349
STORING THE MACHINE ………………………………………………………………… 347
STORING THE HYDRAULIC BREAKER ……………………………………………. 349

IMAGES PREVIEW OF THE MANUAL:

CASE 788 “PLUS” & 788 COMPACT “PLUS” OPERATOR’S MANUAL 6-9290 – PDF DOWNLOAD:

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