Part of the Case Repair Manuals.
All 272 pages of this Case 689G Service Manual (OEM #Bur 7-88730) zero in on one machine: the 689G Telescopic Handler, covering diesel engine, fuel system, electrical, steering, power train, brakes, hydraulics, and boom assembly from end to end. Inside, you get full electrical schematics with troubleshooting procedures, hydraulic schematics with fluid routing for the complete cylinder and valve circuit, exploded-view diagrams across the drive axle and power train components, and a dedicated troubleshooting section for steering, brakes, and hydraulics. Torque tables and general specifications run throughout, including the 4-cylinder, 4-litre engine rated at 80 kW (108 hp) with a 100 x 127 mm bore and stroke and an 8.5-litre oil capacity. Your machine is down. Stop chasing specs across forum threads and get the factory answer on the first try. Bookmarked and keyword-searchable, this PDF lets you jump straight to any system on your tablet before you touch a wrench.
What's Inside This Case 689G, 689G Telescopic Handler Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 5-26 | Section Index - General, Safety, General Information |
| Engine | 27-40 | Section Index-Engine, Diesel Engine, Engine and Transmission Removal and Installation |
| Fuel System | 41-46 | Section Index-Fuel System, Fuel System and Filters |
| Electrical | 47-64 | Section Index - Electrical, Electrical General Information, Electrical Schematics and Troubleshooting, Electrical Gauges and Senders |
| Steering | 65-106 | Section Index - Steering, How It Works, Steering Specifications, Steering Troubleshooting, Steering Pump and Steering Column, Steering Selector Valve, Steering Cylinders |
| Power Train | 107-144 | Section Index - Power Train, How It Works, Removal and Installation of Power Train Components, Transmission Specifications, Pressure Checks and Troubleshooting, Drive Axle |
| Brakes | 145-178 | Section Index - Brakes, How It Works, Brake System Checks, Adjustments and Specifications, Removal and Installation of Brake Components, Brake Troubleshooting, Parking Brake |
| Hydraulics | 179-220 | Section Index - Hydraulics, How It Works, Removal and Installation of Hydraulic Components, Hydraulic Troubleshooting, Checks/Adjustments and Specifications, Hydraulic Cylinders |
| Mounted Equipment and Chassis | 221-272 | Section Index - Mounted Equipment and Chassis, How It Works, Troubleshooting, Checks/Adjustments and Specifications, Removal and Installation of Boom Components, Removal of Hoods |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine Power Rating | 80 kW (108 hp) | p. 21 |
| Engine Cylinders | 4 | p. 21 |
| Engine Bore x Stroke | 100 x 127 mm | p. 21 |
| Engine Displacement | 4 litres | p. 21 |
| Engine Oil Capacity | 8.5 liters | p. 21 |
| Cooling System Capacity | 22.7 liters | p. 21 |
| Electrical System Voltage | 12 volts | p. 22 |
| Transmission Pump Capacity | 60.5 liters/min | p. 22 |
| Axle Gear Reduction (Total) | 19.31:1 | p. 22 |
Case 689G, 689G Telescopic Handler Common Problems This Manual Covers
Case 689G telescopic handler hydraulic cylinders move slowly or not at all, boom won't lift p. 179
Check hydraulic fluid level first. Inspect all lines and fittings for leaks. Verify the transmission pump is delivering at least 60.5 liters/min (64 qt/min). If pressure is low, inspect the relief valve setting and pump for wear. Review the hydraulic system section starting at page 179 for complete pressure specifications.
Manual Section: HydraulicsSteering pulls hard to one side, wheel requires excessive force to turn p. 65
Check hydraulic fluid level in the reservoir. Inspect steering lines for kinks or loose connections. Verify the steering selector valve moves freely, not stuck in one position. Test battery voltage: this machine runs a 12-volt system, and a weak battery will reduce steering pump output. Inspect the spool and sleeve in the control valve for wear or scoring.
Manual Section: SteeringBoom fails to extend or retract smoothly, operation is jerky under load p. 221
Check for air in the hydraulic system by slowly cycling the boom 3 to 5 complete strokes. Inspect the extend cylinder seals for bypassing. Verify hydraulic fluid is clean and at operating level. If the pump is noisy, confirm delivery matches the 60.5 liters/min (64 qt/min) specification before condemning cylinders or control valves.
Manual Section: Mounted Equipment and ChassisBrakes slow to apply, pedal pressure required is excessive in cold mornings p. 145
Inspect the accumulator: it must reach its high-pressure limit before braking is effective. Check that the 12-volt pressure switch is signaling correctly to start the charging pump. Verify all brake lines for leaks or blockage. If the accumulator starts charging but stalls short of the high limit, replace the pump. See the Brakes section at page 145.
Manual Section: BrakesGauge cluster shows erratic readings or dead gauges, temperature sender not responding p. 47
Check the 12-volt supply to the gauge cluster and inspect the wire harness plug for corrosion or disconnection. Test each sender with a multimeter: an open circuit or short indicates a defective sender. Clean all ground connections at the chassis. Replace any gauge showing resistance outside the normal operating range.
Manual Section: ElectricalDrive axle grinding noise when turning corners, oil seeping from planetary hubs p. 107
Drain and inspect axle housing oil for metal particles. Remove the planetary hub cover and check for worn ring or planet gears; total axle gear reduction should be 19.31:1 when assembled correctly. Inspect all axle seals and O-rings. Torque hub bolts to specification after reassembly. See the Power Train section at page 107.
Manual Section: Power TrainFrequently Asked Questions
How do you fix case 689G telescopic handler hydraulic cylinders move slowly or not at all, boom won't lift?
Check hydraulic fluid level first. Inspect all lines and fittings for leaks. Verify the transmission pump is delivering at least 60.5 liters/min (64 qt/min). If pressure is low, inspect the relief valve setting and pump for wear. Review the hydraulic system section starting at page 179 for complete pressure specifications.
How do you fix steering pulls hard to one side, wheel requires excessive force to turn?
Check hydraulic fluid level in the reservoir. Inspect steering lines for kinks or loose connections. Verify the steering selector valve moves freely, not stuck in one position. Test battery voltage: this machine runs a 12-volt system, and a weak battery will reduce steering pump output. Inspect the spool and sleeve in the control valve for wear or scoring.
How do you fix boom fails to extend or retract smoothly, operation is jerky under load?
Check for air in the hydraulic system by slowly cycling the boom 3 to 5 complete strokes. Inspect the extend cylinder seals for bypassing. Verify hydraulic fluid is clean and at operating level. If the pump is noisy, confirm delivery matches the 60.5 liters/min (64 qt/min) specification before condemning cylinders or control valves.
How do you fix brakes slow to apply, pedal pressure required is excessive in cold mornings?
Inspect the accumulator: it must reach its high-pressure limit before braking is effective. Check that the 12-volt pressure switch is signaling correctly to start the charging pump. Verify all brake lines for leaks or blockage. If the accumulator starts charging but stalls short of the high limit, replace the pump. See the Brakes section at page 145.
Is this Service Manual a digital download?
Instant PDF download. You get the full 272-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Are there any print restrictions on this Case 689G, 689G Telescopic Handler?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
Can I find hydraulic circuit diagrams in this Case 689G, 689G Telescopic?
Yes, this Case 689G, 689G Telescopic Handler Service Manual includes hydraulic system diagrams, circuit schematics, and component specifications.
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