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

Information and Specications

Table 2-3. Electrical Specications

ITEM SPECIFICATION

Batteries (2) 12 VDC, Maintenance Free
Cold Cranking Amps (CCA) 800 CCA Per Battery (1600 CCA Total)
Alternator 135 amp

Table 2-5. Operational Specications

ITEM SPECIFICATION

Travel Speed (@ 2200 RPMs) 0 - 20 mph (0- 32.2 kph)
Recommended Speed While Grading 0 - 10 mph (0 - 16 kph)

Table 2-6. Fuel and Lubricant Specications

ITEM SPECIFICATION

Engine Oil API CJ-4 or ACEA-E9 (Low Ash) 15W40 WT
Hydraulic Oil AW32 or AW68 Hydraulic Oil
Coolant Ethylene/Glycol or Propylene Glycol
Fuel Ultra Low Sulphur Diesel (ULSD)
Transfer Case (2-Speed) 80-90 WT Gear Oil
Tandem Gear Box 80-90 WT Gear Oil
Differential Oil 80-90 WT Gear Oil
Planetary Hub 80-90 WT Gear Oil
Grease Shell Avania EP Grease or Equivalent

Table 2-7. Machine System Capacity Specications

ITEM SPECIFICATION

Fuel 45 gal (170.3 L)
Engine Lubrication Oil 15.4 qt (14.6 L)
Engine Coolant 5.75 gal (22 L)
Hydraulic Oil Reservoir 30 gal (113.56 L)
Transfer Case (2-Speed) .92 gal (3.48 L)
Differential Oil 2.2 gal (8.4 L)
Planetary Hub .63 gal (2.4 L) per hub
Tandem Gear Box 2.32 gal (8.78 L) per side

2

ITEM SPECIFICATION

Tires 15-19.5 TL 8PR; 30 PSI

Brakes

Front Drive Axle

LeeBoy 685D Motor Grader

Table 2-8. Chassis Specications

Foot-Operated, hydrostatic traction drive system.
Hydraulic park brake is electrically actuated.

Oscillating axle supported by tapered roller bearings
and bushings. Wheel lean 15° left or right. Ground
clearance of 1.2 feet (.36 m)

2-5

Information and Specications

Table 2-9. Hydraulic Specications

ITEM SPECIFICATION

Traction Pump Variable Piston 4.58 cu in (75 cu cm)
Function Pump Gear 0.93 cu in (15.2 cu cm)
Steering Pump Gear 0.93 cu in (15.2 cu cm)
Drive Motor Variable Volume 4.8 cu in (80 cu cm)
Hydraulic Filters Remote Pressure and Return

Table 2-10. System Pressures

ITEM SPECIFICATION

Operating Pressure 0 - 6000 psi (0 - 414 Bar)
Accumulator 2300 psi (158.579 Bar)
Accumulator Low-Pressure Switch 1300 psi (89.6 Bar)
Relief Valve 3000 psi (206.8 Bar)
Charge Valve to Orbital (At Relief) 2465 psi (170 Bar)
10-Section Valve 1900psi (131 Bar)
Main Drive Pump 6000 psi (413.68 Bar)
Charge Pressure 350 psi (24 Bar)
Park Brake Release 350 psi (24 Bar)

Table 2-11. Moldboard Specications

ITEM SPECIFICATIONS

Width and Height

Side Shift, Tilt and Rotation 3 ft (.91 m); 30° Tilt; 64° Rotation
Penetration 1 ft 2 in (.365 m)
Raised Clearance 1 ft 1 in (.335 m)

Table 2-12. Front Blade Specications

ITEM SPECIFICATION

Width and Height

Raised Clearance 1.9 ft (.533 m)
Penetration 6 in (15.1 cm)

Table 2-13. Rear Scarier Specications

ITEM SPECIFICATION

Width 6 ft (1.8 m)
Number of Teeth 9

Raised Clearance

Penetration

Width: 11 ft (3.3 m)

Height: 1 ft 9 in (.579 m)

Width: 8 ft (2.4 m)

Height: 1.3 ft (.381 m)

Low: 11.5 in (29 cm)

High: 13.7 in (34 cm)
Low: 8.5 in (21 cm)

High: 6 in (15 cm)

2-6

LeeBoy 685D Motor Grader

TORQUE SPECIFICATIONS

Information and Specications

The following tables list torque values for standard
hardware. This is a guide for average application
involving typical stresses and machined surfaces.
Values are based upon physical limitations of clean,
plated and lubricated hardware. Under more extreme
conditions, individual torque value should be followed.
Conversion formulas are provided in the adjacent table:

ft-lb to N•m [ft-lb]*1.3558 = [N•m)
ft-lb to in-lb [ft-lb]*12 = [in-lb]
N•m to in-lb [N•m]*8.8508 = [in-lb]

Conversion Formula

Standard Inch Fasteners

Table 2-14. Torque Specications For Standard Inch Fasteners

CAPSCREWS: SAE GRADE 5 CAPSCREWS: SAE GRADE 8

SIZE THREAD

1/4 20 UNC 8 6 11 8 12 9 16 12

28 UNF 10 7 14 9 14 10 19 14

5/16 18 UNC 17 13 23 18 25 18 34 24

24 UNF 19 15 26 20 27 20 37 27

3/8 16 UNC 31 23 42 31 44 33 60 45

24 UNF 35 26 47 35 49 37 66 50

7/16 14 UNC 49 37 66 50 70 52 95 71

20 UNF 55 41 75 56 78 58 106 79

1/2 13 UNC 75 57 102 77 106 80 144 108

20 UNF 85 64 115 87 120 90 163 122

9/16 12 UNC 109 82 148 111 154 115 209 156

18 UNF 121 91 164 123 171 128 232 174

5/8 11 UNC 150 113 203 153 212 159 287 216

18 UNF 170 127 230 172 240 180 325 244

3/4 10 UNC 267 200 362 271 376 282 510 382

16 UNF 297 223 403 302 420 315 569 427

7/8 9 UNC 429 322 582 437 606 455 822 617

14 UNF 474 355 643 481 669 502 907 681

1 8 UNC 644 483 873 655 909 681 1232 923

14 UNF 722 542 979 735 1020 765 1383 1037

1-1/4 7 UNC 1121 840 1520 1139 1817 1363 2464 1848

12 UNF 1241 930 1683 1261 2012 1509 2728 2046

1-1/2 6 UNC 1950 1462 2644 1982 3162 2371 4287 3215

12 UNF 2194 1645 2975 2230 3557 2668 4823 3617

TORQUE (ft lb) TORQUE N•m TORQUE (ft lb) TORQUE N•m

Dry Lubed Dry Lubed Dry Lubed Dry Lubed

2

LeeBoy 685D Motor Grader

2-7

Information and Specications

Metric Fasteners

Table 2-15. Torque Specications for Metric Fasteners

CLASS 8.8 [GRADE 5 EQUIVALENT] CLASS 10.9 [GRADE 8 EQUIVALENT]

NOMINAL SIZE

AND PITCH

M4 x 0.7 2 2 3 2 3 2 4 3
M5 x 0.8 5 3 7 4 7 5 9 7
M6 x 1 8 6 11 8 11 8 15 11
M8 x 1.25 19 14 26 19 27 20 37 27
M10 x 1.5 37 28 50 38 53 40 72 54
M12 x 1.75 65 49 88 66 93 70 126 95
M14 x 2 104 78 141 106 148 111 201 150
M16 x 2 161 121 218 164 230 173 312 235
M18 x 2.5 222 167 301 226 318 239 431 324
M20 x 2.5 314 236 426 320 449 337 609 457
M22 x 2.5 428 321 580 435 613 460 831 624
M24 x 3 543 407 736 552 777 582 1053 789
M27 x 3 796 597 1079 809 1139 854 1544 1158
M30 x 3.5 1079 809 1463 1097 1544 1158 2093 1570

TORQUE (ft lb) TORQUE N•m TORQUE (ft lb) TORQUE N•m
Dry Lubed Dry Lubed Dry Lubed Dry Lubed

Hydraulic Fittings

Tightening Flare-Type Tube Fittings

1. Check the are and are seat for defects that might
cause leakage.

2. Align tube with tting before tightening.

3. Lubricate connection.

4. Hand tighten swivel nut until snug.

5. To prevent twisting the tube(s), use two wrenches.
Place one wrench on the connector body and
tighten the swivel nut with the second to the torque
shown in the following table:

NOTE: The torque values shown are based upon

lubricated connections.

Table 2-16. Torque Specications for Steel Flare

Type Tube Fittings

TUBE SIZE

OUTER

DIAMETER

(IN) (IN) (LB FT) (N•m)

3/16 7/16 8 11

1/4 9/16 12 16

5/16 5/8 16 22

3/8 11/16 23 31

1/2 7/8 38 52

5/8 1 54 73

3/4 1 1/4 75 102

7/8 1 3/8 83 113

NUT SIZE

ACROSS

FLATS

TORQUE VALUE

2-8

LeeBoy 685D Motor Grader

Determining Proper Torque

LA

L

E

LA

LH

The only reliable method of creating a consistently
leak-free and long-lasting connection is to ensure the
coupling is brought to the proper torque. Using a torque

wrench with crowfoot is the best method, but the ats

method can be used if a torque wrench is not available.

The most straightforward method of determining the
correct torque setting is to multiply the desired torque
by the length of the wrench from the center of the handle
to the center of the drive (L); divided by the length of the
wrench from the center of the handle to the crowfoot
center (LA) as shown below:

L

Figure 2-2. Torque Wrench - Crowfoot

Information and Specications

2

The minimum torque values are
adequate for sealing most applications. Maximum
torque values should never be exceeded.

There are several methods of determining the correct
setting on the torque wrench when using a crowfoot. All
of the methods involve making the setting proportional
to the effective change in length of the wrench multiplied

by the desired nal torque. The equations and

illustration below describe proper measurements.

Equations

• Torque setting if the crowfoot is placed in line with

respect to the wrench:

TS = TD * L / LA

OR

TS = TD * L / (L+E)

• Torque setting if the crowfoot is placed at 90° with

respect to the wrench

TS = TD * L / LH

OR

TS = TD * L / √(L2 + E2)

• To estimate the crowfoot size (E)

Figure 2-3. Measurements Needed

LEGEND

L = Distance from center of torque wrench handle to the
center of socket drive

E = Distance from center of socket drive to the center of
crowfoot

LA = Distance from center of torque wrench handle to
the center of crowfoot

LH = Distance from center of torque wrench handle to
the center of crowfoot, when mounted at 90°

TD = Desired torque at the tting

TS = Torque setting indicated on wrench

E = Drive Size * 0.5 + Distance between Drive and

Open End + Wrench Size * 0.5774

LeeBoy 685D Motor Grader

2-9

Mark Line on Nut

Information and Specications

Coupling Installation

Use the following steps for proper coupling installation:

1. Determine the correct torque value for your
coupling.

NOTE: Only use the torque values specied from

the manufacturer. DO NOT use SAE torque
recommendations.

2. Ensure the seal face and threads are clean and in
good condition. O-Rings should be lubricated with
light oil, but threads should be completely dry unless
making pipe thread connections (interference seal).

NOTE: Attach the male end of the hose onto the

equipment rst since it may be necessary to

rotate the entire hose assembly to tighten
the male threads. Then route the hose into
position while avoiding twisting the hose.

3. Tighten the connection (by hand), bringing the seal
face into contact and rotating the nut until it stops.

4. Mark a line across the coupling nut and backup hex

for the ats method verication of coupling torque.

5. Apply a wrench to the backup hex to prevent the
coupling and hose from moving while tightening the
nut with a torque wrench.

Failure to retain the backup hex during
installation will also result in additional clamp load
force that could cause damage to the seal face.

NOTE: The coupling nut must be in motion for an

accurate torque reading. If the nut is stopped

before nal torque value is achieved, it must

be loosened and retightened until the torque
is attained while the nut is in motion.

If a torque wrench cannot t into the coupling area or if
it is unavailable, the ats method may be used to ensure

that the coupling is properly tightened.

Example 2 Flats

difference

Figure 2-14. Flats Method Tightening

NOTE: The mark placed on the nut and backup hex

after tightening by hand should rotate during

nal tightening according to the table below.

The nut and backup hex can then be marked
to indicate if the coupling loosens over time.

Table 2-17. Flats Method Values for Selected

Terminations

FLATS METHOD VALUES

Termination

Type

JIC -4 1.5 - 1.75

JIC -6 1.0 - 1.5

JIC -8 1.5 - 1.75

JIC -10 1.0 - 1.5

JIC -12 1.0 - 1.5

JIC -16 .75 - 1.0

JIC -20 .75 - 1.0

JIC -24 .75 - 1.0

JIC -32 .75 - 1.0

JIS -4 .5 - 1.5

1. Seal faces must be in contact with the tting fully

tightened by hand before marking ats.

2. The ats method is most accurate for the rst
assembly cycle. For multiple disassembly and
assembly cycles, torque values are more reliable.

Dash Size Flats

2-10

3. Tightening two (2) ats or more may damage seal
faces.

LeeBoy 685D Motor Grader

Information and Specications

Table 2-18. Torque Specications For US Style Coupling Terminations

JIC, SAE 45°, ORFS, O-RING BOSS, GATES ADAPTERLESS AND MEGASEAL

JIC 37°, SAE 45°

DASH

SIZE

-3 8 10

-4 10 11 5 6 10 12 14 16 14 16

-5 13 15 7 9 18 20

-6 17 19 12 15 18 20 24 26 24 26

-8 34 38 20 24 32 40 37 44 50 60

-10 50 56 34 40 46 56 50 60 72 80

-12 70 78 53 60 65 80 75 83 125 135

-14 65 80 160 180

-16 94 104 74 82 92 105 111 125 200 220

-20 124 138 75 83 125 140 133 152 210 280

-24 156 173 79 87 150 180 156 184 270 360

-32 219 243 158 175

& Mega-Seal

(Steel)

Min Max Min Max Min Max Min Max Min Max

JIC 37°, SAE 45°

& Mega-Seal

(Brass)

Flat Face O-Ring

Seal (Steel)

SAE O-Ring Boss

(Steel) & Gates

Adapterless

≤ 4000 PSI

SAE O-Ring Boss

(Steel) & Gates

Adapterless

> 4000 PSI

2

Table 2-19. Torque Specications for DIN 24, DIN 60,

and Inverted Cone Style Coupling Terminations

DIN 24, DIN 60, AND INVERTED CONE

Size (mm) Torque (lb ft)

Light

Series

Tube OD

6 7 15

8 15 26

10 8 18 30

12 10 22 33

14 12 26 37

15 14 30 52

18 20 44 74

22 25 59 89

28 30 74 111

35 133 184

42 148 221

Heavy

Series

Tube OD

16 30 52

38 74 162

Min Max

Table 2-20. Torque Specications for 4-Bolt

Flange Connections

4-BOLT FLANGES

Dash Size Bolt Size (in) Torque (lb ft)

-8 0.31 17

-12 0.38 26

-16 0.44 43

-20 0.50 65

-24 0.63 130

-32 0.75 220

1. Align faces and tighten bolts (by hand) before

applying nal torque in a pattern. The seal faces

must be parallel with an even bolt tension to seal
properly.

2. Torque values apply to bolts that are plated or
coated in light engine oil.

3. Before assembly, lubricate O-Ring with light oil
(SAE 10W or 20W).

LeeBoy 685D Motor Grader

2-11

Information and Specications

Table 2-21. Torque Specications for NPTF Dry Seal

Pipe Threads

NPTF

Dash Size Max Torque (ft-lb)

-2 20

-4 25

-6 35

-8 45

-12 55

-16 65

-20 80

-24 95

-32 120

1. The torque values obtained from tightening pipe
threads can vary considerably depending upon
thread condition. Adequate sealing can occur at
values much lower than the maximum values listed
above. Only enough torque to achieve adequate
sealing should be used.

2. When using a male tapered pipe thread with a
female straight or parallel pipe thread, maximum
values are 50% of those listed in the table above.

Table 2-22. Torque Specications for BSP 30°

Inverted Cone and JIS Coupling Terminations

BSP 30° INVERTED CONE AND JIS

Torque (ft-lb)

Dash Size

Min Max

-2 7 9

-4 11 18

-6 19 28

-8 30 36

-10 37 44

-12 50 60

-16 79 95

-20 127 152

-24 167 190

-32 262 314

3. If thread sealant is used, maximum values shown
should be decreased by 25%.

2-12

LeeBoy 685D Motor Grader

Section 3

COMPONENT LOCATION

Page

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

3

3-1LeeBoy 685D Motor Grader

Components

NOTES

LeeBoy 685D Motor Grader3-2

Components

COMPONENTS OVERVIEW

The LeeBoy 685D Motor Grader is a compact motor
grader with the functionality of a large motor grader.
It’s versatility and specialized applications include
spreading base materials, ditch and shoulder projects,

ne grading, medium cutting and even snow removal.

Graders can also be used for bank sloping, leveling,
crowning, and road/runway maintenance. This self­propelled, wheeled grader has an adjustable, 11-foot
(3.35 meter) moldboard blade positioned between the
front and rear wheels. An optional 12-foot (3.65 meter)
moldboard is also available. Optional attachments
include an 8-foot (2.4 meter) front blade, front or rear

scariers or a blade-mounted, ip-down scarier. Be

familiar with all the grader’s components and optional
attachments purchased before operating this machine.

Engine

The 685D Motor Grader
is equipped with a
Cummins QSF3.8 Tier
4F diesel engine. This

Tier 4 Final fuel-efcient

engine offers the latest
in innovative emission
solutions to reduce diesel
particulate matter (DPM)
and other toxins released
into the air.

Advanced emission-control devices and low-sulfur fuel
requirements--only Ultra-Low Sulfur Diesel (ULSD)
can be used in this engine--combine with new after-

treatment methods. The SCR system is an efcient,
effective means of ltering dirt and other contaminates

for optimum engine performance and reducing air
pollution from exhaust emissions. The Selective
Catalytic Reduction (SCR) system precisely injects
Diesel Exhaust Fluid (DEF) into the engine’s exhaust
system to transform those toxic exhaust gases into
harmless water vapor and nitrogen. SCR technology is

also cost-effective and fuel-efcient.

3

Operator Station

The 685D Motor Grader is equipped with a canopy, but
an optional fully-enclosed cab version offers additional
operator comfort on the job site. Air conditioning,
heating, and other options are also available for a cab
model.

Levers, control switches and joystick controls are within
easy reach for operator comfort. The PV485 digital
controller unit on the steering control panel includes
throttle control, tachometer, fuel gauge, oil pressure
gauge, coolant temperature, voltmeter and hour meter
along with gauges and warning alerts. The steering
column can be tilted for comfort. Complete control
panel information is described in the following pages.

The High-Pressure Common Rail (HPCR) fuel system
offers a new level of cleanliness, performance and

fuel economy. The fuel lter removes contaminants
from diesel fuel before it ows into the injection pump,

providing better protection against harmful particles.

The Direct Flow™ air ltration system holds 30 percent
more dust particles than conventional lters, enabling

longer service intervals and reducing maintenance
costs. The radiator cools the engine. A mechanically­driven fan removes heat, saves horsepower and
reduces noise.

Lockable engine access doors on both sides of the
grader allow convenient access to components with
vandalism protection.

Refer to the Engine Owner’s Manual accompanying your
machine for additional engine information.

3-3LeeBoy 685D Motor Grader

Components

Hydrostatic Drive

This grader is powered by a diesel engine with dual­range, hydrostatic transmission system that propels
the machine forward or reverse at varying speeds with
dynamic braking action. Components of the hydrostatic
drive system include a hydrostatic traction pump,
variable-speed hydraulic motor, two-speed tandem axle,
rear axle carrier assembly and gear drive. A two-speed
transfer case mounted between the drive motor and
rear axle carrier provides high and low gear selection.
The rear axle carrier assembly converts input rotation to
axle shaft output rotation to drive the wheels.

The function and steering pump is mounted on the rear
of the traction pump and driven by the traction pump

output shaft. This provides hydraulic pressure and ow

to operate all the hydraulic cylinders that controls the
steering cylinder and other grader functions.

Electrical System

The electrical system is powered by two 12-volt
batteries, wired in parallel and mounted in a battery
compartment on the frame. Each battery produces
800 cold cranking amperes (CCA) for a total of 1600
CCA. An engine-mounted alternator with 135 amperes
of charging capacity keeps the batteries charged during
normal operation.

Moldboard

The moldboard is a major component of the 685D Motor
Grader. This adjustable, hydraulically-controlled blade
is mounted between the front and rear wheels that can
cut, move and spread materials to grade requirements.
The moldboard blade is mounted under the turntable
circle that can be hydraulically rotated right and left.
The moldboard height is controlled by two hydraulic
cylinders mounted to ball joints at a turntable.

The blade can be aggressively angled perpendicular
to the line of travel or parallel to the direction of travel.
The blade’s curved shape allows material to roll more
freely along the blade. The moldboard can be moved
forward and also shifts three (3) feet (.9 meters) left or
right. It can tilt side-to-side and front-to-rear, rotate

64 degrees, and features oat controls that can cut 1.2

feet (.355 meter) below grade. This versatility allows
extreme moldboard positioning to meet a variety of road
construction and maintenance needs, including easier
bank sloping and ditch cutting.

LeeBoy 685D Motor Grader3-4

Components

Scarifier (Optional)

The scarier, or ripper, is a mechanism with large teeth

mounted on shanks for penetrating and loosening earth,
gravel, asphalt and similar surfaces to shallow depths.
This attachment is used to break up material too hard
for the moldboard blade to cut, such as a surface
preparation device for ripping asphalt or breaking up
packed soil for construction site preparation, digging
and even landscaping purposes.

Hydraulically raised and lowered, the scarier has ve

replaceable teeth (with space for a total of nine teeth if
needed) for penetrating the grading surface. The tooth
supports are adjustable and secured with pin locks.

Standard Equipment/Options

Component

Sliding Moldboard: 11-Foot (3.3 m)
(Includes Tilt and Float)

Articulated Frame
Safety Beacon and Work Light Package
Hydrostatic Traction Drive with Secondary

Brakes, 2-Speed Tandem Axle
Cushioned, Adjustable Suspension Seat
Anti-Vandalism Package
Heavy-Duty Rear Hitch
Canopy with ROPS/FOPS
Exterior Side Mirrors
Circle Turn Cushion Valve
Cab Version (Includes Heat) Option
Cab Options: A/C, Defrost Fan, Rear Window

Wiper/Washer, Radio

Rear Scarier Option
Front Scarier Option

Front Blade 8-Foot (2.4 m) Option
Front Blade-Mounted, Flip-Down Scarier Option
Front Blade Float Option
12-Foot (3.6 m) Sliding Moldboard Option
AWD (All-Wheel Drive) Option
Secondary Steering Option
Circle Side Shift Option
Cold Weather Engine Package Option
Back-Up Camera Option

v

v

v

v

v

v

v

v

v

v

Option

3

Front or rear scarier options offer the ripping power

to penetrate tough material fast. Choose from front or

rear scarier options (rear shown). The blade-mounted,
ip-down scarier option offers the convenience and

versatility of using the same attachment for plowing
or scarifying operations. This multi-use option also
attaches to the front nose of the grader.

3-5LeeBoy 685D Motor Grader

Components

MACHINE OVERVIEW

3

2

1

4

5

Figure 3-1. Machine Overview

ITEM

NO.

1 Front Attachment Mount

2 Front Boom

3 Lift Cylinders Cylinders lift and lower moldboard blade.
4 Turntable Rotates the moldboard left and right.

5 Moldboard

6 Engine Access Panel

7 Rear Scarier (Option)

CONTROL NAME FUNCTION

Optional attachments can be mounted to the attachment plate on the nose of

the grader, including an 8-foot blade or scarier..

The front part of the grader that pivots. The moldboard and optional
attachments are mounted onto the boom.

The moldboard blade is used for grading and smoothing surfaces. Also used
for ditch digging. Mounted under the boom, supported by a drawbar and
turntable.

Lockable access doors on both sides of the machine for easy access to
engine and other components.

Used for penetrating and loosening earth, gravel, asphalt and similar surfac­es. Includes nine (9) replaceable teeth mounted on adjustable shanks and
secured with pin locks..

6

7

LeeBoy 685D Motor Grader3-6

OPERATOR STATION

1

Components

2

3

4

Figure 3-2. Operator Station

ITEM

NO.

1 Steering Column Controls

2 PV485 Digital Controller Displays engine operating parameters, warnings and alerts.
3 Foot Brake Press on the foot brake to stop the grader.

4 Heat/AC Controls (Option)

5

6 Throttle

7 Main Control Panel

CONTROL NAME FUNCTION

Contains steering wheel, component indicator lights, and grader work
function levers.

If equipped with the cab option, this additional option contains controls for
the heat and air conditioner.

FNR (Forward/Neutral/
Reverse) Pedal

Step on the front part of the pedal to move forward; step on the rear part of
the pedal to move in reverse. The center position is NEUTRAL. The FNR
pedal must be in the neutral (center) position to start the engine.

Use to increase and decrease engine speed (RPMs) when in gear (low or
high gear). Push lever forward to increase speed. Push lever rearward to
decrease speed.

Contains numerous machine component controls, including the ignition
switch, lights, park brake, gears, fan, and wipers.

3

5

6

7

3-7LeeBoy 685D Motor Grader

1

12

13

14

15

Components

STEERING COLUMN CONTROLS

Grader operations involve using levers on the steering control panel. When levers are released from the forward or

back position, they return to the neutral center position (except the oat position on the moldboard), suspending the

function or component movement.

2

8

9

3

4

5

6

10

11

7

ITEM

NO.

1 PV485 Digital Controller Displays engine operating parameters, warnings and alerts.
2 Left Turn Signal Indicator Light Blinks when the left turn signal is engaged.
3 Brake Failure Warning Light Illuminates when there is low service brake pressure.
4 All Wheel Drive (AWD) OPTION If equipped with this option, illuminates when AWD is engaged.

CONTROL NAME FUNCTION

16

17

Figure 3-3. Steering Column Controls

LeeBoy 685D Motor Grader3-8

Components

ITEM

NO.

5

6 High Gear Indicator Light Illuminates when operating in high gear.

7 High Beam Indicator Light Illuminates when the headlights are switched to high beam.

8 Moldboard Blade Angle Lever Rotates moldboard. Pull lever to rotate left; push lever to rotate right.

9 Moldboard Slide Lever

10 Moldboard Lift Lever (Left)

11 Moldboard Lift Lever (Right)

12 Circle Side Shift (Option)

13

14 Wheel Lean Lever

15 Moldboard Tilt Lever

16 Rear Scarier Lever (Option) Raises/lowers rear attachment. Pull lever to raise; push lever to lower.

17 Articulate Lever

CONTROL NAME FUNCTION

Right Turn Signal Indicator
Light

Front Attachment Lever
(Option)

Blinks when the right turn signal is engaged.

Shifts moldboard left or right. Pull lever to shift moldboard left; push lever
to shift moldboard right.

Raises/lowers left moldboard edge. Pull lever to raise left edge; push

lever to lower left edge. Continue to push lever forward into oat detent.

Push or pull both the left and right moldboard lift levers to raise and lower
the entire moldboard.

Raises/lowers right moldboard edge. Pull lever to raise right edge; push

lever to lower right edge. Continue to push lever forward into oat detent.

Push or pull both the left and right moldboard lift levers to raise and lower
the entire moldboard.

Rotates drawbar left or right. Pull lever to shift drawbar left; push lever
to shift drawbar right. (This lever is nonfunctional if not equipped with
option.)

Raises/lowers optional front attachments. Pull lever to raise, push lever
to lower. (This lever is nonfunctional if not equipped with option.)

Tilts the front wheels left or right. Push lever forward to tilt tires left; pull
lever to tilt tires right.

Tilts moldboard. Pull lever to tilt top of the moldboard backward. Push
lever to tilt top of moldboard forward.

Rotates front “boom” portion of the grader. Pull lever to rotate boom right;
push lever to rotate boom left.

NOTE: The articulation angle can affect the stability of the

machine. Efcient and safe articulation requires skill and

experience to take advantage of its full capabilities.

3

3-9LeeBoy 685D Motor Grader

11

Components

MAIN CONTROL PANEL

4

12

1

5 6

13

14

7 8

15

2

16

9

10

3

17

18

21

ITEM

NO.

1 (Emergency) E-Stop

2 Headlight High/Low Beam

CONTROL NAME FUNCTION

19

20

Figure 3-4. Main Control Panel

Immediately stops the engine and all electronic functions. Turn clockwise to
release the emergency stop. If machine is moving, the park brake will apply
and the grader will stop rapidly.

Use this switch to select HIGH or LOW beam when the headlights are on.
Turn the switch up for HIGH BEAM and down for LOW BEAM.

LeeBoy 685D Motor Grader3-10

Components

ITEM

NO.

3 Cupholder A convenient holder for beverages.
4 Horn Press this button to sound the horn.

5 Front work lights

6 Rear Lights

7 Beacon Light

8 Fan

9 Headlights Hi/Low Beam Turn the switch UP for high beam; turn the switch DOWN to dim lights.

10

11 Rear Wiper/Washer

12 2-Speed High/Low

13 Axle Travel/Work

14

15 Front Blade Float (Option) Turn switch up to turn on the front blade oat.
16 Secondary Steering Turn switch up to activate secondary power steering.

17 Ignition

18 Park Brake

CONTROL NAME FUNCTION

Turns the front work lights ON and OFF. Turn the switch up to turn ON or
down to turn OFF the front work lights.

Turns the rear lights ON and OFF. Turn the switch up to turn ON or down to
turn OFF the rear lights. The center position is OFF.

Turns the beacon light ON and OFF. Turn the switch up to turn beacon light
ON or down to turn it OFF.

Turns the fan ON and OFF. Turn the switch up to turn fan ON or down to turn
it OFF.

Front Windshield Wiper/
Washer

All-Wheel Drive (AWD)
(Option)

Turns the front windshield wiper ON and OFF. Rotate switch clockwise one
position for low-speed wiper or two positions for high-speed wiper. Rotate
fully counterclockwise to turn off wiper. Push button to spray washer.

Turns the rear wiper ON and OFF. Rotate switch clockwise one position
for low-speed wiper or two positions for high-speed wiper. Rotate fully
counterclockwise to turn off wiper. Push button to spray washer.

Turn switch up to place rear axle gearbox into HIGH gear, used when
traveling to and from job sites. Turn switch down to place rear axle gear box
into LOW gear, used when grading. You must come to a complete STOP
with the FNR pedal in neutral and apply the park brake to shift gears.

Turn the switch up to select TRAVEL speed. Turn the switch down to
select WORK speed. Work speed maintains the hydrostatic drive motor
at maximum torque and a constant speed (with the ability to increase or
decrease speed using the FNR pedal). Travel speed allows the grader
to travel at a higher speed when maximum torque isn’t needed, but
automatically slows when more torque is needed.

If equipped with this option, turn the switch up to turn ON the AWD feature.
Turn the switch down to disengage AWD.

Starts and stops engine. The park brake must be engaged and the FNR
pedal in the neutral (center) position to start the engine.

Engages and disengages the park brake. Push the switch up to engage the
park brake. Push the switch down to disengage the park brake. The park
brake must be applied to start the engine and to shift axle between HIGH and
LOW modes.

3

19 12-Volt Outlet An outlet socket that can provide power for external devices.

20 Fuse Panel Access

21 Throttle

NOTE: Always engage the park brake when the machine is parked.

Provides easy access to the fuse panel. Locks and unlocks to prevent
vandalism.

Use to increase and decrease engine speed (RPMs) when in gear (low or
high gear). Push lever forward to increase speed. Push lever rearward to
decrease speed.

3-11LeeBoy 685D Motor Grader

1 2 3 4

Heat Valve

Components

HEAT AND AIR CONDITIONING
(CAB OPTION)

Figure 3-5. Heat and Air Conditioning Controls

Item

No.

• Before turning on heat for the rst time each

winter, open the heat valve beside the master
battery switch located inside the left engine panel
by turning the lever clockwise.

• At the end of winter, shut off the valve by turning
the lever counterclockwise (perpendicular to the
hose).

COMPONENT FUNCTION

1 Vent Knobs

2 Heat

3 Fan

4 Air Conditioning

Opens and closes
recirculation vents.

Adjusts temperature and
turns heat on and off.

Controls blower fan for heat
and air conditioning.

Adjusts temperature and
turns air conditioning on
and off.

Master Battery Switch

Figure 3-6. Heat Valve in the Open Position

LeeBoy 685D Motor Grader3-12

Section 4

OPERATION

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

Page

4

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

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

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

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

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

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

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

LeeBoy 685D Motor Grader

4-1

Operation

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

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

LeeBoy 685D Motor Grader4-2

Operation

GENERAL INFORMATION

The LeeBoy 685D Motor Grader is a hydrostatic,
articulating grader designed with the functionality of
a larger grader but more compact. The 685D model

has the versatility for ne grading, spreading base

materials, ditch and shoulder work, medium cutting,
general construction, shaping, bank sloping, , and even
snow removal. The 685D is excellent for driveways,
parking lots, landscaping and road/runway maintenance
projects as this smaller grader is very maneuverable
and easier to transport than a larger machine.

This section offers information to help you understand
how to operate this grader and its components and
attachments, along with basic grading techniques. Pay
particular attention to safety warnings in Section 1 and
throughout this manual.

Ensure operators are properly

licensed if required in your location.

Use only Ultra-Low Sulfur Diesel
(ULSD) with a maximum sulfur content of 15
ppm or less in this machine. This is a regulatory
requirement. Failure to do so will result in damage to
the engine and after-treatment system within a short
period of time.

Only authorized personnel who are
properly trained should operate this machine. DO
NOT allow others on the operator platform or near
this industrial machine and its heavy equipment at
any time.

DO NOT leave the operator station
unattended while the engine is running.

Keep the steps, hand-hold bars,
operation station and machine components clean
and clear of debris, mud and grease to prevent
falls or other accidents. Be careful mounting and
dismounting the motor grader. Always use the hand­hold bars and steps. NEVER mount or dismount the
grader while it is moving. DO NOT jump from the
grader at any time.

Receiving the Machine

Although the machine has been checked thoroughly by
the manufacturer, road hazards or other factors during
transport may result in damage. Inspect machine for
any damage during transport. Contact your authorized
dealer immediately if any damage has occurred.

Be sure to check the machine thoroughly upon receipt:

1. Check engine oil. (Page 5-13)

2. Check hydraulic uid level. (Page 5-25)

3. Check DEF tank uid level. (Page 5-17)

4. Check machine hoses for any damage or leaks.

5. Rotate the beacon light bracket from its shipping
position to its operating position. Ensure the
bracket “clicks” into position.

6. Inspect machine for any damage during transport.
Contact your authorized dealer immediately if any
damage has occurred in transit.

Initial and Daily Inspection

The following inspections are essential and should be
performed before starting the machine. Visually inspect
the unit to check its general condition. Continue with a
check of the systems and components shown in Table
4-1 below:

Table 4-1. Initial and Daily Inspection

INSPECT PROCEDURE

Engine Oil
Level

Fuel Tank

Hydraulic
Tank

DEF Tank

Radiator

Brake

Battery

Air Cleaner

Drain Plugs Make sure plugs are inserted and tight.

Engine Belt Check for wear or damage.

Grease
Fittings

Maintain oil level between ADD and FULL
marks on dipstick.

Check for adequate fuel supply. Fill if

needed. Always ll tank at end of the day to

prevent condensation in the tank.

Check the tank for oil level and leaks.

Check the DEF tank level and rell if needed.

Check coolant level.

Always perform a pre-start brake check
before operating using the procedure shown
on Page 4-4.

Ensure all cables are tight and clean. Check
for corrosion on the battery terminals.

Check the air lter element and connections.

Air cleaner has both a primary and

secondary lter.

Ensure ttings are greased and in good

working order.

4

LeeBoy 685D Motor Grader 4-3

Operation

START-UP PROCEDURE

Brake Check

A Neutral Start feature has been installed for safety.
The grader will not start unless the FNR pedal is in the
neutral position. It is recommended that operators
always check the brake before operating.

Verify there are no people, obstacles
or other equipment in the machine’s path before
starting the engine.

Be sure the park brake is engaged
and the FNR pedal is in the neutral position before
starting the engine. DO NOT put your foot on the
FNR pedal when starting.

To check that the park brake is functioning properly:

1. Engage the park brake. (Figure 4-2)

2. Step on the foot brake pedal. (Figure 4-1)

Foot Brake

GENTLY
Press for
Forward

Press for
Reverse

FNR

Starting the Engine

ALWAYS fasten your seat belt and
adjust steering console, seat and mirrors BEFORE
starting the engine.

To start the 685D Motor Grader:

1. Ensure the park brake is engaged. (Figure 4-2)

2. Fasten seat belt, adjust steering console, seat

position and mirrors.

3. Place the FNR pedal into the NEUTRAL position.

(Figure 4-1)

4. Ensure the throttle is in the idle position (completely

rearward). Check control panel gauges for proper
readings.

5. Insert key into the ignition and turn clockwise to the

ON position. (Figure 4-2)

• The PV485 digital controller on the steering
control console (described on the following
pages) will “boot” for a few seconds when
starting the engine. A “Wait to Start” banner will
appear for a few seconds while booting. AFTER
the Wait to Start light disappears, turn key to the
START position to crank engine.

DO NOT hold the starter longer than
10 - 15 seconds. If the engine does not start, allow
the starter to cool two or three minutes between
attempts to prevent damage to the starter.

Figure 4-1. FNR Pedal

3. Turn the ignition key to the START position. The
engine should not start unless the FNR pedal is in
NEUTRAL (center position).

• If the engine starts with the FNR pedal in
either FORWARD or REVERSE, contact your
authorized dealer immediately for service. DO
NOT drive the grader until repaired.

The FNR pedal is very sensitive. Use
only a little pressure on the pedal when moving
in forward or reverse to prevent lunging. DO NOT
engage FNR pedal before releasing park brake.

The engine is equipped with an
electric heat starting system. Using start additives,
such as ether, is not recommended as it could cause
an explosion resulting in severe injury and/or engine
damage.

6. Check control panel gauges for proper readings.

7. Allow the engine to idle a few minutes before moving

in either direction.

A safety sensor system in the seat
detects whether the operator is properly seated.
The grader will remain in neutral and will not move
forward or reverse, despite movement of the FNR
pedal, if the operator is not seated.

LeeBoy 685D Motor Grader4-4

4

Operation

Stopping the Engine

Before leaving the operator station,
place the machine in neutral, lower the moldboard
(and any other attachments) to the ground, and apply
the park brake.

1. Lower all attachments to the ground.

3
2

1

Figure 4-2. Start-Up Controls

1 - Throttle Lever

2 - Park Brake Switch

3 - Ignition Switch

4 - E-Stop Button

Cold Weather Starting

1. Engage the park brake. (Figure 4-2)

2. Insert key into the ignition and turn clockwise to

the START position. (The “Wait to Start” light will
illuminate for a few seconds on the steering control
panel). AFTER the Wait to Start light disappears,
turn key to the ON position to crank engine.

3. Allow the engine to idle about ten minutes before
driving the machine.

2. Apply park brake.

3. Turn ignition key counterclockwise to the OFF
position and remove key.

NOTE: The electrical system will continue to

operate for approximately 20 seconds after
the ignition is turned off. This allows the
engine ECU (Engine Control Unit) to store
critical engine data as it powers down.

NOTE: You may also hear a slight noise for a few

seconds after turning off the engine. This
is the DEF (Diesel Exhaust Fluid) system
automatically purging.

Emergency Stop Button

The purpose of the Emergency Stop Button (E-Stop)
is to shut down the engine and all machine functions in
an emergency situation. This additional safety feature
should only be used if the operator needs to shut down
all machine operations quickly. (Figure 4-2)

ALWAYS wear your seat belt! If you
engage the E-Stop button, the grader will stop very
quickly and could result in serious injury if you are
not wearing seat belt securely.

4

LeeBoy 685D Motor Grader 4-5

Operation

REGENERATION
(REGEN)

Regeneration is the term given to the
cleaning process where the exhaust
temperature is raised to safely
burn off any soot and undesired combustion gas to

signicantly reduce toxic emissions as required by Tier

4 Final engine standards.

Maintenance is kept at a minimum with a crankcase

ventilation breather that requires no lter element, and

a Cummins Filtration Direct Flow air cleaner that has a
higher dust capacity. It is particularly important that the
operator understand the regeneration process before
operating the grader.

This engine uses Diesel Exhaust Fluid (DEF), (known as
AdBlue® in Europe), a critical element of its Selective
Catalytic Reduction (SCR) after-treatment system.
Alerts and messages illuminate on the PV485 digital
display controller (described in the following pages)

when the DEF tank needs to be lled or the regeneration

process needs to be performed.

When the soot saturation in the exhaust system reaches
a certain level, the onboard engine ECU (Engine
Control Unit) will activate a regeneration cycle. During
normal operation, the regeneration process begins
automatically. This engine requires little to no operator
interaction, but under certain circumstances, the
operator may have to initiate the regeneration process.

The exhaust system cleaning light will illuminate during
regeneration. It is important not to shut off the engine

as the regeneration cycle will fail and could possibly
damage the engine. Once regeneration is complete,

the light will turn off. If the regeneration cycle fails, the
ECU may attempt a second regeneration.

Use only Ultra-Low Sulfur Diesel (ULSD) with a maximum
sulfur content of 15 ppm or less in this machine. Failure
to do so will result in damage to the engine and after­treatment system within a short period of time.

Modifying or disconnecting any

emission-related component will subject you to
government penalties and void your warranty.
Tampering with emission controls is in violation of
federal law, and can result in serious civil penalties.

Diesel Exhaust Fluid (DEF)
After-Treatment System

The LeeBoy 685D Motor Grader is equipped with a
DEF after treatment system that treats post-combustion
exhaust gases prior to tailpipe emission. This system
allows greater engine power, higher torque and fuel
economy while decreasing exhaust pollution. The
DEF system is an important factor in operating the

machine. Keeping the DEF tank lled is critical to engine

operation. (Figure 4-3)

DO NOT operate the machine with
an empty DEF tank to prevent serious engine and
emission system damage.

DEF Tank
Filler Cap

Figure 4-3. DEF Fluid Tank

If the DEF tank level runs low (below 15 percent) during
operation, a solid yellow DEF warning symbol will
illuminate on the PV485 controller screen. If the level

drops to ve (5) percent, the warning icon ashes yellow.

Engine torque will be reduced 50 percent and engine
speed will be reduced 40 percent after 45 minutes.

If the operator continues to ignore the warning and

the DEF tank is still not relled after an additional 45
minutes, the warning icon will illuminate red and ash

continuously. At this point, there will be no available
torque--the engine will only idle.

In either of these conditions, relling the DEF tank will

restore engine performance.

LeeBoy 685D Motor Grader4-6

If the DEF tank level has fallen to 0 percent, a STOP

warning symbol will also illuminate and ash red. At this

level, there is no ability for DPF regeneration or DEF
injection into the exhaust system, therefore no ability to
cool the DEF injector as needed. The DEF injector may

now be damaged by heat and require replacement
from your authorized dealer.

DEF Thaw Control Mode: Sensors on the DEF tank

also detect the ambient air temperature within seconds
of starting the engine. If the DEF is frozen, the SCR
system automatically starts the Thaw Control Mode and
turns on the DEF pump, tank and tube heaters. Engine
maximum torque may be limited to protect the DEF
injector.

DEF Purge: The SCR system will automatically purge
DEF after shutting down the engine. You will hear the
pumping noise as the system circulates DEF to cool
the DEF injector, then the pump reverses to return DEF
back to the tank. Always allow this purging process to
nish to prevent damage to the injector and other SCR
components.

Operation

Figure 4-4. PV485 Digital Display Controller

NEVER disconnect battery until the
purge cycle has completed to prevent serious
damage to components in the SCR system.

Be sure the DEF uid in the tank is not
contaminated before relling. Dispose of DEF uid in

accordance with environmental laws.

PV485 DIGITAL DISPLAY

Before driving the LeeBoy 685D Motor Grader, it is
important to be familiar with the PV485 PowerView™
digital controller located on the steering control panel.
This system is a multi-functional display that enables
operators to view standard engine parameters along
with active and stored trouble codes.

• The digital display screen show single or multiple
text descriptions, i.e., engine temperature, voltage,
oil pressure, engine RPMs, and service reminders
or fault conditions. The operator can toggle through
different screens for displaying critical data broadcast
by the electronic engine and transmission Engine
Control Unit (ECU).

• Diagnostic codes with text descriptions of fault
conditions are enhanced by ultra-bright alarm
indicators that illuminate amber or red to alert the
operator of a condition requiring attention.

• An amber warning light illuminates to alert the
operator that a trouble code or service reminder
is being shown on the display.

4

LeeBoy 685D Motor Grader 4-7

• If the red warning light illuminates, the operator
should shut down the machine and promptly
repair the problem to prevent possible damage.

2

3

4

5

6

Operation

When turning the ignition key to the ON position, you
will see a logo with the “Wait to Start” banner along the
bottom of the screen while the system “boots.” DO NOT

start the engine until this message disappears and
the gauge screen appears.

Gauge Screen

The gauge screen is the rst screen to appear on the

PV485 digital controller when starting the engine. This
is the default screen. (Figure 4-5)

Pressing the “soft key” buttons along the bottom of the
controller unit allows the operator to navigate to various
other screens. The banner icons along the bottom of
the screen correspond with these buttons, and change
accordingly when navigating to other screens as
described on the following pages. Table 4-2 shows the
icons that appear on the banner with descriptions.

Pressing the center button ( ) navigates to the Main
Menu screen. (Page 4-10)

Soft Keys (Buttons)

The following table shows icons appearing on the
bottom banner that correspond to the soft key button,
depending upon the screen mode. (Some sources may
not be present on your model.)

Table 4-2. Soft Key Choices

Icon Description

Displays the default speed (RPMs) set
points.

Displays the DPF commands to access
Uninhibit Regen and Inhibit Regen.

Sends message to the ECU to start DPF
regeneration.

Sends message to the ECU to stop DPF
regeneration. (DO NOT use unless
necessary.)

Requests freeze frame data from the
ECU when faults are present.

Navigates to the Main Menu screen
where you can scroll to choose action
items (such as settings and diagnostics).

1

Soft Keys

Figure 4-5. Gauge Screen

1 - Engine Coolant Temperature

2 - Engine Speed/RPMs

3 - Hydraulic Oil Temperature

4 - Battery Voltage

5 - Actual Engine Torque Percentage

Use to scroll down through a list of items.

Use to up scroll through a list of items.

Select: Enters the action item selected.

Deselect: Closes pop-up messages.

6 - Soft Key Banner

LeeBoy 685D Motor Grader4-8

Operation

The soft menu screen also displays engine torque
percentage, DEF tank level, engine oil pressure, total
hours of operation, and fuel level in the lower left
quadrant of the screen. (Figure 4-6)

1

2

3

Figure 4-6. Status Quadrant

1 - DEF Tank Level

2 - Engine Oil Pressure

3 - Engine Total Hours of Operation

4 - Fuel Level

Warning lights will illuminate and fault codes will also
display:

• The engine oil light is normally illuminated green,
but will illuminate red if the hydraulic or engine oil
pressure is too low and display a warning icon on the
screen.

• A warning icon will also display if the hydraulic or
engine oil temperature is too high.

• Other warning and status icons may also illuminate.

(Table 4-3)

4

Status

Icon

Table 4-3. Status Icons

Description

Check Engine. When this lamp is illuminated

yellow, a fault exists within the control
system.

Take action immediately to

correct the fault.
Stop Engine. Illuminates red (and may ash)

when continued operation could result in
damage to the exhaust system. Shut down
the engine and do not operate the machine
until repair has been made. Contact your
authorized dealer if needed.

Park Brake. The park icon displays when
the parking brake is applied.

Alternator. Illuminates when the alternator
isn’t charging properly.

Coolant. Illuminates when the engine is
running too hot.

4

Fuel. Illuminates when the fuel tank is almost
empty.

Hydraulic Oil. Illuminates to warn operator
when the hydraulic oil is too hot.

Refer to Section 5, Troubleshooting, for a complete
list of Fault Codes.

LeeBoy 685D Motor Grader 4-9

Oil Pressure. Illuminates when the oil
pressure is low. A wavy line underneath
indicates the engine oil level is too low.

DEF Tank Level Warning Icon. This lamp
illuminates if the DEF tank level runs low
(below 15 percent). Rell the DEF tank.

DEF Lamp with Check Engine Lamp. The
yellow check engine and DEF tank warning
lamps illuminate if DEF tank is critically low.
Rell the DEF tank. Engine power will be

reduced, but will return when lled.

Diesel Exhaust Fluid (DEF) System
Warning. Indicates a failure of the emission

system or that engine emissions are too
high. The DEF may be contaminated and
need to be replaced, or the system may need
service. Contact your authorized dealer for
assistance if needed.

Operation

Status

Icon

Description

Flashing DEF Lamp with Stop Engine
Lamp. Illuminates when the DEF tank is near

zero, further limiting power. Rell DEF tank
immediately to avoid damage! Normal

power will restored when DEF tank is lled.

Insufcient DEF can result

in damage to the DEF injector and other
components.

Flashing DEF Lamp with Red Stop Engine
Lamp. Illuminates when the DEF has read

zero for 30 minutes. Power will be limited to
IDLE. STOP the machine and rell the DEF

tank immediately! If relling the DEF tank

does not turn the lamps off and/or restore
normal engine power, stop operation and
contact your authorized dealer immediately.

High Exhaust System Temperature (HEST)
Lamp. May illuminate when higher than

normal exhaust temperature exists due to
regeneration.

Main Menu Screen

Pressing the Main Menu ( ) soft key navigates to the
Main Menu action items. (Figure 4-7) Scroll through
the list using the UP/DOWN arrow keys, then press the
( ) key when the cursor (>) points to screen you wish
to view to select that screen mode. The Main Menu
choices are listed below and described on the following
pages:

• Gauge (default screen)

• Diagnostics

• System Info

• User Settings

• Tier 4

NOTE: Continue scrolling using the DOWN arrow

key to access the Tier 4F menu action items.
(Page 4-14)

Ensure the exhaust

pipe is not directed at any ammable

or combustible surface if any high
temperature icons illuminate.

DPF Regeneration Set to Inhibit — The

user may choose to inhibit the REGEN
if conditions are too hazardous for high
exhaust temperatures. When this lamp is
illuminated, a REGEN cannot be performed
and soot levels will continue to rise.

Unless hazardous
conditions exist, the REGEN Inhibit switch
and this lamp should remain off.

Exhaust System Cleaning. Illuminates

when the exhaust system is unable to
complete regeneration. As soon as
possible, performed a parked regeneration
procedure. (Pages 4-14 to 4-15) The icon

will ash during regeneration and stop once

regeneration is complete.

Exhaust System Cleaning and Check
Engine Lamps. Indicates a failure of the

emission system because the operator failed
to perform regeneration in a timely manner.

Engine power will be signicantly reduced.

Perform parked regeneration immediately.
Contact your authorized dealer for
assistance if engine power does not return.

Figure 4-7. Main Menu Screen

LeeBoy 685D Motor Grader4-10

Operation

Diagnostics

Use the UP/DOWN soft keys and stop the cursor (>) for
to view either active or logged diagnostics, then press
the Select ( ) soft key. (Figure 4-8)

Figure 4-8. Diagnostics Screen

Logged Diagnostics

The Logged Diagnostics screen displays nonactive
warnings or faults with the appropriate Suspect
Parameter Number (SPN) and Failure Mode Indicator
(FMI) that are stored in the system. (Figure 4-10) Use
the UP/DOWN soft keys to scroll through list if needed.

NOTE: Select the Freeze Frame ( ) button to

request that frame data from the ECU when

faults are present.

4

Active Diagnostics

The Active Diagnostics screen displays active warnings
or faults with the appropriate Suspect Parameter
Number (SPN) and Failure Mode Indicator (FMI).
(Figure 4-9) Use the UP/DOWN soft keys to scroll
through list if needed.

Figure 4-10. Logged Diagnostics Screen

Figure 4-9. Active Diagnostics Screen

LeeBoy 685D Motor Grader 4-11

Operation

System Info

Scroll through the Menu list using the UP/DOWN soft
keys, then press the select ( ) soft key when the
cursor (>) points to the desired information. (Figure
4-11) The screen displays the engine model, serial
number, ECU Software ID, fuel rate, and the amount of
time since the last active regeneration process was
performed.

User Settings

These screens displays the following action items:
Screen Color; Brightness; Language; Units; Date and
Time.

Screen Color

Use the UP/DOWN soft keys and stop the cursor (>)
next to the action item Colors. (Figures 4-13 and 4-14)
Set your preference for day or night vision using the +/–
soft keys.

Figure 4-11. System Info Screen

Press the UP/DOWN soft keys to scroll to the screen

with application and conguration information. (Figure
4-12)

Figure 4-12. Application and Conguration

Information Screen

Figure 4-13. Set Night Vision Color Preferences

Screen

Figure 4-14. Set Day Vision Color Preferences

Screen

LeeBoy 685D Motor Grader4-12

Operation

Screen Brightness

Use the UP/DOWN soft keys and stop the cursor (>)
next to the action item Brightness. (Figure 4-15) Set
the brightness of the backlight by using the +/– soft keys.

Figure 4-15. Set Brightness Of Backlight Screen

Units

Use the UP/DOWN soft keys and stop the cursor (>)
next to the action item Units. (Figure 4-17) Set your unit
preference using the +/– soft keys. (US Standard, Metric
kPa or Metric Bar.)

Figure 4-17. Set Unit Preferences Screen

4

Language

Use the UP/DOWN soft keys and stop the cursor (>)
next to the action item Language. (Figure 4-16) Set
your language preference using the +/– soft keys.
(English, French, German, Spanish, Italian or Japanese)

Figure 4-16. Set Language Preferences Screen

LeeBoy 685D Motor Grader 4-13

Operation

Date and Time Setting

Use the UP/DOWN soft keys and stop the cursor (>)
next to the action item Date or Time. (Figure 4-18)

• Press the select ( ) soft key to initiate change to
the month value. Use the (+/–) soft keys to increment
or decrement the number.

• Use the DOWN arrow to reach the day value and year
value, using the +/– soft keys to make changes.

NOTE: A reboot is required for changes to the Date

Setting to take effect.

Tier 4F

During normal operation, the regeneration process
begins automatically. If for some reason automatic
regeneration does not proceed, the operator should
navigate to the Tier 4 screen from the Main Menu.
(Figure 4-19) Use the UP/DOWN soft keys and stop the
cursor (>) next to the action item.

The machine should be maintained in an operating
condition so the system can automatically regenerate.
(A complete listing of Fault Codes is shown in
Troubleshooting, Section 5.)

NOTE: Only an authorized technician can access

the Panel Conguration screen for service

purposes.

Figure 4-18. Time Setting Screen

NOTE: Pressing the “X” button closes the pop-up

messages.

Figure 4-19. Tier 4 Navigation

The engine speed will increase during regeneration
and there may be a noticeable sound difference.

It is important not to shut off the engine as the
regeneration cycle will fail and could possibly
damage the engine. Once regeneration is complete,

the engine will return to normal idle speed. If the
regeneration cycle fails, the ECU may attempt a second
regeneration.

LeeBoy 685D Motor Grader4-14

Operation

The HEST Lamp will illuminate and ash during the

regeneration process. (Table 4-3, Page 4-9) When
regeneration is complete, the engine will return to
normal idle speed and the HEST lamp will disappear.

DO NOT TURN OFF THE ENGINE,
ATTEMPT TO OPERATE THE UNIT, CHANGE ENGINE
RPM OR MOVE FROM PARK TO NEUTRAL WHILE
REGENERATION IS OCCURRING. This will abort the
regeneration process and require you to start the
process over.

EXHAUST TEMPERATURES WILL BE
EXTREMELY HIGH. BE SURE EXHAUST WILL NOT
COME INTO CONTACT WITH ANY FLAMMABLE OR
COMBUSTIBLE MATERIALS.

Regeneration Auto

The Regen Auto screen is the default screen
when navigating the Tier 4 as the system is set to
automatically regenerate when needed. (Figure 4-20)

Regen Request

To initiate the regeneration process, use the DOWN soft
key to select Regen Request and follow the procedure
below. (Figure 4-21)

Figure 4-21. Regen Request

Figure 4-20. Regen Auto Screen

BEFORE initiating the regeneration process:

1. Park the machine in a safe location where

the exhaust pipe does not face ammable or

combustible materials.

2. Engage the park brake and place the transmission
in either Park or Neutral.

3. With the engine running at IDLE speed, press the
Request Regen soft key to initiate the regeneration
process. (Figure 4-21) The HEST lamp will
illuminate.

4. Allow the regeneration process to proceed,
monitoring the machine and surrounding area for
safety.

NOTE: If you must stop the regeneration process,

DO NOT turn the engine off while

regeneration is in process. The Request

Regen soft key changes to Cancel Regen
once regeneration begins. Simply push
the (fourth) button under “Cancel Regen”
to communicate with the engine that
regeneration is unwanted or unsafe at this
time. Perform the regeneration process as
soon as possible.

4

LeeBoy 685D Motor Grader 4-15

Operation

Regen Inhibit

You can scroll to the Regen Inhibit mode if the
regeneration process is unwanted or unsafe. (Figure
4-22)

Be sure to perform the regeneration process as soon
as possible to prevent engine damage.

Figure 4-23. Driving the 685D Motor Grader

Figure 4-22. Regen Inhibit Screen

NOTE: Continued operation without completing

a parked regeneration can cause engine
damage. If the exhaust soot level builds up
too much, non-warranty factory assistance
from the engine manufacturer is required.

DRIVING THE GRADER

Motor graders can be used for a number of different
tasks in a variety of ways. This type of vehicle handles
differently than other industrial machines, with numerous
capabilities and techniques that require skill and
experience. Fine, delicate jobs must be done slowly,
while others such as snow removal or knocking rocks
off a gravel road can be done faster. Keeping control
of the grader during the entire operation is key for job
quality and overall safety.

The 685D Motor Grader offers several features to

maximize the machine’s potential and efciency while

grading. Regardless of your skill level, it is important
to read this manual thoroughly to understand the
machine’s performance. Pay particular attention to
Section 1, Safety and safety warnings contained
throughout this manual. Know and understand the
various controls and functions before operating the
machine.

NEVER allow bystanders near the
machine while operating. Never allow anyone but the
operator on the operator platform.

ALWAYS WEAR YOUR SEAT BELT.
Adjust the seat belt BEFORE driving the grader.
Failure to wear seat belt can result in serious injury
or death.

Because the 685D Motor Grader
is a large industrial machine, the operator should
ALWAYS sound the horn to alert others before
moving in either direction.

LeeBoy 685D Motor Grader4-16

2

Operation

Before driving on public roads, check
state and local laws that may apply to industrial
self-propelled machines. Additional lights, mirrors,

slow-moving vehicle emblems, or reectors may be

required.

STAY SEATED while operating
the grader. For additional safety, the grader will
automatically return to neutral and stop if the
operator stands while moving in forward or reverse.

Drive the grader with care and at
speeds compatible with conditions. Use extra
caution when operating over rough ground, on
slopes, while turning and “ditching.”

Drive cautiously when entering or
leaving a road shoulder to prevent a possible roll­over.

Keep in mind:

• Walk around the grader and visually inspect the

entire machine, ensuring the moldboard and any
other attachments are in an elevated position before
starting the engine. Perform an operational safety
check before operating the grader, ensuring all
equipment functions properly and all safety equipment

(i.e., re extinguisher) is present.

Adjust Seat

The operator seat suspension provides comfort by
absorbing some of the machine movements during
operation. It can also be adjusted for individual comfort.

(Figure 4-24)

Always make seat and seat belt adjustments BEFORE
driving the grader. The seat belt is designed for safe
operator retention if the machine is involved in an
accident or roller-over.

• Use the suspension adjustment knob to set the
suspension for operator weight. Rotate knob to
increase or decrease setting as shown on the knob
face.

• Use the Seat Position adjustment lever to move the
seat forward or backward. Pull up on the lever to
adjust and release to lock into place.

4

• Adjust the seat, steering console and mirrors
BEFORE driving the grader. Wear your seat belt!

• Stop at all railroad crossings and look both ways
before proceeding.

• Stop the grader before changing gears and before
changing directions while driving.

• Watch your speed. At higher speeds, inertia forces
tend to make the grader less stable. Use extra
caution at intersections.

• Keep both ends of the moldboard high and within
the width of the grader when travelling. Pay extra
attention to obstacles that can damage the blade, i.e.,
manholes, signs, and road debris, etc.

• Be aware of trafc behind you. Pull over to the side of
the road to allow vehicles to safely pass if needed.

• Ensure proper warning ags and/or devices are in

place to warn trafc of road construction, slow-moving
vehicle or other trafc alerts. If working at night,

ensure the work site is well-lit and well-marked.

• Caution should be taken to keep the blade away from
the tires in all driving and operational situations.

Seatbelt

1

Figure 4-24. Seat Adjustment

1 - Suspension Adjustment Knob

2 - Seat Position Adjustment Lever

• If using front or rear attachments, work in low gear and
reduce speed.

LeeBoy 685D Motor Grader 4-17

Operation

Adjust Steering Console

You can adjust the steering wheel console using the
console tilt lock toe pedal at the bottom of the steering
wheel column. (Figure 4-25) To adjust, simply depress
the toe pedal and push the steering console forward or
backward to a comfortable position, then release the tilt
lock pedal and it locks it into place.

Tilt Lock

Toe Pedal

Figure 4-25. Tilt Lock Toe Pedal

2-Speed High/Low

Grader speed is controlled by the 2-Speed High/Low
switch on the control panel to the right of the operator
seat. (Figure 4-26) This switch controls the rear axle
gearbox. Turn the switch down for Low gear. Always
use low gear while grading.

NOTE: You MUST STOP the machine on level

ground, place the FNR pedal in neutral and
engage the park brake to shift between high
and low gear.

E-Stop

Axle
Work/
Travel

2-Speed

High/

Low

Park Brake

Figure 4-26. 2-Speed, Axle Work/Travel,Park Brake

and E-Stop Controls

Axle Travel/Work

This switch controls the hydrostatic drive motor (Figure
4-26).

• Work Speed: Turn the switch DOWN for Work

speed. This maintains the hydrostatic drive motor
at a constant speed, but you can use the FNR pedal
to increase or decrease speed as needed. Use this
setting when grading for constant speed regardless
of load.

• Travel Speed: Turn the switch UP to select Travel

speed. This allows the grader to travel at a higher
speed when maximum torque is not needed, but
automatically slows when more torque is needed. Use
this setting when grading or traveling between job
sites.

ALWAYS move the FNR lever (or foot
pedal if equipped) SLOWLY after changing gears to
prevent lunging.

High Gear: Turn the switch UP for HIGH gear, used

when traveling to and from the work site. Maximum
speed in high gear is 20 mph (32 kph).

• Low Gear: Turn the switch DOWN for LOW gear.

The machine may reach up to 10 mph (16 kph),
depending upon speed in relation to torque condition.

NOTE: If equipped with the AWD option, it only

functions in Low gear.

Throttle

After selecting high or low gear, use the red-tipped
throttle lever beside the operator seat to increase or
decrease RPMs. (Figure 4-27)

A tachometer on the PV485 digital display controller
shows engine RPM speed. (Page 4-8)

• Pushing the throttle lever forward increases engine
speed.

• Pulling the throttle lever rearward decreases engine
speed.

LeeBoy 685D Motor Grader4-18

Operation

NOTE: Use slower ground speed when operating

with any attachment on the front or rear of
the grader.

After selecting high or low gear, use the red-tipped
throttle lever beside the operator seat to speed up and
slow down (increase or decrease RPMs). (Figure 4-27)

Throttle

Lever

Figure 4-27. Throttle Lever

Inexperienced grader operators
should always operate at slower speeds until gaining
the skills needed for faster operation. Extra care
must be taken by all operators in rough terrain,
bad weather and other hazardous situations to
prevent injury or even death. Before starting any
work, make sure you understand the machine, its
maneuverability, and its limitations.

Foot Brake

GENTLY

Press for

FNR

Reverse

Figure 4-28. FNR Pedal

To move the grader forward or in reverse:

1. Ensure the FNR pedal is in the neutral position, the
park brake is engaged, and follow the instructions
for Starting the Engine on Page 4-4.

2. Select High or Low gear.

NOTE: You MUST STOP the machine on level

ground and engage the park brake in
order to shift between High and Low speed
modes. (Figure 4-28)

3. Release the park brake by moving the switch
DOWN. (Figure 4-28)

• To drive forward, GENTLY push the front rail of

the FNR pedal forward with your foot.

• To drive in reverse, GENTLY push the back rail of

the FNR pedal backward with your foot.

• To stop, remove foot from pedal and allow it to

return to the center (neutral) position.

Press for
Forward

4

Directional Control

The 685D Motor Grader is equipped with a forward/
reverse variable-speed, hydrostatic transmission and
variable hydraulic motor that are controlled separately.

The FNR pedal controls the hydraulic ow and direction
of ow through the hydrostatic transmission. (Figure

4-28)

The FNR pedal is very sensitive.
Ensure nobody is near the grader before engaging
the FNR pedal and use only a little pressure on the
pedal when moving either direction to prevent the
grader from lunging.

LeeBoy 685D Motor Grader 4-19

Braking

Typically, operators use the FNR foot pedal for slowing
down by simply releasing it into neutral. This method is
recommended.

To quickly bring the grader to a complete stop, gently
step on the foot brake pedal. (Figure 4-28) Be sure
your seat belt is securely fastened as using the foot
brake will stop the grader very quickly and can abruptly
throw the operator in the direction of travel.

In an emergency, use the E-Stop (Emergency Stop)
button on top of the control panel. (Figure 4-26)

NOTE: If you use the E-Stop method, always check

brake function afterward as described
on Page 4-4. It is recommended that you
check brake function daily, but especially
important after E-Stop use.

Operation

Steering

Steering a six-wheeled motor grader may seem a
little complex for inexperienced operators, but skilled

operators know the extra wheels can boost efciency

and productivity in all applications. An option for
secondary steering is also available.

Keep the tires properly inated to get

the best results. Over-inated tires result in less

traction between the tire and road surface. Air­pressure differences in the rear tires can cause tire
slippage and grader bucking.

Operators steer the grader using a traditional steering
wheel. It is important to make slow turns to maintain
stability, especially for new operators. All operators
should become comfortable with driving and steering
the motor grader before operating at a work site.

The LeeBoy 685D Motor Grader has an articulated
frame, which means the front “boom” portion of the

machine can pivot left and right, adding exibility and

maneuverability for many applications. (Figure 4-29)
The front wheels can also be leaned in the direction of
the turn for more steering assistance in tight turns and
grading techniques. (Page 4-22)

Articulation

Articulating into turns gives the shortest turn radius
for close-quarter work, cul-de-sacs and corners.
Articulation also provides more control, maneuverability
and safety when operating in tight quarters, and
counters side draft when making a heavy cutting pass
or grading wet ditches. Experienced operators also use
articulation techniques to maintain a straight path when
working with a windrow or lessen the blade load without
using the circle.

The articulation angle can affect the stability of the

machine. Efcient and safe articulation requires skill and

experience to take advantage of its full capabilities.

Use articulation ONLY in WORK GEAR.
Articulation can adversely affect machine stability,
therefore, DO NOT articulate in Travel gear.

Other uses for articulation include:

Counteracting Side Loads: You can counteract side
draft when making a heavy cutting pass by articulating
the back frame toward the toe of the moldboard.

Reducing Blade Loads: Articulate the back frame
toward the heel of the moldboard to reduce blade loads
without “circling” the blade under the load or where
maximum circle torque has been reached. This reduces
the width of cut and the load.

Articulate

Left

Figure 4-29. Articulation

Use the articulate lever on the steering control column
to articulate left or right (Figure 4-30):

• To articulate to the left, push the articulate lever

forward.

• To articulate to the right, pull the articulate lever back.

Articulate

Right

Articulate Lever

Figure 4-30. Articulate Lever

LeeBoy 685D Motor Grader4-20

Inexperienced operators should
pay particular attention and watch both ends of the
moldboard blade when articulating to ensure the
blade is far enough away to prevent slashing a tire.

For new operators, it’s a good idea to practice turning
around in both directions to get familiar with using
articulation:

1. ALWAYS raise the moldboard (and any other

attachments) before turning the grader around.

(See Pages 4-23 to 4-24)

Operation

2. Set the Work/Travel switch to Work mode.

3. With the grader moving forward, turn the steering

wheel into the direction of the turn (the example in
Figure 4-31 is shown turning left), then move the
articulate lever forward if turning left or move the
lever back if turning right.

Figure 4-31. Turning Around Using Articulation

4. Upon completing the turn, move the articulate lever

back to it’s neutral position as you straighten the
steering wheel.

Figure 4-32. Front Wheel Lean

Front Wheel Lean

The proper use of the front wheels is a great aid in
steering and grading. The front wheels can be leaned in
either direction to lean the weight of the grader toward
and balance the weight against the pulling forces
(inertia) caused by the angled moldboard. The leaning
wheels, combined with the angled blade, increase
the grader’s ability to excavate and move material in a
specic direction.

The top of the front wheels are normally leaned in the
direction the material comes off the angled moldboard
(heel) to counteract inertia exerted on the front end of
the moldboard (toe). Leaning the front wheels can also
be used in conjunction with articulation to achieve an
even tighter turning radius if needed. Front wheel lean
helps keep the front wheels from sliding off the desired
straight line, shortens turn radius, reduces front sliding
on slopes, and is especially helpful when cutting ditches.

Use the front wheel lean feature:

• To increase slope angle capability when cutting high
or ditch-back slopes. It allows keeping the front
wheels in a vertical position when working slopes or
ditches to enhance steering in this terrain.

4

LeeBoy 685D Motor Grader 4-21

• For cutting ditches, lean the wheels toward the top of
the ditch.

• For high bank-cutting operations, lean the top of the
wheels toward the bank to counteract inertia.

• For side slope work, use articulation and lean the front
wheels up the slope.

Operation

Use the wheel lean lever on the steering control column
to lean the front wheels left or right (Figure 4-33):

• Push the lever forward to lean the wheels left.

• Pull the lever back to lean the wheels right.

Wheel Lean Lever

Figure 4-33. Front Wheel Lean Lever

MOTOR GRADER TERMS

To understand techniques and applications discussed
on the following pages, an understanding of grading
terms is essential:

Moldboard Blade: The moldboard blade is attached
the bottom of the moldboard. This is what makes
contact with the surface.

Moldboard Toe: This is the leading end of the
moldboard closest to the front wheels. (Figure 4-34)

Moldboard Heel: This is the trailing end of the
moldboard farthest from the front wheels.

Moldboard Angle: The angle of the moldboard as
measured from the moldboard toe to the center line of
the front frame.

Moldboard Pitch: Tilting the top of the moldboard
forward or backward from its vertical position is pitch.

Moldboard Side Shift: The moldboard can be shifted
outward up to three (3) feet right or left.

Turntable (Circle): This is the circular part of motor
grader located under the frame. The turntable (or circle)
rotates, which moves the moldboard blade left and right.

Windrow: This is the ridge of loose material, also known
as a berm, that pushes to the side while grading.

Angle

Crown: This is the process of building up the middle
part of a road bed so water will drain to the sides. This is
especially important for road maintenance projects.

Scarify: This term means loosening or ripping up
the grading surface. The 685D Motor Grader offers

scarier optional attachments that mount on the front or

rear of the grader.

Toe

Turntable

(Circle)

Heel

Figure 4-34. Moldboard Angle, Toe and Heel

LeeBoy 685D Motor Grader4-22

Operation

Pitching the moldboard forward or backward changes
the depth of cut across the entire moldboard. (Figure
4-36) Most grading passes start with the top of the
moldboard tilted about two inches (5 cm) ahead of the
bottom. For better penetration, tilt the moldboard more
rearward.

Figure 4-35. Grading with the Moldboard

MOLDBOARD

Grading is most efcient when material is consistently

rolling across the moldboard blade toe to heel. This is
achieved by proper moldboard angle while grading. The
operation of the entire motor grader machine rotates
around the moldboard blade and its precise movement
from the turntable and frame to the hydraulic cylinders
and gears. Levers on the steering column control
moldboard movement.

DO NOT allow others near the grader
while working, especially near the moldboard area.
Serious injury or even death can occur if a bystander
is struck by a moving moldboard.

Moldboard angle is one of the most important elements
of grading since the angle is what allows material to roll
along the moldboard. Improper blade angle and pitch
will overwork the grader and burn more fuel. It can also
cause unnecessary wear on the machine, moldboard
and attachments.

NOTE: When the blade is angled straight across

(perpendicular to the direction of
movement, it is at 0 degrees.

• Most grader work is done at moldboard angles of
10 to 45 degrees.

Forward Pitch (Tilt)

Figure 4-36. Moldboard Pitch (Tilt)

• For normal cutting action, the moldboard blade is
used in the upright position only slightly tilted forward.

• Tilting the moldboard forward allows material to roll
for spreading or compacting. Use a forward pitch to
make light cuts, spread material, smoothing material
and typical road maintenance projects.

There are high levels of wear and tear
on the moldboard blade, therefore, inspect the blade
daily. Replace the blade if worn or damaged. (See
Section 5) For maximum cutting edge life in road
maintenance work, maintain consistent moldboard
pitch as frequent position changes can result in
accelerated blade edge wear.

Counteract the resulting side thrust
(inertia) from blade angle and pitch by leaning the
wheels toward the moldboard heel. You may also
need to articulate slightly toward the blade toe for
additional side thrust control.

Rearward Pitch (Tilt)

4

• Lower moldboard angles (10 - 30 degrees) are

normally used for light, free-owing material.

• Higher moldboard angles (30 - 50 degrees)
are required when processing wet and sticky
material, mixing large windrows, and ditching,
among others. The greater the moldboard angle,
the more material is carried across, allowing for
deeper cuts and heavier grading.

LeeBoy 685D Motor Grader 4-23

Operation

2

1

NOTE: Continuing to push both moldboard lift

levers forward moves the moldboard into

“oat” detent, if equipped with this option.

3

4

5

5 - Moldboard Tilt Lever: Push this lever forward to tilt
the top of the moldboard blade forward. Pull the lever
back to tilt the top of the moldboard backward.

Floating means there is no down pressure
(except the weight of the blade). This is

useful for moving ne materials across the

surface, snow removal, and removing loose
material from a hard surface. Pull both

levers back to release the oat detent.

Figure 4-37. Moldboard Control Levers

1 - Moldboard Angle Lever: Push this lever forward to
rotate the moldboard blade to the right. Pull the lever
back to rotate the moldboard blade to the left. (Figure

4-37)

2 - Moldboard Slide Lever: The moldboard slide lever

enables the moldboard to shift outward (left or right)
as much as three feet (.9 m) to extend the moldboard
blade’s reach. Push this lever forward to shift the
moldboard to the right. Pull the lever back to shift the
moldboard to the left.

3 - Moldboard Lift Lever (Left): Push this lever forward
to lower the left side of the moldboard. Pull it back to
raise the left side of the moldboard.

4 - Moldboard Lift Lever (Right): Push this lever
forward to lower the right side of the moldboard. Pull it
back to raise the right side of the moldboard.

NOTE: Push both moldboard lift levers together to

lower the entire moldboard. Pulling both
moldboard lift levers back to raise the
entire moldboard.

Circle Turn Cushion Valve

The circle turn cushion valve is an optional valve built
into the steering and circle (turntable) turn circuits at the
factory. It protects both sides of the circuit from high
pressure spikes created by shock (extreme) loads. If
the moldboard strikes an immovable object, this valve
allows the circle (turntable) to turn, thus preventing
damage to the machine.

LeeBoy 685D Motor Grader4-24

Operation

GRADER ATTACHMENTS

The LeeBoy 685D Motor Grader can be equipped with a
variety of optional attachments to extend its capabilities
for grading, plowing and scarifying. These rugged
attachments can be hydraulically raised and lowered.

Front attachments are designed for maximum

operator visibility, safety and efciency. A variety of

interchangeable attachments can be mounted on

the front nose of the grader. A rear scarier option is

mounted at the factory, and typically is not removed.
(See Page 4-27)

Both front and rear attachment
lift cylinders and joints must be lubricated with
multipurpose grease weekly. (See Page 5-7)

Mounting Front Attachments

Replacing optional attachments to the front nose of the

grader is not difcult, but care must be taken to prevent

injury or damage as the attachments are heavy. It is
recommended an assistant help when mounting or
exchanging grader attachments.

ALWAYS use a sling or secured lift
to raise high enough for installation or removal on
the nose plate. Place a block under the attachment,
ensuring the attachment cannot fall and possibly
cause serious injury or damage.

Use the following procedure to mount a front attachment
(reverse procedure to remove):

1. If replacing a front attachment, rst disconnect and

cap hydraulic hoses to prevent contamination from
entering the hydraulic system. (Figure 4-40)

2. Using a sling or lift, raise the attachment so that all

six holes on the attachment plate align with the six
holes on the grader nose plate.

3. Install bolts and washers. Torque to 260 ft lbs.

Figure 4-38. Front Blade Option

The front blade attachment is a dozer blade used for

moving material, backlling and general plowing or

grading. Some operators also use it for snow plowing.

NOTE: Be especially careful if using the front blade

for snow plowing. Objects can be hidden
under the snow, so be sure to wear your

seat belt and work in the direction of trafc

when possible. Snow also adversely affects

traction, so use tire chains or equip the

grader with snow tires.

There are two front-mounted scarier options available:
A standard scarier and blade-mounted, ip-down
scarier

See your authorized dealer to purchase optional front
attachments.

Bolts and

Washers

Lift

Nose
Plate

Cylinder

Figure 4-39. Mounting Front Attachment

4

LeeBoy 685D Motor Grader 4-25

Operation

4. Uncap and connect the two hydraulic hoses as

shown in Figure 4-41.

• Connect hydraulic hose at top of the lift cylinder
to the right side of the grader nose.

• Connect hydraulic hose at bottom of the lift
cylinder to the left side of the grader nose.

Ensure the attachment is properly
secured before operating to prevent serious injury or
damage.

Hydraulic Hose

Connection

Figure 4-40. Connect Hydraulic Hoses

Front Blade Float

The front blade oat option allows the blade to follow

a varying surface using only the weight of the drawbar,

circle and moldboard. Blade oat prevents damage

to uneven surfaces but requires a hard surface such
as asphalt or frozen ground to prevent gouging the
surface. In areas with loose gravel on the road surface,

using blade oat may windrow the gravel onto the road

shoulder.

Turn the Front Float switch on the main control panel up
to the ON position to engage this feature. (Figure 4-42)

Operating Front Attachments

The front blade lever is used to raise and lower all front
attachments. This lever is located on the steering
control panel. (Figure 4-41)

• Pull lever rearward to raise the attachment.

• Push lever forward to lower the attachment.

Front
Float

Figure 4-42. Front Blade Float Switch

Front Attachments Lever

Figure 4-41. Front Attachments Control Lever

LeeBoy 685D Motor Grader4-26

Operation

Scarifiers

Scariers strong enough to penetrate material too hard

for the moldboard blade to cut or spread are available
that can be mounted on the front or rear of the grader.

Scarier “teeth” shanks “rip” and loosen earth, gravel,

and similar surfaces. After “scarifying” compacted or
hard material, the operator can then use the moldboard
to grade and reshape the road surface.

The rear-mounted scarier option features nine large,

replaceable teeth. (Figure 4-43)

A front blade-mounted, ip-down scarier option offers

the convenience of using either component at the front
of the grader. (Figure 4-45) If the job needs scarifying

operations, mount the attachment with the scarier side
down. Or “ip” attachment the other direction and mount

on the nose plate to use the dozer blade.

Scarier

Dozer
Blade

Figure 4-45. Front Blade-Mounted, Flip-Down

Scarier Attachment

Keep these items in mind when using a scarier:

4

Figure 4-43. Using the Rear Scarier

The front scarier option also features nine replaceable

teeth mounted on a plow-shaped plate. (Figure 4-44)

Figure 4-44. Front Scarier Attachment

• Be sure to drive in a straight line when the scarier is
in the ground to avoid breaking the teeth.

• The proper way to reshape a dirt road with ruts
and potholes is to scarify its surface to the depth
of the depressions to break up all the compacted
surrounding surface.

• To control dust, especially on a dirt road, wet the
surface. This also helps supporting the binding of

ll material if the dirt road will be compacted after

grading.

• To scarify extremely hard or compacted material,

remove alternate scarier teeth. DO NOT remove

more than ve teeth as the force against the

remaining teeth could shear them off.

NEVER make sharp turns or articulate

with scarier teeth in the ground. DO NOT drag the
scarier teeth along hard surfaces such as pavement

or large rocks. Damage or bent/broken teeth can
occur.

Scarify down the slope for better
stability whenever possible. If scarifying or ripping
across a slope, keep the moldboard parallel with the
front axle, extended toward the downhill side, and
lowered close to the ground to provide protection
against rolling over.

LeeBoy 685D Motor Grader 4-27

Operation

Operating a Scarifier

Use the following procedure for scarifying roads or

other areas using the optional rear scarier:

1. Raise the moldboard at least one foot (.304 m) off
the ground to allow unrestricted movement. Rotate
the moldboard so that it is perpendicular with the
frame and pitch the blade forward halfway.

2. Position the grader ahead of the working area and
ensure the front wheels are vertical.

3. Slowly move the grader forward.

If the rear wheels lose traction, raise

the scarier until the wheels regain traction.

4. At the starting point for the job and while still moving,

lower the scarier.

• If equipped with a rear scarier, use the rear

scarier lever shown in Figure 4-46.

Replacing Scarifier Teeth

The scarier tooth supports are adjustable and secured

with pin locks.

Always support the scarier and other

attachments using a block or sling before servicing.

1. Raise the scarier. Support the scarier on

blocks or use a sling for support.

2. Using a pry bar or lock pin tool, remove the shank

lock pin and tooth from the scarier frame. (Figure
4-47)

• If only removing tooth, be sure to store tooth
shank and locking pin together for later use.

Pin

Lock

(Pin

Lock)

Tooth
Shank

Rear Attachment Lever

Figure 4-46. Rear Attachment Control Lever

5. When nished with the rst pass, raise the scarier
by pulling rearward on the scarier lever.

6. If more passes are needed, repeat the procedure.

DO NOT remove more than ve teeth

as the force against the remaining teeth could shear
them off.

Figure 4-47. Scarier Shank Lock Pin and Tooth

3. Position new tooth shank into the desired slot on the

scarier frame.

4. Insert lock pin. It is recommended using a rubber
hammer if you wish to hammer the lock pin back into
place to prevent damage.

LeeBoy 685D Motor Grader4-28

Figure 4-48. Operating the 685D Motor Grader

OPERATING TECHNIQUES

The information provided on the following pages are
basic grading techniques. Every road construction
project is different with a unique set of variables
operators must take into account, such as terrain and
weather conditions, that affect operation. Mastering
such versatile grading skills requires experience.

Grading Tips

The following are general tips for project success when
operating your motor grader:

• Keep your grader and its attachments in good
mechanical condition. Pay extra attention in checking
for wear on the moldboard blade edge often. If
the blade edge is worn or damaged, contact your
authorized dealer for replacement.

• Be very familiar with the controls, attachments and
component functions. Be especially familiar with
blade movement that are made possible by the
hydraulic controls for different tasks. Know the
settings needed, angle, height, and what you want the
blade to do before you lower it to the ground.

Operation

• Moldboard angles of 10 - 30 degrees can be used for

light, free-owing material. Higher angles of 30 - 50

degrees is required when processing wet or sticky
material, mixing large windrows, and ditch work.

• Remember that pitching, or tilting the top of the
moldboard tip forward or backward, changes the
depth of the cut across the entire moldboard.

• If material starts to ow around the leading end of the
moldboard or the rolling action stops, increase the
blade angle.

• Apply only enough downward pressure with the
moldboard to accomplish the task. Excessive
pressure, especially on hard, dry surfaces, causes
rapid cutting edge wear, requires more horsepower
and fuel, and reduces productivity.

• Choosing the right speed for a task is just as important
as the moldboard angle. Drive slowly for delicate
work, but faster if removing rocks from a road surface.

• Avoid moving material more often than needed.

• Trimming is much easier with good compaction.

• If dressing a road, the surface should be moist
whether from rain or hosed from a water truck. Ensure
there is good drainage by grading with appropriate
crown.

• Articulating the rear frame toward the toe of the
moldboard by 2 - 5 degrees helps reduce the
machine’s tendency to bounce. This is extremely
effective when cutting “washboards.”

• Wheel leans can help an operator make steering
adjustments without taking hands off the controls.
Wheel lean is also useful for moving heavy windrows.

• Graders remove snow the same as snow plows. Be
sure to raise the moldboard 1/2 to 1 inch (1.3 - 2.5 cm)
if removing snow from uneven pavement or other
surfaces to prevent damage to the blade.

4

• Every job requires a specic blade setting with the
right speed for optimum production. Be familiar with
the moldboard blade movements. Know what you
want to do before lowering the moldboard.

LeeBoy 685D Motor Grader 4-29

Operation

Grading Around Objects

Avoid hazards and obstructions
such as overhangs, ledges, slide areas, electrical
lines, underground cable, water main and gas lines,
etc., that can result in serious injury or even death.
ALWAYS request assistance from the appropriate
authorities if operating close to electrical or gas
lines, water main and any underground cables.

Method 1: Slowly drive around.

Method 2: Use moldboard slide.

There are two basic methods for grading around objects

(Figure 4-49):

Method 1:

1. Reduce speed before approaching object.

2. Slowly maneuver the grader around the object,
driving as close as possible (depending upon
skill level) to reduce the amount of hand shoveling
needed.

Method 2:

1. Reduce speed before approaching object.

2. Use the moldboard slide shift lever to shift the
moldboard in the opposite direction of the object.
(Figure 4-50)

• Pull lever to slide the moldboard left.

• Push lever to slide the moldboard right.

Moldboard
Slide Lever

Figure 4-49. Grading Around Objects

Figure 4-50. Moldboard Slide Lever

3. Slowly follow the shape of the object, sliding the
moldboard more if needed.

4. Slide the moldboard back to its original position
after passing the object.

LeeBoy 685D Motor Grader4-30

Operation

Spreading and Leveling

The 685D Motor Grader can also be used for spreading,
leveling, planing and side casting material. Graders
have less power and traction than dozers, but can move
the loads faster. The moldboard blade is lower and
more concave, which gives the grader increased rolling
action of the load so more material is pushed without
spilling over the top.

NOTE: Do not pile windrows in front of the rear

wheels because it will adversely affect
traction and grader control.

• If there is space to work around the sides of the
windrows, extend the blade well to the side and
reduce the windrow using a series of side cuts.

• Leveling large windrows may require two or more side
cuts.

Planing

Set the blade at an angle to “plane off” irregular surfaces

and use that material to ll hollows:

1. Cut enough material to keep some in front of the
blade, moving the loosened material forward to
distribute it evenly.

2. On the next pass, pick up the windrow left from the
trailing edge of the blade.

3. On the nal pass, make a lighter cut and lift the
trailing edge of the blade enough to allow surplus
material to under rather than around the end to
avoid leaving a ridge.

Figure 4-51. Leveling a Windrow

• You can also use articulation and lean the wheels
slightly to move and spread large windrows:

• Angle the moldboard blade toward the windrow,
tilting it forward slightly. Be sure the moldboard is
positioned high enough above the surface to obtain
the desired depth.

• Lean the front wheels slightly in the opposite direction
to overcome side thrust.

4

Figure 4-52. Planing

Sidecasting

The side casting technique is often used for lling

ditches, shaping and road maintenance.

• To shape and maintain most roads, the moldboard
blade should be at an angle of 25 - 30 degrees.

• Decrease the angle for spreading windrows.

• Increase the angle for hard cuts and ditching.

1. Angle the moldboard blade so the load being

pushed at the toe rolls off the heel. This rolling
action assists side movement.

2. Move forward, side casting the material into the

ditch.

3. Make the passes necessary to compact the ll.

LeeBoy 685D Motor Grader 4-31

Operation

Figure 4-53. Slope Work

Slope Work

Use extreme caution and drive slowly
while working on slopes. While unlikely, the grader
can roll over and result in serious injury or even
death.

Operating the grader on slopes can be dangerous,
especially for inexperienced operators. Maneuvering
on or along steep slopes requires excellent operator
skills and experience.

The slope perpendicular to the machine’s direction of
travel is commonly known as “side sloping.” Typically
steep slopes require articulation to navigate, but ONLY
experienced operators familiar with the machine
should perform this type of work.

The slope parallel to the machine’s direction of travel
that affects the grader’s ability to travel up or down
terrain is known as gradeability. This is established
by the grader’s ability to stop without skidding the tire
while moving downhill. The grader can climb steeper
slopes than it can safely descend. If working on hills and
slopes, it is important to consider the following points:

• New lls may give way with the grader’s weight while
rocky surfaces can cause side slipping.

• Position the moldboard toe outside and behind the
uphill wheel so the moldboard heel deposits material
outside the downhill tandem wheels.

• Excessive loads or side draft can also cause wheel
slippage as the downhill tires “dig in” and increase the
angle of the grader.

• Articulation and wheel lean angles also affect the
stability of the grader. Only experienced operators
should articulate when working on slopes.

• Lean the front wheel vertically and position the uphill
front wheel on the edge of the windrow created from
previous pass to provide extra stability and create an
even grade.

If possible, make a rst pass from above the slope to

establish the moldboard blade angle you will need.
Experienced grader operators can also use articulation
for added reach, ensuring the tandem wheels (rear) are
on a level surface.

1. Angle the toe of the moldboard outside and behind

the uphill wheel, with the moldboard heel downhill
outside the tandem wheels.

2. Tilt the moldboard forward slightly and make the rst

pass.

3. On the second pass, lean the front wheels toward

slope and slightly articulate rear wheels down slope
to increase machine stability.

4. Make as many passes as needed for the desired

result, then clean with the moldboard less angled
but tilted more forward away to clean any windrow
away from the bottom of the slope.

• NEVER climb a slope steeper than you can safely
descend.

• At higher speeds, inertia forces make the grader less
stable. If you must work on a slope, work SLOWLY.

• Attachments can cause the grader to balance
differently. Ample allowance for the moldboard
and any other attachments should be made where
the terrain or surface is uneven to avoid damage to
attachments or injury from an unbalanced machine.
The position of the moldboard can affect the stability
of the grader considerably.

LeeBoy 685D Motor Grader4-32

Figure 4-54. Bank Cutting

Operation

Bank Cutting

1. Make a rst pass at base of bank to level and
smooth a platform for the machine.

2. Tilt the moldboard slightly forward and sharply
angle the moldboard so the heel is in the opposite
direction of the bank you’re cutting. (You can
articulate slightly if more reach is needed.)

3. After making the bank cut, make a second pass with
the moldboard less angled but tilted more forward
to clean any loose material from the bottom of the
bank.

Grading an “S” Curve Shoulder

1. Slowly approach the rst curve.

2. Lean the front wheels slightly toward the opposite
direction of the curve to counteract side thrust.

• Push the lever forward to lean the wheels left.

• Pull the lever back to lean the wheels right.

3. Position the toe of the moldboard behind and
outside the front wheel closest to the edge of the
shoulder (in the opposite direction of the wheel
lean).

4. As you straighten the grader when nishing the
curve, return wheels to their normal position.

5. Slowly approach the second curve and repeat
Steps 2 - 4.

NOTE: If a windrow has been created while grading,

make a “clean-up” pass and reshape the
shoulder if necessary.

Figure 4-55. Road Maintenance

ROAD MAINTENANCE

Much of a grader’s road maintenance work involves
smoothing, shaping the travel surface and providing
drainage to prevent road deterioration.

Begin road maintenance work by tipping the top of
the moldboard approximately two inches ahead of the
cutting edge, then adjust to the material conditions.
Maintaining the material rolling action across the
moldboard blade reduces the horsepower required and
provides maximum productivity.

• The most important factor in road maintenance
grading is providing and maintaining a good drainage
system. Drainage of water from the road surface to a
ditch, even a minimal ditch, helps maintain good road
conditions longer.

• Remember that tipping the moldboard forwards or
backwards changes the depth of cut across the entire
moldboard. The best time to reshape earth and gravel
roads is after it’s rained. Dry roads should be sprayed
with water before grading for easy compaction and to
minimize dust while working.

• Articulating the rear frame toward the tow of the
moldboard 2 - 5 degrees helps reduce the motor
grader’s tendency to bounce.

• Keep the turntable circle clean. Material buildup may
increase wear and prevent smooth material rolling
action, reducing productivity.

4

LeeBoy 685D Motor Grader 4-33

Operation

• For the widest possible pass on the travel surface,
keep the moldboard angle as square to the frame

as possible. If material starts to ow around the

moldboard toe or the rolling action stops, increase the
blade angle.

• The moldboard blade’s tip angle should be position
with the cutting edge at 90 degrees to the road
surface so the downward pressure places less stress
on the cutting edge and retaining bolts. To cut hard

material or for nishing work, tilt the moldboard further

forward.

• Keep your travel speed between 3 - 5 mph (4.8 - 8
kph) for maximum productivity with less machine
bounce. At higher speeds, the grader can “lope” or
bounce, causing ridges and depressions. Moisture,
material quality and road grade stability vary, so
operating speed must be slow enough to ensure the
grader remains stable.

• Grader efciency is directly proportional to the
number of passes made. Operator skill and project
good planning are most important for eliminating
unnecessary passes that increase time and cost of
the job.

• Before performing any road maintenance project, a

formal project plan or specications to control the

work is an important factor in road improvement. Be
sure to check with local and state departments of
transportation about roadway construction standards
and requirements before beginning the project. You
may also need to contact utility companies to verify
location of any utilities within the construction area
and arrange for temporary location if needed.

• Tree stumps, large rocks and other obstructions need
to be cleared and removed before grading. Tree
branches extending over the roadbed may also need
to be trimmed for adequate grader clearance.

• On straight sections, steer the grader as straight as
possible to maintain a straight shoulder and uniform
crown on the road.

Figure 4-56. Grading a Dirt or Gravel Road

Gravel and Dirt Roads

Level and maintain the gravel or dirt surface by working
the material across the road (or runway) from one side
to the other. The surface is easier to work with if it’s
damp. If grading a dry surface, work material from the
edges and shoulders toward the center to maintain a
satisfactory result.

Good gravel road maintenance depends upon proper
use of the grader and quality gravel that is the right
size correctly distributed onto the road surface. It is
important to properly shape the road surface before
spreading gravel to achieve quality results. The gravel
should also be damp.

Trafc, wind and grading can kick up

dust and cause loss of any binder material present,
so be cautious when disturbing dry road surfaces.
It is recommended that road maintenance grading
projects be done just after it rains, or use a water
truck to dampen the surface before grading. A damp

surface results in a better, smoother nish.

1. Start at the edge of the road shoulder and cut the
material into a windrow, depositing it toward the
center of the road (outside the tandem wheels).

2. Angle the moldboard 30 - 50 degrees and pitch
halfway back to cut. This removes ridges and
potholes.

NOTE: Scarify the surface rst on dirt roads with

deep ruts or extremely rough surfaces.

3. Lower moldboard until the toe and heel slightly
touch the ground, just enough to penetrate the
surface.

LeeBoy 685D Motor Grader4-34

Operation

4. Lean the front wheels toward the moldboard heel as
you work toward the center of the road, maintaining
a straight course.

• You may need to adjust the moldboard slightly to
carry the material the length of the project.

• Pitch the moldboard forward and use very little
down pressure to feather the material at the end of
the pass.

5. Make as many passes as needed, continuing to
push the material toward the road center.

6. Repeat Steps 1 - 5 on the other side of the road.

7. Finish the road crown using the procedure
described in the next section.

Crowning the Road

Crowning a road is simply constructing the surface so
the center of the road is higher than the road edge to
allow water to drain. If the crown is not built properly,
water will be trapped and break up the road crust,
producing potholes and ruts. If also constructing

ditches, complete the ditch work rst, grading the

excess material to the center of the road, creating a
windrow.

• For good drainage, a road should have a crown of
1/3 inch (8.4 mm) to 1 /2 inch (12.7 mm) per foot (305
mm) as measured from the center of the road to the
outside edge where the road meets the shoulder.

To establish the road crown in the center and smooth
any ridges left:

1. Position the moldboard parallel to the front axle.

2. Raise the moldboard heel and tilt the moldboard

forward between 60 - 75 degrees.

3. Drive the grader straight down the center of the

windrow, keeping the moldboard high enough to
feather the material on both sides of the grader.
You can increase speed as this throws loose
material from the blade, feathers the material, and
blends the top.

4

Figure 4-57. Crowning

Ditch Work

Ditch work is typically done on the right side of the
grader. Cutting a ditch is called “Vee Ditching.”
Remember the following guidelines for ditch
construction:

• Make each ditch cut as deep as possible (without
stalling or losing control of the grader).

• Start with the blade positioned so the moldboard toe
is in line with the center of the lead wheel. Bring each
successive cut in from the edge of the bank slope so

the toe is in line with the ditch bottom on the nal cut.

• Ensure the moldboard is high enough off the surface
to allow unrestricted movement.

• Side shift the blade if needed to extend the moldboard
edge to the outside edge of the front wheel.

LeeBoy 685D Motor Grader 4-35

Operation

1. Begin a ditch by establishing a marking cut.

• Pitch the moldboard forward halfway until top
of the moldboard is in line with the center of
the front tire, raising the heel just ahead of rear
wheels (so dirt spills between the rear tires).

• Rotate the moldboard so the toe is just behind
the outside edge of the right front wheel (about a
45-degree angle).

• Lean wheels toward the discharge end (heel) of
the moldboard.

• Make the rst cut light to establish the line of the
ditch.

2. Move the grader forward. As the front wheel
passes over the starting point of the ditch, lower
the moldboard toe, applying enough pressure to
penetrate the grounds surface 3-4 inches (7.6 - 10
cm).

3. On the second pass, position the wheels in the

ditch made by the rst pass to compensate for side

thrust and make a deeper cut. You can increase
speed on the second pass and apply as much down
pressure on the moldboard toe as the grader can
handle.

4. Continue along the ditch line until reaching the

nishing point.

NOTE: When making ditch cuts, windrows form

between the heel of the blade and the rear
wheel. Move or level these windrows when
either the ditch is at the planned depth or
the windrow becomes higher than the road
clearance of the grader. You can use this
material for the road shoulder.

6. Establish the road shoulder by sliding the
moldboard blade farther out, rotated to a 90-degree
angle (perpendicular with the frame), and tilted
slightly forward. Apply only enough downward
pressure to clean-up the ditch and skim the material
smoothly across the road shoulder.

Cul-De-Sacs

Articulating the grader helps when grading cul-de­sacs. Articulate the rear frame away from the curb (or
cul-de-sac radius), being careful not to articulate too
fast, and lean the wheels to keep the moldboard toe
position to the curb (or cul-de-sac radius). Remember
the center line crown extends all the way to the center
of the cul-de-sac, so do not straddle the crown or grade
perpendicular to the cul-de-sac entrance.

1. Angle the moldboard about 30 degrees and tilt
forward 5 - 10 degrees, keeping the toe toward
the outside cul-de-sac radius. Start grading at the
perimeter of the cul-de-sac in a circular pattern,
working material toward the center as you go.

2. To begin nishing the cul-de-sac, drive grader in the
opposite direction at the outside edge, forming a
windrow toward the center.

3. Tilt moldboard forward slightly and move windrows
toward the center of the cul-de-sac, checking the
slope as you grade.

4. When you have nished pushing all the excess
material to the center, straighten the moldboard
(parallel to the front axle) and push the excess
material out of the cul-de-sac entrance.

5. As dirt builds up between rear tires, make a clean­up pass, pushing material toward the road edge:

• Side-shift the moldboard blade toward the ditch
with front wheels positioned outside the windrow.

• Angle the moldboard heel between rear wheels
and pitch the moldboard blade slightly forward.
Be sure the moldboard toe is well beyond the
windrow to minimize spillage back into the ditch.

• Articulate the grader slightly to deposition
windrow between the rear tires if needed.

• Feather the material by raising and tilting the
moldboard blade slightly forward until all the
material passes under it.

LeeBoy 685D Motor Grader4-36

Operation

TRANSPORT

LeeBoy recommends transporting the grader on a at-

bed trailer rather than towing.

Remember the following guidelines:

• Ensure the ramp, trailer and transport vehicle are
strong enough to safely handle the size and weight of
this large industrial machine.

• Raise the moldboard and any other attachments to
the highest position. Pay close attention to clearance
when entering the ramp.

• NEVER load the grader onto a transport trailer without
assistance from another person serving as a ground
guide.

• Park the trailer in a clear, level area when loading or
unloading the machine.

• Keep the loading area clear. Work slowly and
carefully to avoid accidents.

• DO NOT place tie-down chains or cables over or
against hydraulic hoses, cylinders or valves, etc., to
prevent machine damage.

Check local and state regulations for

height restrictions on the transit route.

Ensure the transport route is free of

low bridges and other obstacles that can damage

the machine and/or cause a trafc accident that can

result in serious injury or even death.

Use extra caution steering when
loading and unloading the grader as slight steering
changes on ramps and trailers can cause the
machine to fall off. Serious injury or even death can
occur.

Loading

To prevent damage to the machine
undercarriage, frame and components, reduce
speed before wheels come into contact with loading
ramps or any abrupt change in the surface. The drive
system or other components can be damaged by
excessive shock.

1. Center grader with the ramp.

2. BEFORE moving onto the ramp:

• Ensure the hauling vehicle has its park brake
engaged.

• Ensure the moldboard and any attachments are
raised. The moldboard should be perpendicular
for added balance when moving up the ramp.

• Use only WORK gear.

3. SLOWLY drive the grader straight forward up the

ramp to position machine in the center of trailer.
The grader should centered between the left and
right side of the trailer.

4. Engage park brake and set engine speed to IDLE.

5. Angle the moldboard so it is inside the width of the
trailer. Lower the moldboard and any attachments
(without applying down-pressure) once the grader
is situated. Block the moldboard and all wheels.

6. Turn off the engine. Relieve residual hydraulic
pressure by operating all the console control levers
after turning off the engine.

7. Secure machine to the transport trailer using the
tie-down procedure that follows.

8. Ensure cab doors and all engine access panels are
closed and secured.

4

Figure 4-58. Correct Loading and Unloading

Position

LeeBoy 685D Motor Grader 4-37

9. Cover the exhaust with heavy-gauge plastic to
prevent turbo damage. Don’t forget to remove

before starting the engine!

Operation

Unloading

1. Remove tie-down equipment.

2. Start the engine and allow machine to warm a few
minutes to ensure the hydraulic pump is providing

sufcient ow to operate all functions properly.

3. BEFORE backing machine down ramp:

• Ensure the moldboard and any attachments are
raised and secured to the machine frame.

• Use only WORK gear.

• Ensure the hauling vehicle has its park brake
engaged.

4. SLOWLY move machine down the ramp.

Tie-Down Procedure

1. Position grader in center of the trailer.

2. Place chocks at wheels to prevent machine
movement while securing and during transport.

3. Attach chains to the front and the rear D-ring tie­downs. (Figure 4-59). The front D-ring is located
under the frame. The rear D-rings are located on
each side of the frame behind the rear tandem tires.

4. Ensure that all chains are tightly secured before
transporting the grader.

TOWING

LeeBoy strongly recommends transporting the grader
on a truck trailer, but if you must tow the machine for a
short distance, use a tow hitch. A professional towing
service is recommended.

Improper towing methods can result in

severe personal injury or even death.

Stay clear of tow chains or cable,
especially when tension is applied. A broken cable
or chain can cause severe injury or even death. DO
NOT allow bystanders near the tow truck and grader
at any time. DO NOT allow the tow chain or bar to
contact any grader components.

Some state and local laws prohibit or
limit the use of tow chains on highways. Check state
and local regulations before towing with chains.

If the grader must be towed, remember the following
guidelines:

• DO NOT tow the grader a long distance. Transport it.

• Operator must be in the operator’s seat to control

steering and braking when towing the grader.

• NEVER tow the grader more than 5 mph (8 km/h).

• Ensure the tow truck has sufcient braking capacity to

stop the grader while being towed.

• Ensure the towline or tow bar is in good condition and

strong enough to tow the grader.

D-Ring

Figure 4-59. Tie-Down Locations

D-

Ring

• Sudden cab movement can cause the towline or tow

bar to break. When turning, keep the towing angle
and speed to a minimum. Proceed gradually and
smoothly, avoiding any sudden turns, braking or jerky
steering movements.

To tow the grader:

1. Block the wheels to prevent machine for moving

while preparing to tow the grader.

2. Ensure the FNR lever (or pedal) is in the NEUTRAL

position and the park brake is engaged.

3. Disconnect, plug and tag the hydraulic hoses on

the rear axle, being very careful to prevent any
contamination when plugging the hydraulic hose

ttings.

4. Use a small screwdriver or small pry bar to pull out

the shifting rod as far as it will go, then push it back

until you nd neutral. (Figure 4-60)

LeeBoy 685D Motor Grader4-38

OPTIONS

Shifting

Cab Option

Operation

Rod

Figure 4-60. Shifting Rod

5. Locate both brake release screws on bottom of the

rear axle. (Figure 4-61)

Release Screw

The 685D Motor Grader offers the option of building
the machine with a comfort cab in lieu of the standard
canopy. (Figure 4-62)

Additional options for the cab include:

• Rear windshield wiper and washer.

• Air conditioning and heat with defroster.

• AM/FM radio.

4

Figure 4-61. Brake Release Screw

6. Using a caliper, measure the exact extension of the
screw and record measurement. Turn the screw
clockwise as far as it will go to release the brakes
for towing.

7. Repeat on the other side.

8. Raise and secure the moldboard and any other
attachments before towing. Use chains or cables
that are in good condition to secure attachments.

9. Fasten chain (or tow bar) to the front D-Ring.

10. Mark the center of the towline or tow bar with an

orange ag and attach a “Slow-Moving Vehicle” sign

onto the rear of the grader.

11. Remove wheel blocks and activate all warning lights

to alert trafc.

12. After towing the grader, readjust the brake release
screw according to the recorded measurement.

LeeBoy 685D Motor Grader 4-39

Figure 4-62. Cab Option

Float

Operation

Sliding Moldboard

The 685D Motor Grader is equipped with an 11-foot
(3.35 m) sliding moldboard. A 12-foot (3.65 m) sliding
moldboard option is also available for even more reach.
See your LeeBoy dealer for installation.

Circle Side Shift

The circle side shift option allows the circle (or
turntable) and moldboard to reach far beyond the
wheels on either side. In its extreme position, it allows
the grader to position the moldboard blade in the bottom
of a highway ditch while traveling on secure footing on
the highway surface. For slope trimming, the moldboard
can swing out to either side and position at any angle
from horizontal to vertical.

Secondary Steering

The secondary steering option serves as a temporary
emergency steering back-up in the event of engine
failure or loss of hydraulic pressure. The secondary
steering system has a separate electrically-driven pump

that delivers hydraulic uid to the steering motor in the

event primary steering fails due to loss of hydraulic
pressure. This is an emergency feature that allows the
ability to steer the grader off the road, but is not intended
for traveling any distance as it will overheat quickly.

• To activate, turn the secondary steering switch on the

control panel up to the ON position. (Figure 4-64)

• Turn the switch down to disengage secondary
steering.

Secondary

Circle Side
Shift Lever

Figure 4-63. Circle Side Shift Lever

The circle side shift lever is located on the steering
control panel. (Figure 4-63)

• Pull lever rearward to shift the circle (and moldboard)
left.

• Push lever forward to shift the circle (and moldboard)
right.

Steering

AWD

Front

Figure 4-64. AWD, Secondary Steering and Front

Blade Float Switches

LeeBoy 685D Motor Grader4-40

Operation

All-Wheel Drive (AWD)

The AWD option provides additional traction in all
weather conditions. The tires maintain a better grip
during rain or snow, in mud, and on gravel. AWD
provides better torque power for grading, pulling or low­speed climbing and is especially useful when operating
on loose, low-traction surfaces.

DO NOT modify or alter any switch or

other component in the AWD system. Modications

can cause premature engagement or prevent
disengagement of the system, which could cause
injury and/or property damage.

NOTE: The Axle Work/Travel switch must be in the

Work position for AWD to function. AWD will
not function in the Travel mode.

To activate AWD:

1. Set the Axle Work/Travel switch to Work mode.

2. Turn the AWD switch to the ON position. (Figure
4-64)

3. Turn the AWD switch down (OFF) to disengage
AWD.

Cold Weather Engine Package

Reverse Camera System

A reverse camera system is also an available option.
(Figure 4-66) This additional safety feature assists
operators when moving in reverse by using the rear
camera to see directly behind the machine when moving
in reverse.

4

Figure 4-66. Back-Up Camera

The Cold Weather Engine package provides the ability
to keep the coolant system warm when the grader is not
in use for easier engine start-up during cold weather.
Simply plug the connector into the engine as shown in
Figure 4-65, then plug the other end into a standard
electrical outlet (110-volt). Be sure to remove the cord
and keep it in a safe place when not in use.

To Outlet

Connector

Figure 4-65. Cold Weather Engine Plug-In Location

LeeBoy 685D Motor Grader 4-41

Operation

NOTES

LeeBoy 685D Motor Grader4-42

Section 5

MAINTENANCE

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

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

Page

5

LeeBoy 685D Motor Grader

5-1

Maintenance

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Change Hydraulic Oil and Filter . . . . . . . . . . . . . . . . . . . . . 5-25

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

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

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

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

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

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

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

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

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

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

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

LeeBoy 685D Motor Grader5-2

Maintenance

MAINTENANCE SCHEDULE

This section gives the necessary procedures for
routine and general maintenance on the LeeBoy 685D
Motor Grader. Keep the grader clean and follow all
maintenance schedules and procedures to maintain the
machine in top operating condition.

Maintenance must be a planned program including
periodic machine inspection and lubrication (see
Lubrication, Pages 5-6 and 5-7).

The operator should inspect the machine daily. Worn or
damaged parts should be replaced or repaired promptly
to prevent damage to other areas of the machine. Daily
inspections should include checking for loose bolts,

uid leaks, worn or damaged hoses, and debris or dirt

accumulations to prevent potential service or safety
problems.

The maintenance program should be done based on the
machine “Operating Hours” recorded on the hour meter
or by following the Periodic Schedule shown below:

Table 5-1. Periodic Maintenance Schedule

SYSTEM ITEM

Lubricate steering and tie rods, drawbar ball, lift
trunnions, and trunnion housing.

Lubricate hydraulic cylinder ends, front blade
pivots, moldboard pivots, axle pivot, stabilizer rod

Grader

Hydraulic

Engine

Electrical

Fuel Replace fuel lter cartridge. X

DEF

ends, turntable, and control levers.

Lubricate articulate joint. X

Lubricate king pin bearings. X

Check and adjust toe-in if needed. X

Check hydraulic oil level. Add more if needed. X

Replace hydraulic oil. X

Replace hydraulic charge and return lters. X

Check drive axle, gear box and planetary hub oil
levels. Add more gear oil if needed.

Change drive axle, gear box and planetary hub oil. X

Check gear box breather. X
Check oil level - Change at initial 50 hours. X

Replace engine oil and oil lter cartridge. X

Check engine coolant. Add more if needed. X

Change engine coolant. X

Check air cleaner indicator. Clean or replace if
indicator is red.

Change air cleaner lter. X

Check engine drive belt. Replace if needed. X

Inspect the drive belt tensioner, idler and drive
pulleys for dirt, wear and cracks

Check battery, cables and connectors. X

Service battery. X

Clean DEF tank lter (or replace if needed). X

Clean DEF Dosing Unit lter (or replace if needed).

Every

X

X

Inspect every 3000 hours (or 3 years). Clean or replace if
needed.

Every

10 Hours

X

Every

50 Hours

Every

100 Hours

X

250 Hours

Every

500 Hours

X

Every

1000 Hours

Every

2000 Hours

5

LeeBoy 685D Motor Grader 5-3

Maintenance

MAINTENANCE SCHEDULE

Before performing any maintenance procedures on
the LeeBoy 685D Grader, review Section 1, Safety.
Follow all maintenance schedules and procedures to
maintain the machine in top operating order. Preventive
maintenance on the grader will provide years of trouble­free operation. Adjustments can be performed in the

eld with ordinary tools. The maintenance schedule

begins with 10-hour, or daily, maintenance intervals
and continues through the 1000-hour, or annual,
maintenance schedule intervals.

NOTE: When performing any routine maintenance,

always include previous routine
maintenance procedures to the higher
hourly schedule.

Engine preventive maintenance, (other than oil, air

and fuel lter changes), can be found in the Engine

Operator’s Manual. Anytime the grader has been
repainted or the decals removed, damaged or illegible,
replace immediately for safe operation.

Tool Hazard! ALWAYS use tools
appropriate for the task. Be sure to use the correct
sized tool for loosening or tightening parts.

Changing oil and cleaning the grader
should only be done in a designated area where
the oil and chemicals can be contained. These by­products should be discarded in accordance with
environmental regulations.

DO NOT operate a machine that is
in need of repair. Put an information tag on the
instrument panel that says “DO NOT OPERATE”
and remove key from the ignition switch. Repair all
damage promptly as even minor damage can result
in major system failures.

If any maintenance must be
performed while the engine is running, DO NOT leave
the grader unattended.

ALWAYS lower attachments to the
ground. NEVER leave attachments in the raised
position when working on the grader. Securely block
moldboard or other attachments that may fall before
working on them.

Allow the engine and hydraulic system
to cool before working on the machine.

Prepare for Maintenance

1. Park the machine on an even surface and lower all
attachments to the ground and block wheels to

prevent machine movement.

2. Place the FNR (Forward/Neutral/Reverse) lever in
the NEUTRAL (center) position and engage park
brake.

3. Place ignition switch in the OFF position.

10-Hour or Daily Routine
Maintenance

1. Check coolant level. Add more if needed. (Page
5-15)

2. Check air lter indicator. Clean or replace lter if
indicator is red. (Page 5-15)

3. Check hydraulic oil level. Add more if needed.
(Page 5-25) Check hydraulic hoses for leaks and
wear.

4. Check engine drive belt. Adjust or replace if
needed. (Page 5-14)

5. Lubricate steering and tie rods, drawbar ball,
moldboard lift trunnions and cylinders, trunnion
housing, and moldboard swing cylinders. (Pages

5-6 and 5-7)

6. Check tire air pressure and wheels for any damage
and missing or loose lug nuts. (Page 5-29)

50-Hour Routine Maintenance

1. Perform previous maintenance procedures.

2. Check battery connections and remove any
corrosion present. Service battery if needed.

(Page 5-21)

3. Check engine oil and lter. Add more oil if needed.

CHANGE ENGINE OIL AND FILTER AT INITIAL 50
HOURS. (Page 5-13)

4. Lubricate hydraulic cylinder ends, front blade pivots,
moldboard pivots, axle pivot, stabilizer rod ends,
turntable, FNR pedal, and control levers. (Pages

5-6 and 5-7)

5. Perform any other engine preventative maintenance
as described in the Engine Operator’s Manual.

LeeBoy 685D Motor Grader5-4

Maintenance

100-Hour or Monthly Routine
Maintenance

1. Perform previous maintenance procedures.

2. Inspect air lters and intake hoses/clamps. Clean or
replace if needed.

3. Check breathers. Replace if needed. (Pages 5-8

and 5-9)

4. Check various axle oil levels. Add more oil if
needed. (Pages 5-8 and 5-9)

5. Lubricate articulate joint and chain box pivots.

(Pages 5-6 and 5-7)

6. Lubricate king pin bearings. (Pages 5-6 and 5-7)

7. Perform any other engine preventative maintenance
as described in the Engine Operator’s Manual.

250-Hour or Quarterly Routine
Maintenance

1. Perform previous maintenance procedures.

2. Change engine oil and replace oil lter. (Page 5-13)

1000-Hour or Annual Routine
Maintenance

1. Perform previous maintenance procedures.

2. Clean, pack and adjust front wheel bearings. (Page

5-30)

3. Drain, ush and ll axle, gearbox and planetary hub

oil. (Pages 5-8 and 5-10)

4. Perform the 1000-hour preventative maintenance as
described in the Engine Operator’s Manual.

2000-Hour or Every Two Years
Maintenance

1. Clean the Diesel Exhaust Fluid (DEF) tank lter.
Replace if needed. (Page 5-18)

2. Drain, ush and ll hydraulic tank. Clean hydraulic
tank strainers. (Page 5-26)

3. Drain, ush and ll radiator coolant. (Page 5-15)

4. Perform any other engine preventative maintenance
as described in the Engine Operator’s Manual.

3. Check engine drive belt. Adjust or replace if

needed. (Page 5-14)

4. Check drive axle, gear box and planetary hub oil

levels. Add more gear oil if needed. (Pages 5-8 -
5-10)

5. Perform any other engine preventative maintenance
as described in the Engine Operator’s Manual.

500-Hour or Semi-Annual
Routine Maintenance

1. Perform previous maintenance procedures.

2. Inspect engine drive belt tensioner, idler and drive
pulleys for dirt, wear and cracks. (Page 5-14)

3. Check and adjust toe-in if needed. (Page 5-12)

4. Change hydraulic oil, and replace charge and return

lters.

5. Replace fuel lter. (Page 5-20)

6. Service battery. (Page 5-21)

7. Adjust park brake. (Page 5-12)

3000-Hour or Every Three Years
Maintenance

1. Inspect the DEF Dosing Unit Filter. Clean or replace

if needed. (Page 5-19)

2. Perform any other engine preventative maintenance
as described in the Engine Operator’s Manual.

5

8. Perform any other engine preventative maintenance
as described in the Engine Operator’s Manual.

LeeBoy 685D Motor Grader 5-5

12

8

15

15

Maintenance

LUBRICATION

Proper lubrication is very important for maintaining the machine at top efciency. Use multi-purpose grease to

lubricate the grease points shown below. Additional lubrication requirements are described on the following pages.

Grease Points

1

1

9

10

2

11

13

3

14

5

6

4

7

7

16

17

LeeBoy 685D Motor Grader5-6

Maintenance

Table 5-2. Lubrication Points

No. ITEM INTERVAL

18

19

20

20

1 Front Axle Joints (both sides) Weekly

2 Front King Pins (both sides) Monthly

Drawbar Ball (until grease es-

3

capes from the ball joint)

4 Steering Cylinders and Tie Rod Daily

5 Moldboard Swing Cylinders Daily

6 Turntable (4 grease ttings) Weekly

Articulated Cylinder (until grease

7

escapes from clevis pin joints)

8

Rear Axle
Moldboard Lift Trunnion (both

9

sides)
Moldboard Lift Cylinders (both

10

sides)

11 Moldboard Stabilizer Weekly

Articulated Joint (until grease

12

escapes from the upper and
lower joints)

13 Moldboard Tilt Cylinder Weekly

Moldboard Mounting Pins (both

14

sides)
15 Valve Handles Monthly
16 Door Handle Monthly

17 FNR Pedal Weekly

Front Blade/Scarier Lift Cylinder

18 **

(See Below)

19 ** Front Blade Joints Weekly

20 ** AWD Front King Pins (both sides) Weekly

Rear Scarier Lift Cylinders (both

21 **

sides)

* (6 on each side)

Daily

Weekly

Monthly

Daily

Daily

Monthly

Weekly

Weekly

Weekly

5

21

LeeBoy 685D Motor Grader 5-7

* Not all grease ttings are shown on rear axle

graphic. Be sure to look closely and grease all

ttings on inside of tandems at the pivot point (6 on

each side of axle.

** OPTION. Only applicable if equipped with options
as shown:

Maintenance

Axle Lubricants

Check the gear box, tandem box, axle and hydraulic
motor oil levels quarterly, shown in Figures 5-1 and
5-2). Add more gear oil if needed. Change the oil on
these components every year for optimum performance.

NOTE: The manufacturer recommens axle lubricant

that meets API GL-5/MT-1 or SAE J2360

specication.

Use the following procedure to change oil at the various
oil plug points as shown:

1. Park machine on level ground.

2. Remove the oil plug(s) shown in Figures 5-1 and

5-2.

3. Add oil until it starts coming out of the level plug.

4. Replace the level plug.

5. Allow the axle to sit level for at least ve minutes to

allow the oil to ow throughout components.

6. Remove the level plug and check oil level.

7. Add more oil if needed.

Breathers

Hydraulic gear boxes, axles, pumps and tanks need to
“breathe” as air is drawn in when hydraulic components
activate. Breathers stop water, dirt and debris from
contaminating the oil. If the breathers are clogged, the
resulting heat and pressure increase will force lubricant
to escape through seals and joints in the housing,
leading to bearing or gear failure. To prolong the
operational life of a bogie axle, regular inspections and
maintenance of the breathers is essential. (Figure 5-2)

• Always inspect the breathers when checking oil levels.
Simply dusting and brushing off the gear breathers
regularly will keep out dirt and debris that can clog the
breathers.

• Check for oil leaks. Leaks indicate that seals
have failed, thus allowing dust, debris and water to
contaminate the oil.

• If the breathers and/or seals are damaged, they
should be replaced without delay to prevent internal
contamination and inadequate lubrication.

• To replace, simply unscrew the breather and discard,
then reinstall the new breather.

Side View

Tandem Oil

Level Plug

Figure 5-1. Side View of Bogie Axle

LeeBoy 685D Motor Grader5-8