LeeBoy 685D Guide

Operations, Service, and Parts Manual
LEEBOY 685D MOTOR GRADER
Manual No. 1020287-01
This manual applies to
Serial Number 183712
and above.

Safety
Information and Specifications
Component Location
Operation
Maintenance
Schematics
Illustrated Parts List (IPL)
1
2
3
4
5
6
7
Thumb Index

iv LeeBoy 685D Motor Grader
Legal Notices

TABLE OF CONTENTS
LeeBoy 685D Motor Grader v
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

vi LeeBoy 685D Motor Grader
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
Table of Contents

vii LeeBoy 685D Motor Grader
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
Table of Contents

viii LeeBoy 685D Motor Grader
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
Table of Contents

ix LeeBoy 685D Motor Grader
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
Table of Contents

x LeeBoy 685D Motor Grader
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
Table of Contents

xi LeeBoy 685D Motor Grader
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
Table of Contents

LeeBoy 685D Motor Graderxii
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
Table of Contents

xiii LeeBoy 685D Motor Grader
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 ma-
chine. 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 relat-
ed supplemental books, engine, transmission manuals,
and any other manuals supplied by other manufactur-
ers. Related Service Bulletins should also be reviewed
to provide information regarding some of the recent
changes. If any questions arise concerning this publi-
cation 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 mainte-
nance procedures, mechanical adjustments, com-
ponent 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 hy-
draulic schematics for product functionality.
Section 7 - Illustrated Parts List (IPL): Contains parts
numbers and illustrations for serviceable components.
Introduction
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 Graderxiv
NOTES

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
LeeBoy 685D Motor Grader
1
1-1
Section 1
SAFETY

NOTES
Safety
LeeBoy 685D Motor Grader1-2

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.
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.
NOTE: Indicates a procedure, practice or condition
that should be followed in order for the
machine or component to function in the
manner intended.
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
www.safety.fhwa.dot.gov/
1
Safety
LeeBoy 685D Motor Grader 1-3

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.
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.
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.
• 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.
Safety
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.
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 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 well-
ventilated area, away from any combustibles or
sources of ignition.
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.
1
Safety
LeeBoy 685D Motor Grader 1-5

• 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.
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.
Flying Object Hazard
Always wear eye protection when cleaning
the machine with compressed air or high-
pressure 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.
Safety
LeeBoy 685D Motor Grader1-6