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LeeBoy 8608 Manual

Commercial paver
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Safety and Operations Manual
LeeBoy Model 8608 Commercial Paver
Manual No. 1027553-SOP
REV A
This manual applies
to machines beginning
with Serial Number
341183

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  • Page 1 Safety and Operations Manual LeeBoy Model 8608 Commercial Paver Manual No. 1027553-SOP REV A This manual applies to machines beginning with Serial Number 341183...
  • Page 3 The LeeBoy family of companies is committed to total quality management with a strong focus on meeting customer needs. LeeBoy is also proud to be an accredited ANAB manufacturer, which is a certification process comprised of quality standards established by the American National Standards Institute (ANSI) and the American Society for Quality (ASQ).
  • Page 4 2023 LeeBoy 2023 LeeBoy LeeBoy reserves all copyright and other rights in this manual and its content. No part of this manual may be reproduced or used in any way without the written permission of LeeBoy, except as necessary to operate LeeBoy equipment.

  • Page 5: Table Of Contents

    Components Overview ......3-3 Dual Operator Platform ..... . . 3-3 LeeBoy 8608 Commercial Paver...
  • Page 6 Plus One Controller ......4-24 Driving the 8608 Paver ......4-25...
  • Page 7 Blade Light ......4-45 Magnetic Cup Holder ......4-46 LeeBoy 8608 Commercial Paver...
  • Page 8 DEF Storage ......5-20 DPF Service ......5-21 viii LeeBoy 8608 Commercial Paver...
  • Page 9 Under Auger Material Cut-Offs ....5-39 Auger Inner Bearings ......5-40 LeeBoy 8608 Commercial Paver...
  • Page 10 DP700 Diagnostic Trouble Code (DTC) Chart ....5-55 PV485 Troubleshooting ..... . . 5-63 LeeBoy 8608 Commercial Paver...

  • Page 11: Safety

    Safety Decals Care ......1-12 Decal Application ......1-12 LeeBoy 8608 Commercial Paver...

  • Page 12: Safety

    Safety NOTES LeeBoy 8608 Commercial Paver...
  • Page 13 IMPORTANT FOR THE SAFETY OF YOU AND YOUR COWORKERS. READ AND UNDERSTAND read and understand this manual before operating the LeeBoy Model 8608 Commercial Paver and follow its THOROUGHLY. HEED THE WARNINGS AND instructions when operating the machine. FOLLOW THE INSTRUCTIONS.

  • Page 14: Safety Precautions

    • Failure to observe these directions could result in electrocution or death. • Contact LeeBoy or an authorized LeeBoy dealer for additional training. • Make sure you are aware of all laws and regulations Electrocution Hazard...
  • Page 15 When operating machinery there is a risk for Never modify the LeeBoy machine without the written fire. Always have appropriate safety consent of LeeBoy. Any modification can affect the safe equipment available. operation of the paver and may cause personal injury or death.
  • Page 16 • Never check for a hydraulic fluid 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 8608 Commercial Paver...

  • Page 17: Machine Precautions

    Natural separation will occur in about 48 to 72 hours. • Only use replacement parts approved by LeeBoy. Get medical attention as soon as possible. Other replacement parts may affect warranty •...

  • Page 18: Refueling Precautions

    • Check brakes, steering and other control devices in trees, cliffs, overhead power lines, and areas where accordance with instructions before starting. Be sure there is danger of a slide. both steering levers (joysticks) are in neutral with the neutral lock engaged. LeeBoy 8608 Commercial Paver...

  • Page 19: Poor Visibility

    While the machine is equipped with a beacon and a • Never make repairs on pressurized components such work light, contact your authorized LeeBoy dealer for as fluid lines, the gas system, or mechanical items until additional lighting packages if working under these the pressure has been relieved.

  • Page 20: Safety Decals

    DANGER safety decals as shown in the following readable and located on the paver as designated by graphics. For additional help, refer to the parts listing in LeeBoy. Section 7 and contact your authorized LeeBoy dealer to order a replacement kit. Safety Decal Locations Safety Decal Locations...
  • Page 21 Both Sides Part # 988634 Part # 856441 Part # 856438 Part # 856482 Both Sides Both Sides Part # 856437 Both Sides Part # 856598 Part # 1010489 Part # 856442 Both Sides Both Sides LeeBoy 8608 Commercial Paver 1-11...

  • Page 22: Safety Decals Care

    5. Slowly remove the remaining backing and carefully smooth the remaining portion of the decal into place. 6. Small air pockets can be pierced with a pin and smoothed using a piece of the decal backing. 1-12 LeeBoy 8608 Commercial Paver...

  • Page 23: Information And Specifications

    Hydraulic Fittings ......2-8 Determining Proper Torque ..... 2-9 LeeBoy 8608 Commercial Paver...

  • Page 24: Two Year Limited Warranty

    Exclusion of Other Warranties/Limitation of Liability 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 LIKE.

  • Page 25: Contact Information

    Dealership Address: Dealership Phone: Record of Ownership Record of Ownership Please complete the following information to use if you need to contact your authorized LeeBoy dealer for service, parts or literature. Machine Model Number: _____________________________________________ Paver Serial Number: Date of Purchase:...

  • Page 26: Specifications

    Manufacturer and Model Kubota, V3800-TIH-2183 Engine Type Vertical Liquid Cooled Diesel, 4-Cylinder, Turbocharged Bore, Stroke and Displacement 3.9 in; 4.72 in; 230 in Maximum Gross Power 125 HP High Idle 2200 RPMs Maximum Gross Torque 324.5 ft lb LeeBoy 8608 Commercial Paver...
  • Page 27 Track Tension Pressure 900 psi Park Brake Release 290 psi Table 2-7. Hopper Specifications ITEM SPECIFICATION 9 Tons Material Capacity 31.75 in Height Heavy duty; 1/2 in with large radius corners and rear hopper wing Hopper Wings wipers. LeeBoy 8608 Commercial Paver...
  • Page 28 14,400 watt Voltage 120/240 Volts Frequency 57 - 63 Hz Table 2-11. Track Specifications ITEM SPECIFICATION Length: 94 in Poly/Steel (2-Speed, 35 Pads) Width: 14 in Length: 94 in Smooth Poly/Steel (2-Speed, 35 Pads) Width: 14 in LeeBoy 8608 Commercial Paver...

  • Page 29: Torque Specifications

    1520 1139 1817 1363 2464 1848 12 UNF 1241 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 LeeBoy 8608 Commercial Paver...

  • Page 30: Metric Fasteners

    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 1 1/4 lubricated connections. 1 3/8 LeeBoy 8608 Commercial Paver...

  • Page 31: Determining Proper Torque

    TS = Torque setting indicated on wrench Equations Equations • Torque setting if the crowfoot is placed in line with respect to the wrench: TS = TD * L / LA TS = TD * L / (L+E) LeeBoy 8608 Commercial Paver...
  • Page 32 2. The flats method is most accurate for the first assembly cycle. For multiple disassembly and assembly cycles, torque values are more reliable. 3. Tightening two (2) flats or more may damage seal faces. LeeBoy 8608 Commercial Paver 2-10...
  • Page 33 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 8608 Commercial Paver 2-11...
  • Page 34 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. 3. If thread sealant is used, maximum values shown should be decreased by 25%. LeeBoy 8608 Commercial Paver 2-12...

  • Page 35: Component Location

    Screed Control Box ......3-10 Steering and Speed Control Box ..... . 3-11 LeeBoy 8608 Commercial Paver...

  • Page 36: Component Location

    Component Location NOTES LeeBoy 8608 Commercial Paver...

  • Page 37: Components Overview

    Engine Engine A powerful, turbo- This section describes the major components for the charged 125 HP LeeBoy 8608 Commercial Paver. Become familiar engine equipped with with these components and manual guidelines before the latest technologies operating the paver. and advanced...

  • Page 38: Augers

    The modular auger assembly, in one-foot sections, Screed Screed allows for a simple quick change of the assembly. The LeeBoy 8608 Commercial Paver is equipped with Hopper and Conveyors Hopper and Conveyors the Heavy Duty 815HD screed. It features heavy-duty...

  • Page 39: Machine Overview

    Push Rollers or Hydraulic The optional truck hitch is hydraulically driven for roll-up, but also hooks Truck Hitch Option around the inside of the asphalt truck wheel, hitching the paver to the truck. Controlled from the main control panel. LeeBoy 8608 Commercial Paver...

  • Page 40: Control Panel

    Turns on the spray down system for spraying release agent to lubricate and prevent asphalt from Spray Down hardening on machine surfaces. Auger Reverse Push momentary switch UP and hold to reverse auger rotation. Ignition Starts and stops engine. LeeBoy 8608 Commercial Paver...
  • Page 41 Push switch to the IN position to close hopper wings. Extends or retracts right screed extension. (Switch also located on the remote control box. Right Extension Push switch IN to retract right screed extension. Push switch to OUT to extend right screed extension. LeeBoy 8608 Commercial Paver...

  • Page 42: Screed Controls

    Control box for the electric screed heat (and heated end gate option if Electric Heat Box equipped). Adjusts for positive crown or negative valley in wear plate. Crown and Valley Adjuster NOTE: Power Crown option available. LeeBoy 8608 Commercial Paver...

  • Page 43: Screed Electric Heat Controls

    (if equipped with the Automatic Temperature Control option). If equipped with this option, the power crown automatically adjusts positive or negative crown as needed. Power Crown [Option] • Push switch up for increased positive crown. • Push switch down for negative crown (valley). LeeBoy 8608 Commercial Paver...

  • Page 44: Screed Control Box

    Opens and closes Under Cut-Offs Auger Material Cut-Offs. Sets the thickness of the asphalt and Tow Switch controls the electric tow screws. Figure 3-6. Screed Control Box Extends and retracts Screed Extension (Right Control Box Shown) screed extension. 3-10 LeeBoy 8608 Commercial Paver...

  • Page 45: Steering And Speed Control Box

    STOP, control station is deactivated, parking brake Run/Stop applied, and machine will Switch not move. When set to RUN, control station is activated, parking brake is released, and machine resumes previously set speed. LeeBoy 8608 Commercial Paver 3-11...
  • Page 46 Component Location NOTES 3-12 LeeBoy 8608 Commercial Paver...

  • Page 47: Operation

    Plus One Controller ......4-24 Driving the 8608 Paver ......4-25 Activate/Deactivate Operator Control Station .
  • Page 48 Blade Light ......4-45 Magnetic Cup Holder ......4-46 8608 Commercial Paver...

  • Page 49: Receiving The Machine

    Hopper Lock Valves The hopper cylinder valves can be used to lock the hopper The LeeBoy Model 8608 Commercial Paver offers the wings when they are open or closed, and are located inside latest technology to deliver asphalt more evenly and the right engine access panel.

  • Page 50: Start-Up Procedure

    E-Stop system automatically starts the Thaw Control Mode and button. turns on the DEF pump, tank and tube heaters. Engine maximum torque may be limited to protect the DEF injector. 8608 Commercial Paver...

  • Page 51: Dpf Regeneration (Regen)

    Pressing the DEF Info button navigates to the DEF information screen. Using the arrow button allows the operator to scroll a series of screens. (Pages 4-8 to 4-11) • Pressing the center button ( ) navigates to the Main Menu screen. (Page 4-12) 8608 Commercial Paver...

  • Page 52: Soft Key Buttons

    SCR system. to decrease speed. Complete DEF alerts and warning screens are Increases the engine speed (RPMs). described on the following pages. Decreases the engine speed (RPMs). NOTE: Some icons may not be present on your model. 8608 Commercial Paver...

  • Page 53: Set Points And Throttle Speed

    RPMs), PAVE (1900 RPMs), and TRAVEL (2200 RPMs). (Figure 4-5) Figure 4-6. Engine Throttle Speeds Screen with Generator ON Figure 4-5. Engine Throttle Speeds Screen 1 - IDLE (1300 RPMs) 2 - PAVE (1900 RPMs) 3 - TRAVEL (2200 RPMs) 8608 Commercial Paver...

  • Page 54: Def Info

    Always allow this purging process to finish to prevent damage to the injector and other SCR components. NEVER disconnect battery until the purge cycle has completed to prevent serious damage to components in the SCR system. Figure 4-8. DEF Info Error Screen 8608 Commercial Paver...
  • Page 55 (center button) to exit and return to main screen. the bottom right of the bar. (Figure 4-12) Press Main Screen (center button) to exit and return to main screen. Figure 4-10. DEF Info Thaw Mode Screen Figure 4-12. DEF Info Low Screen 8608 Commercial Paver...
  • Page 56 Figure 4-14. DEF Temperature >140° Alert Message If the fluid temperature reaches 120° F, a diagnostic message appears, instructing the operator to fill the DEF tank to lower the temperature. (Figure 4-13) Figure 4-13. DEF Temperature >120° Alert Message 4-10 8608 Commercial Paver...
  • Page 57 DEF Info screen for complete details. (Figure 4-17) Contact your authorized dealer for ser- vice immediately. Press Main Screen (center button) to exit and return to main screen. Figure 4-17. DEF Info Temperature Screen 8608 Commercial Paver 4-11...

  • Page 58: Main Menu Screen

    “pop-up” window. The Main Menu choices on the first screen are: • Gauge (Default Screen) • Diagnostics • System Info • Lamp Info Figure 4-19. Main Menu - Second Screen Figure 4-18. Main Menu - First Screen 4-12 8608 Commercial Paver...

  • Page 59: Diagnostics

    Freeze Frame to view a snapshot of certain engine parameters and the hour meter reading at the time of the fault. This can help correlate recent machine activity with the faults that have been recorded. Figure 4-22. Application and Configuration Information Screen 8608 Commercial Paver 4-13...

  • Page 60: Lamp Info

    Pages 4-21 to 4-23. Figure 4-25. Machine Inhibiting DPF Regeneration Screen If an engine fault is present, the Check Engine icon illuminates solid or flashing yellow or red, depending upon the severity of the problem. 4-14 8608 Commercial Paver...
  • Page 61 Scroll DOWN using the (V) arrow button to view the DEF tank level icon. The icon changes color with the DEF fluid level. A WHITE icon indicates the DEF level is normal. (Figure 4-27) Figure 4-29. DEF Empty Screen Figure 4-27. DEF Level Screen 8608 Commercial Paver 4-15...

  • Page 62: User Settings

    NOTE: During the regeneration process, the Engine Speed will increase and there may be a noticeable sound difference. The HEST Lamp will appear in the alerts window until regeneration is complete. Figure 4-31. User Settings Screen 4-16 8608 Commercial Paver...
  • Page 63 (indicated by the DPF level shown on the main screen) will continue to rise. If the DPF level reaches Level 3, the operator must perform the parked regeneration process described on Pages 4-21 to 4-23. 8608 Commercial Paver 4-17...
  • Page 64 Level 4, non-warranty factory assistance from the engine manufacturer is required. Regen Level 1: The DPF is loaded with soot and needs to be regenerated. (Figure 4-36) This message alerts the operator of the system’s need for regeneration. 4-18 8608 Commercial Paver...
  • Page 65 The DPF is loaded with soot and needs to be regener- damage. The operator should perform the parked ated. (Figure 4-37) regeneration described on Pages 4-21 to 4-23 immediately! Figure 4-37. Regen Level 2 Warning Figure 4-39. Regen Level 3 Warning 8608 Commercial Paver 4-19...
  • Page 66 ECU must be reset by a qualified engine or OEM service technician. IMMEDIATELY take the machine to a safe location, shut down, and contact your authorized dealer. (Figure 4-41) Figure 4-41. Secondary Regen Level 5 Warning 4-20 8608 Commercial Paver...

  • Page 67: Perform Parked Regeneration

    DPF level warnings or engine faults are 3. Set the engine to low idle. The first DPF message ignored. will appear. (Figure 4-44) Figure 4-43. Engine Fault DPF Notification Screen Figure 4-44. DPF (First) Notification Screen 8608 Commercial Paver 4-21...
  • Page 68 (Figure 4-48). The HEST icon will also illuminate when the exhaust temperature reaches >842° F. Both alerts will stay on during the regeneration process. Figure 4-48. Fourth DPF Request Regen Screen Figure 4-46. Third DPF Notification Screen 4-22 8608 Commercial Paver...

  • Page 69: Status And Warning Alert Icons

    REGEN cycle to warn of high exhaust temperatures. This lamp will turn off when normal operating temperatures are reached after the REGEN cycle. Be sure engine exhaust is away from any potentially combustible materials when this warning icon is illuminated. 8608 Commercial Paver 4-23...

  • Page 70: Plus One Controller

    Brake valve/pump neutral bypass coil fault. • The fault happens in the steering control box that has control (Run/Stop switch in the RUN position). • The fault occurs when neither steering control box is in control. 4-24 8608 Commercial Paver...

  • Page 71: Driving The 8608 Paver

    Place both joysticks in the NEUTRAL (center) posi- tion. (Figure 4-51) 2. Move the RUN/STOP switch to the STOP position on the control box not being used to deactivate: DRIVING THE 8608 PAVER • The Run/Stop switch controls stopping the machine and also activating/deactivating the The dual operator platforms allow easy and convenient operator control station.

  • Page 72: Steering And Speed Control

    The screed should be warm, but not hot. Before leaving the operator platform, the operator must return joysticks to the neutral position and switch the Run/Stop (on the Steering and Speed Control Box) to the STOP position. 4-26 8608 Commercial Paver...

  • Page 73: Heating The Screed And End Gates

    Operation There is a spray down system on both sides of the Leeboy 8608 paver. A spray wand is conveniently located by the engine access panel on each side of the paver. (Figure 4-53) The hose reels are located inside the access panel.
  • Page 74 2. Raise the screed plate one or two inches off the ground. 3. Turn the electric heat control box power on. (Figure 4-56) • Push the switch UP to select MANUAL screed heat operation. • Push the switch DOWN to select AUTO screed 4-28 8608 Commercial Paver...

  • Page 75: Hopper Wings

    The hopper wings are hydraulically opened so the wings when they are open or closed. The valves are hopper can be filled with paving material. The 8608 located inside the right engine access door. (Figure paver features a 9-ton, rounded design to reduce cold...

  • Page 76: Conveyors

    Section 5) Figure 4-58. Conveyor Chains Never leave the paver unattended while the conveyor is operating. Do not leave paver running with conveyors set to AUTO for any length of time to prevent hydraulic oil overheating. 4-30 8608 Commercial Paver...

  • Page 77: Under Auger Material Cut-Offs

    5. Use the Thicker/Thinner switch on both sides of the control panel to adjust mat thickness as you pave. 6. While paving, refer to both gauges to make minor Left/Right Cut-O screed adjustments using the tow point. Figure 4-61. Left and Right Cut-Off Switches 8608 Commercial Paver 4-31...

  • Page 78: Sonic Auger Sensor

    • Turning counterclockwise decreases material height. • When the material height moves into the sonic range, the auger speed will slow down proportionately and turn off. It will turn back on when the material level drops. 4-32 8608 Commercial Paver...
  • Page 79 “float” when paving. screed. (Figure 4-66) NOTE: Never allow the end gate to carry the weight of the screed to prevent uneven compaction. Right Screed Left Screed Screed Extension Extension Lift/Float Figure 4-69. Screed Switches 8608 Commercial Paver 4-33...
  • Page 80 Starting to Pave The LeeBoy 8608 paver provides superior paving for driveways, small to large parking lots, and secondary roads. It has a production rate of approximately 250 tons per hour. This paver is capable of placing a mat thickness of six inches (20 centimeters) for: •...

  • Page 81: Basic Paving

    6. Turn the left and right conveyors on to the AUTO position. (Page 4-30) When the material begins to discharge from under the screed, set the screed lift switch to the FLOAT position. (Page 4-33) 8608 Commercial Paver 4-35...

  • Page 82: Setting The Crown

    11. Return paver back to starting position to begin the Figure 4-74. Loosen Lock-Down Bolts next pull. 2. Use the crown handle adjuster for setting positive or negative crown: (Figure 4-75) Crown Handle Adjuster Gauge Figure 4-75. Crown Adjustment 4-36 8608 Commercial Paver...

  • Page 83: Mat Texture Adjustment

    NOTE: Too much pressure on the back of the screed extension will take the weight off the screed wearplate and cause poor material compaction, resulting in a poor finish. 8608 Commercial Paver 4-37...

  • Page 84: Unloading And Loading

    2. BEFORE moving the machine, ensure: • The screed position is UP. Figure 4-78. Correct Loading and Unloading Position • Auger extensions are removed. • The extendible screed is IN. • The Under Auger Material Cut-Offs are CLOSED. 4-38 8608 Commercial Paver...

  • Page 85: Tie-Down Procedure

    Figure 4-79. Tie-Down D-Ring Locations Figure 4-81. Be sure to push release mechanism back into place and reinstall/tighten bolts on cap when finished moving the paver. 8608 Commercial Paver 4-39...

  • Page 86: Optional Components

    NEUTRAL (center) position. Screed vibration helps compact material. If equipped with this option, use the Vibrators button on the main control panel to turn vibration on and off. (Pages 3-6 to 3-7) 4-40 8608 Commercial Paver...

  • Page 87: Extendable Push Roller

    To initiate the TopCon P-32 system: The LeeBoy 8608 Commercial Paver is equipped with poly-pad tracks, but a rubber track option is also 5. Start the engine and idle a few minutes to warm available.

  • Page 88: Screed Sloping Extensions

    13. Turn the Mode Select Knob until the number 50 • Press the Slope/Berm switch up and down to adjust appears in the Mode Select display window. the extensions. 14. Repeat Steps 5 and 6 to set. 4-42 8608 Commercial Paver...

  • Page 89: Slope Meter

    (if equipped), or a solid, straight, flat area on the main screed frame that will not twist or strain during operation. It cannot be emphasized enough that the paver needs to be on level ground for correct instal- lation and operation. 8608 Commercial Paver 4-43...

  • Page 90: Heated End Gate

    The screed single-point lube system combines all screed lubrication points into one. When you pump grease into the central point, valves distribute the grease evenly to all the screed grease points. Figure 4-90. Automatic Temperature Control 4-44 8608 Commercial Paver...

  • Page 91: Tool Rack

    See your authorized operator convenience. See dealer for purchase. your authorized dealer for Figure 4-94. Blade purchase. Light Option Figure 4-92. Tool Rack 8608 Commercial Paver 4-45...

  • Page 92: Magnetic Cup Holder

    Magnetic Cup Holder Holder Your paver is shipped with two magnetic cup holders, but you can purchase more. (Figure 4-95) See your authorized dealer for details. Ask for Part Number 1020521. Figure 4-95. Magnetic Cup Holder 4-46 8608 Commercial Paver...

  • Page 93: Maintenance

    Check Engine Lubrication Oil ....5-16 Change Engine Oil and Filter ..... 5-17 LeeBoy 8608 Commercial Paver...
  • Page 94 Front Idler ......5-36 Track Tension Cylinder ..... . . 5-37 LeeBoy 8608 Commercial Paver...
  • Page 95 DP700 Diagnostic Trouble Code (DTC) Chart ....5-55 PV485 Troubleshooting ..... . . 5-63 LeeBoy 8608 Commercial Paver...
  • Page 96 Maintenance NOTES LeeBoy 8608 Commercial Paver...

  • Page 97: Maintenance Schedule

    Before performing any maintenance procedures on damage or possible injury. the LeeBoy Model 8608 Commercial Paver, review the When performing any routine safety information in Section 1. Refer to the Engine maintenance, always include the previous routine Operator’s Manual accompanying your paver for more...

  • Page 98: Accessing Components

    Raise and Lower Engine Hood Raise and Lower Engine Hood Accessing the radiator and other engine components is simple and convenient on the 8608 paver. The engine hood pivots forward for convenient access to the radiator and other engine service points. (Figure 5-1) Access doors on each side of the paver also provide easy access for servicing various components.

  • Page 99: Routine Maintenance

    Engine Operator’s Manual. NOTE: In cold weather, keep conveyor flight chains properly oiled with cleaning solvent or release agent. This will prevent conveyor bars from sticking. Neglect could result in conveyor bar damage or drive chain failure. LeeBoy 8608 Commercial Paver...

  • Page 100: Every 50 Hours Or Weekly Routine Maintenance

    3. Adjust generator belt. (Page 5-31) 2. Perform previous routine maintenance and any 4. Perform previous routine maintenance and any other engine preventive maintenance described in other engine preventive maintenance described in the Engine Operator’s Manual. the Engine Operator’s Manual. LeeBoy 8608 Commercial Paver...

  • Page 101: Lubrication

    Augers (one centralized grease point lubricates auger components). Daily Conveyor chains (one on each side of each conveyor). Daily Spray all parts of paver that come into contact with asphalt. Daily LeeBoy 8608 Commercial Paver...

  • Page 102: Daily Lubrication

    (beneath the operator platform). When you pump grease into the central pint, valves distribute the grease evenly to the auger bearings and other moving parts. Use Shell Avania EP Grease 2 or equivalent. 5-10 LeeBoy 8608 Commercial Paver...

  • Page 103: Weekly Lubrication

    • Screen crown chain. • All screed extensions screws and bearings (both • Depth screw U-Joints (both sides). sides). • Screed extension tilt screws (both sides). Monthly Lubrication Monthly Lubrication Spray the track chains with release agent monthly. LeeBoy 8608 Commercial Paver 5-11...

  • Page 104: Torque Hub Lubrication

    Figure 5-5. Conveyor Drive Chain Bolts 3. Turn the chain adjuster to loosen or tighten the chain, leaving approximately 1/4-inch of slack. DO NOT overtighten. 4. Retighten jam nuts. 5. Repeat steps on the opposite drive chain. 5-12 LeeBoy 8608 Commercial Paver...

  • Page 105: Conveyor Flight Chains

    (more than 1/4 inch), this is why the chain is climbing the sprocket. Repeat steps 1 through 4 for the opposite side. • If excessive, replace chain or sprocket. LeeBoy 8608 Commercial Paver 5-13...

  • Page 106: Auger Drive Chain

    9. Tighten hold-down bolts and torque. (See Torque Tables in Section 2.) Motor Bolts 10. Check operation and adjust if needed. Allen Screws Allen Tension Screw Adjusters Guide Figure 5-7. Auger Drive Chain Bolts Figure 5-8. Screed Extension Top Guide Adjustment 5-14 LeeBoy 8608 Commercial Paver...

  • Page 107: Torque Hub Hydraulic Motor Gear Adjustment

    Torque Hub Hydraulic Motor ENGINE MAINTENANCE Gear Adjustment Gear Adjustment The LeeBoy 8608 Commercial Paver features the latest in emissions compliance and electronically-controlled Torque hub hydraulic motors are engine technology. Tier 4 engines comply with emission calibrated and set at the factory. These adjustment requirements established by the U.S.

  • Page 108: Check Engine Lubrication Oil

    SAE 15W-40 SAE 30 DO NOT overfill. Oil can drain through the air intake system if overfilled and cause oil leaks SAE 10W-30 14°F to 77°F from breather piping. SAE 15W-40 Below 14°F SAE 10W-30 5-16 LeeBoy 8608 Commercial Paver...

  • Page 109: Change Engine Oil And Filter

    5. Remove cap on end of the hose and drain all engine oil into the container. 6. Reinstall cap back onto the hose and reinsert hose back into place. Fill the engine with 2.5 quarts of oil at the oil fill cap. LeeBoy 8608 Commercial Paver 5-17...

  • Page 110: Change Air Filter

    Check clamps to ensure filter elements are tight and filter elements are making proper contact. 8. Start engine. If engine does not run smoothly, Alternator recheck filter element contact. Bolts Belt Figure 5-12. Engine Belt 5-18 LeeBoy 8608 Commercial Paver...

  • Page 111: Change Oil Separator Element

    4. Insert a new filter element and gasket. Use compressed air to remove any loose debris. 5. Reattach the cover cap to the oil separator body. LeeBoy 8608 Commercial Paver 5-19...

  • Page 112: Def (Diesel Exhaust Fluid)

    DEF fluid has started to break down and DEF tanks always have a blue cap with a smaller fill neck LeeBoy recommends it be changed or discarded. to prevent erroneously filling with the wrong fluid. If DEF is stored or used above 86°F, the DEF life will It is critical that you prevent contamination be reduced.

  • Page 113: Dpf Service

    To reduce the amount of soot and maximize DPF efficiency, use API-CJ4 (or ACEA-E9 European equivalent) engine oil. Running the engine at 1800 RPMs will also provide more efficient operation and allow automatic regeneration more efficiently while paving. LeeBoy 8608 Commercial Paver 5-21...

  • Page 114: Replace Radiator Hoses

    4. Replace fuel cap. the hose clamps on each. 6. Disconnect hoses and inspect for damage. • If clamps are not damaged, retain for reinstallment (or replace if damaged). Install new hoses and reconnect with hose clamps. 5-22 LeeBoy 8608 Commercial Paver...

  • Page 115: Change Fuel Filter

    10. Start the engine and check for any fuel leaks. Separator Fuel Explosion Hazard! Stop the engine Filter immediately if any fuel leakage is noted. DO NOT start the engine until the leak has been corrected. Figure 5-17. Front Engine Access Panel LeeBoy 8608 Commercial Paver 5-23...

  • Page 116: Hydraulic System

    (preferred method for an accurate reading). • Slowly unscrew the hydraulic oil strainer fill cap (above sight gauge) and add hydraulic oil. • Keep the hydraulic oil filled to the correct level. 5-24 LeeBoy 8608 Commercial Paver...

  • Page 117: Change Hydraulic Oil And Filters

    (close enough for the drain hose to reach). Leeboy uses a leak-detection dye that may turn the hydraulic oil a slight yellow tint. 6. Carefully remove the plugs from the hydraulic drain hose and open the valve over the container.

  • Page 118: Electrical System

    Ensure the vent caps are tight to prevent solution from entering the cells. 5. Pour clean water over the battery and surrounding area to rinse away the solution. 6. Check vent cap breather openings to ensure they are clear. 5-26 LeeBoy 8608 Commercial Paver...

  • Page 119: Alternator

    • Ensure wiring is properly connected before connecting the battery. • Always connect a booster battery in the proper polarity: Negative (-) to negative (-) and positive (+) to positive (+). Figure 5-24. Fuse Panel LeeBoy 8608 Commercial Paver 5-27...

  • Page 120: Electric Heat Control Box

    Disconnect elements one at a time from the con- 8 - Wire Junction Block nection point on the lower side of the control box, 9 - Manual Mode Timer keeping track of connector placement. 10 - Heat ON Button 5-28 LeeBoy 8608 Commercial Paver...

  • Page 121: Heating Elements

    Wattage Per Element 1500 W Total Wattage 3000 W Resistance per Element 52.5 - 62.6 Ω Heated Endgate Elements (2) ** Wattage Per Element Total Wattage 1000 Resistance per Element 88 - 108 Ω ** Optional item. LeeBoy 8608 Commercial Paver 5-29...

  • Page 122: Generator Voltage Testing

    Hz meter (valve should be 60 - 63 Hz. 3. If the voltage is still low, contact your authorized LeeBoy dealer for generator speed tuning (see next section). 5-30 LeeBoy 8608 Commercial Paver...

  • Page 123: Adjust Generator Belt

    Examine the routing of the harness and ensure it is not Figure 5-30. Correct Application of Dielectric subjected to excessive movement, which often causes Grease broken wiring. LeeBoy 8608 Commercial Paver 5-31...

  • Page 124: Replacement Procedures

    The gear pump assemblies are very heavy and must be properly supported with a sling before continuing the following steps. DO NOT Figure 5-31. Incorrect Application of Dielectric loosen mounting bolts unless the pump is sufficiently Grease supported. 5-32 LeeBoy 8608 Commercial Paver...

  • Page 125: Two-Speed Hydraulic Motors

    (Refer to Torque Tables in Section 2 to torque bolts.) Reconnect hydraulic hoses. 8. Start the engine and let machine run for 10 minutes to work air out of the system. Check for any leaks. LeeBoy 8608 Commercial Paver 5-33...

  • Page 126: Hydraulic Pumps/Motor Installation Start-Up Procedure

    It is CRITICAL to use the correct Once all system connections are made, the motor mounting hardware. should be run for 15 - 30 minutes at no-load and half- speed to bleed air from the hydraulic system. 5-34 LeeBoy 8608 Commercial Paver...

  • Page 127: Torque Hub

    Lower paver to the ground. needed. 8. Start paver and check for any leaks with engine running. Stop the engine immediately if any hydraulic leak is noted. DO NOT start the engine until the leak has been repaired. LeeBoy 8608 Commercial Paver 5-35...

  • Page 128: Front Idler

    4. Remove the clip pin from the cylinder rod and idler center. bracket. Idler will slide out. 5. Remove the idler bracket and bolt to the new idler. 5-36 LeeBoy 8608 Commercial Paver...

  • Page 129: Track Tension Cylinder

    9. Place master pin back in track and place thread- started. locking adhesive on bolts. 8. Ensure the track chain remains fully seated with 10. Tighten relief cartridge in manifold. drive sprocket and rollers aligned with the chain center. LeeBoy 8608 Commercial Paver 5-37...

  • Page 130: Rear Conveyor Shaft, Bearings And Sprockets

    4. Slide new or repaired drive motor into slide mount. 5. Secure with four bolts. Adjuster 6. Reconnect hydraulic hoses to motor. Bolts Check for leaks. Conveyor Motors Chain Sprocket Shaft (Inside Tubing) Main Chains Main Conveyor Chains Figure 5-40. Conveyor Components 5-38 LeeBoy 8608 Commercial Paver...

  • Page 131: Conveyor Wear Plates

    13. Place front idler assemblies back into place. 14. Place main conveyor chains in and adjust chain tension. Once adjusted, torque all idler hold-down bolts. (See Torque Tables in Section 2). LeeBoy 8608 Commercial Paver 5-39...

  • Page 132: Auger Inner Bearings

    12. Operate augers to ensure proper function. NOTE: Auger chains should be lubricated each day Figure 5-44. Auger Motor Bolts and Tensioners by spraying oil or chain lube through the slots where the auger motor is adjusted. 5-40 LeeBoy 8608 Commercial Paver...

  • Page 133: Auger End Mounts

    NOTE: Heating asphalt may be required. 6. Loosen auger tension adjusters. Loosen the two bolts securing the auger motor mounting brackets. 8. Loosen the auger chains by sliding the auger motors out from the backside. LeeBoy 8608 Commercial Paver 5-41...

  • Page 134: Quick Change Augers

    Figure 5-49. Lubrication Hoses at Auger Chain Cover Remove the bolts holding the lower auger cover in place, then remove cover. (Figure 5560) Clevis Pin Cotter Pin Figure 5-48. Remove Operator Seat Lower Auger Cover Figure 5-50. Remove Lower Auger Cover 5-42 LeeBoy 8608 Commercial Paver...

  • Page 135: Main Screed Wear Plate

    NOTE: Clamp the center portion of the screed frame 14. Start the engine and idle for a few minutes, then turn to hold the frame in place before lifting it on the auger and check for proper operation. from the worn wear plate. LeeBoy 8608 Commercial Paver 5-43...

  • Page 136: Hopper Wing Cylinders

    18. Adjust crown so the rear of the wear plate is flat. Use rear adjusters to ensure rear of wear plate is Figure 5-55. Rear Hopper Wing Cylinder flat. 19. Reinstall the screed covers in reverse order, then the walk boards. 5-44 LeeBoy 8608 Commercial Paver...

  • Page 137: Screed Extension Wear Plate

    NOTE: If equipped with electric screed heat option, remove all wiring and heating elements. Reinstall the endgate and tilt screw. AOA Adjuster Adjuster Pivot Pin Shoulder Bolt and Nut Figure 5-56. Wear Plate Replacement LeeBoy 8608 Commercial Paver 5-45...

  • Page 138: Main Screed Wear Plate

    2) starting inside, then moving outward, by rotating from the left to the right side to keep the screed relaxed. 16. Reinstall the screed covers in reverse order, then the walk boards. Figure 5-58. Inner Screed Element Covers 5-46 LeeBoy 8608 Commercial Paver...

  • Page 139: Weldment

    DO NOT MAKE MODIFICATIONS TO THE MACHINE. ONLY weld if needed for repair purposes. Weldment modifications to the machine can void your warranty. LeeBoy 8608 Commercial Paver 5-47...

  • Page 140: Winterizing For Storage

    If you do not run the engine for six months or months. If storing any longer, drain the DEF fluid into longer, apply engine oil to the valve guide and stem an approved container. seal before starting. 5-48 LeeBoy 8608 Commercial Paver...

  • Page 141: Troubleshooting

    3. If adjustment is needed, locate the pressure- reducing valve on left side of main manifold. 4. Remove valve cap with an allen wrench. 5. Adjust the pressure-reducing valve clockwise for more tension or counterclockwise for less tension. LeeBoy 8608 Commercial Paver 5-49...

  • Page 142: Spray Down Pump

    NOTE: Change filter as needed. will try to reactivate the pump at preset intervals. If the overload reaches a dangerous level, the red LED will become solid and you must switch the power off and start the pump again. 5-50 LeeBoy 8608 Commercial Paver...

  • Page 143: Auger And Conveyor Chain Tension Adjustment

    0.4 - 0.6 0.6 - 0.9 1.0 - 1.5 1.4 - 2.1 2.0 - 3.0 45° To Vertical (5 - 8) (10 - 15) (15 - 23) (25 - 38) (36 - 53) (51 - 76) LeeBoy 8608 Commercial Paver 5-51...

  • Page 144: Troubleshooting Chart

    Maintenance TROUBLESHOOTING CHART The troubleshooting chart below identifies the most If the problem persists, contact your authorized LeeBoy common symptoms of mechanical problems. dealer for assistance or repair. Table 5-6. Paver Troubleshooting SYMPTOM CAUSE REMEDY Defective battery or low battery Replace or charge battery as applicable.
  • Page 145 Check oil cooler and thermostat. Low level in hydraulic tank. Refill to proper level. Clogged filters. Replace filters. Hydraulic pump cavitation or lost power. Suction hose loose. Retighten. Charge pump worn. Rebuild or replace charge pump. LeeBoy 8608 Commercial Paver 5-53...
  • Page 146 Ensure generator is “spinning.” Check voltage and Generator malfunction. to pave. frequency. Rebuild or replace if needed. Elements have been tested, Faulty element wiring. Inspect and test element wiring. but the breaker still trips. 5-54 LeeBoy 8608 Commercial Paver...

  • Page 147: Dp700 Diagnostic Trouble Code (Dtc) Chart

    Engine power drops.) Diagnostic counter = zero Barometric pressure sen- (Default value is set in consideration Barometric voltage 1.6V or less. sor error: Low with high altitude usage. Engine power drops.) LeeBoy 8608 Commercial Paver 5-55...
  • Page 148 MAF sensor: High built-in MAF sensor voltage: 4.9V or more. Ground short circuit of sensor/har- Intake air temperature ness. Intake air temperature built-in Diagnostic counter = zero built-in MAF sensor: Low MAF sensor voltage: 0.1V or less. 5-56 LeeBoy 8608 Commercial Paver...
  • Page 149 Open circuit of harness/ Open circuit of harness or injector coil. coil in 2nd cylinder injec- Engine vibration increases. Injectors Key switch turn OFF. tor. that have no error are operated. LeeBoy 8608 Commercial Paver 5-57...
  • Page 150 Key switch turn OFF. sensor 1: High sensor voltage 4.92V or more. Ground short circuit of sensor/har- Exhaust gas temperature 3242 ness. DPF inlet temperature sensor Key switch turn OFF. sensor 1: Low voltage 0.08V or less. 5-58 LeeBoy 8608 Commercial Paver...
  • Page 151 High 527° F (300° C). Open circuit or +B short circuit of sen- Exhaust gas temperature 4765 sor/harness. DOC inlet temperature Key switch turn OFF. sensor 0: High sensor voltage 4.92V or more. LeeBoy 8608 Commercial Paver 5-59...
  • Page 152 Estimated temperature is 113° F (45° 523537 Diagnostic counter = zero ture error. C) or above. EGR stops. QR data read error from EEPROM. 523538 QR data error. Key switch turn OFF. Nozzle correction is not executed. 5-60 LeeBoy 8608 Commercial Paver...
  • Page 153 Key switch turn OFF. ceived via CAN. EGR stops. EGR (DC motor) temperature error 523576 EGR (DC motor) overheat. signal received via CAN (exceeds Key switch turn OFF. 257° F or 125° C). EGR stops. LeeBoy 8608 Commercial Paver 5-61...
  • Page 154 Key switch turn OFF. eration. ously. EGR stops. Engine coolant temperature ≥ 230° F 523603 Overheat precaution. Diagnostic counter = zero (220° C). 523604 CAN1 bus off. CAN1 bus off. EGR stops. Key switch turn OFF. 5-62 LeeBoy 8608 Commercial Paver...

  • Page 155: Pv485 Troubleshooting

    Figure 5-67. Terminal Seat the red retaining clip and slide away from the wires. (Figure 5-66) Reinstall connector on to the PV485 panel, making sure the connector shell locks into its mate on the display panel. LeeBoy 8608 Commercial Paver 5-63...
  • Page 156 OR checking for +12VDC on will not operate. each pin on the back of the fuse. If none of these procedures correct the problem, contact your authorized LeeBoy dealer for assistance. 5-64 LeeBoy 8608 Commercial Paver...
  • Page 158 ST Engineering LeeBoy, Inc., dba LeeBoy 500 Lincoln County Parkway Ext. Lincolnton, North Carolina 28092 Phone: (704) 966-3300 - Fax Sales: (704) 483-5802 Scan QR Code to download and view this manual. www.LeeBoy.com Printed in the U.S.A.

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