Part of the Case Repair Manuals.
This is the factory service manual for the Case 788, 788 Plus, 988 and 988 Plus excavators, and one book covers both the crawler and the wheeled versions, which is rare and handy if you run mixed iron. Be clear on what it is: a composite binder built from separately numbered reference booklets tied together by a master contents sheet, so there is no single publication number - the cover reads 'Service Manual Cre 7-79415'. Inside you get engine removal and installation, the full electrical system with fault finding by circuit, undercarriage, drive train, both hydraulic sections with pressure setting procedures in bar, and cab work. Revision No. 1, issued 04-01, updates the electrical section and rides at the back.
What's Inside This Case 788, 788 Plus, 988, 988 Plus Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-64 | Machine Identification, Service Precautions, Standard Maintenance Intervals, Reference Booklet Numbering, Master Table of Contents |
| Engine Removal and Installation | 65-94 | Step-By-Step Engine Removal and Refitting for the 788 and 988, Lifting Points, Coupling and Hose Disconnection Order |
| Electrical System | 95-408 | Schematic Symbols, Electrical Cabinet Printed Circuit, Wiring by Circuit, Sensors and Senders, Instrument Panel, Fault Finding by Circuit |
| Undercarriage | 409-430 | Track Chain, Rollers, Idler and Recoil, Sprocket, Track Tension |
| Drive Train | 431-600 | Travel Motor and Reduction Gear, Swing Motor and Swing Reduction, Axles and Final Drives on the Wheeled Version |
| Undercarriage Hydraulics | 601-700 | Centre Swivel Joint, Travel Circuit, Track Motor Lines, Brake and Parking Circuits on the Wheeled Excavator |
| Upperstructure Hydraulics | 701-1010 | Main Pumps and Regulators, Control Valve Blocks, Boom, Arm and Bucket Circuits, Pilot Control, Pressure Setting and Testing Procedures |
| Upperstructure and Cab | 1011-1046 | Cab Removal, Glass Replacement, Counterweight, Covers and Guards, Operator Station Components |
| Revision No. 1 - Electrical System Update | 1047-1146 | Revised Electrical Section Issued 04-01, Updated Schematic Symbols, Standard and Optional Electrical Cabinet Printed Circuit Descriptions |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Attachment limiter pressure | 390 to 425 bar / 380 to 400 bar | p. 733 |
| Boom raising pressure | 390 to 420 bar / 410 to 440 bar | p. 733 |
| Maximum pump pressure in Max mode | under 125 bar / under 100 bar | p. 731 |
| Pilot circuit pressure in Max mode | over 34 bar | p. 731 |
| Load sensing valve pressure in Fine mode | 8 to 12 bar | p. 731 |
| Load sensing valve pressure difference M1 to M3 | 21 to 25 bar | p. 731 |
| Proportioning valve pressure, Auto and Low idle | 19.5 to 23.5 bar | p. 726 |
| Proportioning valve pressure, Max mode | 5.5 to 9.5 bar | p. 726 |
| Proportioning valve pressure, Auto idle | 23 to 27 bar | p. 728 |
| Proportioning valve pressure, Low idle | 26 to 30 bar | p. 728 |
| Rated power to SAE J1995 | 68.6 kW (93 hp) / 81 kW (110 hp) | p. 22 |
| Fuel tank capacity | 249 litres | p. 22 |
| Average fuel consumption | 10 L/h on the 788, 14.5 L/h on the 788 Plus | p. 22 |
| Engine displacement | 3920 cm3 / 5880 cm3 | p. 22 |
| Engine bore and stroke | 102 mm bore, 120 mm stroke | p. 22 |
Case 788, 788 Plus, 988, 988 Plus Common Problems This Manual Covers
Machine feels weak in the dig, or one function stalls before the others under load
Do not guess at the pumps. The Upperstructure Hydraulics section walks you through pressure setting and testing on the main pumps, regulators and control valve blocks, with limiter figures in bar listed per mode and per model. Check attachment limiter and boom raising pressure against the table before condemning a pump.
Manual Section: Upperstructure Hydraulics p. 731Work modes act wrong - MAX feels like LOW IDLE, or engine load does not match the selected mode
The proportioning valve figures change with mode: roughly 19.5 to 23.5 bar in AUTO and LOW idle against 5.5 to 9.5 bar in MAX on one model, and the manual gives the full per-mode table plus load sensing valve checks. The pressure testing procedures in Upperstructure Hydraulics tell you which port to gauge and what to expect in each mode, and the Multitester diagnostic function helps confirm what the cabinet is commanding.
Manual Section: Upperstructure Hydraulics p. 701Track thrown, sloppy tension, or the machine creeps to one side when travelling
The Undercarriage section covers track chain, rollers, idler and recoil unit, sprocket and correct track tension procedure. If tension is right and it still tracks crooked, move to Undercarriage Hydraulics for the travel circuit, track motor lines and the centre swivel joint, a common leak point that starves one side.
Manual Section: Undercarriage p. 431Intermittent electrical gremlins - gauges dropping out, senders reading wrong, dead circuits from the cabinet
Work the Electrical System section circuit by circuit: it gives the cabinet printed circuit layout, wiring by circuit, sensor and sender specs and a fault finding chart per circuit. Use the Revision No. 1 pages at the back first, since the 04-01 update supersedes the original schematics and covers both standard and optional cabinets.
Manual Section: Electrical System p. 95Frequently Asked Questions
Does this manual cover engine rebuilds on the 4T 390, 4TA 390 or 6T 590?
No, and the book says so itself. It covers engine removal and installation only - lifting points, coupling and hose disconnection order for the 788 and 988 - and its own contents page sends you to the separate Case engine service manual for internals. If you need pistons, liners or a head job, budget for that second book. p. 731
My machine is a wheeled 988. Is that version actually in here, or is this a crawler book?
Both versions are in the one binder. The Drive Train section covers axles and final drives on the wheeled machine alongside the travel and swing motors, and the Undercarriage Hydraulics section includes the brake and parking circuits specific to the wheeled excavator. Track chain, rollers, idler and recoil are there for the crawler. p. 65
Are the hydraulic pressure settings included, and how are they listed?
Yes, in the Upperstructure Hydraulics section, printed in bar because this is a European market book, and listed per work mode (AUTO, LOW IDLE, FINE, ECO, MAX) and per model - so check both before you touch a limiter. Examples straight from the tables: attachment limiter 390 to 425 bar on one model and 380 to 400 bar on another, boom raising 390 to 420 or 410 to 440 bar, pilot circuit over 34 bar in MAX. Test procedures with gauge points are included. p. 95
Can I trace electrical faults with this, given these machines have the electronic control cabinet?
Yes. The Electrical System section has the schematic symbols, the cabinet printed circuit descriptions, wiring broken out by circuit, sensors and senders, the instrument panel and fault finding by circuit. Bonus: Revision No. 1 at the back, issued 04-01, is a revised electrical section with updated symbols and both standard and optional cabinet printed circuits. p. 733
Which engine does my model have, so I can order the right engine manual?
788 runs the Case 4T 390 turbocharged 4 cylinder diesel, 788 Plus the 4TA 390, and both the 988 and 988 Plus the 6T 590 turbocharged 6 cylinder. Rated power to SAE J1995 is 68.6 kW (93 hp) or 81 kW (110 hp) depending on model, fuel tank is 249 litres. p. 1047
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