Part of the Case Repair Manuals.
Case 686G, 686GXR and 688G telescopic handlers all work from this 636-page factory service manual, form 7-16041, which follows the machine from the diesel engine out to the boom wear pads. This Case 686G, 688G service manual PDF pairs electrical and hydraulic schematics with troubleshooting charts for the engine, steering, brakes and boom, so you can trace a fault from the steering priority valve through to the tilt compensation cylinder. Nearly a quarter of the book goes to the T12000 powershift transmission, including clutch engagement and converter stall checks, and the Type 212 drive axle gets its own long section down to the planetary reduction and differential. Refill the transmission with 12.9 liters (13.6 quarts); run a 1/2 inch Grade 8 bolt to 110 to 132 pound-feet. A made-up torque figure lets go under load. Bookmarks and a live text layer let you pin down the right seal or bearing before calling the parts counter, so you order it once.
What's Inside This Case 686G, 686GXR, 688G Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 3-24 | Section Index - General, Standard Torque Specification, Fluids and Lubricants, Safety and General Information, Loctite Product Chart |
| Engine | 25-42 | Section Index - Engine, Diesel Engine Specifications, Engine and Transmission Removal and Installation, Engine Troubleshooting |
| Fuel System | 43-44 | Section Index - Fuel System |
| Electrical | 45-82 | Section Index - Electrical, Electrical System General, Electrical Schematics and Troubleshooting, Electrical Gauges and Senders, Alternator |
| Steering | 83-110 | Section Index - Steering, How It Works, Steering Specifications, Steering Troubleshooting, Steering Pump and Steering Column, Steering Selector Valve, Steering Priority Valve |
| Power Train | 111-134 | Section Index - Power Train, How It Works, Removal and Installation of Power Train Components, Transmission Specifications and Troubleshooting, Drive Axle |
| Brakes | 135-154 | Section Index - Brakes, How It Works, Brake System Specifications, Brake System Troubleshooting, Brake System Removal and Installation of Components |
| Hydraulics | 155-236 | Hydraulics How It Works, Hydraulic Specifications, Schematic and Troubleshooting, Removal and Installation of Hydraulic Components, Hydraulic Cylinders, Hydraulic and Fuel Tanks |
| Mounted Equipment and Chassis - Introduction and Specifications | 237-246 | Mounted Equipment, Chassis, Boom Assembly, Troubleshooting |
| Boom Components Removal and Installation | 247-268 | Crowd Cylinder, Carriage Tilt Cylinder, Tilt Compensation Cylinder, Boom Lift Cylinders, Retract Chain, Extend Chain, Wear Pads, Boom Sections |
| Electrical and Hydraulic Schematics | 269-272 | Electrical Schematics, Hydraulic Schematics |
| Drive Axle Type 212 | 273-388 | Maintenance, Lubrication, Braking Disks, Steering Case, U-Joint, Planetary Reduction, Steering Cylinder, Differential Unit |
| Troubleshooting and Optionals | 389-496 | Troubleshooting, Optionals, Hydraulic Negative Brake, Incoming Drum Brake, Limited Slip Differential, Hydraulic Differential Lock, Reduction Gear |
| T12000 Powershift Transmission | 497-636 | Transmission Assembly, Operation, Disassembly, Reassembly, Clutch Engagement, Converter Stall, Troubleshooting |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Grade 5 Bolts, Nuts, and Studs (1/4 inch) | 108 to 132 Pound-Inches | p. 6 |
| Grade 5 Bolts, Nuts, and Studs (1/2 inch) | 80 to 96 Pound-Feet | p. 6 |
| Cold Cranking Amperes | 1000 amperes | p. 51 |
| System Voltage | 12 volts, Negative ground | p. 57 |
| Transmission oil capacity | 12.9 liters (13.6 quarts) | p. 125 |
| Hydraulic Pump Filter replacement interval | 1000 hour | p. 189 |
| Hydraulic pump standby pressure | 550 psi | p. 191 |
| Hydraulic pump compensated pressure setting | 3045 psi | p. 191 |
| Dry weight of the fuel tank | 38 kg (85 lbs) | p. 235 |
| Dry weight of the hydraulic tank | 58 kg (128 lbs) | p. 235 |
| Transmission oil filter change interval | Every 1000 hours | p. 618 |
| Engine Oil Capacity with Filter Change | 11 litres (11.6 U.S. quarts) | p. 13 |
Case 686G, 686GXR, 688G Common Problems This Manual Covers
T12000 powershift transmission shows low clutch pressure, overheats, or lacks power when driving
Check transmission oil level before anything else; the unit holds 12.9 litres (13.6 quarts) per page 125. Change the transmission oil filter if it is past its 1000 hour interval noted on page 618. Then measure clutch pressure and charging pump output and compare readings against the transmission troubleshooting steps.
Manual Section: Transmission Troubleshooting p. 125Hydraulic cylinders move slowly or not at all, or movement is not smooth
Check the reservoir level and look for air in the system; refill capacity is 151 litres (160 U.S. quarts) per page 13. Replace the hydraulic pump filter if it has passed its 1000 hour interval on page 189. Test pump standby pressure against 550 psi and compensated pressure against 3045 psi, both listed on page 191.
Manual Section: Hydraulic System TroubleshootingBoom extension is jerky, boom will not extend or retract, or boom settles
Inspect the wear pads, extend chain, and retract chain following the boom component procedures starting on page 247. Check the crowd cylinder and boom lift cylinders before pulling boom sections. If you service the counterbalance cartridge valves, torque them into the manifold to 50 Nm (37 lb-ft) per page 211.
Manual Section: Boom Troubleshooting p. 247Frequently Asked Questions
What is the torque specification for the wheel lug nuts on the Case 686G telehandler?
The lug nut specification for the tires on the Case 686G, 686GXR, and 688G Series 2 telehandlers is 619 Nm (442 pound-feet). p. 91
How do you fix case 686G telehandler diesel engine will not start or is very difficult to start?
Check the starter and alternator using the electrical troubleshooting before you chase fuel. Verify the battery is rated at the 1000 cold cranking amperes listed on page 51 and that the system reads 12 volts, negative ground, per page 57. Then work through the no-start and hard-start checks on page 41 step by step. p. 41
How do you fix diesel engine overheating on the job or showing low oil pressure and excessive noise?
Check coolant and oil levels first. When refilling, the cooling system takes 18.9 litres (20.0 U.S. quarts), and an oil and filter change takes 11 litres (11.6 U.S. quarts), as listed on page 13. If temperature or pressure is still off, follow the overheating and low oil pressure checks on page 42. p. 42
How do you fix steering is hard to turn, wanders or drifts, or works on and off?
Check tire pressure first and set each tire to 448 kPa (65 psi) as listed on page 91. Test steering relief pressure and compare it to 14986 kPa, 150 bar (2175 psi). If pressure falls short, work through the steering troubleshooting checks for no steering, hard steering, and on and off steering.
What do I get after purchasing this Case 686G manual?
Straight to your device: 636 pages of searchable Service Manual, downloadable the moment payment goes through.
Are there any print restrictions on this Case 686G manual?
No restrictions at all. Print individual pages, full chapters, or the entire manual. The PDF is completely unlocked.
Is there a wiring diagram in this Case 686G Service Manual?
Yes. The 686G, 686GXR and 688G Series 2 electrical schematic is included on page 269, with wire colors and circuit descriptions for each system.
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