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LeeBoy 685D MOTOR GRADER Operation, Service And Parts Manual

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Operations, Service, and Parts Manual
LEEBOY 685D MOTOR GRADER
Manual No. 1030025-SOP
Manual No. 1030025-SOP
This manual applies to
Serial Number 354450
REV A
REV A
and above.

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  • Page 1 Operations, Service, and Parts Manual LEEBOY 685D MOTOR GRADER Manual No. 1030025-SOP Manual No. 1030025-SOP REV A REV A This manual applies to Serial Number 354450 and above.

  • Page 3: Specifications

    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: Legal Notices

    2025 LeeBoy 2025 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

    Hydraulic Fittings ......2-8 Determining Proper Torque ..... 2-9 LeeBoy 685D Motor Grader...
  • Page 6 Regen Request ......4-17 Regen Inhibit ......4-18 LeeBoy 685D Motor Grader...
  • Page 7 Gravel and Dirt Roads ......4-45 Crowning the Road ......4-45 LeeBoy 685D Motor Grader...
  • Page 8 Moldboard Blade ......5-12 Drawbar Ball and Socket ..... . . 5-13 viii LeeBoy 685D Motor Grader...
  • Page 9 Side-Cut Edges ......5-40 Moldboard Slide Cylinder ..... . 5-41 LeeBoy 685D Motor Grader...
  • Page 10 PV485 Troubleshooting ..... . . 5-62 (Cummins Engine) ......5-62 LeeBoy 685D Motor Grader...

  • Page 11: Safety

    Cab Option Safety Decals ..... . 1-13 Decal Installation (Top Protected) ....1-14 LeeBoy 685D Motor Grader...

  • Page 12: Safety

    Safety NOTES LeeBoy 685D Motor Grader...
  • Page 13 IMPORTANT FOR THE SAFETY OF YOU AND YOUR COWORKERS. READ AND UNDERSTAND read and understand this manual before operating the LeeBoy 685D Motor Grader and follow its instructions THOROUGHLY. HEED THE WARNINGS AND 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: Explosion Hazard

    Always have appropriate safety Never modify the LeeBoy machine without the written equipment available. consent of LeeBoy. Any modification can affect the safe • Keep a charged fire extinguisher within reach when operation of the grader and may cause personal injury working in an environment where a fire may occur.
  • 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 685D Motor Grader...

  • Page 17: Machine Precautions

    Natural separation will occur in about 48 to 72 hours. cause it to operate improperly. Get medical attention as soon as possible. • Only use replacement parts approved by LeeBoy. • DO NOT remove radiator cap, drain plugs, service Other replacement parts may affect warranty grease fittings, or pressure taps while engine is hot.

  • Page 18: Refueling Precautions

    Use caution on rough • Check brakes, steering and other control devices in ground, slopes, and while turning. accordance with instructions before starting. Be sure the engine is in neutral with the park brake engaged. LeeBoy 685D Motor Grader...

  • Page 19: Poor Visibility

    • While the machine is equipped with a beacon and a work light, contact your authorized LeeBoy dealer for • Avoid lubrication or mechanical adjustments while the additional lighting packages if working under these grader is in motion or while engine is operating.

  • Page 20: Tire Precautions

    Check the valve stem by running a piece of wire through the stem to make sure it is not plugged. • DO NOT attempt to demount a tire unless you have the proper equipment and experience to do the job. 1-10 LeeBoy 685D Motor Grader...

  • Page 21: Safety Decals

    DANGER safety decals in the proper locations. For readable and located on the grader as designated additional help, contact your authorized LeeBoy dealer by LeeBoy. to order a replacement kit. Safety Decal Locations...
  • Page 22 Part #856579-07 Part #856579-08 Part #983125-10 Part #856579-04 Part #856579-12 Part #856625 (Scari er Option Only) Part #856579-09 Part #1011404 Part #983125-21 Cab Decals Part #1005474 (Option) Part #39141-19 Part #73824 Part #956639 (Panel Under Seat) 1-12 LeeBoy 685D Motor Grader...

  • Page 23: Safety Decals Care

    5. Slowly remove remaining backing and carefully smooth into place. • Obtain replacement safety decals or signs from your authorized dealer. 6. Small air pockets can be pierced with a pin and smoothed using a piece of decal backing. LeeBoy 685D Motor Grader 1-13...
  • Page 24 Safety NOTES 1-14 LeeBoy 685D Motor Grader...

  • Page 25: Information And Specifications

    Hydraulic Fittings ......2-9 Determining Proper Torque ..... 2-10 LeeBoy 685D Motor Grader...

  • Page 26: Limited Warranty Policy

    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 27: Contact Information

    Sales Representative: Dealership Name: Dealership Address: Dealership Phone: 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 Nameplate The nameplate contains the model and serial numbers used to identify the machine and its components for parts or service information.

  • Page 28: Specification Charts

    229 cu in; 4.02 in; 4.53 in 221 cu in; 3.9 in; 4.7 in Stroke High Idle Speed 2200 RPMs 2200 RPMs Maximum Gross Torque 360 ft lbs 369 ft lbs Idle Speed 1200 RPMs 1200 RPMs LeeBoy 685D Motor Grader...
  • Page 29 15-19.5 TL 8PR; 30 PSI Foot-Operated, hydrostatic traction drive system. Hydraulic Brakes park brake is electrically actuated. Oscillating axle supported by tapered roller bearings and Front Drive Axle bushings. Wheel lean 15° left or right. Ground clearance of 1.2 feet. LeeBoy 685D Motor Grader...
  • Page 30 Height: 1.3 ft Raised Clearance 1.9 ft 6 in Penetration Table 2-12. Rear Scarifier Specifications ITEM SPECIFICATION 6 ft Width Number of Teeth Low: 11.5 in Raised Clearance High: 13.7 in Low: 8.5 in Penetration High: 6 in LeeBoy 685D Motor Grader...

  • Page 31: 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 685D Motor Grader...

  • Page 32: 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 685D Motor Grader...

  • Page 33: Determining Proper Torque

    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 685D Motor Grader...

  • Page 34: Coupling Installation

    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 685D Motor Grader 2-10...
  • Page 35 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...
  • Page 36 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 685D Motor Grader 2-12...

  • Page 37: Component Location

    Main Control Panel ......3-10 Heat and Air Conditioning (Cab Option) ....3-12 LeeBoy 685D Motor Grader...
  • Page 38 Components NOTES LeeBoy 685D Motor Grader...

  • Page 39: Components Overview

    COMPONENTS OVERVIEW Engine Engine The 685D Motor Grader is equipped with a either a The LeeBoy 685D Motor Grader is a compact motor Cummins QSF3.8 or Deutz TCD 3.6 Tier 4F diesel grader with the functionality of a large motor grader.

  • Page 40: Hydrostatic Drive

    Each battery produces 800 cold cranking amperes (CCA) for a total of 1600 CCA. An engine-mounted alternator with 135 amperes (standard Cummins engine) or 140 amperes (Deutz engine) of charging capacity keeps the batteries charged during normal operation. LeeBoy 685D Motor Grader...

  • Page 41: Scarifier (Optional)

    (rear shown). The blade-mounted, flip-down scarifier 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. LeeBoy 685D Motor Grader...

  • Page 42: Machine Overview

    Engine Access Panel engine and other components. Used for penetrating and loosening earth, gravel, asphalt and similar surfac- Rear Scarifier (Option) es. Includes nine (9) replaceable teeth mounted on adjustable shanks and secured with pin locks.. LeeBoy 685D Motor Grader...

  • Page 43: Operator Station

    Use to increase and decrease engine speed (RPMs) when in gear (low or Throttle high gear). Push lever forward to increase speed. Push lever rearward to decrease speed. Contains numerous machine component controls, including the ignition Main Control Panel switch, lights, park brake, gears, fan, and wipers. LeeBoy 685D Motor Grader...

  • Page 44: Steering Column Controls

    Left Turn Signal Indicator Light Blinks when the left turn signal is engaged. Brake Failure Warning Light Illuminates when there is low service brake pressure. All Wheel Drive (AWD) OPTION If equipped with this option, illuminates when AWD is engaged. LeeBoy 685D Motor Grader...
  • Page 45 Rotates front “boom” portion of the grader. Pull lever to rotate boom right; push lever to rotate boom left. Articulate Lever NOTE: The articulation angle can affect the stability of the machine. Efficient and safe articulation requires skill and experience to take advantage of its full capabilities. LeeBoy 685D Motor Grader...

  • Page 46: Main Control Panel

    Use this switch to select HIGH or LOW beam when the headlights are on. Headlight High/Low Beam Turn the switch up for HIGH BEAM and down for LOW BEAM. 3-10 LeeBoy 685D Motor Grader...
  • Page 47 Provides easy access to the fuse panel. Locks and unlocks to prevent Fuse Panel Access vandalism. Use to increase and decrease engine speed (RPMs) when in gear (low or Throttle high gear). Push lever forward to increase speed. Push lever rearward to decrease speed. LeeBoy 685D Motor Grader 3-11...

  • Page 48: Heat And Air Conditioning (Cab Option)

    • At the end of winter, shut off the valve by turning the lever counterclockwise (perpendicular to the hose). Cummins Engine Deutz Engine Heat Valve Heat Valve Master Battery Switch Figure 3-6. Heat Valve (Cummins Engine) Master Battery Switch Figure 3-7. Heat Valve (Deutz Engine) 3-12 LeeBoy 685D Motor Grader...

  • Page 49: Operation

    Diagnostics ......4-23 Regeneration ......4-24 LeeBoy 685D Motor Grader...
  • Page 50 Unloading ......4-48 Tie-Down Procedure ......4-48 LeeBoy 685D Motor Grader...
  • Page 51 Reverse Camera System ..... . . 4-51 Magnetic Cup Holder ......4-51 LeeBoy 685D Motor Grader...
  • Page 52 Operation NOTES LeeBoy 685D Motor Grader...

  • Page 53: General Information

    GENERAL INFORMATION Be sure to check the machine thoroughly upon receipt: Check engine oil. (Page 5-15) The LeeBoy 685D Motor Grader is a hydrostatic, 2. Check hydraulic fluid level. (Page 5-31) articulating grader designed with the functionality of a larger grader but more compact. The 685D model 3.

  • Page 54: Start-Up Procedure

    A Neutral Start feature has been installed for safety. The grader will not start unless the FNR pedal is in the To start the 685D Motor Grader: neutral position. It is recommended that operators Ensure the park brake is engaged. (Figure 4-2) always check the brake before operating.

  • Page 55: Cold Weather Starting

    ON position to crank engine. not wearing seat belt securely. 3. Allow the engine to idle about ten minutes before driving the machine. LeeBoy 685D Motor Grader...

  • Page 56: Regeneration (Regen)

    Diesel Exhaust Fluid (DEF) After-Treatment System After-Treatment System (REGEN) The LeeBoy 685D Motor Grader is equipped with a Regeneration is the term given to the DEF after treatment system that treats post-combustion cleaning process where the exhaust exhaust gases prior to tailpipe emission. This system...

  • Page 57: Pv485 Digital Display

    At this level, there is no ability for DPF regeneration or DEF Before driving the LeeBoy 685D Motor Grader, it is injection into the exhaust system, therefore no ability to important to be familiar with the PV485 PowerView™...

  • Page 58: Pv485 - Cummins Engine

    Soft Keys Figure 4-4. Gauge Screen 1 - Engine Coolant Temperature 2 - Engine Speed/RPMs 3 - Hydraulic Oil Temperature 4 - Battery Voltage 5 - Actual Engine Torque Percentage 6 - Soft Key Banner 4-10 LeeBoy 685D Motor Grader...
  • Page 59 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. LeeBoy 685D Motor Grader 4-11...

  • Page 60: Main Menu Screen

    Engine power will be significantly reduced. Perform parked regeneration immediately. Contact your authorized dealer for assistance if engine power does not return. 4-12 LeeBoy 685D Motor Grader...

  • Page 61: Diagnostics

    Figure 4-9. Logged Diagnostics Screen or faults with the appropriate Suspect Parameter Number (SPN) and Failure Mode Indicator (FMI). (Figure 4-8) Use the UP/DOWN soft keys to scroll through list if needed. Figure 4-8. Active Diagnostics Screen LeeBoy 685D Motor Grader 4-13...

  • Page 62: System Info

    Press the UP/DOWN soft keys to scroll to the screen with application and configuration information. (Figure 4-11) Figure 4-12. Set Night Vision Color Preferences Screen Figure 4-11. Application and Configuration Information Screen Figure 4-13. Set Day Vision Color Preferences Screen 4-14 LeeBoy 685D Motor Grader...

  • Page 63: Screen Brightness

    Use the UP/DOWN soft keys and stop the cursor (>) next to the action item Language. (Figure 4-15) Set your language preference using the +/– soft keys. (English, French, German, Spanish, Italian or Japanese) Figure 4-15. Set Language Preferences Screen LeeBoy 685D Motor Grader 4-15...

  • Page 64: Date And Time Setting

    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. 4-16 LeeBoy 685D Motor Grader...

  • Page 65: Regen 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. LeeBoy 685D Motor Grader 4-17...

  • Page 66: Regen Inhibit

    - then shut it down. 4-18 LeeBoy 685D Motor Grader...
  • Page 67 DEF tank level runs low the ignition to the on position, then start. (below 15 percent). Refill the DEF tank. Oil Pressure. Illuminates when the oil Alternator Failure. Illuminates when the pressure is low. alternator isn’t charging properly. LeeBoy 685D Motor Grader 4-19...

  • Page 68: Overspeed Warning

    • Press the soft key beneath the return arrow (  ) to return to the previous screen. NOTE: The service menu requires password access that can only be used by an authorized service technician. Figure 4-25. Overspeed Alert Screen 4-20 LeeBoy 685D Motor Grader...

  • Page 69: User Settings

    Select units and use the soft key beneath the plus (+) or minus (-) symbols to select desired units of mea- surement. (Figure 4-28) • Unit selection is USA Standard, Metric Bar, Metric kPa and British standard. Figure 4-28. System Information Screen LeeBoy 685D Motor Grader 4-21...

  • Page 70: Date Setting

    The PV485 display the engine is running. The PV485 display reboots when you save your changes. reboots when you save your changes. Figure 4-29. Date Setting Screen Figure 4-30. Time Setting Screen 4-22 LeeBoy 685D Motor Grader...

  • Page 71: Diagnostics

    UP () and DOWN () arrow icons. The text illuminates yellow to denote item selection. Press OK to select desired item. Figure 4-31. Warning Diagnostic Pop-Up Message Figure 4-33. Diagnostics Menu Screen LeeBoy 685D Motor Grader 4-23...

  • Page 72: Regeneration

    Engine Hours, Battery Voltage, engine speed (RPMs), oil pressure and coolant tem- perature. • Scroll through the list using the soft keys corresponding to the UP () and DOWN () arrow icons. 4-24 LeeBoy 685D Motor Grader...
  • Page 73 When regeneration is required due to rising levels, the Regen Required message will appear. (Figure 4-35) Follow the regeneration procedure on the previous page. Figure 4-36. Regeneration Urgently Required Screen Figure 4-35. Regeneration Required Screen LeeBoy 685D Motor Grader 4-25...
  • Page 74 Cancel button to cancel the regeneration process. • It cannot be emphasized enough that completing the regeneration process at the earliest opportunity is critical to preventing damage to the engine. Figure 4-37. Regen Inhibited Screen Figure 4-38. Regen in Progress Screen 4-26 LeeBoy 685D Motor Grader...

  • Page 75: Driving The Grader

    BEFORE driving the grader. Wear your seat belt! quality and overall safety. • Stop at all railroad crossings and look both ways The 685D Motor Grader offers several features to before proceeding. maximize the machine’s potential and efficiency while • Stop the grader before changing gears and before grading.

  • Page 76: Adjust Seat

    Pull up on the lever to adjust and release to lock into place. Figure 4-40. Tilt Lock Toe Pedal Seatbelt Figure 4-39. Seat Adjustment 1 - Suspension Adjustment Knob 2 - Seat Position Adjustment Lever 4-28 LeeBoy 685D Motor Grader...

  • Page 77: 2-Speed High/Low

    NOTE: Use slower ground speed when operating Park with any attachment on the front or rear of the grader. Brake Throttle Lever Figure 4-41. 2-Speed, Axle Work/Travel,Park Brake and E-Stop Controls Figure 4-42. Throttle Lever LeeBoy 685D Motor Grader 4-29...

  • Page 78: Directional Control

    Directional Control Directional Control Braking Braking The 685D Motor Grader is equipped with a forward/ reverse variable-speed, hydrostatic transmission and Typically, operators use the FNR foot pedal for slowing variable hydraulic motor that are controlled separately. down by simply releasing it into neutral. This method is The FNR pedal controls the hydraulic flow and direction recommended.

  • Page 79: Steering

    Articulation can adversely affect machine stability, the motor grader before operating at a work site. therefore, DO NOT articulate in Travel gear. The LeeBoy 685D Motor Grader has an articulated Other uses for articulation include: frame, which means the front “boom” portion of the...

  • Page 80: Front Wheel Lean

    • 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. Figure 4-46. Turning Around Using Articulation 4-32 LeeBoy 685D Motor Grader...

  • Page 81: Circle Turn Cushion Valve

    Scarify: This term means loosening or ripping up strikes an immovable object, this valve allows the the grading surface. The 685D Motor Grader offers circle (turntable) to turn, thus preventing damage to the scarifier optional attachments that mount on the front or machine.

  • Page 82: Moldboard

    • 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. 4-34 LeeBoy 685D Motor Grader...

  • Page 83: Grader Attachments

    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 efficiency.

  • Page 84: Mounting Front Attachments

    • 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. 4-36 LeeBoy 685D Motor Grader...

  • Page 85: Front Blade Float

    Front Float Figure 4-56. Using the Rear Scarifier Figure 4-55. Front Blade Float Switch The front scarifier option also features nine replaceable teeth mounted on a plow-shaped plate. (Figure 4-57) Figure 4-57. Front Scarifier Attachment LeeBoy 685D Motor Grader 4-37...

  • Page 86: Operating A Scarifier

    • To scarify extremely hard or compacted material, remove alternate scarifier teeth. DO NOT remove more than five teeth as the force against the remaining teeth could shear them off. Rear Attachment Lever Figure 4-59. Rear Attachment Control Lever 4-38 LeeBoy 685D Motor Grader...

  • Page 87: Replacing Scarifier Teeth

    • Remember that pitching, or tilting the top of the moldboard tip forward or backward, changes the hammer if you wish to hammer the lock pin back into place to prevent damage. depth of the cut across the entire moldboard. LeeBoy 685D Motor Grader 4-39...

  • Page 88: Grading Around Objects

    There are two basic methods for grading around objects (Figure 4-61): Method 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. 4-40 LeeBoy 685D Motor Grader...

  • Page 89: Spreading And Leveling

    Spreading and Leveling Method 2: Reduce speed before approaching object. The 685D Motor Grader can also be used for spreading, leveling, planing and side casting material. Graders 2. Use the moldboard slide shift lever to shift the have less power and traction than dozers, but can move moldboard in the opposite direction of the object.

  • Page 90: Slope Work

    The position of the moldboard can affect the stability of the grader considerably. 4-42 LeeBoy 685D Motor Grader...

  • Page 91: Grading An "S" Curve Shoulder

    “clean-up” pass and reshape the but tilted more forward away to clean any windrow shoulder if necessary. away from the bottom of the slope. Figure 4-66. Bank Cutting LeeBoy 685D Motor Grader 4-43...

  • Page 92: Road Maintenance

    If material starts to flow around the Figure 4-67. Grading a Dirt or Gravel Road moldboard toe or the rolling action stops, increase the blade angle. 4-44 LeeBoy 685D Motor Grader...

  • Page 93: Gravel And Dirt Roads

    6. Repeat Steps 1 - 5 on the other side of the road. Finish the road crown using the procedure described in the next section. LeeBoy 685D Motor Grader 4-45...

  • Page 94: Ditch Work

    You can use this material for the road shoulder. 4-46 LeeBoy 685D Motor Grader...

  • Page 95: Transport

    Operation TRANSPORT Loading Loading To prevent damage to the machine LeeBoy recommends transporting the grader on a undercarriage, frame and components, reduce flat-bed trailer rather than towing. speed before wheels come into contact with loading Remember the following guidelines: ramps or any abrupt change in the surface. The drive system or other components can be damaged by •...

  • Page 96: Unloading

    Unloading Unloading Remove tie-down equipment. LeeBoy strongly recommends transporting the grader on a truck trailer, but if you must tow the machine for a 2. Start the engine and allow machine to warm a few short distance, use a tow hitch. A professional towing minutes to ensure the hydraulic pump is providing service is recommended.

  • Page 97: Options

    OPTIONS Cab Option Cab Option Shifting The 685D Motor Grader offers the option of building the machine with a comfort cab in lieu of the standard canopy. (Figure 4-73) Additional options for the cab include: • Rear windshield wiper and washer.

  • Page 98: Sliding Moldboard

    Sliding Moldboard Sliding Moldboard Secondary Steering Secondary Steering The 685D Motor Grader is equipped with an 11-foot The secondary steering option serves as a temporary sliding moldboard. A 12-foot sliding moldboard option emergency steering back-up in the event of engine is also available for even more reach.

  • Page 99: All-Wheel Drive (Awd)

    (and the rest of your fleet). (Figure 4-78) See your authorized dealer for details. Ask for Part Number 1020521. Figure 4-78. Magnetic Cup Holder Connector Figure 4-76. Cold Weather Engine Plug-In Location LeeBoy 685D Motor Grader 4-51...
  • Page 100 Operation NOTES 4-52 LeeBoy 685D Motor Grader...

  • Page 101: Maintenance

    Air Filter ....... 5-17 Engine Drive Belt ......5-18 LeeBoy 685D Motor Grader...

  • Page 102: Maintenance

    Wheel Lean Cylinder ......5-46 Scarifier Lift Cylinder ......5-46 LeeBoy 685D Motor Grader...
  • Page 103 PV485 Troubleshooting ..... . . 5-62 (Cummins Engine) ......5-62 LeeBoy 685D Motor Grader...
  • Page 104 Maintenance NOTES LeeBoy 685D Motor Grader...

  • Page 105: Maintenance Schedule

    This section gives the necessary procedures for inspections should include checking for loose bolts, routine and general maintenance on the LeeBoy 685D fluid leaks, worn or damaged hoses, and debris or dirt Motor Grader. Keep the grader clean and follow all...

  • Page 106: Prepare For Maintenance

    Park the machine on an even surface and lower all Before performing any maintenance procedures on attachments to the ground and block wheels to the LeeBoy 685D Grader, review Section 1, Safety. prevent machine movement. Follow all maintenance schedules and procedures to maintain the machine in top operating order.

  • Page 107: 100-Hour Or Monthly Routine Maintenance

    4. Change hydraulic oil, and replace charge and return filters. (Page 5-32) 5. Replace fuel filter. (Page 5-26) 6. Service battery. (Page 5-27) Adjust park brake. (Page 5-14) 8. Perform any other engine preventative maintenance as described in the Engine Operator’s Manual. LeeBoy 685D Motor Grader...

  • Page 108: Lubrication

    LUBRICATION Proper lubrication is very important for maintaining the machine at top efficiency. Use multi-purpose grease to lubricate the grease points shown below. Additional lubrication requirements are described on the following pages. Grease Points Grease Points LeeBoy 685D Motor Grader...
  • Page 109 * Not all grease fittings are shown on rear axle graphic. Be sure to look closely and grease all fittings on inside of tandems at the pivot point (6 on each side of axle. ** OPTION. Only applicable if equipped with options as shown: LeeBoy 685D Motor Grader...

  • Page 110: Axle Lubricants

    6. Remove the level plug and check oil level. • To replace, simply unscrew the breather and discard, Add more oil if needed. then reinstall the new breather. Side View Tandem Oil Level Plug Figure 5-1. Side View of Bogie Axle 5-10 LeeBoy 685D Motor Grader...

  • Page 111: Front View

    Maintenance Front View Gearbox Gearbox Oil Breather Level Plug Top View Axle Oil Level Axle Breathers Hydraulic Motor Coupling Oil Level Figure 5-2. Front and Top Views of Bogie Axle LeeBoy 685D Motor Grader 5-11...

  • Page 112: Planetary Hubs

    If excessive clearance is noted between the front and rear of the moldboard slide bar: Remove bolts and nuts holding upper and lower shims and clamps on back side of the moldboard. (Figure 5-4) 5-12 LeeBoy 685D Motor Grader...

  • Page 113: Drawbar Ball And Socket

    Remove more shims, one at a time, if Jam Nuts needed. NOTE: If replacing the drawbar ball, you may need Figure 5-5. Adjustment Set Screws and Jam Nuts to add shim(s) to adjust properly. LeeBoy 685D Motor Grader 5-13...

  • Page 114: Toe-In

    5. Turn the adjuster screw clockwise five (5) complete turns. 6. Reinstall the bolt and retainer clip. Repeat Steps 2 - 6 on the other side. 5-14 LeeBoy 685D Motor Grader...

  • Page 115: Engine Maintenance

    Wait five minutes after engine shut own before removing the dipstick from the engine The 685D Motor Grader features a Cummins 3.8 Tier and checking the oil level to ensure accuracy. 4F or Deutz TCD 3.6 Tier 4F diesel engine. Lockable...

  • Page 116: Change Engine Oil And Filter

    4 - Engine Fan Belt 11 - SCR (Selective Catalytic Reduction) 5 - Alternator 12 - Fuel Water Separator 6 - Oil Cap 13 - Fuel Pump 7 - Engine Oil Filter 14 - Fuel Filter 5-16 LeeBoy 685D Motor Grader...

  • Page 117: Air Filter

    14. Check oil level using the oil dipstick. Add more if needed. Figure 5-11. Air Filter Location (Cummins Air Filter Shown) 15. Dispose of used oil in accordance with local and federal environmental laws. NOTE: Discard the used rubber gasket with the filter element. LeeBoy 685D Motor Grader 5-17...

  • Page 118: Engine Drive Belt

    NOTE: Pay close attention to the correct fit with new belts. Run the engine for 15 minutes after replacing the belt and then recheck belt tension. Dust Discharge Valve Figure 5-14. Deutz Air Filter Housing 5-18 LeeBoy 685D Motor Grader...
  • Page 119 8. Start the engine and listen for belt “squeal,” which indicates belt slippage. If you hear the belt squealing, recheck the routing to ensure it is installed correctly on each pulley. LeeBoy 685D Motor Grader 5-19...

  • Page 120: Selective Catalytic Reduction (Scr) System

    DO NOT pressure wash or steam belt. Replace with new belt. clean this unit to avoid damaging the components. Use compressed air to remove any loose debris. 3. Tighten the clamping bolt. 4. Adjust belt tension using the adjuster bolt. 5-20 LeeBoy 685D Motor Grader...

  • Page 121: Diesel Exhaust Fluid (Def)

    Be DEF Tank sure the ambient temperature is within the correct Filler Cap storage range if bringing DEF to the work site. Figure 5-18. DEF Tank LeeBoy 685D Motor Grader 5-21...

  • Page 122: Def Tank Filter

    3. Shut off the engine. Wait at least five minutes after shutting down the engine for the after treatment DEF dosing unit to complete its automatic purge cycle. DO NOT disconnect battery until the purge cycle has completed to prevent damage to the unit. 5-22 LeeBoy 685D Motor Grader...

  • Page 123: Def Dosing Unit Filter

    5. Discard both the filter element and equalizing element in accordance with environmental regulations. 6. Reinstall the new filter and equalizing element. Reinstall and tighten the cap. NOTE: Lubrication on the DEF filter O-ring is not required. LeeBoy 685D Motor Grader 5-23...

  • Page 124: Cooling System

    If low, fill with a solution of 50 percent water and 50 percent ethylene- glycol antifreeze. Flush the radiator system every 500 5-24 LeeBoy 685D Motor Grader...

  • Page 125: Fuel System

    NEVER loosen a fuel injector line as contents are under high pressure. DO NOT try to bleed air by loosening injector lines. Fuel Fuel Water Pump Filter Separator Figure 5-23. Fuel Filler Cap, Filter, Pump and Water Separator (Deutz Engine) LeeBoy 685D Motor Grader 5-25...

  • Page 126: Fuel Filter

    Figure 5-24. Water Separator To clean the water separator: Follow the previous steps for draining the water separator. 2. Loosen and remove the filter body and clean it with light oil. 3. Reinsert and tighten. 5-26 LeeBoy 685D Motor Grader...

  • Page 127: Electrical System

    (-) post of away. Check vent cap breather openings to make sure the dead battery because a spark could cause an they are open. explosion. LeeBoy 685D Motor Grader 5-27...

  • Page 128: Alternator Servicing

    If you replace a fuse, but it continues to blow, contact your authorized LeeBoy dealer for assistance. Always replace a blown fuse with the same rating as specified. Never replace with a higher amperage rating.
  • Page 129 (Figure 5-30) Fuel Pump Fuel Pump Throttle Relay DEF Supply NOX ECU Key Switch Relay Box Figure 5-29. Cab Door Fuse Panel (Cummins Engine) Figure 5-30. Deutz Engine Fuse Panel LeeBoy 685D Motor Grader 5-29...

  • Page 130: Dielectric Grease

    Figure 5-32. Incorrect Application of Dielectric Figure 5-31. Correct Application of Dielectric Grease Grease 5-30 LeeBoy 685D Motor Grader...

  • Page 131: Hydraulic System

    Using hydraulic fluids that do not have equal characteristics can result in substandard performance or possible failure of the hydrostatic system. Contact your authorized LeeBoy dealer if you need assistance. Always wear eye protection when Figure 5-33. Hydraulic Sight Gauge and Filler Cap inspecting for leaks in the hydraulic system.

  • Page 132: Change Hydraulic Oil And Filter

    (Figure 5-36) Hydraulic Charge Filter Figure 5-34. Hydraulic Filter Location (Cummins Engine) AWD Charge RWD Charge Hydraulic Return Filter Filter Filter Figure 5-36. Hydraulic Charge Filters Location (Deutz Engine) 5-32 LeeBoy 685D Motor Grader...
  • Page 133 13. Replace the hydraulic oil fill strainer cap onto the reservoir filler neck and tighten securely. 14. Start the engine and operate hydraulic controls several times. 15. Check the hydraulic system for any leaks. LeeBoy 685D Motor Grader 5-33...

  • Page 134: Change Hydraulic Oil Cap Strainer

    The hydraulic pump and motor generally require no regularly scheduled maintenance. Frequent inspection for leaks will indicate the need for service of these components. See your authorized dealer for service if needed. Figure 5-39. Hydraulic Test Ports 5-34 LeeBoy 685D Motor Grader...

  • Page 135: Hydraulic Pump/Motor Installation Start-Up Procedure

    4. Install the capscrew-hardened washer and lock washer in the SAE two-bolt flange. Torque the capscrew to the wet torque value defined for the capscrew grade and size. It is CRITICAL to use the correct mounting hardware. LeeBoy 685D Motor Grader 5-35...

  • Page 136: Chassis

    Never exceed the tire manufacturer’s maximum recommended inflation pressure. Never cut or weld on inflated tire/rim assembly. Heat from welding can cause an increase in pressure and may result in tire explosion. 5-36 LeeBoy 685D Motor Grader...

  • Page 137: Repack Front Wheel Bearings

    3. Beginning with one side, remove dust cover and lug nuts from wheel, then remove tire and wheel hub, placing it clearly away from the work area. (Figure 5-42) Lug Nuts Dust Cap Figure 5-42. Wheel Dust Cap and Lug Nuts LeeBoy 685D Motor Grader 5-37...
  • Page 138 12. Reinstall tire and wheel. Torque lug nuts. (See Section 2, Torque Specifications) 13. Repeat procedure on the other wheel. Spindle Seal Wheel Hub with Bearing Races Cotter Wheel Bearing Wheel Nuts/ Bearing Washers Figure 5-43. Axle Spindle, Seal and Wheel Bearings 5-38 LeeBoy 685D Motor Grader...

  • Page 139: Replacement Procedures

    5. To remove lower hose, loosen the two hose clamps plate, noting battery position during removal. and disconnect. If clamps are not damaged, retain for installation. 6. Install new hoses in reverse order of procedures above. LeeBoy 685D Motor Grader 5-39...

  • Page 140: Moldboard Blade

    The moldboard side-cut edges can become damaged size. or worn over time, requiring replacement. Follow the same procedure previously outlined for removing the bolts to replace the side-cut edges. (Figure 5-45) There are four bolts on each side-cut edge. 5-40 LeeBoy 685D Motor Grader...

  • Page 141: Moldboard Slide Cylinder

    13. Start the engine and idle for a few minutes to ensure the hydraulic oil has warmed in the system. 14. Extend and retract the moldboard several times to Cylinder ensure proper operation and check for leaks. Cotter Pin Figure 5-46. Moldboard Slide Cylinder LeeBoy 685D Motor Grader 5-41...

  • Page 142: Moldboard Lift Cylinders

    Remove the four (4) bolts and washers on the front side of the lift cylinder, then the lift cylinder mount slide plate as shown in Figure 5-47. Lift (Front Side Cylinders of Cylinders) Cylinder Pin Bolts Bushing Ball Joint Figure 5-47. Moldboard Lift Cylinders 5-42 LeeBoy 685D Motor Grader...

  • Page 143: Moldboard Tilt Cylinders

    Position the new moldboard tilt cylinder into place. 8. Insert the cylinder and cotter pins. (It is recommended that you use new cotter pins.) Figure 5-49. Moldboard Angle Cylinders 9. Reconnect the hydraulic hoses according to the tags for correct reconnection. LeeBoy 685D Motor Grader 5-43...

  • Page 144: Articulate Cylinders

    NOTE: Inspect the hydraulic fittings. Replace any damaged or worn fittings. 5. Remove the cotter and cylinder pins on each side of one of the articulate cylinders. (Figure 5-50) 5-44 LeeBoy 685D Motor Grader...

  • Page 145: Wheel Steering Cylinder

    12. Start the engine and idle for a few minutes to ensure the hydraulic oil has warmed in the system. 13. Turn the steering wheel right and left several times to ensure proper operation and check for leaks. LeeBoy 685D Motor Grader 5-45...

  • Page 146: Wheel Lean Cylinder

    12. Raise and lower the scarifier several times to 9. Start the engine and idle for a few minutes to ensure ensure proper operation and check for leaks. the hydraulic oil has warmed, check wheel lean operation, and check for leaks. 5-46 LeeBoy 685D Motor Grader...

  • Page 147: Front Blade Lift Cylinder (Option)

    Start the engine and idle for a few minutes to ensure the hydraulic oil has warmed in the system. 8. Raise and lower the blade several times to ensure proper operation and check for leaks. LeeBoy 685D Motor Grader 5-47...

  • Page 148: Winterizing For Storage

    Add cold-weather additive when appropriate. If machine is equipped with Diesel Exhaust Fluid (DEF), the DEF may stored in the machine’s tank up to four months. If storing any longer, drain the DEF fluid into an approved container. 5-48 LeeBoy 685D Motor Grader...

  • Page 149: Periodic Maintenance In Storage

    If you do not run the engine for six months or longer, apply engine oil to the valve guide and stem seal before starting. LeeBoy 685D Motor Grader 5-49...

  • Page 150: Troubleshooting Chart

    The troubleshooting chart below identifies the most common symptoms of mechanical problems. Fault codes are also shown on the Digital Display unit on the Operator Control Panel. If the problem persists, contact your authorized LeeBoy dealer for assistance or repair. Table 5-4. Troubleshooting Chart...
  • Page 151 Repair or replace switch or solenoid. Broken teeth on flywheel ring or Replace starter motor or ring gear. See your Excessive noise when starter pinion gear. authorized dealer. starting engine. Major engine malfunction. See your authorized dealer. LeeBoy 685D Motor Grader 5-51...
  • Page 152 Check for bent, worn, or loose speed control Slow idle speed set too low. linkage. Repair and/or readjust linkage. Fuel transfer pump malfunction. Repair or replace. Injection pump or nozzle malfunction. See your authorized dealer. 5-52 LeeBoy 685D Motor Grader...
  • Page 153 Steering motor priority relief valve set setting. It should be 2200 PSI. Adjust setting if Steering is difficult. incorrectly. necessary. Worn hydraulic pump. Repair or replace. Worn steering orbital motor. Repair or replace. Worn steering cylinder. Repair or replace. LeeBoy 685D Motor Grader 5-53...
  • Page 154 Check for 12 volts on both sides of switch while Neutral start switch on pump. the machine is in neutral. If 12 volts are present, check wiring harness. Major engine malfunction. See your authorized dealer. 5-54 LeeBoy 685D Motor Grader...
  • Page 155 Clean or replace air filter elements. Excessive fuel Fuel system leak. Drain and flush fuel tank, then refill. Replace fuel consumption. filter. If this doesn’t correct the problem, contact Incorrect grade of fuel. your authorized dealer. LeeBoy 685D Motor Grader 5-55...
  • Page 156 See your authorized dealer. responds slowly. Hydraulic oil is cold. Allow machine to warm completely before driving. Drive selector levers or pedal does not Bent, damaged or corroded linkage. Clean, straighten and adjust linkage. move freely. 5-56 LeeBoy 685D Motor Grader...

  • Page 157: Pv485 Diagnostic Trouble Code (Dtc) Chart

    Accelerator pedal or lever position 1 sensor circuit frequency. Data valid but above normal operational range. Most severe level. Engine coolant temperature. Data valid but above normal operational range. Most severe level. Intake manifold 1 temperature sensor circuit. Voltage above normal or shorted to high source. LeeBoy 685D Motor Grader 5-57...
  • Page 158 Injector solenoid driver cylinder 2 circuit. Current below normal or open circuit. Injector solenoid driver cylinder 4 circuit. Current below normal or open circuit. Engine control module warning internal hardware failure. Bad intelligent device or component. 5-58 LeeBoy 685D Motor Grader...
  • Page 159 Engine camshaft speed/position sensor data erratic, intermittent or incorrect. 1117 3597 Power supply lost with ignition on. Data erratic, intermittent or incorrect. Accelerator pedal or lever position sensor 2 circuit voltage above normal or shorted to 1239 2623 high source. LeeBoy 685D Motor Grader 5-59...
  • Page 160 Injector solenoid driver cylinder 2 out of calibration. 2444 Injector solenoid driver cylinder 3 out of calibration. 2445 Injector solenoid driver cylinder 4 out of calibration. 2448 Coolant level data valid but below normal operating range. Least severe level. 5-60 LeeBoy 685D Motor Grader...
  • Page 161 Water in fuel indicator data valid but above normal operating range. Most severe level. 4734 Auxiliary input/output 1 special instructions. 4789 1639 Fan speed data valid but above normal operational range. Most severe level. 4791 1639 Fan speed data valid but above below operational range. Most severe level. LeeBoy 685D Motor Grader 5-61...

  • Page 162: Pv485 Troubleshooting

    3. Inspect the terminals in positions 14 (green) and 26 (yellow) for the CANbus communication. 4. If terminals are properly seated, carefully “unlock” the red retaining clip and slide away from the wires. (Figure 5-56) 5-62 LeeBoy 685D Motor Grader...
  • Page 164 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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