LeeBoy 1000G Guide

Operations, Service, and Parts Manual
Manual No. 1012035-04
LeeBoy Model 1000G Tilt Hopper Paver
This manual applies to
Serial Number 206561
and above.

SafetySafety
Information and SpecificationsInformation and Specifications
Component LocationComponent Location
OperationOperation
MaintenanceMaintenance
SchematicsSchematics
Illustrated Parts List (IPL)Illustrated Parts List (IPL)
11
22
33
44
55
66
77
Thumb Index

iv LeeBoy 1000G Tilt Hopper Paver
Legal Notices
Disclaimer
All information, illustrations and specications in this manual are based on the latest information available
at the time of publishing. The illustrations used in this manual are intended as representative reference
views only. Moreover, because of our continuous product improvement policy, we may modify information,
illustrations and/or specications to explain and/or exemplify a product, service or maintenance
improvement. We reserve the right to make any change at any time without notice. ST Engineering
LeeBoy, Inc., dba LeeBoy, (“LeeBoy”), is referred to as LeeBoy throughout this manual.
Title 40, Code of Federal Regulations (CFR) 1068Title 40, Code of Federal Regulations (CFR) 1068
This product meets certied-emission requirements set by the EPA (Environmental Protection Agency),
governed by Title 40 CFR 1068, which species actions that are prohibited by law and lists civil penalties
for noncompliance. As part of those regulations, modication or rendering inoperative any emission-
related component can subject you to government penalties (and void your warranty). Tampering with
emission controls is in violation of federal law, and can result in monetary penalties for each day an engine
or piece of equipment is operated in violation.
Please be aware that you are responsible for maintaining the machine and the certied emission engine
installation. Failure to comply to comply could result in penalties as listed above and void the warranty on
this engine and this machine.
For more information, visit: https://www.epa.gov/laws-regulations/regulations
California Proposition 65 WarningCalifornia Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and other related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and other reproductive harm. Wash hands after handling.
2021 LeeBoy2021 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.

TABLE OF CONTENTSTABLE OF CONTENTS
vLeeBoy 1000G Tilt Hopper Paver
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
Storage Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . 1-9
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Safety Decal Locations . . . . . . . . . . . . . . . . . . . . . . . 1-10
Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Information and Specications . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Two 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
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Operator Platform . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

vi LeeBoy 1000G Tilt Hopper Paver
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Torque Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Standard Equipment/Options . . . . . . . . . . . . . . . . . . . . 3-4
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Left Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Steering Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Right Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Burner Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Propane Tank Controls . . . . . . . . . . . . . . . . . . . . . . . 3-10
Screed Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Receiving the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Side Wings Transport Lock . . . . . . . . . . . . . . . . . . . . . 4-3
Initial and Daily Inspection . . . . . . . . . . . . . . . . . . . . . . 4-3
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Cold Weather Start-Up . . . . . . . . . . . . . . . . . . . . . . . . 4-4
DPF Regeneration (REGEN) . . . . . . . . . . . . . . . . . . . . . . . . 4-5
PV480 Powerview™ Display . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Gauge Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Set Points and Throttle Speed . . . . . . . . . . . . . . . . . . . . 4-6
Main Menu Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
System Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Lamp Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
User Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
DPF Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Perform Parked Regeneration . . . . . . . . . . . . . . . . . . . . 4-15
Status and Warning Alert Icons . . . . . . . . . . . . . . . . . . . . 4-17
Driving the Paver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Steering and Speed Control . . . . . . . . . . . . . . . . . . . . . 4-18
Paver Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Spray Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Heating the Screed . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

viiLeeBoy 1000G Tilt Hopper Paver
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Hopper Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Under Auger Material Cut-Offs . . . . . . . . . . . . . . . . . . . . 4-23
Set the Screed, Flight Screw and End Gates . . . . . . . . . . . . . 4-24
Vertical Height Adjustment . . . . . . . . . . . . . . . . . . . . . . 4-26
Setting the Crown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Mat Texture Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-27
Auger and Optional Sonic Auger Sensor . . . . . . . . . . . . . . . 4-27
Starting To Pave . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Basic Paving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Unloading and Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Tie-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Optional Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Umbrella Option . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Fail-Safe Brake Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Two-Speed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Work Light Package . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Electric Screws for Grade Control . . . . . . . . . . . . . . . . . . 4-31
Rubber Tire Drive System . . . . . . . . . . . . . . . . . . . . . . 4-31
Spray Down Hose Reel . . . . . . . . . . . . . . . . . . . . . . . 4-32
Magnetic Cup Holder . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Slope Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Sonic Auger Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Topcon® Sonic Slope and Dual Grade Control . . . . . . . . . . . . 4-33
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Accessing Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Prepare Paver for Maintenance . . . . . . . . . . . . . . . . . . . 5-5
Every 10 Hours or Daily Routine Maintenance . . . . . . . . . . . . 5-5
Every 50 Hours or Weekly Routine Maintenance . . . . . . . . . . . 5-6
Every 100 Hours or Monthly Maintenance . . . . . . . . . . . . . . 5-6
Every 250 Hours or Quarterly Routine Maintenance . . . . . . . . . 5-6
Every 500 Hours or Semi-Annual Routine Maintenance . . . . . . . 5-6
Every 1000 Hours or Annual Routine Maintenance . . . . . . . . . . 5-6
Every 1500 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

viii LeeBoy 1000G Tilt Hopper Paver
Table of Contents
Every 3000 Hours . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Daily Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Weekly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Torque Hub Lubrication . . . . . . . . . . . . . . . . . . . . . . . 5-10
Monthly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Quarterly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Maintenance Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Auger Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Screed Extension Top Guide Adjustment . . . . . . . . . . . . . . . 5-11
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Check Engine Lubrication Oil . . . . . . . . . . . . . . . . . . . . 5-13
Change Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . 5-13
Change Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Engine Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Change Oil Separator Element . . . . . . . . . . . . . . . . . . . . 5-15
DPF Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Replace Radiator Hoses . . . . . . . . . . . . . . . . . . . . . . 5-17
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Change Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Fuel Water Separator . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Check Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Change Hydraulic Oil and Filter . . . . . . . . . . . . . . . . . . . 5-19
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Battery Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Beacon and Work Lights . . . . . . . . . . . . . . . . . . . . . . . 5-22
Dielectric Grease . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Hydraulic Motor Installation Start-Up Procedure . . . . . . . . . . . 5-25
Replace Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Drive Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

ixLeeBoy 1000G Tilt Hopper Paver
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Front Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Torque Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Single-Speed Hydraulic Motors . . . . . . . . . . . . . . . . . . . 5-29
Under Auger Material Cut-Offs . . . . . . . . . . . . . . . . . . . . 5-30
Auger Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Auger End Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Auger and Inner Bearings . . . . . . . . . . . . . . . . . . . . . . 5-32
Screed Extension Wear Plate . . . . . . . . . . . . . . . . . . . . 5-33
Main Screed Wear Plate . . . . . . . . . . . . . . . . . . . . . . . 5-34
Weldment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Winterizing for Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Hydraulic Test Ports . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Plus One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Track Tension Pressure . . . . . . . . . . . . . . . . . . . . . . . 5-38
Torque Hub Hydraulic Motor Gear Adjustment . . . . . . . . . . . . 5-38
Spray Down Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . 5-40
PV480 Diagnostic Trouble Code (DTC) Chart. . . . . . . . . . . . . . . . 5-42
PV480 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Schematic, Main, Electrical (Tier 4) , 1 of 2 . . . . . . . . . . . . . . . . . . 6-3
Schematic, Main, Electrical (Tier 4) , 2 of 2 . . . . . . . . . . . . . . . . . 6-5
Harness, Neutral Safety (Tier 4) . . . . . . . . . . . . . . . . . . . . . . 6-7
Electrical, Harness, Main (Tier 4) . . . . . . . . . . . . . . . . . . . . . . 6-9
Electrical, Harness, Control Box (1 of 2) . . . . . . . . . . . . . . . . . . . 6-11
Electrical, Schematic, Control Box (2 of 2) . . . . . . . . . . . . . . . . . 6-13
Hydraulic, Schematic, Main (1 of 2) . . . . . . . . . . . . . . . . . . . . . 6-15
Hydraulic, Schematic, Main (2 of 2) . . . . . . . . . . . . . . . . . . . . . 6-17
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Track Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Hopper and Hopper Side Wings Components . . . . . . . . . . . . . . . 7-8
Hopper Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Engine Hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Hydraulic Reservoir and Hopper Lift Cylinder . . . . . . . . . . . . . . . . 7-14
Hopper Wing Sequence Manifold . . . . . . . . . . . . . . . . . . . . . 7-16

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Auger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Hydraulic Components and Accessories LH Side . . . . . . . . . . . . . 7-20
Control Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Valve Control Stations LH Side and Components . . . . . . . . . . . . . . 7-24
Main Valve Manifold Detail . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Hydraulic Group Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
RH Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Misc. Detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Propane Heater Assembly and Automatic Ignitors . . . . . . . . . . . . . 7-40
Propane Heater and Rear Cluster . . . . . . . . . . . . . . . . . . . . . 7-42
Battery and Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Vibrator Assembly (1012224) . . . . . . . . . . . . . . . . . . . . . . . . 7-46
Engine Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Engine with Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Axial Piston Tandem Pump (M46) . . . . . . . . . . . . . . . . . . . . . . 7-52
Engine Assembly (1011799) . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
Screed Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Base (Screed) Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Screed Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
LH Extension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
RH Extension Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Screed Jointers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
RH End Gate Assembly (851683) . . . . . . . . . . . . . . . . . . . . . . 7-70
LH End Gate Assembly (851682) . . . . . . . . . . . . . . . . . . . . . . 7-72
Screed Arms with Depth Screw End Gate . . . . . . . . . . . . . . . . . . 7-74
Screed Walkboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
Control Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78
Electric Screw for Grade Control (Option) . . . . . . . . . . . . . . . . . 7-80
Work Lights (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
2-Speed (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
Spray Down Hose (Standard & Optional) . . . . . . . . . . . . . . . . . . 7-86
Fail-Safe Brake Kit (Option) . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Topcon / Sonic Assembly (Option) . . . . . . . . . . . . . . . . . . . . . 7-90
OPTION - Rubber Tire Drive System . . . . . . . . . . . . . . . . . . . . 7-92
Alphabetical Parts Index . . . . . . . . . . . . . . . . . . . . . . . . . . 7-94

xiLeeBoy 1000G Tilt Hopper Paver
Introduction
Thank you for purchasing the LeeBoy Model 1000G Tilt
Hopper Paver. 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.
LeeBoy 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 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 LeeBoy family of companies is committed to
total quality management with a strong focus on meeting customer needs.

xii LeeBoy 1000G Tilt Hopper Paver
NOTES
Introduction

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
Storage Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . 1-9
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Safety Decal Locations . . . . . . . . . . . . . . . . . . . . . . . 1-10
Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
LeeBoy 1000G Tilt Hopper Paver 1-1
Section 1Section 1
SAFETYSAFETY

NOTES
Safety
LeeBoy 1000G Tilt Hopper Paver1-2

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 Model 8616D Commercial Paver 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 paver 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/
11
Safety
LeeBoy 1000G Tilt Hopper Paver 1-3

The safety messages that follow have DANGER level
hazards.
Power Lines HazardPower 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 HazardElectrocution Hazard
Disconnect the battery before welding anywhere on the
machine.
Suffocation HazardSuffocation 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 HazardExhaust 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 HazardPre-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 paver is
operated.
• Make sure you have all necessary licenses to operate
the paver.
• Never operate a unit in need of repair.
• Ensure all covers are installed.
Poor Lighting HazardPoor 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 HazardTool 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 1000G Tilt Hopper Paver1-4

The safety messages that follow have WARNING
level hazards.
Crush HazardCrush Hazard
Keep bystanders away from work area before and
during operation.
Modification HazardModification Hazard
Never modify the LeeBoy machine without the written
consent of LeeBoy. Any modication can affect the safe
operation of the paver and may cause personal injury or
death.
Exposure HazardExposure Hazard
Operators of the paver 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 HazardExplosion 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 paver.
• 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 HazardFire 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 HazardFire 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 HazardEntanglement/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
paver.
11
Safety
LeeBoy 1000G Tilt Hopper Paver 1-5

• If you must run the engine during maintenance
procedures, make sure you have a helper to keep
bystanders clear of the paver 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
paver 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 HazardAlcohol and Drug Hazard
Never operate the machine while under the
inuence of alcohol, drugs, or when ill.
Piercing HazardPiercing 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 HazardFlying 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 HazardCoolant 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 HazardBurn 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 1000G Tilt Hopper Paver1-6

The safety messages that follow have NOTICE level
hazards.
• Any part that is found defective as a result of
inspection or any part whose measured value does
not satisfy the standard or limit must be replaced.
• Always tighten components to the specied torque.
Loose parts can cause damage to the machine or
cause it to operate improperly.
• Only use replacement parts approved by LeeBoy.
Other replacement parts may affect warranty
coverage.
Follow the guidelines of the EPA or other
governmental agencies for the proper
disposal of hazardous materials such as
oils, diesel fuel, coolant, etc. Consult the
local authorities or reclamation facility.
• Dispose of hazardous materials in accordance with
all applicable laws and regulations. Never dispose of
hazardous materials by dumping them into a sewer, on
the ground, or into groundwater or waterways.
• Clean all accumulated dirt and debris away from the
body of the paver and its components before you
inspect the paver or perform preventive maintenance
procedures or repairs. Operating a paver with
accumulated dirt and debris will cause premature
wear of paver components. Accumulated dirt and
debris also hinders effective paver inspection.
• Retrieve any tools or parts that may have dropped
inside of the paver to avoid improper paver operation.
• If any alert indicator illuminates during paver
operation, stop the engine immediately. Determine
the cause and repair the problem before continuing to
operate the paver.
Machine Precautions
Hot Material PrecautionsHot Material Precautions
• Wear protective gear for face, hands, feet, and body
when operating the paver.
• Allow machine to cool before repairing or maintaining
working components.
• If hot asphalt touches skin, ush area immediately with
cold water. DO NOT apply ice to the affected area.
DO NOT ATTEMPT TO REMOVE ASPHALT CEMENT
with products containing solvents or ammonia.
Natural separation will occur in about 48 to 72 hours.
Get medical attention as soon as possible.
• DO NOT remove radiator cap, drain plugs, service
grease ttings, or pressure taps while engine is hot.
Add coolant to the radiator and perform other services
only when the engine is stopped and fully cooled.
Hydraulic Systems PrecautionsHydraulic Systems Precautions
• Ensure all components are in good working condition.
Replace any worn, cut, abraded, attened or crimped
hoses and metal lines.
• DO NOT attempt makeshift repairs using tape, clamps
or cements. The hydraulic system operates under
extremely high pressure and such repairs could
cause serious injury.
• Wear proper hand and eye protection when checking
for a high pressure leak. Use a piece of wood or
cardboard as a back stop to isolate and identify leaks.
Hydraulic oil under pressure can
cause serious personal injury. Check for oil leaks
with a piece of cardboard. DO NOT expose hands to
possible high-pressure oil. Turn off engine before
attempting to tighten oil lines and ttings.
• Escaping pressurized hydraulic uid has force
sufcient to penetrate the skin, which could cause
serious personal injury. Ensure all pressure is
relieved before disconnecting line, hoses or valves.
• If injury from concentrated high pressure steam
or hydraulic uid occurs, seek medical attention
immediately. Injuries resulting from hydraulic uid
penetrating the skin’s surface can result in serious
infections or toxic reactions.
11
Safety
LeeBoy 1000G Tilt Hopper Paver 1-7

Refueling PrecautionsRefueling Precautions
• Do NOT overll the fuel tank as overow creates a re
hazard when spilled on hot components.
• DO NOT smoke when refueling and never refuel when
the engine is running. Fuel is highly ammable and
should be handled with care. Death or serious injury
can occur due to explosion and/or re.
• DO NOT ll tank to capacity. Allow room for expansion
to reduce the risk of fuel expanding and spilling from
the tank.
• Tighten fuel cap securely. Should fuel cap be lost,
replace it with an original manufacturer’s approved
cap. Pressurization of the tank may result from use of
non-approved cap.
• Prevent res by keeping the machine clean of
accumulated debris, grease, and spilled fuel.
• Use ultra-low sulfur diesel fuel (ULSD) only.
Battery PrecautionsBattery Precautions
• Keep all sparks and ames away from batteries, as
gas given off by electrolytes is explosive.
• Acid propelled by an explosion can cause blindness
if it comes in contact with eyes. Always wear safety
glasses when working near batteries.
• If you come in contact with battery electrolyte solution,
wash off immediately. Chemicals can cause burns.
• Always disconnect the battery ground cable before
working on the electrical system to avoid injury from
spark or short circuit. Electrical shock and burns can
occur.
• To avoid electrolyte loss, DO NOT tip batteries more
than 45 degrees.
Starting and StoppingStarting and Stopping
PrecautionsPrecautions
• Check all around the paver to make sure there are no
people working on the machine or in the path of the
machine before starting. DO NOT start until area is
clear. Death or serious injury can occur to bystanders
from being crushed under a moving machine.
• Check brakes, steering and other control devices in
accordance with instructions before starting. Be sure
both steering levers (joysticks) are in neutral with the
neutral lock engaged.
• DO NOT bypass the paver neutral-start system.
• Be aware of job site conditions and terrain. Adjust
your speed if operating in rough or hilly conditions.
DO NOT operate the engine in an
enclosed area without proper ventilation. Exhaust
gasses are odorless and deadly.
Parking PrecautionsParking Precautions
• Park paver on level ground whenever possible, set
steering levers in neutral and lock. Apply the parking
brake. Park the paver with wheels securely blocked
on grades.
• Remove ignition key when leaving paver parked or
unattended.
Operating PrecautionsOperating Precautions
• Always comply with local regulations regarding
moving equipment on public roads and highways.
• Know and use the hand signals required for a
particular job. Know who has the responsibility for
signaling.
• Make sure that all lights and reectors comply with
state and local regulations. Make sure that they are
clean, in good working order, and can be seen clearly
by all trafc.
• DO NOT stand between the equipment and the truck
while the truck is being backed to the paver. Death or
serious injury can result from being crushed between
the two machines.
• DO NOT ride on attachments.
• Check all gauges and warning instruments for proper
operation. If malfunctions are found, shut down the
machine and report the problem for resolution. If the
failure causes loss of steering control, loss of brake
control, or loss of engine power, stop paver motion as
quickly as possible. Apply parking brake (if equipped).
Keep the machine securely parked until the failure is
corrected or the machine can be safely towed.
• Drive the machine with care. Make sure speed is
compatible with conditions. Use caution on rough
ground, slopes, and while turning.
• Be alert for hazards and obstructions such as ditches,
trees, cliffs, overhead power lines, and areas where
there is danger of a slide.
Safety
LeeBoy 1000G Tilt Hopper Paver1-8