LeeBoy 685D Operation, Service And Parts Manual

Operations, Service, and Parts Manual

LEEBOY 685D MOTOR GRADER

Manual No. 1020287-01

This manual applies to

Serial Number 183712

and above.

Thumb Index

Safety

Information and Specifications

Component Location

Operation

1

2

3

4

Maintenance

Schematics

Illustrated Parts List (IPL)

5

6

7

Legal Notices

iv

LeeBoy 685D Motor Grader

TABLE OF CONTENTS

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Machine Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hot Material Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hydraulic Systems Precautions . . . . . . . . . . . . . . . . . . . 1-7

Refueling Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . 1-8

Parking Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Poor Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Snow Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Storage Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . 1-9

Tire Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Decal Installation (Sticker Type) . . . . . . . . . . . . . . . . . . . 1-12

Decal Installation (Top Protected) . . . . . . . . . . . . . . . . . . 1-12

Cab Option Safety Decals . . . . . . . . . . . . . . . . . . . . . . 1-12

Information and Specications . . . . . . . . . . . . . . . . . . . . . . . . 2-1

One Year Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Specication Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Torque Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Standard Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . 2-7

Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Determining Proper Torque . . . . . . . . . . . . . . . . . . . . . 2-9

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Table of Contents

Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Operator Station . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Hydrostatic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Scarier (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Standard Equipment/Options . . . . . . . . . . . . . . . . . . . . 3-5

Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Operator Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Steering Column Controls . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Main Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Heat and Air Conditioning (Cab Option) . . . . . . . . . . . . . . . . . . . 3-12

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Receiving the Machine . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Initial and Daily Inspection . . . . . . . . . . . . . . . . . . . . . . 4-3

Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Brake Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Emergency Stop Button . . . . . . . . . . . . . . . . . . . . . . . 4-5

Regeneration (REGEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Diesel Exhaust Fluid (DEF) After-Treatment System . . . . . . . . . 4-6

PV485 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Gauge Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Main Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

System Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

User Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Tier 4F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Regen Request . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Driving the Grader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Regen Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Adjust Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Adjust Steering Console . . . . . . . . . . . . . . . . . . . . . . . 4-18

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2-Speed High/Low . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Axle Travel/Work . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Directional Control . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Articulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Front Wheel Lean . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Motor Grader Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Moldboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Circle Turn Cushion Valve . . . . . . . . . . . . . . . . . . . . . . 4-24

Grader Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Mounting Front Attachments . . . . . . . . . . . . . . . . . . . . . 4-25

Operating Front Attachments . . . . . . . . . . . . . . . . . . . .4-26

Front Blade Float. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Scariers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Operating a Scarier . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Replacing Scarier Teeth . . . . . . . . . . . . . . . . . . . . . .4-28

Operating Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Grading Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Grading Around Objects . . . . . . . . . . . . . . . . . . . . . . . 4-30

Spreading and Leveling . . . . . . . . . . . . . . . . . . . . . . . 4-31

Slope Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Grading an “S” Curve Shoulder . . . . . . . . . . . . . . . . . . . .4-33

Road Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Gravel and Dirt Roads . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Crowning the Road . . . . . . . . . . . . . . . . . . . . . . . . .4-35

Ditch Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Cul-De-Sacs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37

Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Tie-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39

Cab Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39

Sliding Moldboard . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

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Circle Side Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Secondary Steering . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

All-Wheel Drive (AWD) . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Cold Weather Engine Package . . . . . . . . . . . . . . . . . . . . 4-41

Reverse Camera System . . . . . . . . . . . . . . . . . . . . . . . 4-41

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Prepare for Maintenance . . . . . . . . . . . . . . . . . . . . . . . 5-4

10-Hour or Daily Routine Maintenance . . . . . . . . . . . . . . . . 5-4

50-Hour Routine Maintenance . . . . . . . . . . . . . . . . . . . . 5-4

100-Hour or Monthly Routine Maintenance . . . . . . . . . . . . . . 5-5

250-Hour or Quarterly Routine Maintenance . . . . . . . . . . . . . 5-5

500-Hour or Semi-Annual Routine Maintenance . . . . . . . . . . . 5-5

1000-Hour or Annual Routine Maintenance . . . . . . . . . . . . . . 5-5

2000-Hour or Every Two Years Maintenance . . . . . . . . . . . . 5-5

3000-Hour or Every Three Years Maintenance . . . . . . . . . . . . 5-5

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Grease Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Axle Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Breathers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Planetary Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

Machine Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

Moldboard Blade . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

Drawbar Ball and Socket . . . . . . . . . . . . . . . . . . . . . . . 5-11

Toe-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Park Brake (Rear Bogie Axle) . . . . . . . . . . . . . . . . . . . .5-12

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

Change Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . 5-13

Engine Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Radiator Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Selective Catalytic Reduction (SCR) System . . . . . . . . . . . . . 5-16

DEF Tank Filter . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

DEF Dosing Unit Filter . . . . . . . . . . . . . . . . . . . . . . . . 5-19

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Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Fuel Water Separator . . . . . . . . . . . . . . . . . . . . . . . .5-20

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Battery Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Alternator Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Fuse Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25

Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . .5-25

Change Hydraulic Oil and Filter . . . . . . . . . . . . . . . . . . .5-26

Change Hydraulic Oil Cap Strainer . . . . . . . . . . . . . . . . . . 5-27

Hydraulic Pump and Motor . . . . . . . . . . . . . . . . . . . . . . 5-27

Hydraulic Test Ports . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Repack Front Wheel Bearings . . . . . . . . . . . . . . . . . . . . 5-30

Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Radiator Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

Moldboard Blade . . . . . . . . . . . . . . . . . . . . . . . . . .5-33

Side-Cut Edges . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Moldboard Slide Cylinder . . . . . . . . . . . . . . . . . . . . . .5-34

Moldboard Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . 5-35

Moldboard Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . 5-36

Moldboard Angle Cylinder . . . . . . . . . . . . . . . . . . . . . . 5-37

Articulate Cylinders . . . . . . . . . . . . . . . . . . . . . . . . .5-37

Wheel Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . 5-38

Wheel Lean Cylinder . . . . . . . . . . . . . . . . . . . . . . . . .5-39

Scarier Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

Welding on Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

Front Blade Lift Cylinder (Option) . . . . . . . . . . . . . . . . . . . 5-40

Winterizing for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Periodic Maintenance in Storage . . . . . . . . . . . . . . . . . . . 5-42

Removing from Storage . . . . . . . . . . . . . . . . . . . . . . . 5-42

Hydraulic Motor Start-Up . . . . . . . . . . . . . . . . . . . . . . . 5-43

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Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

PV485 Diagnostic Trouble Code (DTC) Chart . . . . . . . . . . . . . . . . 5-51

PV485 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 5-56

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Electrical Schematic (1 of 9) . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Electrical Schematic (2 of 9) . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Electrical Schematic (3 of 9) . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Electrical Schematic (4 of 9) . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Electrical Schematic (5 of 9) . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Electrical Schematic (6 of 9) . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Electrical Schematic (7 of 9) . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Electrical Schematic (8 of 9) . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Electrical Schematic (9 of 9) . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Rear Harness (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Rear Harness (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Front Harness (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Front Harness (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27

Cab Harness (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Cab Harness (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Engine Harness (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Engine Harness (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

Steering Console Harness (1 of 2) . . . . . . . . . . . . . . . . . . . . .6-37

Steering Console Harness (2 of 2) . . . . . . . . . . . . . . . . . . . . . 6-39

Control Panel (1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

Control Panel (2 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43

Control Panel (3 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Control Panel (4 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

Control Panel (5 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49

Hydraulic Schematic (1 of 5) . . . . . . . . . . . . . . . . . . . . . . . .6-51

Hydraulic Schematic (2 of 5) . . . . . . . . . . . . . . . . . . . . . . . . 6-53

Hydraulic Schematic (3 of 5) . . . . . . . . . . . . . . . . . . . . . . . . 6-55

Hydraulic Schematic (4 of 5) . . . . . . . . . . . . . . . . . . . . . . . . 6-57

Hydraulic Schematic (5 of 5) . . . . . . . . . . . . . . . . . . . . . . . . 6-59

Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Boom Articulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

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Boom Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Rear Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Front Axle Assembly, 2WD (1 of 3) . . . . . . . . . . . . . . . . . . . . .7-10

Front Axle Assembly, 2WD (2 of 3) . . . . . . . . . . . . . . . . . . . . . 7-12

Front Axle Assembly, 2WD (3 of 3) . . . . . . . . . . . . . . . . . . . . . 7-14

OPTION-Front Axle Assembly, AWD (1 of 3) . . . . . . . . . . . . . . . . . 7-16

OPTION-Front Axle Assembly, AWD (2 of 3) . . . . . . . . . . . . . . . . 7-18

OPTION-Front Axle Assembly, AWD (3 of 3) . . . . . . . . . . . . . . . .7-20

MoldboardTurntable Assembly, 11 Ft/12 Ft (1 of 4) . . . . . . . . . . . . . . 7-22

Moldboard Turntable Assembly, 11 Ft/12 Ft (2 of 4). . . . . . . . . . . . . . 7-24

Moldboard Turntable Assembly, 11 Ft/12 Ft (3 of 4) . . . . . . . . . . . . .7-26

Moldboard Turntable Assembly, 11 Ft/12 Ft (4 of 4) . . . . . . . . . . . . .7-28

Canopy Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Cab Assembly - Exterior (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . 7-32

Cab Assembly - Exterior (2 of 2) . . . . . . . . . . . . . . . . . . . . . .7-34

Cab Assembly - Interior . . . . . . . . . . . . . . . . . . . . . . . . . .7-36

Cab Assembly - AIr Conditioning (1 of 2) . . . . . . . . . . . . . . . . . . . 7-38

Cab Assembly - AIr Conditioning (2 of 2) . . . . . . . . . . . . . . . . . .7-40

Canopy/Cab Details - Seat . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

Canopy/Cab Details - Interior . . . . . . . . . . . . . . . . . . . . . . . . 7-44

Controls - 10 Station (1 of 3) . . . . . . . . . . . . . . . . . . . . . . . .7-46

Controls - 10 Station (2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . 7-48

Controls - 10 Station (3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . 7-50

Controls - Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

Controls - Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

Hydraulics - Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56

Hydraulics - Tanks (Cont.) . . . . . . . . . . . . . . . . . . . . . . . . .7-58

Hydraulics - 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

Hydraulics - Brake, 2WD/AWD . . . . . . . . . . . . . . . . . . . . . . . 7-62

Hydraulics - Valve Bank, 2WD/AWD . . . . . . . . . . . . . . . . . . . . . 7-64

Hydraulics - Pumps, 2WD . . . . . . . . . . . . . . . . . . . . . . . . .7-66

Hydraulics - Pumps, AWD . . . . . . . . . . . . . . . . . . . . . . . . .7-68

Hydraulics - Pumps, AWD (Cont.) . . . . . . . . . . . . . . . . . . . . . . 7-70

Engine - Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72

Engine - Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-74

Engine - Intake/Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . .7-76

LeeBoy 685D Motor Grader

xi

Table of Contents

Engine - Components . . . . . . . . . . . . . . . . . . . . . . . . . . .7-78

Engine - DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80

Engine - Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82

Engine - Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84

Frame Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-86

OPTION - Dozer Blade/Blade Scarier . . . . . . . . . . . . . . . . . . . 7-88

OPTION - Dozer Blade/Blade Scarier (Cont.) . . . . . . . . . . . . . . .7-90

OPTION - Front Scarier . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92

OPTION - Rear Scarier . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94

OPTION - Rear Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . .7-96

OPTION - Cold Weather Start . . . . . . . . . . . . . . . . . . . . . . .7-98

OPTION - Dead Engine Steering . . . . . . . . . . . . . . . . . . . . . .7-100

OPTION - Stereo w/Antenna . . . . . . . . . . . . . . . . . . . . . . . .7-102

Hydraulic Hose Index . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-104

Decal Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-110

Alphabetical Parts Index . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112

LeeBoy 685D Motor Graderxii

Introduction

Thank you for purchasing the LeeBoy 685D Motor

Grader. We wish you many years of safe and efcient

operation of your LeeBoy product.

READ THIS MANUAL PRIOR TO OPERATING the ma­chine. It is an important part of the machine and should
be kept with in the dedicated storage container provided
at all times. Though you may be familiar with similar
equipment, you MUST read and understand this manual
before operating the machine to help prevent injury or
damage.

This manual is intended as a guide for the safe and

efcient use of your machine, including procedures for

proper operation and maintenance. Use it with all relat­ed supplemental books, engine, transmission manuals,
and any other manuals supplied by other manufactur­ers. Related Service Bulletins should also be reviewed
to provide information regarding some of the recent
changes. If any questions arise concerning this publi­cation or to order a replacement manual, contact your
authorized LeeBoy dealer.

This manual contains information that was available
at the time of printing and is subject to change without
notice.

Section 1 - Safety: Contains general and specic

safety guidelines for product and safety label locations.

Section 2 - Information and Specications: Contains

warranty, contact information, machine specication

tables, and machine dimensions.

Section 3 - Component Location: Contains overview
of major component locations and functions.

Section 4 - Operation: Contains instructions for safe
operation and information for optional equipment.

Section 5 - Maintenance: Contains routine mainte­nance procedures, mechanical adjustments, com­ponent replacement and troubleshooting charts for

common problems and corrections. (For specic

engine maintenance procedures, refer to the engine
manufacturer manual.)

Section 6 - Schematics: Contains electrical and hy­draulic schematics for product functionality.

Section 7 - Illustrated Parts List (IPL): Contains parts
numbers and illustrations for serviceable components.

VT LeeBoy, Inc. is proud to be ISO 9001 certied. The International Standards

Organization (ISO) establishes guidelines to ensure that products and

services are safe, reliable and of good quality. ISO certies companies who

demonstrate compliance with all aspects of product safety, customer

satisfaction, efciency, environmental stewardship and social responsibility.

Our teams work hard to deliver quality industrial machines that exceed
customer expectations and we strive for continuous improvement in
everything we do. The VT LeeBoy family of companies is committed to
total quality management with a strong focus on meeting customer needs.

VT LeeBoy, Inc., is also proud to be an accredited ANAB manufacturer,

which is a certication process comprised of quality standards established

by the American National Standards Institute (ANSI) and the American
Society for Quality (ASQ). The ANSI-ASQ National Accreditation Board
plays an important role in ensuring the safety and quality of goods and
services, along with protecting the environment.

LeeBoy 685D Motor Grader

xiii

NOTES

LeeBoy 685D Motor Graderxiv

Section 1

SAFETY

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Machine Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hot Material Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-7

Hydraulic Systems Precautions . . . . . . . . . . . . . . . . . . . 1-7

Refueling Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . 1-8

Parking Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Poor Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1

Snow Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Storage Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . 1-9

Tire Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Decal Installation (Sticker Type) . . . . . . . . . . . . . . . . . . . 1-12

Decal Installation (Top Protected) . . . . . . . . . . . . . . . . . . 1-12

LeeBoy 685D Motor Grader

1-1

Safety

NOTES

LeeBoy 685D Motor Grader1-2

Safety

This manual provides important information to familiarize
you with safe operating and maintenance procedures.
Even though you may be familiar with similar equipment,
read and understand this manual before operating the
LeeBoy 685D Motor Grader and follow its instructions
when operating the machine.

Safety is everyone’s business and our top concern.
Knowing the guidelines covered in this section will help
ensure your safety, the safety of those around you, as
well as proper grader operation.

Keep safety labels in good condition. If safety labels
become missing or damaged, replace them with
new matching labels. Replacement safety labels are
available from your LeeBoy authorized dealer (see
contact information in Section 2).

You can nd more information about occupational health

and safety in the paving industry on the internet. A few
resources are listed below:

www.osha.gov

cdc.gov

www.asphaltpavement.org

LOOK FOR THESE SYMBOLS THROUGHOUT

THIS MANUAL. THESE ITEMS ARE EXTREMELY

IMPORTANT FOR THE SAFETY OF YOU AND

YOUR COWORKERS. READ AND UNDERSTAND

THOROUGHLY. HEED THE WARNINGS AND

FOLLOW THE INSTRUCTIONS.

1

Indicates a hazardous situation which,

if not avoided, will result in death or serious injury.

Indicates a hazardous situation which,

if not avoided, could result in death or serious injury.

Indicates a hazardous situation which,
if not avoided, could result in minor or moderate
injury.

Indicates a situation which can cause
damage to the equipment, personal property and/
or the environment, or cause the machine to operate
improperly.

www.safety.fhwa.dot.gov/

NOTE: Indicates a procedure, practice or condition

that should be followed in order for the
machine or component to function in the
manner intended.

LeeBoy 685D Motor Grader 1-3

Safety

Safety Precautions

The safety messages that follow have CAUTION level

hazards.

Pre-Operation Hazard

Read and understand this Operation Manual

before operating or servicing the engine to
ensure that safe operating practices and maintenance
procedures are followed.

• Never permit anyone to service or operate the

machine without proper training.

• Safety signs and labels are additional reminders for

safe operating and maintenance techniques.

• Contact LeeBoy or an authorized LeeBoy dealer for

additional training.

The safety messages that follow have DANGER level

hazards.

Power Lines Hazard

If your machine comes into contact with electric power
lines, observe the following:

• Stay in the operators seat.

• Warn other workers to stay away and do not touch any
control or any part of the machine.

• If contact can be broken, drive the machine away from
the danger zone.

• If contact cannot be broken, stay in the operators seat
until told that power is off.

• Failure to observe these directions could result in
electrocution or death.

• Make sure you are aware of all laws and regulations
that are in effect for the location in which the grader is
operated.

• Make sure you have all necessary licenses to operate
the grader.

• Never operate a unit in need of repair.

• Ensure all covers are installed.

Poor Lighting Hazard

The work area must be well lit to ensure safe and proper
operation.

• Ensure that the work area is adequately illuminated.

• Always install wire cages on portable safety lights.

Tool Hazard

Always use tools appropriate for the task
at hand and use the correct size tool for
loosening or tightening LeeBoy machine parts.

Electrocution Hazard

Disconnect the battery before welding anywhere on the
machine.

Suffocation Hazard

Carbon monoxide poisoning is a serious
condition that occurs as a result of improper
ventilation.

• Never operate the internal combustion engine on this
machine in an enclosed area with poor ventilation.
Ensure proper ventilation to reduce risk of carbon
monoxide poisoning or death.

Exhaust Hazard

All internal combustion engines create
carbon monoxide gas during operation and
special precautions are required to avoid
carbon monoxide poisoning:

• Never block windows, vents or other means of
ventilation.

• Always ensure that all connections are tightened to

specications after repair is made to the exhaust

system.

LeeBoy 685D Motor Grader1-4

The safety messages that follow have WARNING

level hazards.

Crush Hazard

Keep bystanders away from work area before and
during operation.

Safety

Fire and Explosion Hazard

• Diesel fuel is ammable and explosive under certain
conditions.

• Never use a shop rag to catch fuel.

• Wipe up all spills immediately.

• Never refuel with the engine running.

• Store any containers containing fuel in a well­ventilated area, away from any combustibles or
sources of ignition.

1

Modification Hazard

Never modify the LeeBoy machine without the written

consent of LeeBoy. Any modication can affect the safe

operation of the grader and may cause personal injury
or death.

Exposure Hazard

Operators of the grader must be aware of
their work environment and the equipment
needed to work safely.

• Always wear personal protective equipment, including
appropriate clothing, gloves, work shoes, and
protection for eyes and ears, as required by the task
at hand.

Explosion Hazard

While the engine is running or the battery is
charging, hydrogen gas is being produced
and can be easily ignited. Keep the area
around the battery well-ventilated and keep

sparks, open ame, and any other form of

ignition out of the area.

• Always disconnect the negative (-) battery cable
before servicing the grader.

• Do not start the engine by shorting the starter circuit
or any other starting method not stated in this manual.
Only use the starting procedure as described in this
manual to start the engine.

• Never charge a frozen battery. Always slowly warm the
battery to room temperature before charging.

Fire Hazard

When operating machinery there is a risk for

re. Always have appropriate safety

equipment available.

• Keep a charged re extinguisher within reach when

working in an environment where a re may occur.

• Have all re extinguishers checked periodically for
proper operation and/or readiness.

• Always read and follow safety-related precautions
found on containers of hazardous substances
like parts cleaners, primers, sealants and sealant
removers.

• Undersized wiring systems can cause electrical res.

Entanglement/Sever Hazard

Verify there are no people, obstacles or
other equipment near the machine before
starting the engine. Sound the horn as a
warning before starting the engine.

If the engine must be serviced while it is
operating, remove all jewelry and tie back
long hair before operating or servicing the
machine.

• Keep hands, other body parts, and clothing away from
moving/rotating parts.

• Always stop the engine before beginning service.
Before maintenance, remove negative battery cable
from battery post to ensure vehicle is not operated
during maintenance.

• Verify that all guards and covers are properly attached
before starting the engine. Do not start the engine if
any guards or covers are not properly installed on the
grader.

LeeBoy 685D Motor Grader 1-5

Safety

• If you must run the engine during maintenance
procedures, make sure you have a helper to keep
bystanders clear of the grader and make observations
of moving parts as requested by the operator.

• Always turn the start switch to the OFF position after
operation is complete and remove the key from the
switch. Keep the key in your possession when the
grader is not operating.

• Attach a “Do Not Operate” tag near the key switch
while performing maintenance on the equipment.

• Never operate the engine while wearing a headset to

listen to a radio or music because it will be difcult to

hear the warning signals.

• Always start the engine and operate the controls while
seated in the operators seat.

Alcohol and Drug Hazard

Never operate the machine while under the

inuence of alcohol, drugs, or when ill.

Piercing Hazard

High-pressure hydraulic uid or fuel can

penetrate your skin and result in serious
injury. Avoid skin contact with high-pressure

hydraulic uid or diesel fuel spray caused by

a hydraulic or fuel system leak such as a
broken hydraulic hose, fuel injection or high-pressure,
common-rail engine line.

Flying Object Hazard

Always wear eye protection when cleaning
the machine with compressed air or high­pressure water.

Dust, ying debris, compressed air,

pressurized water or steam may cause eye
injury.

Coolant Hazard

Coolant must be handled properly to ensure
operator safety.

• Wear eye protection and rubber gloves when handling
engine coolant.

• If contact with the eyes occurs, ush eyes with clean
water for 15 minutes.

• If contact with skin occurs, wash immediately with
soap and clean water.

Burn Hazard

Some of the machine’s surfaces become
very hot during operation and shortly after
shutdown.

• Keep hands and other body parts away from hot
machine surfaces.

• Handle hot components with heat-resistant gloves.

If you are exposed to high-pressure hydraulic uid or

fuel spray, obtain prompt medical treatment.

• Never check for a hydraulic uid or fuel leak with your
hands. Always use a piece of wood or cardboard.
Have your authorized LeeBoy dealer or distributor
repair the damaged parts.

LeeBoy 685D Motor Grader1-6

Machine Precautions

Safety

The safety messages that follow have NOTICE level

hazards.

• Any part that is found defective as a result of
inspection or any part whose measured value does
not satisfy the standard or limit must be replaced.

• Always tighten components to the specied torque.
Loose parts can cause damage to the machine or
cause it to operate improperly.

• Only use replacement parts approved by VT LeeBoy.
Other replacement parts may affect warranty
coverage.

Follow the guidelines of the EPA or other
governmental agencies for the proper
disposal of hazardous materials such as
oils, diesel fuel, coolant, etc. Consult the
local authorities or reclamation facility.

• Dispose of hazardous materials in accordance with
all applicable laws and regulations. Never dispose of
hazardous materials by dumping them into a sewer, on
the ground, or into groundwater or waterways.

• Clean all accumulated dirt and debris away from the
body of the grader and its components before you
inspect the grader or perform preventive maintenance
procedures or repairs. Operating a grader with
accumulated dirt and debris will cause premature
wear of grader components. Accumulated dirt and
debris also hinders effective grader inspection.

• Retrieve any tools or parts that may have dropped
inside of the grader to avoid improper grader
operation.

• If any alert indicator illuminates during grader
operation, stop the engine immediately. Determine
the cause and repair the problem before continuing to
operate the grader.

Hot Material Precautions

• Wear protective gear for face, hands, feet, and body
when operating the grader.

• Allow machine to cool before repairing or maintaining
working components.

• If hot asphalt touches skin, ush area immediately with
cold water. DO NOT apply ice to the affected area.
DO NOT ATTEMPT TO REMOVE ASPHALT CEMENT
with products containing solvents or ammonia.
Natural separation will occur in about 48 to 72 hours.
Get medical attention as soon as possible.

• DO NOT remove radiator cap, drain plugs, service

grease ttings, or pressure taps while engine is hot.

Add coolant to the radiator and perform other services
only when the engine is stopped and fully cooled.

• Ensure the machine is properly equipped for

emergencies, i.e., re extinguisher, rst aid kit, etc.

Hydraulic Systems Precautions

• Ensure all components are in good working condition.

Replace any worn, cut, abraded, attened or crimped

hoses and metal lines.

• DO NOT attempt makeshift repairs using tape, clamps
or cements. The hydraulic system operates under
extremely high pressure and such repairs could
cause serious injury.

• Wear proper hand and eye protection when checking
for a high pressure leak. Use a piece of wood or
cardboard as a back stop to isolate and identify leaks.

Hydraulic oil under pressure can
cause serious personal injury. Check for oil leaks
with a piece of cardboard. DO NOT expose hands to
possible high-pressure oil. Turn off engine before

attempting to tighten oil lines and ttings.

1

LeeBoy 685D Motor Grader 1-7

• Escaping pressurized hydraulic uid has force

sufcient to penetrate the skin, which could cause

serious personal injury. Ensure all pressure is
relieved before disconnecting line, hoses or valves.

• If injury from concentrated high pressure steam

or hydraulic uid occurs, seek medical attention
immediately. Injuries resulting from hydraulic uid

penetrating the skin’s surface can result in serious
infections or toxic reactions.

Safety

Refueling Precautions

• Do NOT overll the fuel tank as overow creates a re
hazard when spilled on hot components.

• DO NOT smoke when refueling and never refuel when

the engine is running. Fuel is highly ammable and

should be handled with care. Death or serious injury

can occur due to explosion and/or re.

• DO NOT ll tank to capacity. Allow room for expansion
to reduce the risk of fuel expanding and spilling from
the tank.

• Tighten fuel cap securely. Should fuel cap be lost,
replace it with an original manufacturer’s approved
cap. Pressurization of the tank may result from use of
non-approved cap.

• Prevent res by keeping the machine clean of
accumulated debris, grease, and spilled fuel.

• Use ultra-low sulfur diesel fuel (ULSD) only.

Battery Precautions

• Keep all sparks and ames away from batteries, as
gas given off by electrolytes is explosive.

• Acid propelled by an explosion can cause blindness
if it comes in contact with eyes. Always wear safety
glasses when working near batteries.

• If you come in contact with battery electrolyte solution,
wash off immediately. Chemicals can cause burns.

• Always disconnect the battery ground cable before
working on the electrical system to avoid injury from
spark or short circuit. Electrical shock and burns can
occur.

• To avoid electrolyte loss, DO NOT tip batteries more
than 45 degrees.

Starting and Stopping
Precautions

• Check all around the grader to make sure there are
no people working on the machine or in the path of the
machine before starting. DO NOT start until area is
clear. Death or serious injury can occur to bystanders
from being crushed under a moving machine.

• Check brakes, steering and other control devices in
accordance with instructions before starting. Be sure
the engine is in neutral with the park brake engaged.

• DO NOT bypass the grader neutral-start system.

• Be aware of job site conditions and terrain. Adjust
your speed if operating in rough or hilly conditions.

DO NOT operate the engine in an
enclosed area without proper ventilation. Exhaust
gasses are odorless and deadly.

Parking Precautions

• Park grader on level ground whenever possible.

Apply the parking brake. Park the grader with wheels
securely blocked on grades.

• ALWAYS lower the moldboard and any attachments (if

equipped) to the ground.

• Remove ignition key when leaving grader parked or

unattended.

Operating Precautions

• Always comply with local regulations regarding

moving equipment on public roads and highways.

• Know and use the hand signals required for a

particular job. Know who has the responsibility for
signaling.

• Make sure that all lights and reectors comply with

state and local regulations. Make sure that they are
clean, in good working order, and can be seen clearly

by all trafc.

• DO NOT ride on attachments. or allow riders in or on

the grader.

• Check all gauges and warning instruments for proper

operation. If malfunctions are found, shut down the
machine and report the problem for resolution. If
the failure causes loss of steering control, loss of
brake control, or loss of engine power, stop grader
motion as quickly as possible. Apply parking brake (if
equipped). Keep the machine securely parked until
the failure is corrected or the machine can be safely
towed.

• Adjust seat and fasten the seatbelt before driving the

grader. The seat belt must t snug with the holding

strap free of slack.

• Drive the machine with care. Make sure speed is

compatible with conditions. Use caution on rough
ground, slopes, and while turning.

LeeBoy 685D Motor Grader1-8

Safety

• Be alert for hazards and obstructions such as ditches,
trees, cliffs, overhead power lines, and areas where
there is danger of a slide.

• Be aware of and understand the job site trafc ow
patterns.

• Obey agmen, road signs, and signals.

• Watch for bystanders. Never allow anyone near the
machine during operation. Never allow anyone to
reach into the machine during use.

• Operator must know how to use signaling devices
when driving the grader. Operator must also
understand which circumstances require use of each
signal. Use tail lights, slow moving vehicle signs, and
warning beacon as needed when traveling on public
roads. It is recommended that you provide an escort
on the road.

• DO NOT tow the grader, except to remove from road
or to load on trailer.

• When moving the machine, adjust speed and direction
of travel for the terrain and ground conditions present.
Always consider adjusting travel speed to match
ground conditions.

• DO NOT stop or turn the grader around on curves
or at the crest of hills. Use extra care when grading

against oncoming trafc.

Snow Removal

• Keep windshield and other windows clean and clear,
using defroster and wipers when needed.

• Use the proper attachment(s) before plowing snow.
Additional equipment may also be needed, i.e., tire
chains, additional warning beacon and/or work lights
and other warning markers.

• Snow removal presents unique hazards, including

slippery road surfaces, poor visibility and other trafc

issues. Be alert for any obstructions covered by snow
that may be hazardous and adjust operating speed
according to slippery conditions.

Storage Precautions

• Store grader in an area away from human activity.

• DO NOT permit children to play on or around the
stored machine. Serious injury or death can occur
from improper/unauthorized use of the machine.

• Make sure the unit is stored on a surface that is rm,
level, and free of debris.

• Store the machine inside a building or cover securely
with a weatherproof tarpaulin.

1

Poor Visibility

Increasingly, road construction equipment is used
during less than ideal lighting conditions such as fog
and smog or at night. These conditions present safety

hazards for workers, bystanders and passing trafc.

When operating under restricted light
conditions, equip the machine with special lighting to
prevent serious injury.

• While the machine is equipped with a beacon and a

work light, contact your authorized LeeBoy dealer for
additional lighting packages if working under these
conditions.

• Use reective tape on the sides of machines when

working at night. Ensure all workers wear reective

safety vests. Use impact barriers (movable or

stationary) to protect workers and direct the trafc
ow safely away from the work site.

Maintenance Precautions

• DO NOT attempt repairs unless trained to do so.
Refer to manuals and experienced repair personnel
for help.

• Before working on the machine, securely block the
machine and any components that may fall. Block
any working components to prevent unexpected
movement while repairs are being made.

• Always wear safety glasses and other required safety
equipment when servicing or making repairs.

• Avoid lubrication or mechanical adjustments while the
grader is in motion or while engine is operating.

• Never make repairs on pressurized components such

as uid lines, the gas system, or mechanical items until

the pressure has been relieved.

• When servicing or replacing hardened pins, use a
brass drift or other suitable material between the
hammer and pin.

• Keep brake and steering systems in good operating
condition.

LeeBoy 685D Motor Grader 1-9

Safety

Tire Precautions

DO NOT mount or demount tires
without proper training. A violent explosion can
occur.

Follow all procedures and safety instructions. Charts
containing mounting and demounting instructions are
available from OSHA at www.osha.gov/pls/publications.

Contact your authorized dealer or

a qualied tire dealer or repair service to perform

required tire maintenance.

• Clean rims and repaint to stop corrosion and

facilitate checking air level and tire mounting. Be
careful to clean all dirt and rust from the lock ring
and gutter. This is important to secure lock ring in its
the proper position.

• Check rim components periodically for cracks.

Replace all cracked, badly worn, severely rusted,
and otherwise damaged components with new parts
of the same size and type. If you are not sure about
proper mating of tire and wheel parts, consult your
authorized dealer or a wheel and rim expert.

DO NOT attempt to rework, weld,

heat or braze any rim components that are cracked,
broken or damaged. Replace damaged components
with new parts of the same size and type. Mixing
parts of one type with those of another is potentially
dangerous.

DO NOT reinate a tire that has been
run at without rst inspecting the tire, tube, ap, rim,

and wheel assembly. Double-check the side ring and
O-ring for damage, ensuring they are secured in the

gutter before ination.

Mismatched rim parts are dangerous
and could cause SEVERE injury.

• Remove valve core to exhaust all air from tire.

ALWAYS exhaust all air from tire prior to removing
rim components or wheel components such as nuts
or rim clamps. Check the valve stem by running a
piece of wire through the stem to make sure it is not
plugged.

• DO NOT try to seat rings or other components by

hammering unless tire is fully deated. Double­check all components prior to ination.

• DO NOT inate a tire before all components are
properly in place. Recheck components for proper

assembly. If improperly assembled, deate and

correct.

• Never hammer on a tire/rim assembly that is not fully

deated. If assembly is proper at 10 psi (68,947.572
Pa), continue to inate to fully seat the tire beads.
Then completely deate the tire to prevent overly
stretching the tube. Reinate to recommended

operating pressure.

• NEVER sit on or stand in front of a tire/rim assembly

during ination. Use a clip-on chuck and make sure
ination hose is long enough permit the person
inating the tire to stand to the side of the tire.

• DO NOT hammer components with steel hammers.
Use rubber, lead, plastic, or brass-faced mallets to
tap components together.

• DO NOT try to drive an assembled or partially­assembled tire or rim over a cast spoke wheel by
hammering. DEFLATE and examine to determine

the reason for the improper t. Look for distortion or

components that are not properly locked or sealed.

• Block the tire and wheel on opposite sides of the
vehicle before you place the jack in position. Always
put hardwood blocks under the jack and crib up the
vehicle in case the jack slips.

• DO NOT inate tires beyond the maximum

recommended ination pressure.

• NEVER operate a vehicle on a single tire of a dual
assembly. The carrying capacity of the single tire
and rim is dangerously exceeded and operating a
vehicle in this manner can result in damage to the
rim and tire.

• DO NOT attempt to demount a tire unless you have
the proper equipment and experience to do the job.

LeeBoy 685D Motor Grader1-10

Safety Decals

Safety

If your machine is repainted, it is extremely important
that you replace all the CAUTION, WARNING and
DANGER safety decals in the proper locations. (Figure

1-1) For additional help, refer to the parts listing in
Section 7 and contact your authorized LeeBoy dealer to

order a replacement kit.

NOTE: It is the responsibility of the owner and
operator to make sure that all safety labels are
readable and located on the grader as designated
by LeeBoy.

1

(Both Sides)

(Console)

(Both Sides)

Figure 1-1. Safety Labels and Safety Label Locations

(Both Sides and

Inside Engine Panel)

LeeBoy 685D Motor Grader 1-11

Safety

Cab Option Safety Decals

(Panel Under Seat)

Figure 1-2. Cab Option Additional Safety Decals

Safety Decals Care

1. Keep safety decals and signs clean and legible at all

times.

2. Become familiar with the content and the position

of each safety decal. Decals include important
information.

3. Replace decals and signs that are missing or become

impossible to read.

4. When replacing parts that display a safety decal,

ensure that the new part is tted with a decal as well.

5. Obtain replacement safety decals or signs from your

authorized LeeBoy dealer.

Decal Installation (Sticker Type)

1. Be sure that the installation area is clean and dry. Use

hot, soapy water to clean the surface where the decal
will be applied.

2. Thoroughly dry the surface.

3. Measure and t decal before removing the paper

backing.

4. For decals with no top protection paper, remove the

smallest split-backed paper.

5. Align decal over the specied area and carefully press
exposed portion into place.

6. Slowly remove the remaining backing and carefully
smooth the remaining portion of the decal into place.

7. Small air pockets can be pierced with a pin and
smoothed using a piece of the decal backing.

Decal Installation (Top
Protected)

1. If the decal has a protective top paper, use hot soapy
water on the surface where the decal will be applied.
Leave wet.

2. Determine the proper location, remove protective back
paper and soak decal in clean soapy water before
application. This will help to alleviate air bubbles in the
applied decal.

3. Smooth decal into place with a squeegee and check
for air bubbles.

4. Small air pockets can be pierced with a pin and
smoothed out using a piece of the decal backing.

5. When decal is completely smoothed, carefully remove
top paper.

LeeBoy 685D Motor Grader1-12

Section 2

INFORMATION AND SPECIFICATIONS

Page

Limited Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Specication Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Torque Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Standard Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . 2-8

Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Determining Proper Torque . . . . . . . . . . . . . . . . . . . . . 2-10

2-1LeeBoy 685D Motor Grader

Information and Specications

ONE YEAR LIMITED WARRANTY

Limited Warranty

If a manufacturing defect in factory supplied materials or factory
workmanship is found and the authorized LeeBoy dealer (“Dealer”)

is notied during the warranty period, LeeBoy will be responsible for

repairing or replacing any part or component of the unit or part that
fails to conform to the warranty during the warranty period.

Terms and Conditions

The warranty applies for a period of one year (for unlimited hours of
usage on the unit during the one year), beginning on the date that
the Dealer from which the unit is purchased submits the warranty
registration form to LeeBoy (typically on the date of purchase).

The warranty is not transferable and applies only to the original
purchaser of a new unit from a Dealer.

Warranty work must be performed at an authorized Dealer location.

LeeBoy has the right to repair any component or part before
replacing it with a new one.

Replacement parts furnished by LeeBoy are covered for the
remainder of the warranty period applicable to the unit or
component in which such parts are installed.

All new replacement parts purchased from a Dealer will carry a six
(6) month warranty.

Items Not Covered

LeeBoy is not responsible for the following:

• All used units or used parts of any kind.

• Repairs due to normal wear and tear or brought about by abuse
or lack of maintenance of the machine.

• Attachments not manufactured or installed by LeeBoy.

• Liability for incidental or consequential damages of any type

including, but not limited to, lost prots or expenses of acquiring

replacement equipment.

Exclusions and Limitations

VT LeeBoy has no obligation under this warranty for any defects or
failures caused by:

• Misuse, misapplication, negligence, accident or failure to maintain
or use in accordance with the most current operating instructions;

• Unauthorized alterations or modications;

• Any replacement parts or attachments not manufactured by or
expressly approved by LeeBoy;

• Failure to conduct normal maintenance and operating service,
including without limitation, providing lubricants, coolant, fuel, tune­ups, inspections or adjustments; or

• Unreasonable delay, as determined by LeeBoy, in making the

applicable units or parts available upon notication of a service

notice ordered by LeeBoy.

LeeBoy is not responsible for any of the following:

• Defects or failures with respect to any engine or truck chassis;

• Defects or failures covered by a warranty provided by a third-party,
including without limitation warranties with respect to engines or
truck chassis;

• Costs related to travel time, mileage or overtime;

• Costs related to transporting the unit to and from the place at which
warranty work is performed;

• Airfreight charges related to transporting repair parts to the place at
which warranty work is performed;

• Used units or used parts of any kind;

• Repairs due to normal wear and tear, or brought about by abuse or
lack of maintenance of the equipment, except for premature failures;

• Attachments not manufactured or installed by LeeBoy; or

• Miscellaneous charges.

Exclusion of Other Warranties/Limitation of Liability

OTHER THAN THE EXPRESS WARRANTY PROVIDED IN SECTION A. ABOVE, LEEBOY GIVES NO EXPRESS, STATUTORY, OR

IMPLIED WARRANTY OR GUARANTEE AND HEREBY DISCLAIMS ALL SUCH WARRANTIES, INCLUDING WITHOUT LIMITATION

ANY IMPLIED WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, SUITABILITY, DURABILITY,

CONDITION, QUALITY, OR FREEDOM FROM CLAIMS OF ANY PERSON BY WAY OF INTERFERENCE, INFRINGEMENT, OR THE

IN NO EVENT OR UNDER ANY THEORY OF RECOVERY, WHETHER AS A RESULT OF BREACH OF CONTRACT OR WARRANTY,

ALLEGED NEGLIGENCE, OR LIABILITY WITHOUT FAULT, SHALL LEEBOY BE LIABLE FOR ANY SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES ARISING OUT OF THE SALE, USE, OR LOSS OF USE OF ANY PRODUCT, INCLUDING WITHOUT

LIMITATION LOST PROFITS OR REVENUES, COST OF CAPITAL, COST OF SUBSTITUTED EQUIPMENT, FACILITIES OR SERVICES,

DOWNTIME COSTS, LABOR COSTS, OR DIMINUTION OF VALUE.

2-2

LIKE.

LeeBoy 685D Motor Grader

CONTACT INFORMATION

Information and Specications

For information regarding parts and repairs about your
machine, contact your authorized LeeBoy dealer. If your
dealer is unable to resolve the problem, contact LeeBoy
directly.

Sales Representative:

Dealership Name:

Dealership Address:

Dealership Phone:

Record dealer information in the space provided.
For additional information about LeeBoy, please visit:

www.leeboy.com.

Record of Ownership

Please complete the following information for use if you need to contact LeeBoy for service, parts or literature.

Machine Model Number:

Product Serial Number:

Date of Purchase:

Nameplate

2

The nameplate contains the model and serial numbers used to identify the machine and its components for parts or
service information. Refer to the Engine Operator’s Manual for the location of the engine nameplate.

LeeBoy 685D Motor Grader

Figure 2-1. Nameplate Location

2-3

Information and Specications

SPECIFICATION CHARTS

The specications provided in this section include

screed weights, dimensions, performance, and torque
values for both metric and standard inch fastener.

16’ 1”

(4.9 m)

22’ 3”

(6.8 m)

Table 2-1. Machine Dimensions

Replace original equipment only with

components approved by LeeBoy.

10’ 2”

(3.1 m)

7’ 8”

(2.3 m)

11’

(3.35 m)

ITEM SPECIFICATION

Base Overall Length 22 ft 3 in (6.8 m)
Overall Height with Beacon 10 ft 2 in (3.1 m)
Overall Width (Outside Front Tires) 7 ft 8 in (2.37 m)
Overall Width (Moldboard ) 11 ft (3.3 m)
Base Weight 16,000 lbs (7257.47 kg)

Wheelbase 16 ft 1 in (4.9 m)
Outside Turning Radius 22 ft (6.7 m)

Minimum Ground Clearance 1 ft (30.4 cm)

Table 2-2. Engine Specications

ITEM SPECIFICATION

Model Cummins 3.8 Tier 4F
Engine Type 4-Cylinder, Water-Cooled Diesel
Horsepower 130 HP @ 2200 RPMs (97 kW)
Displacement, Bore and Stroke 229 cu in (3.8 L); 4.02 in (102 mm); 4.53 in (115 mm)
High Idle Speed 2200 RPMs
Maximum Gross Torque 360 ft lbs (488 N•m)
Maximum Gross Torque 360 ft lbs
Idle Speed 1200 RPMs

2-4

LeeBoy 685D Motor Grader