LeeBoy Motor Grader 685D Manual WEB

Operations, Service, and Parts Manual
LEEBOY 685D MOTOR GRADER

Manual No. 1020287-01
This manual applies to
Serial Number 183712
and above.
Thumb Index
Safety 1
Information and Specifications 2
Component Location 3
Operation 4
Maintenance 5
Schematics 6
Illustrated Parts List (IPL) 7

Legal Notices
iv LeeBoy 685D Motor Grader

TABLE OF CONTENTS
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Machine Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hot Material Precautions. . . . . . . . . . . . . . . . . . . . . . . 1-7
Hydraulic Systems Precautions . . . . . . . . . . . . . . . . . . . . 1-7
Refueling Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Battery Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Starting and Stopping Precautions. . . . . . . . . . . . . . . . . . 1-8
Parking Precautions. . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Operating Precautions. . . . . . . . . . . . . . . . . . . . . . . . 1-8
Poor Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Snow Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Storage Precautions. . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-9
Tire Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Decal Installation (Sticker Type) . . . . . . . . . . . . . . . . . . . . 1-12
Decal Installation (Top Protected) . . . . . . . . . . . . . . . . . . 1-12
Cab Option Safety Decals. . . . . . . . . . . . . . . . . . . . . . . 1-12
Information and Specifications. . . . . . . . . . . . . . . . . . . . . . . . 2-1
One Year Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Specification Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Standard Inch Fasteners. . . . . . . . . . . . . . . . . . . . . . . 2-7
Metric Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Determining Proper Torque . . . . . . . . . . . . . . . . . . . . . . 2-9
LeeBoy 685D Motor Grader v

Table of Contents

Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Components Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Operator Station. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hydrostatic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Scarifier (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
vi LeeBoy 685D Motor Grader

Table of Contents

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
Scarifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Operating a Scarifier. . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Replacing Scarifier 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
LeeBoy 685D Motor Grader vii

Table of Contents

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
viii LeeBoy 685D Motor Grader

Table of Contents

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
Scarifier 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
LeeBoy 685D Motor Grader ix

Table of Contents

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 (5 of 9). . . . . . . . . . . . . . . . . . . . . . . . 6-11
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
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Boom Articulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
x LeeBoy 685D Motor Grader

Table of Contents
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
OPTION-Front Axle Assembly, AWD (1 of 3). . . . . . . . . . . . . . . . . 7-16
OPTION-Front Axle Assembly, AWD (2 of 3) . . . . . . . . . . . . . . . . . 7-18
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
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 - Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Controls - Foot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
Hydraulics - Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Hydraulics - Tanks (Cont.). . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Hydraulics - 2WD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Hydraulics - Brake, 2WD/AWD. . . . . . . . . . . . . . . . . . . . . . . 7-62
Hydraulics - Valve Bank, 2WD/AWD. . . . . . . . . . . . . . . . . . . . . 7-64
Hydraulics - Pumps, 2WD . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Hydraulics - Pumps, AWD . . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Hydraulics - Pumps, AWD (Cont.). . . . . . . . . . . . . . . . . . . . . . 7-70
Engine - Shroud. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72
Engine - Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Engine - Intake/Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
LeeBoy 685D Motor Grader xi

Table of Contents
Engine - Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78

Engine - DEF Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80
Engine - Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-82
Engine - Battery Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
Frame Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
OPTION - Dozer Blade/Blade Scarifier . . . . . . . . . . . . . . . . . . . 7-88
OPTION - Dozer Blade/Blade Scarifier (Cont.) . . . . . . . . . . . . . . . 7-90
OPTION - Front Scarifier . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92
OPTION - Rear Scarifier. . . . . . . . . . . . . . . . . . . . . . . . . . 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
xii LeeBoy 685D Motor Grader

Introduction
Thank you for purchasing the LeeBoy 685D Motor Section 1 - Safety: Contains general and specific
Grader. We wish you many years of safe and efficient safety guidelines for product and safety label locations.
operation of your LeeBoy product.
Section 2 - Information and Specifications: Contains
READ THIS MANUAL PRIOR TO OPERATING the ma- warranty, contact information, machine specification
chine. It is an important part of the machine and should tables, and machine dimensions.
be kept with in the dedicated storage container provided
at all times. Though you may be familiar with similar Section 3 - Component Location: Contains overview
equipment, you MUST read and understand this manual of major component locations and functions.
before operating the machine to help prevent injury or
damage. Section 4 - Operation: Contains instructions for safe
operation and information for optional equipment.
This manual is intended as a guide for the safe and
efficient use of your machine, including procedures for Section 5 - Maintenance: Contains routine mainte-
proper operation and maintenance. Use it with all relat- nance procedures, mechanical adjustments, com-
ed supplemental books, engine, transmission manuals, ponent replacement and troubleshooting charts for
and any other manuals supplied by other manufactur- common problems and corrections. (For specific
ers. Related Service Bulletins should also be reviewed engine maintenance procedures, refer to the engine
to provide information regarding some of the recent manufacturer manual.)
changes. If any questions arise concerning this publi-
cation or to order a replacement manual, contact your Section 6 - Schematics: Contains electrical and hy-
authorized LeeBoy dealer. draulic schematics for product functionality.
This manual contains information that was available Section 7 - Illustrated Parts List (IPL): Contains parts
at the time of printing and is subject to change without numbers and illustrations for serviceable components.
notice.
VT LeeBoy, Inc. is proud to be ISO 9001 certified. The International Standards

Organization (ISO) establishes guidelines to ensure that products and
services are safe, reliable and of good quality. ISO certifies companies who
demonstrate compliance with all aspects of product safety, customer
satisfaction, efficiency, 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 certification process comprised of quality standards established
by the American National Standards Institute (ANSI) and the American
Society for Quality (ASQ). The ANSI-ASQ National Accreditation Board
plays an important role in ensuring the safety and quality of goods and
services, along with protecting the environment.
LeeBoy 685D Motor Grader xiii

NOTES
xiv LeeBoy 685D Motor Grader

Section 1 1
SAFETY
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Machine Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Hot Material Precautions. . . . . . . . . . . . . . . . . . . . . . . 1-7
Hydraulic Systems Precautions . . . . . . . . . . . . . . . . . . . . 1-7
Refueling Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Battery Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Starting and Stopping Precautions. . . . . . . . . . . . . . . . . . 1-8
Parking Precautions. . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Operating Precautions. . . . . . . . . . . . . . . . . . . . . . . . 1-8
Poor Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Snow Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Storage Precautions. . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-9
Tire Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Safety Decals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Decal Installation (Sticker Type) . . . . . . . . . . . . . . . . . . . . 1-12
Decal Installation (Top Protected) . . . . . . . . . . . . . . . . . . 1-12
LeeBoy 685D Motor Grader 1-1

Safety
NOTES
1-2 LeeBoy 685D Motor Grader

Safety
This manual provides important information to familiarize LOOK FOR THESE SYMBOLS THROUGHOUT
you with safe operating and maintenance procedures. THIS MANUAL. THESE ITEMS ARE EXTREMELY
Even though you may be familiar with similar equipment, IMPORTANT FOR THE SAFETY OF YOU AND
read and understand this manual before operating the YOUR COWORKERS. READ AND UNDERSTAND
LeeBoy 685D Motor Grader and follow its instructions THOROUGHLY. HEED THE WARNINGS AND
1
when operating the machine. FOLLOW THE INSTRUCTIONS.
Safety is everyone’s business and our top concern.
Knowing the guidelines covered in this section will help
Indicates a hazardous situation which,
ensure your safety, the safety of those around you, as
if not avoided, will result in death or serious injury.
well as proper grader operation.
Keep safety labels in good condition. If safety labels
become missing or damaged, replace them with Indicates a hazardous situation which,
new matching labels. Replacement safety labels are if not avoided, could result in death or serious injury.
available from your LeeBoy authorized dealer (see
contact information in Section 2).
Indicates a hazardous situation which,
if not avoided, could result in minor or moderate
You can find more information about occupational health injury.
and safety in the paving industry on the internet. A few
resources are listed below:
www.osha.gov Indicates a situation which can cause
damage to the equipment, personal property and/
cdc.gov or the environment, or cause the machine to operate
www.asphaltpavement.org improperly.
www.safety.fhwa.dot.gov/
NOTE: Indicates a procedure, practice or condition
that should be followed in order for the
machine or component to function in the
manner intended.

Safety
Safety Precautions
The safety messages that follow have DANGER level
hazards.
The safety messages that follow have CAUTION level

hazards. Power Lines Hazard
If your machine comes into contact with electric power
lines, observe the following:
Pre-Operation Hazard
• Stay in the operators seat.
Read and understand this Operation Manual
before operating or servicing the engine to • Warn other workers to stay away and do not touch any
ensure that safe operating practices and maintenance control or any part of the machine.
procedures are followed. • If contact can be broken, drive the machine away from
• Never permit anyone to service or operate the the danger zone.
machine without proper training. • If contact cannot be broken, stay in the operators seat
• Safety signs and labels are additional reminders for until told that power is off.
safe operating and maintenance techniques. • Failure to observe these directions could result in
• Contact LeeBoy or an authorized LeeBoy dealer for electrocution or death.
additional training.
• Make sure you are aware of all laws and regulations Electrocution Hazard
that are in effect for the location in which the grader is
operated. Disconnect the battery before welding anywhere on the
machine.
• Make sure you have all necessary licenses to operate
the grader. Suffocation Hazard
• Never operate a unit in need of repair. Carbon monoxide poisoning is a serious
• Ensure all covers are installed. condition that occurs as a result of improper
ventilation.
• Never operate the internal combustion engine on this
Poor Lighting Hazard machine in an enclosed area with poor ventilation.
The work area must be well lit to ensure safe and proper Ensure proper ventilation to reduce risk of carbon
operation. monoxide poisoning or death.
• Ensure that the work area is adequately illuminated.

• Always install wire cages on portable safety lights. Exhaust Hazard
All internal combustion engines create
carbon monoxide gas during operation and
Tool Hazard special precautions are required to avoid
Always use tools appropriate for the task carbon monoxide poisoning:
at hand and use the correct size tool for • Never block windows, vents or other means of
loosening or tightening LeeBoy machine parts. ventilation.
• Always ensure that all connections are tightened to
specifications after repair is made to the exhaust
system.

Safety
Fire and Explosion Hazard

• Diesel fuel is flammable and explosive under certain
The safety messages that follow have WARNING conditions.
level hazards.
• Never use a shop rag to catch fuel.
Crush Hazard
Keep bystanders away from work area before and
• Wipe up all spills immediately.
• Never refuel with the engine running. 1
• Store any containers containing fuel in a well-
during operation. ventilated area, away from any combustibles or
sources of ignition.
Modification Hazard Fire Hazard

Never modify the LeeBoy machine without the written When operating machinery there is a risk for
consent of LeeBoy. Any modification can affect the safe fire. Always have appropriate safety
operation of the grader and may cause personal injury equipment available.
or death. • Keep a charged fire extinguisher within reach when
working in an environment where a fire may occur.
• Have all fire extinguishers checked periodically for
Exposure Hazard proper operation and/or readiness.
Operators of the grader must be aware of • Always read and follow safety-related precautions
their work environment and the equipment found on containers of hazardous substances
needed to work safely. like parts cleaners, primers, sealants and sealant
removers.
• Undersized wiring systems can cause electrical fires.
• Always wear personal protective equipment, including
appropriate clothing, gloves, work shoes, and
protection for eyes and ears, as required by the task Entanglement/Sever Hazard
at hand.
Verify there are no people, obstacles or
other equipment near the machine before
Explosion Hazard starting the engine. Sound the horn as a
warning before starting the engine.
While the engine is running or the battery is
charging, hydrogen gas is being produced If the engine must be serviced while it is
and can be easily ignited. Keep the area operating, remove all jewelry and tie back
around the battery well-ventilated and keep long hair before operating or servicing the
sparks, open flame, and any other form of machine.
ignition out of the area.
• Keep hands, other body parts, and clothing away from
• Always disconnect the negative (-) battery cable moving/rotating parts.
before servicing the grader.
• Always stop the engine before beginning service.
• Do not start the engine by shorting the starter circuit Before maintenance, remove negative battery cable
or any other starting method not stated in this manual. from battery post to ensure vehicle is not operated
Only use the starting procedure as described in this during maintenance.
manual to start the engine.
• Verify that all guards and covers are properly attached
• Never charge a frozen battery. Always slowly warm the before starting the engine. Do not start the engine if
battery to room temperature before charging. any guards or covers are not properly installed on the
grader.

Safety
• If you must run the engine during maintenance Flying Object Hazard
procedures, make sure you have a helper to keep
bystanders clear of the grader and make observations Always wear eye protection when cleaning
of moving parts as requested by the operator. the machine with compressed air or high-
pressure water.
• Always turn the start switch to the OFF position after
operation is complete and remove the key from the Dust, flying debris, compressed air,
switch. Keep the key in your possession when the pressurized water or steam may cause eye
grader is not operating. injury.
• Attach a “Do Not Operate” tag near the key switch Coolant Hazard
while performing maintenance on the equipment.
Coolant must be handled properly to ensure
• Never operate the engine while wearing a headset to operator safety.
listen to a radio or music because it will be difficult to
hear the warning signals. • Wear eye protection and rubber gloves when handling
engine coolant.
• Always start the engine and operate the controls while
seated in the operators seat. • If contact with the eyes occurs, flush eyes with clean
water for 15 minutes.
• If contact with skin occurs, wash immediately with
Alcohol and Drug Hazard soap and clean water.
Never operate the machine while under the

influence of alcohol, drugs, or when ill. Burn Hazard
Some of the machine’s surfaces become
very hot during operation and shortly after
Piercing Hazard
shutdown.
High-pressure hydraulic fluid or fuel can • Keep hands and other body parts away from hot
penetrate your skin and result in serious machine surfaces.
injury. Avoid skin contact with high-pressure
hydraulic fluid or diesel fuel spray caused by • Handle hot components with heat-resistant gloves.
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 fluid or
fuel spray, obtain prompt medical treatment.
• 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.

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

Safety
Refueling Precautions • DO NOT bypass the grader neutral-start system.
• Do NOT overfill the fuel tank as overflow creates a fire • Be aware of job site conditions and terrain. Adjust
hazard when spilled on hot components. your speed if operating in rough or hilly conditions.
• DO NOT smoke when refueling and never refuel when DO NOT operate the engine in an
the engine is running. Fuel is highly flammable and enclosed area without proper ventilation. Exhaust
should be handled with care. Death or serious injury gasses are odorless and deadly.
can occur due to explosion and/or fire.
• DO NOT fill tank to capacity. Allow room for expansion
to reduce the risk of fuel expanding and spilling from
Parking Precautions
the tank. • Park grader on level ground whenever possible.
• Tighten fuel cap securely. Should fuel cap be lost, Apply the parking brake. Park the grader with wheels
replace it with an original manufacturer’s approved securely blocked on grades.
cap. Pressurization of the tank may result from use of • ALWAYS lower the moldboard and any attachments (if
non-approved cap. equipped) to the ground.
• Prevent fires by keeping the machine clean of • Remove ignition key when leaving grader parked or
accumulated debris, grease, and spilled fuel. unattended.
• Use ultra-low sulfur diesel fuel (ULSD) only.
Operating Precautions
Battery Precautions • Always comply with local regulations regarding
• Keep all sparks and flames away from batteries, as moving equipment on public roads and highways.
gas given off by electrolytes is explosive. • Know and use the hand signals required for a
• Acid propelled by an explosion can cause blindness particular job. Know who has the responsibility for
if it comes in contact with eyes. Always wear safety signaling.
glasses when working near batteries. • Make sure that all lights and reflectors comply with
• If you come in contact with battery electrolyte solution, state and local regulations. Make sure that they are
wash off immediately. Chemicals can cause burns. clean, in good working order, and can be seen clearly
by all traffic.
• Always disconnect the battery ground cable before
working on the electrical system to avoid injury from • DO NOT ride on attachments. or allow riders in or on
spark or short circuit. Electrical shock and burns can the grader.
occur. • Check all gauges and warning instruments for proper
• To avoid electrolyte loss, DO NOT tip batteries more operation. If malfunctions are found, shut down the
than 45 degrees. machine and report the problem for resolution. If
the failure causes loss of steering control, loss of
brake control, or loss of engine power, stop grader
motion as quickly as possible. Apply parking brake (if
Starting and Stopping equipped). Keep the machine securely parked until
Precautions the failure is corrected or the machine can be safely
towed.
• Check all around the grader to make sure there are
no people working on the machine or in the path of the • Adjust seat and fasten the seatbelt before driving the
machine before starting. DO NOT start until area is grader. The seat belt must fit snug with the holding
clear. Death or serious injury can occur to bystanders strap free of slack.
from being crushed under a moving machine. • Drive the machine with care. Make sure speed is
• Check brakes, steering and other control devices in compatible with conditions. Use caution on rough
accordance with instructions before starting. Be sure ground, slopes, and while turning.
the engine is in neutral with the park brake engaged.

Safety
• Be alert for hazards and obstructions such as ditches, Snow Removal

trees, cliffs, overhead power lines, and areas where
there is danger of a slide. • Keep windshield and other windows clean and clear,
using defroster and wipers when needed.
• Be aware of and understand the job site traffic flow
patterns. • Use the proper attachment(s) before plowing snow.
• Obey flagmen, road signs, and signals.
• Watch for bystanders. Never allow anyone near the
machine during operation. Never allow anyone to
Additional equipment may also be needed, i.e., tire
chains, additional warning beacon and/or work lights
and other warning markers.
1
• Snow removal presents unique hazards, including
reach into the machine during use. slippery road surfaces, poor visibility and other traffic
• Operator must know how to use signaling devices issues. Be alert for any obstructions covered by snow
when driving the grader. Operator must also that may be hazardous and adjust operating speed
understand which circumstances require use of each according to slippery conditions.
signal. Use tail lights, slow moving vehicle signs, and
warning beacon as needed when traveling on public
roads. It is recommended that you provide an escort Storage Precautions
on the road.
• Store grader in an area away from human activity.
• DO NOT tow the grader, except to remove from road
or to load on trailer. • DO NOT permit children to play on or around the
stored machine. Serious injury or death can occur
• When moving the machine, adjust speed and direction from improper/unauthorized use of the machine.
of travel for the terrain and ground conditions present.
Always consider adjusting travel speed to match • Make sure the unit is stored on a surface that is firm,
ground conditions. level, and free of debris.
• DO NOT stop or turn the grader around on curves • Store the machine inside a building or cover securely
or at the crest of hills. Use extra care when grading with a weatherproof tarpaulin.
against oncoming traffic.
Maintenance Precautions
Poor Visibility • DO NOT attempt repairs unless trained to do so.
Increasingly, road construction equipment is used Refer to manuals and experienced repair personnel
during less than ideal lighting conditions such as fog for help.
and smog or at night. These conditions present safety • Before working on the machine, securely block the
hazards for workers, bystanders and passing traffic. machine and any components that may fall. Block
When operating under restricted light any working components to prevent unexpected
conditions, equip the machine with special lighting to movement while repairs are being made.
prevent serious injury. • Always wear safety glasses and other required safety
• While the machine is equipped with a beacon and a equipment when servicing or making repairs.
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.
conditions.
• Never make repairs on pressurized components such
• Use reflective tape on the sides of machines when as fluid lines, the gas system, or mechanical items until
working at night. Ensure all workers wear reflective the pressure has been relieved.
safety vests. Use impact barriers (movable or
stationary) to protect workers and direct the traffic • When servicing or replacing hardened pins, use a
flow safely away from the work site. brass drift or other suitable material between the
hammer and pin.
• Keep brake and steering systems in good operating
condition.

Safety
Tire Precautions • DO NOT try to seat rings or other components by

hammering unless tire is fully deflated. Double-
DO NOT mount or demount tires check all components prior to inflation.
without proper training. A violent explosion can
• DO NOT inflate a tire before all components are
occur.
properly in place. Recheck components for proper
Follow all procedures and safety instructions. Charts assembly. If improperly assembled, deflate and
containing mounting and demounting instructions are correct.
available from OSHA at www.osha.gov/pls/publications.
• Never hammer on a tire/rim assembly that is not fully
Contact your authorized dealer or deflated. If assembly is proper at 10 psi (68,947.572
a qualified tire dealer or repair service to perform Pa), continue to inflate to fully seat the tire beads.
required tire maintenance. Then completely deflate the tire to prevent overly
stretching the tube. Reinflate to recommended
• Clean rims and repaint to stop corrosion and
operating pressure.
facilitate checking air level and tire mounting. Be
careful to clean all dirt and rust from the lock ring • NEVER sit on or stand in front of a tire/rim assembly
and gutter. This is important to secure lock ring in its during inflation. Use a clip-on chuck and make sure
the proper position. inflation hose is long enough permit the person
inflating the tire to stand to the side of the tire.
• Check rim components periodically for cracks.
Replace all cracked, badly worn, severely rusted, • DO NOT hammer components with steel hammers.
and otherwise damaged components with new parts Use rubber, lead, plastic, or brass-faced mallets to
of the same size and type. If you are not sure about tap components together.
proper mating of tire and wheel parts, consult your • DO NOT try to drive an assembled or partially-
authorized dealer or a wheel and rim expert. assembled tire or rim over a cast spoke wheel by
DO NOT attempt to rework, weld, hammering. DEFLATE and examine to determine
heat or braze any rim components that are cracked, the reason for the improper fit. Look for distortion or
broken or damaged. Replace damaged components components that are not properly locked or sealed.
with new parts of the same size and type. Mixing • Block the tire and wheel on opposite sides of the
parts of one type with those of another is potentially vehicle before you place the jack in position. Always
dangerous. put hardwood blocks under the jack and crib up the
DO NOT reinflate a tire that has been vehicle in case the jack slips.
run flat without first inspecting the tire, tube, flap, rim, • DO NOT inflate tires beyond the maximum
and wheel assembly. Double-check the side ring and recommended inflation pressure.
O-ring for damage, ensuring they are secured in the
gutter before inflation. • NEVER operate a vehicle on a single tire of a dual
assembly. The carrying capacity of the single tire
Mismatched rim parts are dangerous and rim is dangerously exceeded and operating a
and could cause SEVERE injury. vehicle in this manner can result in damage to the
• Remove valve core to exhaust all air from tire. rim and tire.
ALWAYS exhaust all air from tire prior to removing
rim components or wheel components such as nuts
or rim clamps. Check the valve stem by running a
piece of wire through the stem to make sure it is not
plugged.
• DO NOT attempt to demount a tire unless you have
the proper equipment and experience to do the job.

Safety
Safety Decals
If your machine is repainted, it is extremely important NOTE: It is the responsibility of the owner and
that you replace all the CAUTION, WARNING and operator to make sure that all safety labels are
DANGER safety decals in the proper locations. (Figure readable and located on the grader as designated
1
1-1) For additional help, refer to the parts listing in by LeeBoy.
Section 7 and contact your authorized LeeBoy dealer to
order a replacement kit.
(Both Sides)
(Console)
(Both Sides and

Inside Engine Panel)
(Both Sides)
Figure 1-1. Safety Labels and Safety Label Locations

Safety
Cab Option Safety Decals
(Panel Under Seat)
Figure 1-2. Cab Option Additional Safety Decals
Safety Decals Care

1. Keep safety decals and signs clean and legible at all 5. Align decal over the specified area and carefully press
times. exposed portion into place.
2. Become familiar with the content and the position 6. Slowly remove the remaining backing and carefully
of each safety decal. Decals include important smooth the remaining portion of the decal into place.
information. 7. Small air pockets can be pierced with a pin and
3. Replace decals and signs that are missing or become smoothed using a piece of the decal backing.
impossible to read.
4. When replacing parts that display a safety decal,
ensure that the new part is fitted with a decal as well. Decal Installation (Top
5. Obtain replacement safety decals or signs from your Protected)
authorized LeeBoy dealer. 1. If the decal has a protective top paper, use hot soapy
water on the surface where the decal will be applied.
Leave wet.
Decal Installation (Sticker Type) 2. Determine the proper location, remove protective back
1. Be sure that the installation area is clean and dry. Use paper and soak decal in clean soapy water before
hot, soapy water to clean the surface where the decal application. This will help to alleviate air bubbles in the
will be applied. applied decal.
2. Thoroughly dry the surface. 3. Smooth decal into place with a squeegee and check
for air bubbles.
3. Measure and fit decal before removing the paper
backing. 4. Small air pockets can be pierced with a pin and
smoothed out using a piece of the decal backing.
4. For decals with no top protection paper, remove the
smallest split-backed paper. 5. When decal is completely smoothed, carefully remove
top paper.

Section 2
INFORMATION AND SPECIFICATIONS
Page
Limited Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Specification Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Standard Inch Fasteners. . . . . . . . . . . . . . . . . . . . . . . 2-8
Metric Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Determining Proper Torque . . . . . . . . . . . . . . . . . . . . . 2-10

Information and Specifications
ONE YEAR LIMITED WARRANTY
Limited Warranty Exclusions and Limitations

If a manufacturing defect in factory supplied materials or factory VT LeeBoy has no obligation under this warranty for any defects or
workmanship is found and the authorized LeeBoy dealer (“Dealer”) failures caused by:
is notified during the warranty period, LeeBoy will be responsible for • Misuse, misapplication, negligence, accident or failure to maintain
repairing or replacing any part or component of the unit or part that or use in accordance with the most current operating instructions;
fails to conform to the warranty during the warranty period.
• Unauthorized alterations or modifications;
• Any replacement parts or attachments not manufactured by or
expressly approved by LeeBoy;
Terms and Conditions
• Failure to conduct normal maintenance and operating service,
The warranty applies for a period of one year (for unlimited hours of
including without limitation, providing lubricants, coolant, fuel, tune-
usage on the unit during the one year), beginning on the date that
ups, inspections or adjustments; or
the Dealer from which the unit is purchased submits the warranty
registration form to LeeBoy (typically on the date of purchase). • Unreasonable delay, as determined by LeeBoy, in making the
applicable units or parts available upon notification of a service
The warranty is not transferable and applies only to the original
notice ordered by LeeBoy.
purchaser of a new unit from a Dealer.
LeeBoy is not responsible for any of the following:
Warranty work must be performed at an authorized Dealer location.
• Defects or failures with respect to any engine or truck chassis;
LeeBoy has the right to repair any component or part before
replacing it with a new one. • Defects or failures covered by a warranty provided by a third-party,
including without limitation warranties with respect to engines or
Replacement parts furnished by LeeBoy are covered for the
truck chassis;
remainder of the warranty period applicable to the unit or
component in which such parts are installed. • Costs related to travel time, mileage or overtime;
All new replacement parts purchased from a Dealer will carry a six • Costs related to transporting the unit to and from the place at which
(6) month warranty. warranty work is performed;
• Airfreight charges related to transporting repair parts to the place at
which warranty work is performed;
Items Not Covered • Used units or used parts of any kind;
LeeBoy is not responsible for the following: • Repairs due to normal wear and tear, or brought about by abuse or
lack of maintenance of the equipment, except for premature failures;
• All used units or used parts of any kind.
• Attachments not manufactured or installed by LeeBoy; or
• Repairs due to normal wear and tear or brought about by abuse
or lack of maintenance of the machine. • Miscellaneous charges.
• Attachments not manufactured or installed by LeeBoy.
• Liability for incidental or consequential damages of any type
including, but not limited to, lost profits or expenses of acquiring
replacement equipment.
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.
IN NO EVENT OR UNDER ANY THEORY OF RECOVERY, WHETHER AS A RESULT OF BREACH OF CONTRACT OR WARRANTY,
ALLEGED NEGLIGENCE, OR LIABILITY WITHOUT FAULT, SHALL LEEBOY BE LIABLE FOR ANY SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES ARISING OUT OF THE SALE, USE, OR LOSS OF USE OF ANY PRODUCT, INCLUDING WITHOUT
LIMITATION LOST PROFITS OR REVENUES, COST OF CAPITAL, COST OF SUBSTITUTED EQUIPMENT, FACILITIES OR SERVICES,
DOWNTIME COSTS, LABOR COSTS, OR DIMINUTION OF VALUE.

CONTACT INFORMATION
For information regarding parts and repairs about your Record dealer information in the space provided.
machine, contact your authorized LeeBoy dealer. If your For additional information about LeeBoy, please visit:
dealer is unable to resolve the problem, contact LeeBoy www.leeboy.com.
directly.
Sales Representative:
Dealership Name:
Dealership Address:
Dealership Phone: 2
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
The nameplate contains the model and serial numbers used to identify the machine and its components for parts or
service information. Refer to the Engine Operator’s Manual for the location of the engine nameplate.
Figure 2-1. Nameplate Location

SPECIFICATION CHARTS
The specifications provided in this section include
Replace original equipment only with
screed weights, dimensions, performance, and torque
components approved by LeeBoy.
values for both metric and standard inch fastener.
10’ 2”
(3.1 m)
16’ 1” 7’ 8”
(4.9 m) (2.3 m)
22’ 3” 11’
(6.8 m) (3.35 m)
Table 2-1. Machine Dimensions

ITEM SPECIFICATION
Base Overall Length 22 ft 3 in (6.8 m)
Overall Height with Beacon 10 ft 2 in (3.1 m)
Overall Width (Outside Front Tires) 7 ft 8 in (2.37 m)
Overall Width (Moldboard ) 11 ft (3.3 m)
Base Weight 16,000 lbs (7257.47 kg)
Wheelbase 16 ft 1 in (4.9 m)
Outside Turning Radius 22 ft (6.7 m)
Minimum Ground Clearance 1 ft (30.4 cm)
Table 2-2. Engine Specifications

ITEM SPECIFICATION
Model Cummins 3.8 Tier 4F
Engine Type 4-Cylinder, Water-Cooled Diesel
Horsepower 130 HP @ 2200 RPMs (97 kW)
Displacement, Bore and Stroke 229 cu in (3.8 L); 4.02 in (102 mm); 4.53 in (115 mm)
High Idle Speed 2200 RPMs
Maximum Gross Torque 360 ft lbs (488 N•m)
Maximum Gross Torque 360 ft lbs
Idle Speed 1200 RPMs

Table 2-3. Electrical Specifications

ITEM SPECIFICATION
Batteries (2) 12 VDC, Maintenance Free
Cold Cranking Amps (CCA) 800 CCA Per Battery (1600 CCA Total)
Alternator 135 amp
Table 2-5. Operational Specifications

ITEM SPECIFICATION
Travel Speed (@ 2200 RPMs) 0 - 20 mph (0- 32.2 kph)
Recommended Speed While Grading
ITEM
0 - 10 mph (0 - 16 kph)
Table 2-6. Fuel and Lubricant Specifications

SPECIFICATION
2
Engine Oil API CJ-4 or ACEA-E9 (Low Ash) 15W40 WT
Hydraulic Oil AW32 or AW68 Hydraulic Oil
Coolant Ethylene/Glycol or Propylene Glycol
Fuel Ultra Low Sulphur Diesel (ULSD)
Transfer Case (2-Speed) 80-90 WT Gear Oil
Tandem Gear Box 80-90 WT Gear Oil
Differential Oil 80-90 WT Gear Oil
Planetary Hub 80-90 WT Gear Oil
Grease Shell Avania EP Grease or Equivalent
Table 2-7. Machine System Capacity Specifications

ITEM SPECIFICATION
Fuel 45 gal (170.3 L)
Engine Lubrication Oil 15.4 qt (14.6 L)
Engine Coolant 5.75 gal (22 L)
Hydraulic Oil Reservoir 30 gal (113.56 L)
Transfer Case (2-Speed) .92 gal (3.48 L)
Differential Oil 2.2 gal (8.4 L)
Planetary Hub .63 gal (2.4 L) per hub
Tandem Gear Box 2.32 gal (8.78 L) per side
Table 2-8. Chassis Specifications

ITEM SPECIFICATION
Tires 15-19.5 TL 8PR; 30 PSI
Foot-Operated, hydrostatic traction drive system.
Brakes
Hydraulic park brake is electrically actuated.
Oscillating axle supported by tapered roller bearings
Front Drive Axle and bushings. Wheel lean 15° left or right. Ground
clearance of 1.2 feet (.36 m)

Table 2-9. Hydraulic Specifications

ITEM SPECIFICATION
Traction Pump Variable Piston 4.58 cu in (75 cu cm)
Function Pump Gear 0.93 cu in (15.2 cu cm)
Steering Pump Gear 0.93 cu in (15.2 cu cm)
Drive Motor Variable Volume 4.8 cu in (80 cu cm)
Hydraulic Filters Remote Pressure and Return
Table 2-10. System Pressures

ITEM SPECIFICATION
Operating Pressure 0 - 6000 psi (0 - 414 Bar)
Accumulator 2300 psi (158.579 Bar)
Accumulator Low-Pressure Switch 1300 psi (89.6 Bar)
Relief Valve 3000 psi (206.8 Bar)
Charge Valve to Orbital (At Relief) 2465 psi (170 Bar)
10-Section Valve 1900psi (131 Bar)
Main Drive Pump 6000 psi (413.68 Bar)
Charge Pressure 350 psi (24 Bar)
Park Brake Release 350 psi (24 Bar)
Table 2-11. Moldboard Specifications

ITEM SPECIFICATIONS
Width: 11 ft (3.3 m)
Width and Height
Height: 1 ft 9 in (.579 m)
Side Shift, Tilt and Rotation 3 ft (.91 m); 30° Tilt; 64° Rotation
Penetration 1 ft 2 in (.365 m)
Raised Clearance 1 ft 1 in (.335 m)
Table 2-12. Front Blade Specifications

ITEM SPECIFICATION
Width: 8 ft (2.4 m)
Width and Height
Height: 1.3 ft (.381 m)
Raised Clearance 1.9 ft (.533 m)
Penetration 6 in (15.1 cm)
Table 2-13. Rear Scarifier Specifications

ITEM SPECIFICATION
Width 6 ft (1.8 m)
Number of Teeth 9
Low: 11.5 in (29 cm)
Raised Clearance
High: 13.7 in (34 cm)
Low: 8.5 in (21 cm)
Penetration
High: 6 in (15 cm)

TORQUE SPECIFICATIONS
The following tables list torque values for standard Conversion Formula
hardware. This is a guide for average application ft-lb to N•m [ft-lb]*1.3558 = [N•m)
involving typical stresses and machined surfaces. ft-lb to in-lb [ft-lb]*12 = [in-lb]
Values are based upon physical limitations of clean,
N•m to in-lb [N•m]*8.8508 = [in-lb]
plated and lubricated hardware. Under more extreme
conditions, individual torque value should be followed.
Conversion formulas are provided in the adjacent table:
Standard Inch Fasteners

Table 2-14. Torque Specifications For Standard Inch Fasteners
CAPSCREWS: SAE GRADE 5 CAPSCREWS: SAE GRADE 8
2
SIZE THREAD TORQUE (ft lb) TORQUE N•m TORQUE (ft lb) TORQUE N•m
Dry Lubed Dry Lubed Dry Lubed Dry Lubed
1/4 20 UNC 8 6 11 8 12 9 16 12
28 UNF 10 7 14 9 14 10 19 14
5/16 18 UNC 17 13 23 18 25 18 34 24
24 UNF 19 15 26 20 27 20 37 27
3/8 16 UNC 31 23 42 31 44 33 60 45
24 UNF 35 26 47 35 49 37 66 50
7/16 14 UNC 49 37 66 50 70 52 95 71
20 UNF 55 41 75 56 78 58 106 79
1/2 13 UNC 75 57 102 77 106 80 144 108
20 UNF 85 64 115 87 120 90 163 122
9/16 12 UNC 109 82 148 111 154 115 209 156
18 UNF 121 91 164 123 171 128 232 174
5/8 11 UNC 150 113 203 153 212 159 287 216
18 UNF 170 127 230 172 240 180 325 244
3/4 10 UNC 267 200 362 271 376 282 510 382
16 UNF 297 223 403 302 420 315 569 427
7/8 9 UNC 429 322 582 437 606 455 822 617
14 UNF 474 355 643 481 669 502 907 681
1 8 UNC 644 483 873 655 909 681 1232 923
14 UNF 722 542 979 735 1020 765 1383 1037
1-1/4 7 UNC 1121 840 1520 1139 1817 1363 2464 1848
12 UNF 1241 930 1683 1261 2012 1509 2728 2046
1-1/2 6 UNC 1950 1462 2644 1982 3162 2371 4287 3215
12 UNF 2194 1645 2975 2230 3557 2668 4823 3617

Metric Fasteners
Table 2-15. Torque Specifications for Metric Fasteners
CLASS 8.8 [GRADE 5 EQUIVALENT] CLASS 10.9 [GRADE 8 EQUIVALENT]

NOMINAL SIZE
TORQUE (ft lb) TORQUE N•m TORQUE (ft lb) TORQUE N•m
AND PITCH
Dry Lubed Dry Lubed Dry Lubed Dry Lubed
M4 x 0.7 2 2 3 2 3 2 4 3
M5 x 0.8 5 3 7 4 7 5 9 7
M6 x 1 8 6 11 8 11 8 15 11
M8 x 1.25 19 14 26 19 27 20 37 27
M10 x 1.5 37 28 50 38 53 40 72 54
M12 x 1.75 65 49 88 66 93 70 126 95
M14 x 2 104 78 141 106 148 111 201 150
M16 x 2 161 121 218 164 230 173 312 235
M18 x 2.5 222 167 301 226 318 239 431 324
M20 x 2.5 314 236 426 320 449 337 609 457
M22 x 2.5 428 321 580 435 613 460 831 624
M24 x 3 543 407 736 552 777 582 1053 789
M27 x 3 796 597 1079 809 1139 854 1544 1158
M30 x 3.5 1079 809 1463 1097 1544 1158 2093 1570
Hydraulic Fittings Table 2-16. Torque Specifications for Steel Flare

Type Tube Fittings
Tightening Flare-Type Tube Fittings TUBE SIZE NUT SIZE
1. Check the flare and flare seat for defects that might OUTER ACROSS TORQUE VALUE
cause leakage. DIAMETER FLATS
2. Align tube with fitting before tightening. (IN) (IN) (LB FT) (N•m)
3. Lubricate connection. 3/16 7/16 8 11

1/4 9/16 12 16
4. Hand tighten swivel nut until snug.
5/16 5/8 16 22
5. To prevent twisting the tube(s), use two wrenches.
Place one wrench on the connector body and 3/8 11/16 23 31
tighten the swivel nut with the second to the torque 1/2 7/8 38 52
shown in the following table:
5/8 1 54 73
NOTE: The torque values shown are based upon
lubricated connections. 3/4 1 1/4 75 102
7/8 1 3/8 83 113

Determining Proper Torque L
The only reliable method of creating a consistently

leak-free and long-lasting connection is to ensure the
coupling is brought to the proper torque. Using a torque
wrench with crowfoot is the best method, but the flats
E
method can be used if a torque wrench is not available.
The most straightforward method of determining the
correct torque setting is to multiply the desired torque
by the length of the wrench from the center of the handle
to the center of the drive (L); divided by the length of the
2
LA
wrench from the center of the handle to the crowfoot
center (LA) as shown below:
LA
L
LH
Figure 2-2. Torque Wrench - Crowfoot

The minimum torque values are
adequate for sealing most applications. Maximum
torque values should never be exceeded.
There are several methods of determining the correct Figure 2-3. Measurements Needed
setting on the torque wrench when using a crowfoot. All
LEGEND
of the methods involve making the setting proportional
to the effective change in length of the wrench multiplied L = Distance from center of torque wrench handle to the
by the desired final torque. The equations and center of socket drive
illustration below describe proper measurements. E = Distance from center of socket drive to the center of
Equations crowfoot
• Torque setting if the crowfoot is placed in line with LA = Distance from center of torque wrench handle to
respect to the wrench: the center of crowfoot
TS = TD * L / LA LH = Distance from center of torque wrench handle to

the center of crowfoot, when mounted at 90°
OR
TD = Desired torque at the fitting
TS = TD * L / (L+E)
TS = Torque setting indicated on wrench
• Torque setting if the crowfoot is placed at 90° with
respect to the wrench
TS = TD * L / LH
OR
TS = TD * L / √(L2 + E2)
• To estimate the crowfoot size (E)
E = Drive Size * 0.5 + Distance between Drive and
Open End + Wrench Size * 0.5774

Coupling Installation Mark Line on Nut
Use the following steps for proper coupling installation:

1. Determine the correct torque value for your
coupling.
NOTE: Only use the torque values specified from
the manufacturer. DO NOT use SAE torque
recommendations.
2. Ensure the seal face and threads are clean and in
good condition. O-Rings should be lubricated with
light oil, but threads should be completely dry unless
making pipe thread connections (interference seal).
Example 2 Flats
NOTE: Attach the male end of the hose onto the difference
equipment first since it may be necessary to
rotate the entire hose assembly to tighten Figure 2-14. Flats Method Tightening
the male threads. Then route the hose into
NOTE: The mark placed on the nut and backup hex
position while avoiding twisting the hose.
after tightening by hand should rotate during
3. Tighten the connection (by hand), bringing the seal final tightening according to the table below.
face into contact and rotating the nut until it stops. The nut and backup hex can then be marked
to indicate if the coupling loosens over time.
4. Mark a line across the coupling nut and backup hex
for the flats method verification of coupling torque. Table 2-17. Flats Method Values for Selected
Terminations
5. Apply a wrench to the backup hex to prevent the
coupling and hose from moving while tightening the FLATS METHOD VALUES
nut with a torque wrench. Termination
Dash Size Flats
Failure to retain the backup hex during Type
installation will also result in additional clamp load JIC -4 1.5 - 1.75
force that could cause damage to the seal face.
JIC -6 1.0 - 1.5
NOTE: The coupling nut must be in motion for an
JIC -8 1.5 - 1.75
accurate torque reading. If the nut is stopped
before final torque value is achieved, it must JIC -10 1.0 - 1.5
be loosened and retightened until the torque JIC -12 1.0 - 1.5
is attained while the nut is in motion.
JIC -16 .75 - 1.0
If a torque wrench cannot fit into the coupling area or if
JIC -20 .75 - 1.0
it is unavailable, the flats method may be used to ensure
that the coupling is properly tightened. JIC -24 .75 - 1.0
JIC -32 .75 - 1.0
JIS -4 .5 - 1.5
1. Seal faces must be in contact with the fitting fully
tightened by hand before marking flats.
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.

Table 2-18. Torque Specifications For US Style Coupling Terminations

JIC, SAE 45°, ORFS, O-RING BOSS, GATES ADAPTERLESS AND MEGASEAL
SAE O-Ring Boss SAE O-Ring Boss
JIC 37°, SAE 45° JIC 37°, SAE 45°
Flat Face O-Ring (Steel) & Gates (Steel) & Gates
DASH & Mega-Seal & Mega-Seal
Seal (Steel) Adapterless Adapterless
SIZE (Steel) (Brass)
≤ 4000 PSI > 4000 PSI
Min Max Min Max Min Max Min Max Min Max
-3 8 10
-4 10 11 5 6 10 12 14 16 14 16
2
-5 13 15 7 9 18 20
-6 17 19 12 15 18 20 24 26 24 26
-8 34 38 20 24 32 40 37 44 50 60
-10 50 56 34 40 46 56 50 60 72 80
-12 70 78 53 60 65 80 75 83 125 135
-14 65 80 160 180
-16 94 104 74 82 92 105 111 125 200 220
-20 124 138 75 83 125 140 133 152 210 280
-24 156 173 79 87 150 180 156 184 270 360
-32 219 243 158 175
Table 2-19. Torque Specifications for DIN 24, DIN 60, Table 2-20. Torque Specifications for 4-Bolt
and Inverted Cone Style Coupling Terminations Flange Connections
DIN 24, DIN 60, AND INVERTED CONE 4-BOLT FLANGES
Size (mm) Torque (lb ft) Dash Size Bolt Size (in) Torque (lb ft)
Light Heavy -8 0.31 17
Series Series Min Max -12 0.38 26
Tube OD Tube OD
-16 0.44 43
6 7 15
-20 0.50 65
8 15 26
-24 0.63 130
10 8 18 30
-32 0.75 220
12 10 22 33
1. Align faces and tighten bolts (by hand) before
14 12 26 37
applying final torque in a pattern. The seal faces
15 14 30 52 must be parallel with an even bolt tension to seal
16 30 52 properly.
18 20 44 74 2. Torque values apply to bolts that are plated or
coated in light engine oil.
22 25 59 89
3. Before assembly, lubricate O-Ring with light oil
28 30 74 111
(SAE 10W or 20W).
38 74 162
35 133 184
42 148 221

Table 2-21. Torque Specifications for NPTF Dry Seal Table 2-22. Torque Specifications for BSP 30°
Pipe Threads Inverted Cone and JIS Coupling Terminations
NPTF BSP 30° INVERTED CONE AND JIS
Dash Size Max Torque (ft-lb) Torque (ft-lb)
Dash Size
-2 20 Min Max
-4 25 -2 7 9
-6 35 -4 11 18
-8 45 -6 19 28
-12 55 -8 30 36
-16 65 -10 37 44
-20 80 -12 50 60
-24 95 -16 79 95
-32 120 -20 127 152
1. The torque values obtained from tightening pipe -24 167 190
threads can vary considerably depending upon -32 262 314
thread condition. Adequate sealing can occur at
values much lower than the maximum values listed
above. Only enough torque to achieve adequate
sealing should be used.
2. When using a male tapered pipe thread with a
female straight or parallel pipe thread, maximum
values are 50% of those listed in the table above.
3. If thread sealant is used, maximum values shown
should be decreased by 25%.

Section 3
COMPONENT LOCATION
Page
Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Components Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Operator Station. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hydrostatic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Scarifier (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

Components
NOTES

Components
COMPONENTS OVERVIEW Engine

The LeeBoy 685D Motor Grader is a compact motor The 685D Motor Grader
grader with the functionality of a large motor grader. is equipped with a
It’s versatility and specialized applications include Cummins QSF3.8 Tier
spreading base materials, ditch and shoulder projects, 4F diesel engine. This
fine grading, medium cutting and even snow removal. Tier 4 Final fuel-efficient
Graders can also be used for bank sloping, leveling, engine offers the latest
crowning, and road/runway maintenance. This self- in innovative emission
propelled, wheeled grader has an adjustable, 11-foot solutions to reduce diesel
(3.35 meter) moldboard blade positioned between the particulate matter (DPM)
front and rear wheels. An optional 12-foot (3.65 meter) and other toxins released
moldboard is also available. Optional attachments into the air.
include an 8-foot (2.4 meter) front blade, front or rear Advanced emission-control devices and low-sulfur fuel
scarifiers or a blade-mounted, flip-down scarifier. Be requirements--only Ultra-Low Sulfur Diesel (ULSD)
familiar with all the grader’s components and optional can be used in this engine--combine with new after-
attachments purchased before operating this machine. treatment methods. The SCR system is an efficient,
3
effective means of filtering dirt and other contaminates
for optimum engine performance and reducing air
pollution from exhaust emissions. The Selective
Catalytic Reduction (SCR) system precisely injects
Diesel Exhaust Fluid (DEF) into the engine’s exhaust
system to transform those toxic exhaust gases into
harmless water vapor and nitrogen. SCR technology is
also cost-effective and fuel-efficient.
The High-Pressure Common Rail (HPCR) fuel system
offers a new level of cleanliness, performance and
fuel economy. The fuel filter removes contaminants
from diesel fuel before it flows into the injection pump,
providing better protection against harmful particles.
The Direct Flow™ air filtration system holds 30 percent
more dust particles than conventional filters, enabling
longer service intervals and reducing maintenance
costs. The radiator cools the engine. A mechanically-
Operator Station driven fan removes heat, saves horsepower and
The 685D Motor Grader is equipped with a canopy, but reduces noise.
an optional fully-enclosed cab version offers additional Lockable engine access doors on both sides of the
operator comfort on the job site. Air conditioning, grader allow convenient access to components with
heating, and other options are also available for a cab vandalism protection.
model.
Refer to the Engine Owner’s Manual accompanying your
Levers, control switches and joystick controls are within machine for additional engine information.
easy reach for operator comfort. The PV485 digital
controller unit on the steering control panel includes
throttle control, tachometer, fuel gauge, oil pressure
gauge, coolant temperature, voltmeter and hour meter
along with gauges and warning alerts. The steering
column can be tilted for comfort. Complete control
panel information is described in the following pages.

Components
Moldboard
The moldboard is a major component of the 685D Motor
Grader. This adjustable, hydraulically-controlled blade
is mounted between the front and rear wheels that can
cut, move and spread materials to grade requirements.
The moldboard blade is mounted under the turntable
circle that can be hydraulically rotated right and left.
The moldboard height is controlled by two hydraulic
cylinders mounted to ball joints at a turntable.
Hydrostatic Drive
This grader is powered by a diesel engine with dual-
range, hydrostatic transmission system that propels
the machine forward or reverse at varying speeds with
dynamic braking action. Components of the hydrostatic
drive system include a hydrostatic traction pump,
variable-speed hydraulic motor, two-speed tandem axle,
rear axle carrier assembly and gear drive. A two-speed
transfer case mounted between the drive motor and
rear axle carrier provides high and low gear selection.
The rear axle carrier assembly converts input rotation to
The blade can be aggressively angled perpendicular
axle shaft output rotation to drive the wheels.
to the line of travel or parallel to the direction of travel.
The function and steering pump is mounted on the rear The blade’s curved shape allows material to roll more
of the traction pump and driven by the traction pump freely along the blade. The moldboard can be moved
output shaft. This provides hydraulic pressure and flow forward and also shifts three (3) feet (.9 meters) left or
to operate all the hydraulic cylinders that controls the right. It can tilt side-to-side and front-to-rear, rotate
steering cylinder and other grader functions. 64 degrees, and features float controls that can cut 1.2
feet (.355 meter) below grade. This versatility allows
extreme moldboard positioning to meet a variety of road
Electrical System construction and maintenance needs, including easier
bank sloping and ditch cutting.
The electrical system is powered by two 12-volt
batteries, wired in parallel and mounted in a battery
compartment on the frame. Each battery produces
800 cold cranking amperes (CCA) for a total of 1600
CCA. An engine-mounted alternator with 135 amperes
of charging capacity keeps the batteries charged during
normal operation.

Components
Scarifier (Optional) Standard Equipment/Options

The scarifier, or ripper, is a mechanism with large teeth Component
mounted on shanks for penetrating and loosening earth,
Sliding Moldboard: 11-Foot (3.3 m)
gravel, asphalt and similar surfaces to shallow depths. v
(Includes Tilt and Float)
This attachment is used to break up material too hard
for the moldboard blade to cut, such as a surface Articulated Frame v
preparation device for ripping asphalt or breaking up Safety Beacon and Work Light Package v
packed soil for construction site preparation, digging
Hydrostatic Traction Drive with Secondary
and even landscaping purposes. v
Brakes, 2-Speed Tandem Axle
Hydraulically raised and lowered, the scarifier has five Cushioned, Adjustable Suspension Seat v
replaceable teeth (with space for a total of nine teeth if
needed) for penetrating the grading surface. The tooth Anti-Vandalism Package v
supports are adjustable and secured with pin locks. Heavy-Duty Rear Hitch v
Canopy with ROPS/FOPS v
Exterior Side Mirrors v
3
Circle Turn Cushion Valve v
Cab Version (Includes Heat) Option
Cab Options: A/C, Defrost Fan, Rear Window
Option
Wiper/Washer, Radio
Rear Scarifier Option
Front Scarifier Option
Front Blade 8-Foot (2.4 m) Option
Front Blade-Mounted, Flip-Down Scarifier Option
Front Blade Float Option
12-Foot (3.6 m) Sliding Moldboard Option
AWD (All-Wheel Drive) Option
Secondary Steering Option
Circle Side Shift Option
Cold Weather Engine Package Option
Back-Up Camera Option
Front or rear scarifier options offer the ripping power

to penetrate tough material fast. Choose from front or
rear scarifier options (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.

Components
MACHINE OVERVIEW
2 6
1
4
7
5
Figure 3-1. Machine Overview

ITEM
CONTROL NAME FUNCTION
NO.
Optional attachments can be mounted to the attachment plate on the nose of
1 Front Attachment Mount
the grader, including an 8-foot blade or scarifier..
The front part of the grader that pivots. The moldboard and optional
2 Front Boom
attachments are mounted onto the boom.
3 Lift Cylinders Cylinders lift and lower moldboard blade.
4 Turntable Rotates the moldboard left and right.
The moldboard blade is used for grading and smoothing surfaces. Also used
5 Moldboard for ditch digging. Mounted under the boom, supported by a drawbar and
turntable.
Lockable access doors on both sides of the machine for easy access to
6 Engine Access Panel
engine and other components.
Used for penetrating and loosening earth, gravel, asphalt and similar surfac-
7 Rear Scarifier (Option) es. Includes nine (9) replaceable teeth mounted on adjustable shanks and
secured with pin locks..

Components
OPERATOR STATION
1
2
3 3
5
6
4
7
Figure 3-2. Operator Station

ITEM
NO.
Contains steering wheel, component indicator lights, and grader work
1 Steering Column Controls
function levers.
2 PV485 Digital Controller Displays engine operating parameters, warnings and alerts.
3 Foot Brake Press on the foot brake to stop the grader.
If equipped with the cab option, this additional option contains controls for
4 Heat/AC Controls (Option)
the heat and air conditioner.
Step on the front part of the pedal to move forward; step on the rear part of
FNR (Forward/Neutral/
5 the pedal to move in reverse. The center position is NEUTRAL. The FNR
Reverse) Pedal
pedal must be in the neutral (center) position to start the engine.
Use to increase and decrease engine speed (RPMs) when in gear (low or
6 Throttle high gear). Push lever forward to increase speed. Push lever rearward to
decrease speed.
Contains numerous machine component controls, including the ignition
7 Main Control Panel
switch, lights, park brake, gears, fan, and wipers.

Components
STEERING COLUMN CONTROLS

Grader operations involve using levers on the steering control panel. When levers are released from the forward or
back position, they return to the neutral center position (except the float position on the moldboard), suspending the
function or component movement.
2 5
8 9 6 10 11
3
4 7
12 13 14 15 16 17
Figure 3-3. Steering Column Controls
ITEM
NO.
1 PV485 Digital Controller Displays engine operating parameters, warnings and alerts.
2 Left Turn Signal Indicator Light Blinks when the left turn signal is engaged.
3 Brake Failure Warning Light Illuminates when there is low service brake pressure.
4 All Wheel Drive (AWD) OPTION If equipped with this option, illuminates when AWD is engaged.

Components
ITEM
NO.
Right Turn Signal Indicator
5 Blinks when the right turn signal is engaged.
Light
6 High Gear Indicator Light Illuminates when operating in high gear.
7 High Beam Indicator Light Illuminates when the headlights are switched to high beam.
8 Moldboard Blade Angle Lever Rotates moldboard. Pull lever to rotate left; push lever to rotate right.
Shifts moldboard left or right. Pull lever to shift moldboard left; push lever
9 Moldboard Slide Lever
to shift moldboard right.
Raises/lowers left moldboard edge. Pull lever to raise left edge; push
lever to lower left edge. Continue to push lever forward into float detent.
10 Moldboard Lift Lever (Left)
Push or pull both the left and right moldboard lift levers to raise and lower
the entire moldboard.
Raises/lowers right moldboard edge. Pull lever to raise right edge; push
lever to lower right edge. Continue to push lever forward into float detent.
3
11 Moldboard Lift Lever (Right)
Push or pull both the left and right moldboard lift levers to raise and lower
the entire moldboard.
Rotates drawbar left or right. Pull lever to shift drawbar left; push lever
12 Circle Side Shift (Option) to shift drawbar right. (This lever is nonfunctional if not equipped with
option.)
Front Attachment Lever Raises/lowers optional front attachments. Pull lever to raise, push lever
13
(Option) to lower. (This lever is nonfunctional if not equipped with option.)
Tilts the front wheels left or right. Push lever forward to tilt tires left; pull
14 Wheel Lean Lever
lever to tilt tires right.
Tilts moldboard. Pull lever to tilt top of the moldboard backward. Push
15 Moldboard Tilt Lever
lever to tilt top of moldboard forward.
16 Rear Scarifier Lever (Option) Raises/lowers rear attachment. Pull lever to raise; push lever to lower.
Rotates front “boom” portion of the grader. Pull lever to rotate boom right;
push lever to rotate boom left.
17 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.

Components
MAIN CONTROL PANEL

4 5 6 7 8 9 10 11
12 13 14 15 16
1 2
3
17 19
18 20
21
Figure 3-4. Main Control Panel

ITEM
NO.
Immediately stops the engine and all electronic functions. Turn clockwise to
1 (Emergency) E-Stop release the emergency stop. If machine is moving, the park brake will apply
and the grader will stop rapidly.
Use this switch to select HIGH or LOW beam when the headlights are on.
2 Headlight High/Low Beam
Turn the switch up for HIGH BEAM and down for LOW BEAM.

Components
ITEM
NO.
3 Cupholder A convenient holder for beverages.
4 Horn Press this button to sound the horn.
Turns the front work lights ON and OFF. Turn the switch up to turn ON or
5 Front work lights
down to turn OFF the front work lights.
Turns the rear lights ON and OFF. Turn the switch up to turn ON or down to
6 Rear Lights
turn OFF the rear lights. The center position is OFF.
Turns the beacon light ON and OFF. Turn the switch up to turn beacon light
7 Beacon Light
ON or down to turn it OFF.
Turns the fan ON and OFF. Turn the switch up to turn fan ON or down to turn
8 Fan
it OFF.
9 Headlights Hi/Low Beam Turn the switch UP for high beam; turn the switch DOWN to dim lights.
Turns the front windshield wiper ON and OFF. Rotate switch clockwise one
Front Windshield Wiper/
3
10 position for low-speed wiper or two positions for high-speed wiper. Rotate
Washer
fully counterclockwise to turn off wiper. Push button to spray washer.
Turns the rear wiper ON and OFF. Rotate switch clockwise one position
11 Rear Wiper/Washer for low-speed wiper or two positions for high-speed wiper. Rotate fully
counterclockwise to turn off wiper. Push button to spray washer.
Turn switch up to place rear axle gearbox into HIGH gear, used when
traveling to and from job sites. Turn switch down to place rear axle gear box
12 2-Speed High/Low
into LOW gear, used when grading. You must come to a complete STOP
with the FNR pedal in neutral and apply the park brake to shift gears.
Turn the switch up to select TRAVEL speed. Turn the switch down to
select WORK speed. Work speed maintains the hydrostatic drive motor
at maximum torque and a constant speed (with the ability to increase or
13 Axle Travel/Work
decrease speed using the FNR pedal). Travel speed allows the grader
to travel at a higher speed when maximum torque isn’t needed, but
automatically slows when more torque is needed.
All-Wheel Drive (AWD) If equipped with this option, turn the switch up to turn ON the AWD feature.
14
(Option) Turn the switch down to disengage AWD.
15 Front Blade Float (Option) Turn switch up to turn on the front blade float.
16 Secondary Steering Turn switch up to activate secondary power steering.
Starts and stops engine. The park brake must be engaged and the FNR
17 Ignition
pedal in the neutral (center) position to start the engine.
Engages and disengages the park brake. Push the switch up to engage the
park brake. Push the switch down to disengage the park brake. The park
18 Park Brake brake must be applied to start the engine and to shift axle between HIGH and
LOW modes.
NOTE: Always engage the park brake when the machine is parked.
19 12-Volt Outlet An outlet socket that can provide power for external devices.
Provides easy access to the fuse panel. Locks and unlocks to prevent
20 Fuse Panel Access
vandalism.
Use to increase and decrease engine speed (RPMs) when in gear (low or
21 Throttle high gear). Push lever forward to increase speed. Push lever rearward to
decrease speed.

Components
HEAT AND AIR CONDITIONING

(CAB OPTION)
1 2 3 4
Figure 3-5. Heat and Air Conditioning Controls
Item
COMPONENT FUNCTION
No.
Opens and closes
1 Vent Knobs
recirculation vents.
Adjusts temperature and
2 Heat
turns heat on and off.
Controls blower fan for heat
3 Fan
and air conditioning.
Adjusts temperature and
4 Air Conditioning turns air conditioning on
and off.
• Before turning on heat for the first time each
winter, open the heat valve beside the master
battery switch located inside the left engine panel
by turning the lever clockwise.
• At the end of winter, shut off the valve by turning
the lever counterclockwise (perpendicular to the
hose).
Heat Valve Master Battery Switch
Figure 3-6. Heat Valve in the Open Position

Section 4
OPERATION Page
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
4
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
Axle Travel/Work. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
2-Speed High/Low. . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Directional Control. . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Operation
Articulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Front Wheel Lean . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Motor Grader Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Moldboard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Circle Turn Cushion Valve. . . . . . . . . . . . . . . . . . . . . . 4-24
Grader Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Mounting Front Attachments. . . . . . . . . . . . . . . . . . . . . 4-25
Operating Front Attachments . . . . . . . . . . . . . . . . . . . . 4-26
Front Blade Float. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Scarifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Operating a Scarifier. . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Replacing Scarifier Teeth . . . . . . . . . . . . . . . . . . . . . . 4-28
Operating Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Grading Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Grading Around Objects . . . . . . . . . . . . . . . . . . . . . . . 4-30
Spreading and Leveling . . . . . . . . . . . . . . . . . . . . . . . 4-31
Slope Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Grading an “S” Curve Shoulder. . . . . . . . . . . . . . . . . . . . 4-33
Road Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Gravel and Dirt Roads. . . . . . . . . . . . . . . . . . . . . . . . 4-34
Crowning the Road . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Ditch Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Cul-De-Sacs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Unloading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Tie-Down Procedure. . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Cab Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Sliding Moldboard . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Circle Side Shift. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Secondary Steering. . . . . . . . . . . . . . . . . . . . . . . . . 4-40
All-Wheel Drive (AWD) . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Cold Weather Engine Package. . . . . . . . . . . . . . . . . . . . 4-41
Reverse Camera System. . . . . . . . . . . . . . . . . . . . . . . 4-41

Operation
GENERAL INFORMATION Be sure to check the machine thoroughly upon receipt:

1. Check engine oil. (Page 5-13)
The LeeBoy 685D Motor Grader is a hydrostatic,
articulating grader designed with the functionality of 2. Check hydraulic fluid level. (Page 5-25)
a larger grader but more compact. The 685D model 3. Check DEF tank fluid level. (Page 5-17)
has the versatility for fine grading, spreading base
materials, ditch and shoulder work, medium cutting, 4. Check machine hoses for any damage or leaks.
general construction, shaping, bank sloping, , and even 5. Rotate the beacon light bracket from its shipping
snow removal. The 685D is excellent for driveways, position to its operating position. Ensure the
parking lots, landscaping and road/runway maintenance bracket “clicks” into position.
projects as this smaller grader is very maneuverable
and easier to transport than a larger machine. 6. Inspect machine for any damage during transport.
Contact your authorized dealer immediately if any
This section offers information to help you understand damage has occurred in transit.
how to operate this grader and its components and
attachments, along with basic grading techniques. Pay
particular attention to safety warnings in Section 1 and
throughout this manual.
Initial and Daily Inspection
The following inspections are essential and should be
Ensure operators are properly
performed before starting the machine. Visually inspect
licensed if required in your location.
the unit to check its general condition. Continue with a
Use only Ultra-Low Sulfur Diesel check of the systems and components shown in Table
(ULSD) with a maximum sulfur content of 15 4-1 below:
4
ppm or less in this machine. This is a regulatory Table 4-1. Initial and Daily Inspection
requirement. Failure to do so will result in damage to
the engine and after-treatment system within a short INSPECT PROCEDURE
period of time. Engine Oil Maintain oil level between ADD and FULL
Level marks on dipstick.
Only authorized personnel who are
properly trained should operate this machine. DO Check for adequate fuel supply. Fill if
Fuel Tank needed. Always fill tank at end of the day to
NOT allow others on the operator platform or near
prevent condensation in the tank.
this industrial machine and its heavy equipment at
any time. Hydraulic
Check the tank for oil level and leaks.
Tank
DO NOT leave the operator station DEF Tank Check the DEF tank level and refill if needed.
unattended while the engine is running.
Radiator Check coolant level.
Keep the steps, hand-hold bars, Always perform a pre-start brake check
operation station and machine components clean Brake before operating using the procedure shown
and clear of debris, mud and grease to prevent on Page 4-4.
falls or other accidents. Be careful mounting and Ensure all cables are tight and clean. Check
dismounting the motor grader. Always use the hand- Battery
for corrosion on the battery terminals.
hold bars and steps. NEVER mount or dismount the Check the air filter element and connections.
grader while it is moving. DO NOT jump from the Air Cleaner Air cleaner has both a primary and
grader at any time. secondary filter.
Drain Plugs Make sure plugs are inserted and tight.
Engine Belt Check for wear or damage.
Receiving the Machine Grease Ensure fittings are greased and in good
Although the machine has been checked thoroughly by Fittings working order.
the manufacturer, road hazards or other factors during
transport may result in damage. Inspect machine for
any damage during transport. Contact your authorized
dealer immediately if any damage has occurred.

Operation
START-UP PROCEDURE Starting the Engine

ALWAYS fasten your seat belt and
Brake Check adjust steering console, seat and mirrors BEFORE
A Neutral Start feature has been installed for safety. starting the engine.
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
always check the brake before operating. 1. Ensure the park brake is engaged. (Figure 4-2)
Verify there are no people, obstacles 2. Fasten seat belt, adjust steering console, seat
or other equipment in the machine’s path before position and mirrors.
starting the engine. 3. Place the FNR pedal into the NEUTRAL position.
(Figure 4-1)
Be sure the park brake is engaged
and the FNR pedal is in the neutral position before 4. Ensure the throttle is in the idle position (completely
starting the engine. DO NOT put your foot on the rearward). Check control panel gauges for proper
FNR pedal when starting. readings.
To check that the park brake is functioning properly: 5. Insert key into the ignition and turn clockwise to the
ON position. (Figure 4-2)
1. Engage the park brake. (Figure 4-2)
• The PV485 digital controller on the steering
2. Step on the foot brake pedal. (Figure 4-1)
control console (described on the following
Foot Brake
pages) will “boot” for a few seconds when
starting the engine. A “Wait to Start” banner will
appear for a few seconds while booting. AFTER
the Wait to Start light disappears, turn key to the
START position to crank engine.
GENTLY DO NOT hold the starter longer than
FNR
Press for Press for 10 - 15 seconds. If the engine does not start, allow
Reverse Forward the starter to cool two or three minutes between
attempts to prevent damage to the starter.
The engine is equipped with an
electric heat starting system. Using start additives,
Figure 4-1. FNR Pedal such as ether, is not recommended as it could cause
3. Turn the ignition key to the START position. The an explosion resulting in severe injury and/or engine
engine should not start unless the FNR pedal is in damage.
NEUTRAL (center position). 6. Check control panel gauges for proper readings.
• If the engine starts with the FNR pedal in 7. Allow the engine to idle a few minutes before moving
either FORWARD or REVERSE, contact your in either direction.
authorized dealer immediately for service. DO
NOT drive the grader until repaired. A safety sensor system in the seat
detects whether the operator is properly seated.
The FNR pedal is very sensitive. Use The grader will remain in neutral and will not move
only a little pressure on the pedal when moving forward or reverse, despite movement of the FNR
in forward or reverse to prevent lunging. DO NOT pedal, if the operator is not seated.
engage FNR pedal before releasing park brake.

Operation
4 Stopping the Engine

Before leaving the operator station,
place the machine in neutral, lower the moldboard
(and any other attachments) to the ground, and apply
the park brake.
1. Lower all attachments to the ground.
2. Apply park brake.
3
3. Turn ignition key counterclockwise to the OFF
2 position and remove key.
NOTE: The electrical system will continue to
1 operate for approximately 20 seconds after
the ignition is turned off. This allows the
engine ECU (Engine Control Unit) to store
critical engine data as it powers down.
Figure 4-2. Start-Up Controls NOTE: You may also hear a slight noise for a few
1 - Throttle Lever seconds after turning off the engine. This
is the DEF (Diesel Exhaust Fluid) system
2 - Park Brake Switch automatically purging.
3 - Ignition Switch
4
4 - E-Stop Button
Emergency Stop Button
The purpose of the Emergency Stop Button (E-Stop)
Cold Weather Starting is to shut down the engine and all machine functions in
an emergency situation. This additional safety feature
1. Engage the park brake. (Figure 4-2)
should only be used if the operator needs to shut down
2. Insert key into the ignition and turn clockwise to all machine operations quickly. (Figure 4-2)
the START position. (The “Wait to Start” light will
illuminate for a few seconds on the steering control ALWAYS wear your seat belt! If you
panel). AFTER the Wait to Start light disappears, engage the E-Stop button, the grader will stop very
turn key to the ON position to crank engine. quickly and could result in serious injury if you are
not wearing seat belt securely.
3. Allow the engine to idle about ten minutes before
driving the machine.

Operation
REGENERATION Diesel Exhaust Fluid (DEF)

(REGEN) After-Treatment System
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
temperature is raised to safely
allows greater engine power, higher torque and fuel
burn off any soot and undesired combustion gas to
economy while decreasing exhaust pollution. The
significantly reduce toxic emissions as required by Tier
DEF system is an important factor in operating the
4 Final engine standards.
machine. Keeping the DEF tank filled is critical to engine
Maintenance is kept at a minimum with a crankcase operation. (Figure 4-3)
ventilation breather that requires no filter element, and
a Cummins Filtration Direct Flow air cleaner that has a DO NOT operate the machine with
higher dust capacity. It is particularly important that the an empty DEF tank to prevent serious engine and
operator understand the regeneration process before emission system damage.
operating the grader.
This engine uses Diesel Exhaust Fluid (DEF), (known as
AdBlue® in Europe), a critical element of its Selective
Catalytic Reduction (SCR) after-treatment system.
Alerts and messages illuminate on the PV485 digital
display controller (described in the following pages)
when the DEF tank needs to be filled or the regeneration
process needs to be performed.
DEF Tank
When the soot saturation in the exhaust system reaches
Filler Cap
a certain level, the onboard engine ECU (Engine
Control Unit) will activate a regeneration cycle. During
normal operation, the regeneration process begins
automatically. This engine requires little to no operator Figure 4-3. DEF Fluid Tank
interaction, but under certain circumstances, the If the DEF tank level runs low (below 15 percent) during
operator may have to initiate the regeneration process. operation, a solid yellow DEF warning symbol will
The exhaust system cleaning light will illuminate during illuminate on the PV485 controller screen. If the level
regeneration. It is important not to shut off the engine drops to five (5) percent, the warning icon flashes yellow.
as the regeneration cycle will fail and could possibly Engine torque will be reduced 50 percent and engine
damage the engine. Once regeneration is complete, speed will be reduced 40 percent after 45 minutes.
the light will turn off. If the regeneration cycle fails, the If the operator continues to ignore the warning and
ECU may attempt a second regeneration. the DEF tank is still not refilled after an additional 45
Use only Ultra-Low Sulfur Diesel (ULSD) with a maximum minutes, the warning icon will illuminate red and flash
sulfur content of 15 ppm or less in this machine. Failure continuously. At this point, there will be no available
to do so will result in damage to the engine and after- torque--the engine will only idle.
treatment system within a short period of time. In either of these conditions, refilling the DEF tank will
Modifying or disconnecting any restore engine performance.
emission-related component will subject you to
government penalties and void your warranty.
Tampering with emission controls is in violation of
federal law, and can result in serious civil penalties.

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

warning symbol will also illuminate and flash red. At this
level, there is no ability for DPF regeneration or DEF
injection into the exhaust system, therefore no ability to
cool the DEF injector as needed. The DEF injector may
now be damaged by heat and require replacement
from your authorized dealer.
DEF Thaw Control Mode: Sensors on the DEF tank
also detect the ambient air temperature within seconds
of starting the engine. If the DEF is frozen, the SCR
system automatically starts the Thaw Control Mode and
turns on the DEF pump, tank and tube heaters. Engine
maximum torque may be limited to protect the DEF
injector.
DEF Purge: The SCR system will automatically purge
DEF after shutting down the engine. You will hear the
pumping noise as the system circulates DEF to cool
the DEF injector, then the pump reverses to return DEF
back to the tank. Always allow this purging process to
finish to prevent damage to the injector and other SCR Figure 4-4. PV485 Digital Display Controller
components.
NEVER disconnect battery until the
purge cycle has completed to prevent serious
damage to components in the SCR system.
Be sure the DEF fluid in the tank is not
PV485 DIGITAL DISPLAY
Before driving the LeeBoy 685D Motor Grader, it is
important to be familiar with the PV485 PowerView™
4
contaminated before refilling. Dispose of DEF fluid in digital controller located on the steering control panel.
accordance with environmental laws. This system is a multi-functional display that enables
operators to view standard engine parameters along
with active and stored trouble codes.
• The digital display screen show single or multiple
text descriptions, i.e., engine temperature, voltage,
oil pressure, engine RPMs, and service reminders
or fault conditions. The operator can toggle through
different screens for displaying critical data broadcast
by the electronic engine and transmission Engine
Control Unit (ECU).
• Diagnostic codes with text descriptions of fault
conditions are enhanced by ultra-bright alarm
indicators that illuminate amber or red to alert the
operator of a condition requiring attention.
• An amber warning light illuminates to alert the
operator that a trouble code or service reminder
is being shown on the display.
• If the red warning light illuminates, the operator
should shut down the machine and promptly
repair the problem to prevent possible damage.

Operation
When turning the ignition key to the ON position, you Soft Keys (Buttons)
will see a logo with the “Wait to Start” banner along the
bottom of the screen while the system “boots.” DO NOT The following table shows icons appearing on the
start the engine until this message disappears and bottom banner that correspond to the soft key button,
the gauge screen appears. depending upon the screen mode. (Some sources may
not be present on your model.)
Table 4-2. Soft Key Choices

Gauge Screen
Icon Description
The gauge screen is the first screen to appear on the
PV485 digital controller when starting the engine. This Displays the default speed (RPMs) set
is the default screen. (Figure 4-5) points.
Displays the DPF commands to access
Pressing the “soft key” buttons along the bottom of the
Uninhibit Regen and Inhibit Regen.
controller unit allows the operator to navigate to various
other screens. The banner icons along the bottom of Sends message to the ECU to start DPF
the screen correspond with these buttons, and change regeneration.
accordingly when navigating to other screens as Sends message to the ECU to stop DPF
described on the following pages. Table 4-2 shows the regeneration. (DO NOT use unless
icons that appear on the banner with descriptions. necessary.)
Pressing the center button ( ) navigates to the Main Requests freeze frame data from the
Menu screen. (Page 4-10) ECU when faults are present.
2 Navigates to the Main Menu screen
where you can scroll to choose action
items (such as settings and diagnostics).
Use to scroll down through a list of items.

1 3
Use to up scroll through a list of items.
4
Select: Enters the action item selected.
5
Deselect: Closes pop-up messages.
6
Soft Keys
Figure 4-5. Gauge Screen
1 - Engine Coolant Temperature
2 - Engine Speed/RPMs
3 - Hydraulic Oil Temperature
4 - Battery Voltage
5 - Actual Engine Torque Percentage
6 - Soft Key Banner

Operation
The soft menu screen also displays engine torque Table 4-3. Status Icons
percentage, DEF tank level, engine oil pressure, total
Status
hours of operation, and fuel level in the lower left Description
Icon
quadrant of the screen. (Figure 4-6)
Check Engine. When this lamp is illuminated
yellow, a fault exists within the control
1 system.
Take action immediately to
2 4 correct the fault.
Stop Engine. Illuminates red (and may flash)
3 when continued operation could result in
damage to the exhaust system. Shut down
the engine and do not operate the machine
Figure 4-6. Status Quadrant until repair has been made. Contact your
authorized dealer if needed.
1 - DEF Tank Level
2 - Engine Oil Pressure Park Brake. The park icon displays when
the parking brake is applied.
3 - Engine Total Hours of Operation
4 - Fuel Level Alternator. Illuminates when the alternator
isn’t charging properly.
Warning lights will illuminate and fault codes will also
display:
4
• The engine oil light is normally illuminated green, Coolant. Illuminates when the engine is
but will illuminate red if the hydraulic or engine oil running too hot.
pressure is too low and display a warning icon on the
screen. Fuel. Illuminates when the fuel tank is almost
• A warning icon will also display if the hydraulic or empty.
engine oil temperature is too high.
Hydraulic Oil. Illuminates to warn operator
• Other warning and status icons may also illuminate.
when the hydraulic oil is too hot.
(Table 4-3)
Refer to Section 5, Troubleshooting, for a complete Oil Pressure. Illuminates when the oil
list of Fault Codes. pressure is low. A wavy line underneath
indicates the engine oil level is too low.
DEF Tank Level Warning Icon. This lamp
illuminates if the DEF tank level runs low
(below 15 percent). Refill the DEF tank.
DEF Lamp with Check Engine Lamp. The

yellow check engine and DEF tank warning
lamps illuminate if DEF tank is critically low.
Refill the DEF tank. Engine power will be
reduced, but will return when filled.
Diesel Exhaust Fluid (DEF) System

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

Operation
Status Main Menu Screen

Description
Icon Pressing the Main Menu ( ) soft key navigates to the
Flashing DEF Lamp with Stop Engine Main Menu action items. (Figure 4-7) Scroll through
Lamp. Illuminates when the DEF tank is near the list using the UP/DOWN arrow keys, then press the
zero, further limiting power. Refill DEF tank ( ) key when the cursor (>) points to screen you wish
immediately to avoid damage! Normal to view to select that screen mode. The Main Menu
power will restored when DEF tank is filled. choices are listed below and described on the following
pages:
Insufficient DEF can result
in damage to the DEF injector and other • Gauge (default screen)
components. • Diagnostics
Flashing DEF Lamp with Red Stop Engine
• System Info
Lamp. Illuminates when the DEF has read
zero for 30 minutes. Power will be limited to • User Settings
IDLE. STOP the machine and refill the DEF
• Tier 4
tank immediately! If refilling the DEF tank
does not turn the lamps off and/or restore NOTE: Continue scrolling using the DOWN arrow
normal engine power, stop operation and key to access the Tier 4F menu action items.
contact your authorized dealer immediately. (Page 4-14)
High Exhaust System Temperature (HEST)
Lamp. May illuminate when higher than
normal exhaust temperature exists due to
regeneration.
Ensure the exhaust
pipe is not directed at any flammable
or combustible surface if any high
temperature icons illuminate.
DPF Regeneration Set to Inhibit — The
user may choose to inhibit the REGEN
if conditions are too hazardous for high
exhaust temperatures. When this lamp is
illuminated, a REGEN cannot be performed
and soot levels will continue to rise.
Unless hazardous
conditions exist, the REGEN Inhibit switch
and this lamp should remain off.
Exhaust System Cleaning. Illuminates
when the exhaust system is unable to Figure 4-7. Main Menu Screen
complete regeneration. As soon as
possible, performed a parked regeneration
procedure. (Pages 4-14 to 4-15) The icon
will flash during regeneration and stop once
regeneration is complete.
Exhaust System Cleaning and Check
Engine Lamps. Indicates a failure of the
emission system because the operator failed
to perform regeneration in a timely manner.
Engine power will be significantly reduced.
Perform parked regeneration immediately.
Contact your authorized dealer for
assistance if engine power does not return.

Operation
Diagnostics Logged Diagnostics

Use the UP/DOWN soft keys and stop the cursor (>) for The Logged Diagnostics screen displays nonactive
to view either active or logged diagnostics, then press warnings or faults with the appropriate Suspect
the Select ( ) soft key. (Figure 4-8) Parameter Number (SPN) and Failure Mode Indicator
(FMI) that are stored in the system. (Figure 4-10) Use
the UP/DOWN soft keys to scroll through list if needed.
NOTE: Select the Freeze Frame ( ) button to
request that frame data from the ECU when
faults are present.
Figure 4-8. Diagnostics Screen

4
Active Diagnostics
The Active Diagnostics screen displays active warnings
or faults with the appropriate Suspect Parameter Figure 4-10. Logged Diagnostics Screen
Number (SPN) and Failure Mode Indicator (FMI).
(Figure 4-9) Use the UP/DOWN soft keys to scroll
through list if needed.
Figure 4-9. Active Diagnostics Screen

Operation
System Info User Settings

Scroll through the Menu list using the UP/DOWN soft These screens displays the following action items:
keys, then press the select ( ) soft key when the Screen Color; Brightness; Language; Units; Date and
cursor (>) points to the desired information. (Figure Time.
4-11) The screen displays the engine model, serial
number, ECU Software ID, fuel rate, and the amount of
time since the last active regeneration process was Screen Color
performed.
Use the UP/DOWN soft keys and stop the cursor (>)
next to the action item Colors. (Figures 4-13 and 4-14)
Set your preference for day or night vision using the +/–
soft keys.
Figure 4-11. System Info Screen

Press the UP/DOWN soft keys to scroll to the screen
with application and configuration information. (Figure
4-12)
Figure 4-13. Set Night Vision Color Preferences
Screen
Figure 4-12. Application and Configuration

Information Screen
Figure 4-14. Set Day Vision Color Preferences

Screen
Operation
Screen Brightness Units

Use the UP/DOWN soft keys and stop the cursor (>) Use the UP/DOWN soft keys and stop the cursor (>)
next to the action item Brightness. (Figure 4-15) Set next to the action item Units. (Figure 4-17) Set your unit
the brightness of the backlight by using the +/– soft keys. preference using the +/– soft keys. (US Standard, Metric
kPa or Metric Bar.)
Figure 4-15. Set Brightness Of Backlight Screen

Figure 4-17. Set Unit Preferences Screen
4
Language
Use the UP/DOWN soft keys and stop the cursor (>)
next to the action item Language. (Figure 4-16) Set
your language preference using the +/– soft keys.
(English, French, German, Spanish, Italian or Japanese)
Figure 4-16. Set Language Preferences Screen

Operation
Date and Time Setting Tier 4F

Use the UP/DOWN soft keys and stop the cursor (>) During normal operation, the regeneration process
next to the action item Date or Time. (Figure 4-18) begins automatically. If for some reason automatic
• Press the select ( ) soft key to initiate change to regeneration does not proceed, the operator should
the month value. Use the (+/–) soft keys to increment navigate to the Tier 4 screen from the Main Menu.
or decrement the number. (Figure 4-19) Use the UP/DOWN soft keys and stop the
cursor (>) next to the action item.
• Use the DOWN arrow to reach the day value and year
value, using the +/– soft keys to make changes. The machine should be maintained in an operating
condition so the system can automatically regenerate.
NOTE: A reboot is required for changes to the Date (A complete listing of Fault Codes is shown in
Setting to take effect. Troubleshooting, Section 5.)
NOTE: Only an authorized technician can access
the Panel Configuration screen for service
purposes.
Figure 4-18. Time Setting Screen

NOTE: Pressing the “X” button closes the pop-up
messages.
Figure 4-19. Tier 4 Navigation
The engine speed will increase during regeneration
and there may be a noticeable sound difference.
It is important not to shut off the engine as the
regeneration cycle will fail and could possibly
damage the engine. Once regeneration is complete,
the engine will return to normal idle speed. If the
regeneration cycle fails, the ECU may attempt a second
regeneration.

Operation
The HEST Lamp will illuminate and flash during the Regen Request
regeneration process. (Table 4-3, Page 4-9) When
regeneration is complete, the engine will return to To initiate the regeneration process, use the DOWN soft
normal idle speed and the HEST lamp will disappear. key to select Regen Request and follow the procedure
below. (Figure 4-21)
DO NOT TURN OFF THE ENGINE,
ATTEMPT TO OPERATE THE UNIT, CHANGE ENGINE
RPM OR MOVE FROM PARK TO NEUTRAL WHILE
REGENERATION IS OCCURRING. This will abort the
regeneration process and require you to start the
process over.
EXHAUST TEMPERATURES WILL BE
EXTREMELY HIGH. BE SURE EXHAUST WILL NOT
COME INTO CONTACT WITH ANY FLAMMABLE OR
COMBUSTIBLE MATERIALS.
Regeneration Auto
The Regen Auto screen is the default screen
when navigating the Tier 4 as the system is set to
automatically regenerate when needed. (Figure 4-20)
Figure 4-21. Regen Request

BEFORE initiating the regeneration process:
1. Park the machine in a safe location where
4
the exhaust pipe does not face flammable or
combustible materials.
2. Engage the park brake and place the transmission
in either Park or Neutral.
3. With the engine running at IDLE speed, press the
Request Regen soft key to initiate the regeneration
process. (Figure 4-21) The HEST lamp will
illuminate.
4. Allow the regeneration process to proceed,
monitoring the machine and surrounding area for
safety.
NOTE: If you must stop the regeneration process,
DO NOT turn the engine off while
Figure 4-20. Regen Auto Screen regeneration is in process. The Request
Regen soft key changes to Cancel Regen
once regeneration begins. Simply push
the (fourth) button under “Cancel Regen”
to communicate with the engine that
regeneration is unwanted or unsafe at this
time. Perform the regeneration process as
soon as possible.

Operation
Regen Inhibit
You can scroll to the Regen Inhibit mode if the
regeneration process is unwanted or unsafe. (Figure
4-22)
Be sure to perform the regeneration process as soon
as possible to prevent engine damage.
Figure 4-23. Driving the 685D Motor Grader
DRIVING THE GRADER

Motor graders can be used for a number of different
tasks in a variety of ways. This type of vehicle handles
differently than other industrial machines, with numerous
capabilities and techniques that require skill and
Figure 4-22. Regen Inhibit Screen experience. Fine, delicate jobs must be done slowly,
while others such as snow removal or knocking rocks
off a gravel road can be done faster. Keeping control
NOTE: Continued operation without completing of the grader during the entire operation is key for job
a parked regeneration can cause engine quality and overall safety.
damage. If the exhaust soot level builds up The 685D Motor Grader offers several features to
too much, non-warranty factory assistance maximize the machine’s potential and efficiency while
from the engine manufacturer is required. grading. Regardless of your skill level, it is important
to read this manual thoroughly to understand the
machine’s performance. Pay particular attention to
Section 1, Safety and safety warnings contained
throughout this manual. Know and understand the
various controls and functions before operating the
machine.
NEVER allow bystanders near the
machine while operating. Never allow anyone but the
operator on the operator platform.
ALWAYS WEAR YOUR SEAT BELT.
Adjust the seat belt BEFORE driving the grader.
Failure to wear seat belt can result in serious injury
or death.
Because the 685D Motor Grader
is a large industrial machine, the operator should
ALWAYS sound the horn to alert others before
moving in either direction.

Operation
Before driving on public roads, check Adjust Seat

state and local laws that may apply to industrial
The operator seat suspension provides comfort by
self-propelled machines. Additional lights, mirrors,
absorbing some of the machine movements during
slow-moving vehicle emblems, or reflectors may be
operation. It can also be adjusted for individual comfort.
required.
(Figure 4-24)
STAY SEATED while operating Always make seat and seat belt adjustments BEFORE
the grader. For additional safety, the grader will driving the grader. The seat belt is designed for safe
automatically return to neutral and stop if the operator retention if the machine is involved in an
operator stands while moving in forward or reverse. accident or roller-over.
Drive the grader with care and at • Use the suspension adjustment knob to set the
speeds compatible with conditions. Use extra suspension for operator weight. Rotate knob to
caution when operating over rough ground, on increase or decrease setting as shown on the knob
slopes, while turning and “ditching.” face.
Drive cautiously when entering or • Use the Seat Position adjustment lever to move the
leaving a road shoulder to prevent a possible roll- seat forward or backward. Pull up on the lever to
over. adjust and release to lock into place.
Keep in mind:
• Walk around the grader and visually inspect the
entire machine, ensuring the moldboard and any
other attachments are in an elevated position before
4
starting the engine. Perform an operational safety
check before operating the grader, ensuring all
equipment functions properly and all safety equipment
(i.e., fire extinguisher) is present.
• Adjust the seat, steering console and mirrors
BEFORE driving the grader. Wear your seat belt! Seatbelt
• Stop at all railroad crossings and look both ways
before proceeding.
• Stop the grader before changing gears and before
changing directions while driving.
• Watch your speed. At higher speeds, inertia forces
tend to make the grader less stable. Use extra
caution at intersections.
• Keep both ends of the moldboard high and within
the width of the grader when travelling. Pay extra
attention to obstacles that can damage the blade, i.e.,
manholes, signs, and road debris, etc.
1
• Be aware of traffic behind you. Pull over to the side of 2
the road to allow vehicles to safely pass if needed.
Figure 4-24. Seat Adjustment
• Ensure proper warning flags and/or devices are in
1 - Suspension Adjustment Knob
place to warn traffic of road construction, slow-moving
vehicle or other traffic alerts. If working at night, 2 - Seat Position Adjustment Lever
ensure the work site is well-lit and well-marked.
• Caution should be taken to keep the blade away from
the tires in all driving and operational situations.
• If using front or rear attachments, work in low gear and
reduce speed.

Operation
Adjust Steering Console E-Stop

You can adjust the steering wheel console using the
console tilt lock toe pedal at the bottom of the steering Axle
wheel column. (Figure 4-25) To adjust, simply depress Work/
the toe pedal and push the steering console forward or Travel
backward to a comfortable position, then release the tilt
2-Speed
lock pedal and it locks it into place.
High/
Low
Park Brake
Tilt Lock
Toe Pedal Figure 4-26. 2-Speed, Axle Work/Travel,Park Brake
and E-Stop Controls
Axle Travel/Work
This switch controls the hydrostatic drive motor (Figure
Figure 4-25. Tilt Lock Toe Pedal 4-26).
• Work Speed: Turn the switch DOWN for Work
speed. This maintains the hydrostatic drive motor
2-Speed High/Low at a constant speed, but you can use the FNR pedal
to increase or decrease speed as needed. Use this
Grader speed is controlled by the 2-Speed High/Low setting when grading for constant speed regardless
switch on the control panel to the right of the operator of load.
seat. (Figure 4-26) This switch controls the rear axle
gearbox. Turn the switch down for Low gear. Always • Travel Speed: Turn the switch UP to select Travel
use low gear while grading. speed. This allows the grader to travel at a higher
speed when maximum torque is not needed, but
NOTE: You MUST STOP the machine on level automatically slows when more torque is needed. Use
ground, place the FNR pedal in neutral and this setting when grading or traveling between job
engage the park brake to shift between high sites.
and low gear.
ALWAYS move the FNR lever (or foot
pedal if equipped) SLOWLY after changing gears to Throttle
prevent lunging.
After selecting high or low gear, use the red-tipped
High Gear: Turn the switch UP for HIGH gear, used throttle lever beside the operator seat to increase or
when traveling to and from the work site. Maximum decrease RPMs. (Figure 4-27)
speed in high gear is 20 mph (32 kph).
A tachometer on the PV485 digital display controller
• Low Gear: Turn the switch DOWN for LOW gear. shows engine RPM speed. (Page 4-8)
The machine may reach up to 10 mph (16 kph),
depending upon speed in relation to torque condition. • Pushing the throttle lever forward increases engine
speed.
NOTE: If equipped with the AWD option, it only
functions in Low gear. • Pulling the throttle lever rearward decreases engine
speed.

Operation
NOTE: Use slower ground speed when operating

with any attachment on the front or rear of Foot Brake
the grader.
After selecting high or low gear, use the red-tipped
throttle lever beside the operator seat to speed up and
slow down (increase or decrease RPMs). (Figure 4-27) GENTLY
FNR
Press for Press for
Reverse Forward
Throttle
Lever
Figure 4-28. FNR Pedal

To move the grader forward or in reverse:
1. Ensure the FNR pedal is in the neutral position, the
park brake is engaged, and follow the instructions
for Starting the Engine on Page 4-4.
2. Select High or Low gear.
NOTE: You MUST STOP the machine on level
ground and engage the park brake in
4
order to shift between High and Low speed
modes. (Figure 4-28)
Figure 4-27. Throttle Lever
3. Release the park brake by moving the switch
Inexperienced grader operators DOWN. (Figure 4-28)
should always operate at slower speeds until gaining
the skills needed for faster operation. Extra care • To drive forward, GENTLY push the front rail of
must be taken by all operators in rough terrain, the FNR pedal forward with your foot.
bad weather and other hazardous situations to • To drive in reverse, GENTLY push the back rail of
prevent injury or even death. Before starting any the FNR pedal backward with your foot.
work, make sure you understand the machine, its
maneuverability, and its limitations. • To stop, remove foot from pedal and allow it to
return to the center (neutral) position.
Directional Control
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.
of flow through the hydrostatic transmission. (Figure To quickly bring the grader to a complete stop, gently
4-28) step on the foot brake pedal. (Figure 4-28) Be sure
The FNR pedal is very sensitive. your seat belt is securely fastened as using the foot
Ensure nobody is near the grader before engaging brake will stop the grader very quickly and can abruptly
the FNR pedal and use only a little pressure on the throw the operator in the direction of travel.
pedal when moving either direction to prevent the In an emergency, use the E-Stop (Emergency Stop)
grader from lunging. button on top of the control panel. (Figure 4-26)
NOTE: If you use the E-Stop method, always check
brake function afterward as described
on Page 4-4. It is recommended that you
check brake function daily, but especially
important after E-Stop use.

Operation
Steering Articulation
Steering a six-wheeled motor grader may seem a Articulating into turns gives the shortest turn radius
little complex for inexperienced operators, but skilled for close-quarter work, cul-de-sacs and corners.
operators know the extra wheels can boost efficiency Articulation also provides more control, maneuverability
and productivity in all applications. An option for and safety when operating in tight quarters, and
secondary steering is also available. counters side draft when making a heavy cutting pass
or grading wet ditches. Experienced operators also use
Keep the tires properly inflated to get
articulation techniques to maintain a straight path when
the best results. Over-inflated tires result in less
working with a windrow or lessen the blade load without
traction between the tire and road surface. Air-
using the circle.
pressure differences in the rear tires can cause tire
slippage and grader bucking. The articulation angle can affect the stability of the
machine. Efficient and safe articulation requires skill and
Operators steer the grader using a traditional steering
experience to take advantage of its full capabilities.
wheel. It is important to make slow turns to maintain
stability, especially for new operators. All operators Use articulation ONLY in WORK GEAR.
should become comfortable with driving and 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
Counteracting Side Loads: You can counteract side
machine can pivot left and right, adding flexibility and
draft when making a heavy cutting pass by articulating
maneuverability for many applications. (Figure 4-29)
the back frame toward the toe of the moldboard.
The front wheels can also be leaned in the direction of
the turn for more steering assistance in tight turns and Reducing Blade Loads: Articulate the back frame
grading techniques. (Page 4-22) toward the heel of the moldboard to reduce blade loads
without “circling” the blade under the load or where
maximum circle torque has been reached. This reduces
the width of cut and the load.
Use the articulate lever on the steering control column
to articulate left or right (Figure 4-30):
• To articulate to the left, push the articulate lever
forward.
• To articulate to the right, pull the articulate lever back.
Articulate Articulate
Left Right
Figure 4-29. Articulation
Articulate Lever
Figure 4-30. Articulate Lever

Operation
Inexperienced operators should

pay particular attention and watch both ends of the
moldboard blade when articulating to ensure the
blade is far enough away to prevent slashing a tire.
For new operators, it’s a good idea to practice turning
around in both directions to get familiar with using
articulation:
1. ALWAYS raise the moldboard (and any other
attachments) before turning the grader around.
(See Pages 4-23 to 4-24)
2. Set the Work/Travel switch to Work mode. Figure 4-32. Front Wheel Lean
3. With the grader moving forward, turn the steering
wheel into the direction of the turn (the example in
Figure 4-31 is shown turning left), then move the Front Wheel Lean
articulate lever forward if turning left or move the
lever back if turning right. The proper use of the front wheels is a great aid in
steering and grading. The front wheels can be leaned in
either direction to lean the weight of the grader toward
and balance the weight against the pulling forces
(inertia) caused by the angled moldboard. The leaning
wheels, combined with the angled blade, increase
4
the grader’s ability to excavate and move material in a
specific direction.
The top of the front wheels are normally leaned in the
direction the material comes off the angled moldboard
(heel) to counteract inertia exerted on the front end of
the moldboard (toe). Leaning the front wheels can also
be used in conjunction with articulation to achieve an
even tighter turning radius if needed. Front wheel lean
helps keep the front wheels from sliding off the desired
Figure 4-31. Turning Around Using Articulation straight line, shortens turn radius, reduces front sliding
on slopes, and is especially helpful when cutting ditches.
4. Upon completing the turn, move the articulate lever
back to it’s neutral position as you straighten the Use the front wheel lean feature:
steering wheel. • To increase slope angle capability when cutting high
or ditch-back slopes. It allows keeping the front
wheels in a vertical position when working slopes or
ditches to enhance steering in this terrain.
• For cutting ditches, lean the wheels toward the top of
the ditch.
• For high bank-cutting operations, lean the top of the
wheels toward the bank to counteract inertia.
• For side slope work, use articulation and lean the front
wheels up the slope.

Operation
Use the wheel lean lever on the steering control column

to lean the front wheels left or right (Figure 4-33):
MOTOR GRADER TERMS
• Push the lever forward to lean the wheels left. To understand techniques and applications discussed
on the following pages, an understanding of grading
• Pull the lever back to lean the wheels right. terms is essential:
Moldboard Blade: The moldboard blade is attached
the bottom of the moldboard. This is what makes
contact with the surface.
Moldboard Toe: This is the leading end of the
moldboard closest to the front wheels. (Figure 4-34)
Moldboard Heel: This is the trailing end of the
moldboard farthest from the front wheels.
Moldboard Angle: The angle of the moldboard as
measured from the moldboard toe to the center line of
the front frame.
Moldboard Pitch: Tilting the top of the moldboard
forward or backward from its vertical position is pitch.
Moldboard Side Shift: The moldboard can be shifted
outward up to three (3) feet right or left.
Turntable (Circle): This is the circular part of motor
Wheel Lean Lever grader located under the frame. The turntable (or circle)
rotates, which moves the moldboard blade left and right.
Figure 4-33. Front Wheel Lean Lever
Windrow: This is the ridge of loose material, also known
as a berm, that pushes to the side while grading.
Crown: This is the process of building up the middle
part of a road bed so water will drain to the sides. This is
especially important for road maintenance projects.
Scarify: This term means loosening or ripping up
the grading surface. The 685D Motor Grader offers
scarifier optional attachments that mount on the front or
rear of the grader.
Angle Toe
Turntable
(Circle)
Heel
Figure 4-34. Moldboard Angle, Toe and Heel

Operation
Pitching the moldboard forward or backward changes

the depth of cut across the entire moldboard. (Figure
4-36) Most grading passes start with the top of the
moldboard tilted about two inches (5 cm) ahead of the
bottom. For better penetration, tilt the moldboard more
rearward.
Forward Pitch (Tilt) Rearward Pitch (Tilt)
Figure 4-35. Grading with the Moldboard
MOLDBOARD
Grading is most efficient when material is consistently
rolling across the moldboard blade toe to heel. This is
Figure 4-36. Moldboard Pitch (Tilt)
achieved by proper moldboard angle while grading. The
operation of the entire motor grader machine rotates • For normal cutting action, the moldboard blade is
around the moldboard blade and its precise movement used in the upright position only slightly tilted forward.
4
from the turntable and frame to the hydraulic cylinders • Tilting the moldboard forward allows material to roll
and gears. Levers on the steering column control for spreading or compacting. Use a forward pitch to
moldboard movement. make light cuts, spread material, smoothing material
DO NOT allow others near the grader and typical road maintenance projects.
while working, especially near the moldboard area. There are high levels of wear and tear
Serious injury or even death can occur if a bystander on the moldboard blade, therefore, inspect the blade
is struck by a moving moldboard. daily. Replace the blade if worn or damaged. (See
Moldboard angle is one of the most important elements Section 5) For maximum cutting edge life in road
of grading since the angle is what allows material to roll maintenance work, maintain consistent moldboard
along the moldboard. Improper blade angle and pitch pitch as frequent position changes can result in
will overwork the grader and burn more fuel. It can also accelerated blade edge wear.
cause unnecessary wear on the machine, moldboard
Counteract the resulting side thrust
and attachments.
(inertia) from blade angle and pitch by leaning the
NOTE: When the blade is angled straight across wheels toward the moldboard heel. You may also
(perpendicular to the direction of need to articulate slightly toward the blade toe for
movement, it is at 0 degrees. additional side thrust control.
• Most grader work is done at moldboard angles of
10 to 45 degrees.
• Lower moldboard angles (10 - 30 degrees) are
normally used for light, free-flowing material.
• Higher moldboard angles (30 - 50 degrees)
are required when processing wet and sticky
material, mixing large windrows, and ditching,
among others. The greater the moldboard angle,
the more material is carried across, allowing for
deeper cuts and heavier grading.

Operation
NOTE: Continuing to push both moldboard lift

levers forward moves the moldboard into
“float” detent, if equipped with this option.
2 3 4 Floating means there is no down pressure
1 (except the weight of the blade). This is
useful for moving fine materials across the
surface, snow removal, and removing loose
material from a hard surface. Pull both
levers back to release the float detent.
5 5 - Moldboard Tilt Lever: Push this lever forward to tilt
the top of the moldboard blade forward. Pull the lever
back to tilt the top of the moldboard backward.
Figure 4-37. Moldboard Control Levers Circle Turn Cushion Valve

1 - Moldboard Angle Lever: Push this lever forward to The circle turn cushion valve is an optional valve built
rotate the moldboard blade to the right. Pull the lever into the steering and circle (turntable) turn circuits at the
back to rotate the moldboard blade to the left. (Figure factory. It protects both sides of the circuit from high
4-37) pressure spikes created by shock (extreme) loads. If
2 - Moldboard Slide Lever: The moldboard slide lever the moldboard strikes an immovable object, this valve
enables the moldboard to shift outward (left or right) allows the circle (turntable) to turn, thus preventing
as much as three feet (.9 m) to extend the moldboard damage to the machine.
blade’s reach. Push this lever forward to shift the
moldboard to the right. Pull the lever back to shift the
moldboard to the left.
3 - Moldboard Lift Lever (Left): Push this lever forward
to lower the left side of the moldboard. Pull it back to
raise the left side of the moldboard.
4 - Moldboard Lift Lever (Right): Push this lever
forward to lower the right side of the moldboard. Pull it
back to raise the right side of the moldboard.
NOTE: Push both moldboard lift levers together to
lower the entire moldboard. Pulling both
moldboard lift levers back to raise the
entire moldboard.

Operation
GRADER ATTACHMENTS Mounting Front Attachments

The LeeBoy 685D Motor Grader can be equipped with a Replacing optional attachments to the front nose of the
variety of optional attachments to extend its capabilities grader is not difficult, but care must be taken to prevent
for grading, plowing and scarifying. These rugged injury or damage as the attachments are heavy. It is
attachments can be hydraulically raised and lowered. recommended an assistant help when mounting or
exchanging grader attachments.
Front attachments are designed for maximum
operator visibility, safety and efficiency. A variety of ALWAYS use a sling or secured lift
interchangeable attachments can be mounted on to raise high enough for installation or removal on
the front nose of the grader. A rear scarifier option is the nose plate. Place a block under the attachment,
mounted at the factory, and typically is not removed. ensuring the attachment cannot fall and possibly
(See Page 4-27) cause serious injury or damage.
Both front and rear attachment Use the following procedure to mount a front attachment
lift cylinders and joints must be lubricated with (reverse procedure to remove):
multipurpose grease weekly. (See Page 5-7) 1. If replacing a front attachment, first disconnect and
cap hydraulic hoses to prevent contamination from
entering the hydraulic system. (Figure 4-40)
2. Using a sling or lift, raise the attachment so that all
six holes on the attachment plate align with the six
holes on the grader nose plate.
3. Install bolts and washers. Torque to 260 ft lbs.
Bolts and
Washers Nose
4
Lift Plate
Figure 4-38. Front Blade Option

Cylinder
The front blade attachment is a dozer blade used for
moving material, backfilling and general plowing or
grading. Some operators also use it for snow plowing.
NOTE: Be especially careful if using the front blade
for snow plowing. Objects can be hidden
under the snow, so be sure to wear your
seat belt and work in the direction of traffic Figure 4-39. Mounting Front Attachment
when possible. Snow also adversely affects
traction, so use tire chains or equip the
grader with snow tires.
There are two front-mounted scarifier options available:
A standard scarifier and blade-mounted, flip-down
scarifier
See your authorized dealer to purchase optional front
attachments.

Operation
4. Uncap and connect the two hydraulic hoses as Front Blade Float
shown in Figure 4-41.
The front blade float option allows the blade to follow
• Connect hydraulic hose at top of the lift cylinder a varying surface using only the weight of the drawbar,
to the right side of the grader nose. circle and moldboard. Blade float prevents damage
• Connect hydraulic hose at bottom of the lift to uneven surfaces but requires a hard surface such
cylinder to the left side of the grader nose. as asphalt or frozen ground to prevent gouging the
surface. In areas with loose gravel on the road surface,
Ensure the attachment is properly using blade float may windrow the gravel onto the road
secured before operating to prevent serious injury or shoulder.
damage.
Turn the Front Float switch on the main control panel up
Hydraulic Hose to the ON position to engage this feature. (Figure 4-42)
Connection
Figure 4-40. Connect Hydraulic Hoses
Operating Front Attachments

Front
The front blade lever is used to raise and lower all front
attachments. This lever is located on the steering
Float
control panel. (Figure 4-41)
Figure 4-42. Front Blade Float Switch
• Pull lever rearward to raise the attachment.
• Push lever forward to lower the attachment.
Front Attachments Lever

Figure 4-41. Front Attachments Control Lever

Operation
Scarifiers A front blade-mounted, flip-down scarifier option offers

the convenience of using either component at the front
Scarifiers strong enough to penetrate material too hard of the grader. (Figure 4-45) If the job needs scarifying
for the moldboard blade to cut or spread are available operations, mount the attachment with the scarifier side
that can be mounted on the front or rear of the grader. down. Or “flip” attachment the other direction and mount
Scarifier “teeth” shanks “rip” and loosen earth, gravel, on the nose plate to use the dozer blade.
and similar surfaces. After “scarifying” compacted or
hard material, the operator can then use the moldboard
to grade and reshape the road surface. Scarifier
The rear-mounted scarifier option features nine large,
replaceable teeth. (Figure 4-43)
Dozer
Blade
4
Figure 4-45. Front Blade-Mounted, Flip-Down
Scarifier Attachment
Keep these items in mind when using a scarifier:
• Be sure to drive in a straight line when the scarifier is
Figure 4-43. Using the Rear Scarifier in the ground to avoid breaking the teeth.
The front scarifier option also features nine replaceable • The proper way to reshape a dirt road with ruts
teeth mounted on a plow-shaped plate. (Figure 4-44) and potholes is to scarify its surface to the depth
of the depressions to break up all the compacted
surrounding surface.
• To control dust, especially on a dirt road, wet the
surface. This also helps supporting the binding of
fill material if the dirt road will be compacted after
grading.
• 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.
NEVER make sharp turns or articulate
with scarifier teeth in the ground. DO NOT drag the
scarifier teeth along hard surfaces such as pavement
or large rocks. Damage or bent/broken teeth can
Figure 4-44. Front Scarifier Attachment occur.
Scarify down the slope for better
stability whenever possible. If scarifying or ripping
across a slope, keep the moldboard parallel with the
front axle, extended toward the downhill side, and
lowered close to the ground to provide protection
against rolling over.

Operation
Operating a Scarifier Replacing Scarifier Teeth

Use the following procedure for scarifying roads or The scarifier tooth supports are adjustable and secured
other areas using the optional rear scarifier: with pin locks.
1. Raise the moldboard at least one foot (.304 m) off Always support the scarifier and other
the ground to allow unrestricted movement. Rotate attachments using a block or sling before servicing.
the moldboard so that it is perpendicular with the
1. Raise the scarifier. Support the scarifier on
frame and pitch the blade forward halfway.
blocks or use a sling for support.
2. Position the grader ahead of the working area and
2. Using a pry bar or lock pin tool, remove the shank
ensure the front wheels are vertical.
lock pin and tooth from the scarifier frame. (Figure
3. Slowly move the grader forward. 4-47)
If the rear wheels lose traction, raise • If only removing tooth, be sure to store tooth
the scarifier until the wheels regain traction. shank and locking pin together for later use.
4. At the starting point for the job and while still moving,
lower the scarifier.
Pin
• If equipped with a rear scarifier, use the rear Lock
scarifier lever shown in Figure 4-46.
(Pin
Lock)
Tooth
Shank
Figure 4-47. Scarifier Shank Lock Pin and Tooth

Rear Attachment Lever
3. Position new tooth shank into the desired slot on the
Figure 4-46. Rear Attachment Control Lever scarifier frame.
5. When finished with the first pass, raise the scarifier 4. Insert lock pin. It is recommended using a rubber
by pulling rearward on the scarifier lever. hammer if you wish to hammer the lock pin back into
6. If more passes are needed, repeat the procedure. place to prevent damage.
DO NOT remove more than five teeth

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

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

light, free-flowing material. Higher angles of 30 - 50
degrees is required when processing wet or sticky
material, mixing large windrows, and ditch work.
• Remember that pitching, or tilting the top of the
moldboard tip forward or backward, changes the
depth of the cut across the entire moldboard.
• If material starts to flow around the leading end of the
moldboard or the rolling action stops, increase the
blade angle.
• Apply only enough downward pressure with the
moldboard to accomplish the task. Excessive
Figure 4-48. Operating the 685D Motor Grader pressure, especially on hard, dry surfaces, causes
rapid cutting edge wear, requires more horsepower
and fuel, and reduces productivity.
OPERATING TECHNIQUES • Choosing the right speed for a task is just as important
as the moldboard angle. Drive slowly for delicate
The information provided on the following pages are
work, but faster if removing rocks from a road surface.
basic grading techniques. Every road construction
project is different with a unique set of variables • Avoid moving material more often than needed.
operators must take into account, such as terrain and
• Trimming is much easier with good compaction.
weather conditions, that affect operation. Mastering
4
such versatile grading skills requires experience. • If dressing a road, the surface should be moist
whether from rain or hosed from a water truck. Ensure
Grading Tips there is good drainage by grading with appropriate
crown.
The following are general tips for project success when
operating your motor grader: • Articulating the rear frame toward the toe of the
moldboard by 2 - 5 degrees helps reduce the
• Keep your grader and its attachments in good
machine’s tendency to bounce. This is extremely
mechanical condition. Pay extra attention in checking
effective when cutting “washboards.”
for wear on the moldboard blade edge often. If
the blade edge is worn or damaged, contact your • Wheel leans can help an operator make steering
authorized dealer for replacement. adjustments without taking hands off the controls.
Wheel lean is also useful for moving heavy windrows.
• Be very familiar with the controls, attachments and
component functions. Be especially familiar with • Graders remove snow the same as snow plows. Be
blade movement that are made possible by the sure to raise the moldboard 1/2 to 1 inch (1.3 - 2.5 cm)
hydraulic controls for different tasks. Know the if removing snow from uneven pavement or other
settings needed, angle, height, and what you want the surfaces to prevent damage to the blade.
blade to do before you lower it to the ground.
• Every job requires a specific blade setting with the
right speed for optimum production. Be familiar with
the moldboard blade movements. Know what you
want to do before lowering the moldboard.

Operation
Grading Around Objects There are two basic methods for grading around objects
(Figure 4-49):
Avoid hazards and obstructions
Method 1:
such as overhangs, ledges, slide areas, electrical
lines, underground cable, water main and gas lines, 1. Reduce speed before approaching object.
etc., that can result in serious injury or even death. 2. Slowly maneuver the grader around the object,
ALWAYS request assistance from the appropriate driving as close as possible (depending upon
authorities if operating close to electrical or gas skill level) to reduce the amount of hand shoveling
lines, water main and any underground cables. needed.
Method 2:
Method 1: Slowly drive around.
1. Reduce speed before approaching object.
2. Use the moldboard slide shift lever to shift the
moldboard in the opposite direction of the object.
(Figure 4-50)
• Pull lever to slide the moldboard left.
• Push lever to slide the moldboard right.
Moldboard
Method 2: Use moldboard slide. Slide Lever
Figure 4-49. Grading Around Objects
Figure 4-50. Moldboard Slide Lever

3. Slowly follow the shape of the object, sliding the
moldboard more if needed.
4. Slide the moldboard back to its original position
after passing the object.

Operation
Spreading and Leveling Planing

The 685D Motor Grader can also be used for spreading, Set the blade at an angle to “plane off” irregular surfaces
leveling, planing and side casting material. Graders and use that material to fill hollows:
have less power and traction than dozers, but can move 1. Cut enough material to keep some in front of the
the loads faster. The moldboard blade is lower and blade, moving the loosened material forward to
more concave, which gives the grader increased rolling distribute it evenly.
action of the load so more material is pushed without
spilling over the top. 2. On the next pass, pick up the windrow left from the
trailing edge of the blade.
NOTE: Do not pile windrows in front of the rear
wheels because it will adversely affect 3. On the final pass, make a lighter cut and lift the
traction and grader control. trailing edge of the blade enough to allow surplus
material to under rather than around the end to
• If there is space to work around the sides of the avoid leaving a ridge.
windrows, extend the blade well to the side and
reduce the windrow using a series of side cuts.
• Leveling large windrows may require two or more side
cuts.
Figure 4-52. Planing

4
Sidecasting
The side casting technique is often used for filling
ditches, shaping and road maintenance.
• To shape and maintain most roads, the moldboard
Figure 4-51. Leveling a Windrow blade should be at an angle of 25 - 30 degrees.
• You can also use articulation and lean the wheels • Decrease the angle for spreading windrows.
slightly to move and spread large windrows: • Increase the angle for hard cuts and ditching.
• Angle the moldboard blade toward the windrow, 1. Angle the moldboard blade so the load being
tilting it forward slightly. Be sure the moldboard is pushed at the toe rolls off the heel. This rolling
positioned high enough above the surface to obtain action assists side movement.
the desired depth.
2. Move forward, side casting the material into the
• Lean the front wheels slightly in the opposite direction ditch.
to overcome side thrust.
3. Make the passes necessary to compact the fill.

Operation
• New fills may give way with the grader’s weight while
rocky surfaces can cause side slipping.
• Position the moldboard toe outside and behind the
uphill wheel so the moldboard heel deposits material
outside the downhill tandem wheels.
• Excessive loads or side draft can also cause wheel
slippage as the downhill tires “dig in” and increase the
angle of the grader.
• Articulation and wheel lean angles also affect the
stability of the grader. Only experienced operators
should articulate when working on slopes.
Figure 4-53. Slope Work
• Lean the front wheel vertically and position the uphill
Slope Work front wheel on the edge of the windrow created from
previous pass to provide extra stability and create an
Use extreme caution and drive slowly even grade.
while working on slopes. While unlikely, the grader
If possible, make a first pass from above the slope to
can roll over and result in serious injury or even
establish the moldboard blade angle you will need.
death.
Experienced grader operators can also use articulation
Operating the grader on slopes can be dangerous, for added reach, ensuring the tandem wheels (rear) are
especially for inexperienced operators. Maneuvering on a level surface.
on or along steep slopes requires excellent operator
1. Angle the toe of the moldboard outside and behind
skills and experience.
the uphill wheel, with the moldboard heel downhill
The slope perpendicular to the machine’s direction of outside the tandem wheels.
travel is commonly known as “side sloping.” Typically
2. Tilt the moldboard forward slightly and make the first
steep slopes require articulation to navigate, but ONLY
pass.
experienced operators familiar with the machine
should perform this type of work. 3. On the second pass, lean the front wheels toward
slope and slightly articulate rear wheels down slope
The slope parallel to the machine’s direction of travel
to increase machine stability.
that affects the grader’s ability to travel up or down
terrain is known as gradeability. This is established 4. Make as many passes as needed for the desired
by the grader’s ability to stop without skidding the tire result, then clean with the moldboard less angled
while moving downhill. The grader can climb steeper but tilted more forward away to clean any windrow
slopes than it can safely descend. If working on hills and away from the bottom of the slope.
slopes, it is important to consider the following points:
• NEVER climb a slope steeper than you can safely
descend.
• At higher speeds, inertia forces make the grader less
stable. If you must work on a slope, work SLOWLY.
• Attachments can cause the grader to balance
differently. Ample allowance for the moldboard
and any other attachments should be made where
the terrain or surface is uneven to avoid damage to
attachments or injury from an unbalanced machine.
The position of the moldboard can affect the stability
of the grader considerably.

Operation
Figure 4-54. Bank Cutting
Bank Cutting Figure 4-55. Road Maintenance
1. Make a first pass at base of bank to level and

smooth a platform for the machine.
ROAD MAINTENANCE
2. Tilt the moldboard slightly forward and sharply
angle the moldboard so the heel is in the opposite Much of a grader’s road maintenance work involves
direction of the bank you’re cutting. (You can smoothing, shaping the travel surface and providing
articulate slightly if more reach is needed.) drainage to prevent road deterioration.
3. After making the bank cut, make a second pass with
the moldboard less angled but tilted more forward
to clean any loose material from the bottom of the
bank.
Begin road maintenance work by tipping the top of
the moldboard approximately two inches ahead of the
cutting edge, then adjust to the material conditions.
Maintaining the material rolling action across the
4
moldboard blade reduces the horsepower required and
provides maximum productivity.
Grading an “S” Curve Shoulder • The most important factor in road maintenance
grading is providing and maintaining a good drainage
1. Slowly approach the first curve.
system. Drainage of water from the road surface to a
2. Lean the front wheels slightly toward the opposite ditch, even a minimal ditch, helps maintain good road
direction of the curve to counteract side thrust. conditions longer.
• Push the lever forward to lean the wheels left. • Remember that tipping the moldboard forwards or
• Pull the lever back to lean the wheels right. backwards changes the depth of cut across the entire
moldboard. The best time to reshape earth and gravel
3. Position the toe of the moldboard behind and roads is after it’s rained. Dry roads should be sprayed
outside the front wheel closest to the edge of the with water before grading for easy compaction and to
shoulder (in the opposite direction of the wheel minimize dust while working.
lean).
• Articulating the rear frame toward the tow of the
4. As you straighten the grader when finishing the moldboard 2 - 5 degrees helps reduce the motor
curve, return wheels to their normal position. grader’s tendency to bounce.
5. Slowly approach the second curve and repeat • Keep the turntable circle clean. Material buildup may
Steps 2 - 4. increase wear and prevent smooth material rolling
NOTE: If a windrow has been created while grading, action, reducing productivity.
make a “clean-up” pass and reshape the
shoulder if necessary.

Operation
• For the widest possible pass on the travel surface,

keep the moldboard angle as square to the frame
as possible. If material starts to flow around the
moldboard toe or the rolling action stops, increase the
blade angle.
• The moldboard blade’s tip angle should be position
with the cutting edge at 90 degrees to the road
surface so the downward pressure places less stress
on the cutting edge and retaining bolts. To cut hard
material or for finishing work, tilt the moldboard further
forward.
• Keep your travel speed between 3 - 5 mph (4.8 - 8 Figure 4-56. Grading a Dirt or Gravel Road
kph) for maximum productivity with less machine
bounce. At higher speeds, the grader can “lope” or
bounce, causing ridges and depressions. Moisture, Gravel and Dirt Roads
material quality and road grade stability vary, so
operating speed must be slow enough to ensure the Level and maintain the gravel or dirt surface by working
grader remains stable. the material across the road (or runway) from one side
to the other. The surface is easier to work with if it’s
• Grader efficiency is directly proportional to the damp. If grading a dry surface, work material from the
number of passes made. Operator skill and project edges and shoulders toward the center to maintain a
good planning are most important for eliminating satisfactory result.
unnecessary passes that increase time and cost of
the job. Good gravel road maintenance depends upon proper
use of the grader and quality gravel that is the right
• Before performing any road maintenance project, a size correctly distributed onto the road surface. It is
formal project plan or specifications to control the important to properly shape the road surface before
work is an important factor in road improvement. Be spreading gravel to achieve quality results. The gravel
sure to check with local and state departments of should also be damp.
transportation about roadway construction standards
and requirements before beginning the project. You Traffic, wind and grading can kick up
may also need to contact utility companies to verify dust and cause loss of any binder material present,
location of any utilities within the construction area so be cautious when disturbing dry road surfaces.
and arrange for temporary location if needed. It is recommended that road maintenance grading
projects be done just after it rains, or use a water
• Tree stumps, large rocks and other obstructions need truck to dampen the surface before grading. A damp
to be cleared and removed before grading. Tree surface results in a better, smoother finish.
branches extending over the roadbed may also need
to be trimmed for adequate grader clearance. 1. Start at the edge of the road shoulder and cut the
material into a windrow, depositing it toward the
• On straight sections, steer the grader as straight as center of the road (outside the tandem wheels).
possible to maintain a straight shoulder and uniform
crown on the road. 2. Angle the moldboard 30 - 50 degrees and pitch
halfway back to cut. This removes ridges and
potholes.
NOTE: Scarify the surface first on dirt roads with
deep ruts or extremely rough surfaces.
3. Lower moldboard until the toe and heel slightly
touch the ground, just enough to penetrate the
surface.

Operation
4. Lean the front wheels toward the moldboard heel as Crowning the Road
you work toward the center of the road, maintaining
a straight course. Crowning a road is simply constructing the surface so
the center of the road is higher than the road edge to
• You may need to adjust the moldboard slightly to allow water to drain. If the crown is not built properly,
carry the material the length of the project. water will be trapped and break up the road crust,
• Pitch the moldboard forward and use very little producing potholes and ruts. If also constructing
down pressure to feather the material at the end of ditches, complete the ditch work first, grading the
the pass. excess material to the center of the road, creating a
windrow.
5. Make as many passes as needed, continuing to
push the material toward the road center. • For good drainage, a road should have a crown of
1/3 inch (8.4 mm) to 1 /2 inch (12.7 mm) per foot (305
6. Repeat Steps 1 - 5 on the other side of the road.
mm) as measured from the center of the road to the
7. Finish the road crown using the procedure outside edge where the road meets the shoulder.
described in the next section.
To establish the road crown in the center and smooth
any ridges left:
1. Position the moldboard parallel to the front axle.
2. Raise the moldboard heel and tilt the moldboard
forward between 60 - 75 degrees.
3. Drive the grader straight down the center of the
windrow, keeping the moldboard high enough to
4
feather the material on both sides of the grader.
You can increase speed as this throws loose
material from the blade, feathers the material, and
blends the top.
Ditch Work
Ditch work is typically done on the right side of the
grader. Cutting a ditch is called “Vee Ditching.”
Figure 4-57. Crowning Remember the following guidelines for ditch
construction:
• Make each ditch cut as deep as possible (without
stalling or losing control of the grader).
• Start with the blade positioned so the moldboard toe
is in line with the center of the lead wheel. Bring each
successive cut in from the edge of the bank slope so
the toe is in line with the ditch bottom on the final cut.
• Ensure the moldboard is high enough off the surface
to allow unrestricted movement.
• Side shift the blade if needed to extend the moldboard
edge to the outside edge of the front wheel.

Operation
1. Begin a ditch by establishing a marking cut. 6. Establish the road shoulder by sliding the
moldboard blade farther out, rotated to a 90-degree
• Pitch the moldboard forward halfway until top
angle (perpendicular with the frame), and tilted
of the moldboard is in line with the center of
slightly forward. Apply only enough downward
the front tire, raising the heel just ahead of rear
pressure to clean-up the ditch and skim the material
wheels (so dirt spills between the rear tires).
smoothly across the road shoulder.
• Rotate the moldboard so the toe is just behind
the outside edge of the right front wheel (about a
45-degree angle). Cul-De-Sacs
• Lean wheels toward the discharge end (heel) of
Articulating the grader helps when grading cul-de-
the moldboard.
sacs. Articulate the rear frame away from the curb (or
• Make the first cut light to establish the line of the cul-de-sac radius), being careful not to articulate too
ditch. fast, and lean the wheels to keep the moldboard toe
2. Move the grader forward. As the front wheel position to the curb (or cul-de-sac radius). Remember
passes over the starting point of the ditch, lower the center line crown extends all the way to the center
the moldboard toe, applying enough pressure to of the cul-de-sac, so do not straddle the crown or grade
penetrate the grounds surface 3-4 inches (7.6 - 10 perpendicular to the cul-de-sac entrance.
cm). 1. Angle the moldboard about 30 degrees and tilt
3. On the second pass, position the wheels in the forward 5 - 10 degrees, keeping the toe toward
ditch made by the first pass to compensate for side the outside cul-de-sac radius. Start grading at the
thrust and make a deeper cut. You can increase perimeter of the cul-de-sac in a circular pattern,
speed on the second pass and apply as much down working material toward the center as you go.
pressure on the moldboard toe as the grader can 2. To begin finishing the cul-de-sac, drive grader in the
handle. opposite direction at the outside edge, forming a
4. Continue along the ditch line until reaching the windrow toward the center.
finishing point. 3. Tilt moldboard forward slightly and move windrows
NOTE: When making ditch cuts, windrows form toward the center of the cul-de-sac, checking the
between the heel of the blade and the rear slope as you grade.
wheel. Move or level these windrows when 4. When you have finished pushing all the excess
either the ditch is at the planned depth or material to the center, straighten the moldboard
the windrow becomes higher than the road (parallel to the front axle) and push the excess
clearance of the grader. You can use this material out of the cul-de-sac entrance.
material for the road shoulder.
5. As dirt builds up between rear tires, make a clean-
up pass, pushing material toward the road edge:
• Side-shift the moldboard blade toward the ditch
with front wheels positioned outside the windrow.
• Angle the moldboard heel between rear wheels
and pitch the moldboard blade slightly forward.
Be sure the moldboard toe is well beyond the
windrow to minimize spillage back into the ditch.
• Articulate the grader slightly to deposition
windrow between the rear tires if needed.
• Feather the material by raising and tilting the
moldboard blade slightly forward until all the
material passes under it.

Operation
TRANSPORT Loading
LeeBoy recommends transporting the grader on a flat- To prevent damage to the machine
bed trailer rather than towing. undercarriage, frame and components, reduce
speed before wheels come into contact with loading
Remember the following guidelines: ramps or any abrupt change in the surface. The drive
• Ensure the ramp, trailer and transport vehicle are system or other components can be damaged by
strong enough to safely handle the size and weight of excessive shock.
this large industrial machine. 1. Center grader with the ramp.
• Raise the moldboard and any other attachments to 2. BEFORE moving onto the ramp:
the highest position. Pay close attention to clearance
when entering the ramp. • Ensure the hauling vehicle has its park brake
engaged.
• NEVER load the grader onto a transport trailer without
assistance from another person serving as a ground • Ensure the moldboard and any attachments are
guide. raised. The moldboard should be perpendicular
for added balance when moving up the ramp.
• Park the trailer in a clear, level area when loading or
unloading the machine. • Use only WORK gear.
• Keep the loading area clear. Work slowly and 3. SLOWLY drive the grader straight forward up the
carefully to avoid accidents. ramp to position machine in the center of trailer.
The grader should centered between the left and
• DO NOT place tie-down chains or cables over or right side of the trailer.
against hydraulic hoses, cylinders or valves, etc., to
4
prevent machine damage. 4. Engage park brake and set engine speed to IDLE.
Check local and state regulations for 5. Angle the moldboard so it is inside the width of the
height restrictions on the transit route. trailer. Lower the moldboard and any attachments
(without applying down-pressure) once the grader
Ensure the transport route is free of is situated. Block the moldboard and all wheels.
low bridges and other obstacles that can damage
the machine and/or cause a traffic accident that can 6. Turn off the engine. Relieve residual hydraulic
result in serious injury or even death. pressure by operating all the console control levers
after turning off the engine.
Use extra caution steering when
7. Secure machine to the transport trailer using the
loading and unloading the grader as slight steering
tie-down procedure that follows.
changes on ramps and trailers can cause the
machine to fall off. Serious injury or even death can 8. Ensure cab doors and all engine access panels are
occur. closed and secured.
9. Cover the exhaust with heavy-gauge plastic to
prevent turbo damage. Don’t forget to remove
before starting the engine!
Figure 4-58. Correct Loading and Unloading

Position

Operation
Unloading TOWING
1. Remove tie-down equipment. LeeBoy strongly recommends transporting the grader
2. Start the engine and allow machine to warm a few on a truck trailer, but if you must tow the machine for a
minutes to ensure the hydraulic pump is providing short distance, use a tow hitch. A professional towing
sufficient flow to operate all functions properly. service is recommended.
3. BEFORE backing machine down ramp: Improper towing methods can result in
severe personal injury or even death.
• Ensure the moldboard and any attachments are
raised and secured to the machine frame. Stay clear of tow chains or cable,
especially when tension is applied. A broken cable
• Use only WORK gear.
or chain can cause severe injury or even death. DO
• Ensure the hauling vehicle has its park brake NOT allow bystanders near the tow truck and grader
engaged. at any time. DO NOT allow the tow chain or bar to
4. SLOWLY move machine down the ramp. contact any grader components.
Some state and local laws prohibit or
limit the use of tow chains on highways. Check state
Tie-Down Procedure and local regulations before towing with chains.
1. Position grader in center of the trailer. If the grader must be towed, remember the following
guidelines:
2. Place chocks at wheels to prevent machine
movement while securing and during transport. • DO NOT tow the grader a long distance. Transport it.
3. Attach chains to the front and the rear D-ring tie- • Operator must be in the operator’s seat to control
downs. (Figure 4-59). The front D-ring is located steering and braking when towing the grader.
under the frame. The rear D-rings are located on • NEVER tow the grader more than 5 mph (8 km/h).
each side of the frame behind the rear tandem tires.
• Ensure the tow truck has sufficient braking capacity to
4. Ensure that all chains are tightly secured before stop the grader while being towed.
transporting the grader.
• Ensure the towline or tow bar is in good condition and
strong enough to tow the grader.
• Sudden cab movement can cause the towline or tow
D-Ring bar to break. When turning, keep the towing angle
D- and speed to a minimum. Proceed gradually and
Ring smoothly, avoiding any sudden turns, braking or jerky
steering movements.
To tow the grader:
1. Block the wheels to prevent machine for moving
while preparing to tow the grader.
2. Ensure the FNR lever (or pedal) is in the NEUTRAL
position and the park brake is engaged.
Figure 4-59. Tie-Down Locations
3. Disconnect, plug and tag the hydraulic hoses on
the rear axle, being very careful to prevent any
contamination when plugging the hydraulic hose
fittings.
4. Use a small screwdriver or small pry bar to pull out
the shifting rod as far as it will go, then push it back
until you find neutral. (Figure 4-60)

Operation
OPTIONS
Shifting
Cab Option
Rod The 685D Motor Grader offers the option of building
the machine with a comfort cab in lieu of the standard
canopy. (Figure 4-62)
Additional options for the cab include:
• Rear windshield wiper and washer.
• Air conditioning and heat with defroster.
Figure 4-60. Shifting Rod
• AM/FM radio.
5. Locate both brake release screws on bottom of the
rear axle. (Figure 4-61)
Release Screw
Figure 4-61. Brake Release Screw

6. Using a caliper, measure the exact extension of the
screw and record measurement. Turn the screw
clockwise as far as it will go to release the brakes
for towing. Figure 4-62. Cab Option
7. Repeat on the other side.

8. Raise and secure the moldboard and any other
attachments before towing. Use chains or cables
that are in good condition to secure attachments.
9. Fasten chain (or tow bar) to the front D-Ring.
10. Mark the center of the towline or tow bar with an
orange flag and attach a “Slow-Moving Vehicle” sign
onto the rear of the grader.
11. Remove wheel blocks and activate all warning lights
to alert traffic.
12. After towing the grader, readjust the brake release
screw according to the recorded measurement.

Operation
Sliding Moldboard Secondary Steering

The 685D Motor Grader is equipped with an 11-foot The secondary steering option serves as a temporary
(3.35 m) sliding moldboard. A 12-foot (3.65 m) sliding emergency steering back-up in the event of engine
moldboard option is also available for even more reach. failure or loss of hydraulic pressure. The secondary
See your LeeBoy dealer for installation. steering system has a separate electrically-driven pump
that delivers hydraulic fluid to the steering motor in the
event primary steering fails due to loss of hydraulic
Circle Side Shift pressure. This is an emergency feature that allows the
ability to steer the grader off the road, but is not intended
The circle side shift option allows the circle (or for traveling any distance as it will overheat quickly.
turntable) and moldboard to reach far beyond the
• To activate, turn the secondary steering switch on the
wheels on either side. In its extreme position, it allows
control panel up to the ON position. (Figure 4-64)
the grader to position the moldboard blade in the bottom
of a highway ditch while traveling on secure footing on • Turn the switch down to disengage secondary
the highway surface. For slope trimming, the moldboard steering.
can swing out to either side and position at any angle
from horizontal to vertical.
Secondary
Steering
Circle Side AWD

Shift Lever
Front
Float
Figure 4-64. AWD, Secondary Steering and Front
Figure 4-63. Circle Side Shift Lever Blade Float Switches
The circle side shift lever is located on the steering
control panel. (Figure 4-63)
• Pull lever rearward to shift the circle (and moldboard)
left.
• Push lever forward to shift the circle (and moldboard)
right.

Operation
All-Wheel Drive (AWD) Reverse Camera System

The AWD option provides additional traction in all A reverse camera system is also an available option.
weather conditions. The tires maintain a better grip (Figure 4-66) This additional safety feature assists
during rain or snow, in mud, and on gravel. AWD operators when moving in reverse by using the rear
provides better torque power for grading, pulling or low- camera to see directly behind the machine when moving
speed climbing and is especially useful when operating in reverse.
on loose, low-traction surfaces.
DO NOT modify or alter any switch or
other component in the AWD system. Modifications
can cause premature engagement or prevent
disengagement of the system, which could cause
injury and/or property damage.
NOTE: The Axle Work/Travel switch must be in the
Work position for AWD to function. AWD will
not function in the Travel mode.
To activate AWD:
1. Set the Axle Work/Travel switch to Work mode.
2. Turn the AWD switch to the ON position. (Figure
4-64)
4
3. Turn the AWD switch down (OFF) to disengage
AWD.
Figure 4-66. Back-Up Camera

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

Operation
NOTES

Section 5
MAINTENANCE Page
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
5
Planetary Hubs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Machine Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Moldboard Blade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Drawbar Ball and Socket. . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Toe-In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Park Brake (Rear Bogie Axle). . . . . . . . . . . . . . . . . . . . . . . 5-12
Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Check Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Change Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . 5-13
Engine Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Radiator Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Selective Catalytic Reduction (SCR) System. . . . . . . . . . . . . . . 5-16
DEF Tank Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
DEF Dosing Unit Filter. . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Maintenance
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 . . . . . . . . . . . . . . . . . . . . . 5-25
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
Scarifier 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
Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
PV485 Diagnostic Trouble Code (DTC) Chart . . . . . . . . . . . . . . . . . . 5-51
PV485 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . 5-56

Maintenance
MAINTENANCE SCHEDULE The operator should inspect the machine daily. Worn or
damaged parts should be replaced or repaired promptly
This section gives the necessary procedures for to prevent damage to other areas of the machine. Daily
routine and general maintenance on the LeeBoy 685D inspections should include checking for loose bolts,
Motor Grader. Keep the grader clean and follow all fluid leaks, worn or damaged hoses, and debris or dirt
maintenance schedules and procedures to maintain the accumulations to prevent potential service or safety
machine in top operating condition. problems.
Maintenance must be a planned program including The maintenance program should be done based on the
periodic machine inspection and lubrication (see machine “Operating Hours” recorded on the hour meter
Lubrication, Pages 5-6 and 5-7). or by following the Periodic Schedule shown below:
Table 5-1. Periodic Maintenance Schedule
2000 Hours
1000 Hours
500 Hours
250 Hours
100 Hours
50 Hours
10 Hours
Every
Every
Every
Every
Every
Every
Every
SYSTEM ITEM
Lubricate steering and tie rods, drawbar ball, lift

X
trunnions, and trunnion housing.
Lubricate hydraulic cylinder ends, front blade
pivots, moldboard pivots, axle pivot, stabilizer rod X
Grader ends, turntable, and control levers.
Lubricate articulate joint. X
Lubricate king pin bearings. X
Check and adjust toe-in if needed. X
Check hydraulic oil level. Add more if needed. X
Replace hydraulic oil. X
Replace hydraulic charge and return filters. X
Hydraulic Check drive axle, gear box and planetary hub oil
levels. Add more gear oil if needed.
X 5
Change drive axle, gear box and planetary hub oil. X
Check gear box breather. X
Check oil level - Change at initial 50 hours. X
Replace engine oil and oil filter cartridge. X
Check engine coolant. Add more if needed. X
Change engine coolant. X
Engine Check air cleaner indicator. Clean or replace if
X
indicator is red.
Change air cleaner filter. X
Check engine drive belt. Replace if needed. X
Inspect the drive belt tensioner, idler and drive
X
pulleys for dirt, wear and cracks
Check battery, cables and connectors. X
Electrical
Service battery. X
Fuel Replace fuel filter cartridge. X
Clean DEF tank filter (or replace if needed). X
DEF Inspect every 3000 hours (or 3 years). Clean or replace if
Clean DEF Dosing Unit filter (or replace if needed).
needed.

Maintenance
MAINTENANCE SCHEDULE Prepare for Maintenance

Before performing any maintenance procedures on 1. Park the machine on an even surface and lower all
the LeeBoy 685D Grader, review Section 1, Safety. attachments to the ground and block wheels to
Follow all maintenance schedules and procedures to prevent machine movement.
maintain the machine in top operating order. Preventive 2. Place the FNR (Forward/Neutral/Reverse) lever in
maintenance on the grader will provide years of trouble- the NEUTRAL (center) position and engage park
free operation. Adjustments can be performed in the brake.
field with ordinary tools. The maintenance schedule
begins with 10-hour, or daily, maintenance intervals 3. Place ignition switch in the OFF position.
and continues through the 1000-hour, or annual,
maintenance schedule intervals.
NOTE: When performing any routine maintenance,
10-Hour or Daily Routine
always include previous routine Maintenance
maintenance procedures to the higher
1. Check coolant level. Add more if needed. (Page
hourly schedule.
5-15)
Engine preventive maintenance, (other than oil, air
2. Check air filter indicator. Clean or replace filter if
and fuel filter changes), can be found in the Engine
indicator is red. (Page 5-15)
Operator’s Manual. Anytime the grader has been
repainted or the decals removed, damaged or illegible, 3. Check hydraulic oil level. Add more if needed.
replace immediately for safe operation. (Page 5-25) Check hydraulic hoses for leaks and
wear.
Tool Hazard! ALWAYS use tools
appropriate for the task. Be sure to use the correct 4. Check engine drive belt. Adjust or replace if
sized tool for loosening or tightening parts. needed. (Page 5-14)
Changing oil and cleaning the grader 5. Lubricate steering and tie rods, drawbar ball,
should only be done in a designated area where moldboard lift trunnions and cylinders, trunnion
the oil and chemicals can be contained. These by- housing, and moldboard swing cylinders. (Pages
products should be discarded in accordance with 5-6 and 5-7)
environmental regulations. 6. Check tire air pressure and wheels for any damage
DO NOT operate a machine that is and missing or loose lug nuts. (Page 5-29)
in need of repair. Put an information tag on the
instrument panel that says “DO NOT OPERATE”
and remove key from the ignition switch. Repair all 50-Hour Routine Maintenance
damage promptly as even minor damage can result
1. Perform previous maintenance procedures.
in major system failures.
2. Check battery connections and remove any
If any maintenance must be corrosion present. Service battery if needed.
performed while the engine is running, DO NOT leave (Page 5-21)
the grader unattended.
3. Check engine oil and filter. Add more oil if needed.
ALWAYS lower attachments to the CHANGE ENGINE OIL AND FILTER AT INITIAL 50
ground. NEVER leave attachments in the raised HOURS. (Page 5-13)
position when working on the grader. Securely block
moldboard or other attachments that may fall before 4. Lubricate hydraulic cylinder ends, front blade pivots,
working on them. moldboard pivots, axle pivot, stabilizer rod ends,
turntable, FNR pedal, and control levers. (Pages
Allow the engine and hydraulic system 5-6 and 5-7)
to cool before working on the machine.
5. Perform any other engine preventative maintenance
as described in the Engine Operator’s Manual.

Maintenance
100-Hour or Monthly Routine 1000-Hour or Annual Routine

Maintenance Maintenance
1. Perform previous maintenance procedures. 1. Perform previous maintenance procedures.
2. Inspect air filters and intake hoses/clamps. Clean or 2. Clean, pack and adjust front wheel bearings. (Page
replace if needed. 5-30)
3. Check breathers. Replace if needed. (Pages 5-8 3. Drain, flush and fill axle, gearbox and planetary hub
and 5-9) oil. (Pages 5-8 and 5-10)
4. Check various axle oil levels. Add more oil if 4. Perform the 1000-hour preventative maintenance as
needed. (Pages 5-8 and 5-9) described in the Engine Operator’s Manual.
5. Lubricate articulate joint and chain box pivots.
(Pages 5-6 and 5-7)
2000-Hour or Every Two Years
6. Lubricate king pin bearings. (Pages 5-6 and 5-7)
Maintenance
as described in the Engine Operator’s Manual. 1. Clean the Diesel Exhaust Fluid (DEF) tank filter.
Replace if needed. (Page 5-18)
2. Drain, flush and fill hydraulic tank. Clean hydraulic
250-Hour or Quarterly Routine tank strainers. (Page 5-26)
Maintenance 3. Drain, flush and fill radiator coolant. (Page 5-15)
1. Perform previous maintenance procedures. 4. Perform any other engine preventative maintenance
2. Change engine oil and replace oil filter. (Page 5-13)
3. Check engine drive belt. Adjust or replace if
needed. (Page 5-14) 3000-Hour or Every Three Years
4. Check drive axle, gear box and planetary hub oil Maintenance
levels. Add more gear oil if needed. (Pages 5-8 -
5-10)
1. Inspect the DEF Dosing Unit Filter. Clean or replace
if needed. (Page 5-19)
5
as described in the Engine Operator’s Manual. 2. Perform any other engine preventative maintenance
500-Hour or Semi-Annual
Routine Maintenance
1. Perform previous maintenance procedures.
2. Inspect engine drive belt tensioner, idler and drive
pulleys for dirt, wear and cracks. (Page 5-14)
3. Check and adjust toe-in if needed. (Page 5-12)
4. Change hydraulic oil, and replace charge and return
filters.
5. Replace fuel filter. (Page 5-20)
6. Service battery. (Page 5-21)
7. Adjust park brake. (Page 5-12)

Maintenance
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
1 12
1 9
10
2 11
13
3
14
5 4
6 15
15
7 7
16
8
17

Maintenance
Table 5-2. Lubrication Points
No. ITEM INTERVAL

18 1 Front Axle Joints (both sides) Weekly
2 Front King Pins (both sides) Monthly
Drawbar Ball (until grease es-
3 Daily
capes from the ball joint)
4 Steering Cylinders and Tie Rod Daily
5 Moldboard Swing Cylinders Daily
6 Turntable (4 grease fittings) Weekly
Articulated Cylinder (until grease
19 7 Weekly
escapes from clevis pin joints)
8 Rear Axle * (6 on each side) Monthly
Moldboard Lift Trunnion (both
9 Daily
sides)
20 Moldboard Lift Cylinders (both
10 Daily
sides)
11 Moldboard Stabilizer Weekly
Articulated Joint (until grease
12 escapes from the upper and Monthly
lower joints)
13 Moldboard Tilt Cylinder Weekly
20 14
Moldboard Mounting Pins (both
Weekly
sides)
15 Valve Handles Monthly
16
17
Door Handle
FNR Pedal
Monthly
Weekly
5
Front Blade/Scarifier Lift Cylinder
18 ** Weekly
(See Below)
19 ** Front Blade Joints Weekly
20 ** AWD Front King Pins (both sides) Weekly
Rear Scarifier Lift Cylinders (both
21 ** Weekly
sides)
* Not all grease fittings are shown on rear axle

graphic. Be sure to look closely and grease all
21 fittings on inside of tandems at the pivot point (6 on
each side of axle.
** OPTION. Only applicable if equipped with options
as shown:

Maintenance
Axle Lubricants Breathers

Check the gear box, tandem box, axle and hydraulic Hydraulic gear boxes, axles, pumps and tanks need to
motor oil levels quarterly, shown in Figures 5-1 and “breathe” as air is drawn in when hydraulic components
5-2). Add more gear oil if needed. Change the oil on activate. Breathers stop water, dirt and debris from
these components every year for optimum performance. contaminating the oil. If the breathers are clogged, the
resulting heat and pressure increase will force lubricant
NOTE: The manufacturer recommens axle lubricant
to escape through seals and joints in the housing,
that meets API GL-5/MT-1 or SAE J2360
leading to bearing or gear failure. To prolong the
specification.
operational life of a bogie axle, regular inspections and
Use the following procedure to change oil at the various maintenance of the breathers is essential. (Figure 5-2)
oil plug points as shown:
• Always inspect the breathers when checking oil levels.
1. Park machine on level ground. Simply dusting and brushing off the gear breathers
2. Remove the oil plug(s) shown in Figures 5-1 and regularly will keep out dirt and debris that can clog the
5-2. breathers.
3. Add oil until it starts coming out of the level plug. • Check for oil leaks. Leaks indicate that seals
have failed, thus allowing dust, debris and water to
4. Replace the level plug. contaminate the oil.
5. Allow the axle to sit level for at least five minutes to • If the breathers and/or seals are damaged, they
allow the oil to flow throughout components. should be replaced without delay to prevent internal
6. Remove the level plug and check oil level. contamination and inadequate lubrication.
7. Add more oil if needed. • To replace, simply unscrew the breather and discard,
then reinstall the new breather.
Side View
Tandem Oil
Level Plug
Figure 5-1. Side View of Bogie Axle

Maintenance
Front View
Gearbox Oil Gearbox

Level Plug Breather
Top View
Axle Oil Level
Axle
Breathers
Hydraulic Motor
Coupling Oil Level
Figure 5-2. Front and Top Views of Bogie Axle

Maintenance
Planetary Hubs MACHINE ADJUSTMENTS

The planetary hubs on the rear bogie axle should be Some components of the motor grader will need
checked quarterly to ensure they contain the proper periodic adjustments for optimum performance and
amount of gear oil. A drain/fill plug is located on the to reduce wear and tear. Always park the vehicle on
outer end of the planetary hub on each of the four tires. level ground and turn off the engine before making
(Figure 5-3) adjustments. Do not make adjustments with load.
1. With assistance from a ground guide, slowly drive DO NOT leave the engine running
the machine forward on a level surface until the while making adjustments or repairs unless
planetary hub plug is at the 3 o’clock or 9 o’clock specifically recommended. NEVER make
position. adjustments to any part of the grader while it is in
motion.
Keep bystanders at a safe distance,
especially when raising or lowering attachments.
Moldboard Blade
Because the moldboard does the hard cutting work,
Fill keeping it in well-maintained and properly adjusted is
crucial for ensuring productivity and longevity.
Plug
Check the blade edge weekly. The blade’s cutting edge
should be at least 1.5 inches (3.8 cm).
• Clean blade and remove debris or material daily.
• Check for loose, damage or missing bolts and linkage.
Tighten or replace immediately to prevent damage.
Figure 5-3. Planetary Hub Fill Plug (Shown in the
3 O’Clock Position) To adjust the moldboard blade:
2. Shut off the engine and apply the park brake. 1. Park the machine on level ground.
3. Unscrew the planetary hub plug. 2. Place a block under the moldboard attachment
and lower the moldboard until it rests lightly on the
4. Oil should be level with bottom of plug hole.
ground.
5. If the oil level isn’t visible or level with the plug hole,
3. Slightly raise and lower the blade a few times
add more gear oil and reinsert plug.
to check tightness of the moldboard bolts and
6. Let the grader sit for at least five minutes to allow the components. Check for any “play” between the
oil to flow to the hubs. moldboard and slide.
7. Remove the plug and recheck the oil level. 4. Engage the park brake, turn off the engine, and
8. Repeat Steps 5 - 7 if needed. block all four wheels to ensure the machine does
not move while making adjustments.
Ensure the weight of the moldboard is
supported and stable before starting procedure:
If excessive clearance is noted between the front and
rear of the moldboard slide bar:
1. Remove bolts and nuts holding upper and lower
shims and clamps on back side of the moldboard.
(Figure 5-4)

Maintenance
Upper Moldboard Drawbar Ball and Socket

The drawbar ball and socket joint can wear over time
and need adjustment. This can be easily adjusted by
removing a shim. You will need an assistant for this
Clamp
procedure:
Shim Clamp
Shim 1. Park the machine on level ground and engage the
park brake.
Lower Moldboard 2. Lower the moldboard until it rests lightly on the
ground, then the assistant can check the drawbar
Slide Bar
and socket assembly for wear and damage. (Figure
5-6)
Clamp
Shim
Clamp
Shim
Figure 5-4. Moldboard Shims and Clamps

2. Remove the upper and lower clamps.
3. Add or remove shims to adjust moldboard to the
needed tightness if needed. Shims Socket
4. Reinstall clamps, bolts and nuts.

Bolts
If excessive clearance is noted between the top and
bottom of the moldboard slide bar:
• Loosen jam nuts and turn adjuster set screws
clockwise to remove excess clearance, then
retighten jam nuts. (Figure 5-5)
Start the engine and check adjustments by raising and
Drawbar Ball
Figure 5-6. Drawbar Ball and Socket

5
lowering the moldboard.
3. With your assistant clear of the blade but watching
Adjusters
the drawbar ball and socket, raise and lower the
moldboard. The ball should move freely.
4. If the ball does not move freely or shows excessive
movement, turn off the engine and block all four
wheels to ensure the machine does not move while
making adjustments.
5. Remove the bolts and nuts around the socket cap,
then carefully pull it back to access the circular
shims.
6. Remove the first shim, then repeat Step 3 to check
adjustment. 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.

Maintenance
Toe-In Park Brake (Rear Bogie Axle)

Toe measurement is the angle between the vehicle The park brake is used to hold the grader in position
center line and the tire. The front wheels of the vehicle while parked and may need adjustment due to wear and
should be adjusted for a slight inward alignment of the extensive use. If you notice any slippage, adjustment is
forward edge of the wheels so they are closer together needed.
at the front than at the back of the vehicle. This toe-in
Adjustment components are located on the top of
adjustment improves steering and equalizes tire wear.
both sides of the front bogie axle. Use the following
To make the toe-in adjustment: procedure if the park brake needs adjustment:
1. Park the machine on level ground and straighten the 1. Park the machine on a level surface, shut down the
front wheels vertical with the grader boom frame. engine and engage the park brake.
2. Lower the moldboard enough to raise the front • Use the brake bleeder port to relieve pressure if
wheels slightly, then block front axle. needed. (Figure 5-8)
3. Engage the park brake and turn off the engine. Top View
4. Measure and mark the center of both front tires with
chalk or white marker.
Brake
5. Measure the distance between the marks on the
Bleeder
front tires.
Adjuster
6. Rotate tires so marks are at the rear and measure Screw
the distance between the marks.
7. If the difference between the tire marks measured
front and rear is more or less than 1/8-inch (3.2 mm),
adjust the front tires by loosening the tie-rod jam
nuts. (Figure 5-7) Turn the wheels completely left
and right, checking for an obstructions or damaged
parts.
Front View
Figure 5-8. Park Brake Adjustment (Right Side
Shown)
2. The park brake adjustment screw is located in the
cavity just below and to the right or left (depending
on the side adjusting) of the bleeder port as shown
in Figure 5-8. Use a flat-head screwdriver to
carefully remove the cavity cover.
Tie Rods 3. Using a 13 mm wrench, loosen and remove the
bolt and retaining clip, which exposes the adjuster
Figure 5-7. Tie Rods
screw.
4. Using a 14 mm wrench, turn the adjuster screw
counterclockwise until snug (5 - 6 ft lb), then mark a
flat side of the adjuster screw.
5. Turn the adjuster screw clockwise five (5) complete
turns.
6. Reinstall the bolt and retainer clip.
7. Repeat Steps 2 - 6 on the other side.

Maintenance
ENGINE MAINTENANCE 4. To add oil, remove the fill cap located next to the
dipstick. Twist to remove cap and twist to install (use
The 685D Motor Grader features a Cummins 3.8 Tier 15W40 motor oil).
4F diesel engine. Lockable engine access doors on
both sides of the grader allow convenient access to
components. The engine oil cap, dipstick and oil filter Change Engine Oil and Filter
are located in the right access door. (Figure 5-9)
The engine lubrication oil and oil filter must be changed
at the same time. (Figure 5-9)
DO NOT change the engine lubrication
oil filter while the engine is running. Serious engine
1 damage will occur.
To change the engine lubrication oil:
1. Park the machine on a level surface and turn off the
engine.
Change the engine lubrication oil
while the engine is WARM, not hot. Hot oil can cause
serious personal injury.
2 3 2. If needed, wait until the engine lubrication oil has

cooled a little. Oil should be warm, not hot.
Figure 5-9. Engine Oil Cap, Dipstick and Filter
3. Place a container large enough to hold 15.4 quarts
1 - Engine Oil Filler Cap (14.6 liters) of oil underneath the drain hose.
2 - Oil Dipstick 4. Remove cap on drain hose (at rear of axle) and
3 - Engine Oil Filter drain all engine oil into the container.
5. After all the oil has drained, reinstall the oil plug.
6. Wipe the area around the oil filter and its mounting
Check Engine Oil
The engine lubrication oil must be kept at a level above
base with a clean cloth.
7. Place the empty container under the filter element.
5
the ADD mark, but not above the FULL mark, on the
engine lubrication oil dipstick. 8. Use a filter removal wrench to remove the filter,
turning counterclockwise.
ALWAYS stop the engine before
9. Wipe inside the oil filter head using a clean, lint-free
checking the engine lubrication oil level as hot oil
cloth.
can be thrown, causing serious injury.
10. Rub a little oil on the rubber gasket area of the new
Wait five minutes after engine filter element.
shutdown before removing the dipstick from the
engine and checking the oil level to assure accuracy. 11. Fill the new filter with fresh oil.
This also prevents filling the engine with too much 12. Install the new filter element onto the filter head.
lubrication oil. Engine oil should be warm when Carefully tighten the filter (by hand only).
checked.
13. Fill the engine with 15.4 quarts (14.6 liters) of oil at
To accurately check the engine lubrication oil level, park the oil fill cap.
the machine on a level surface and stop the engine:
14. Check oil level using the oil dipstick. Add more if
1. Clean around the engine lubrication oil dipstick needed.
before removing it from the engine. (Figure 5-9)
15. Dispose of used oil in accordance with local and
2. Removing dipstick from the engine, wipe with a federal environmental laws.
clean cloth, then reinsert.
NOTE: Discard the used rubber gasket with the filter
3. Pull dipstick out of the engine and check that oil element.
level is near the full mark on the dipstick.

Maintenance
Engine Drive Belt

The engine belt drives the alternator Idler Fan Pulley
and the cooling fan. Check the engine
belt daily for any damage. The engine
drive belt must be replaced if the belt
Water
appears frayed, punctured, badly Alternator
cracked or breaks. Belt damage can Pump
be caused by:
Belt damage can be caused by:
• Incorrect tension.
• Incorrect size or length.
• Pulley misalignment.
• Incorrect installation. Idler
-OR-
• Severe operating environment. (AC Compressor
OPTION) Tensioner Crankshaft Pulley
• Oil or grease on the side of the belt.
Figure 5-10. Engine Belt
Engine must be turned off and the wheels blocked to prevent motion when servicing the
machine to prevent serious injury or death.
Inspect the drive belt for damage regularly. Inspect the 4. Route the new drive belt as shown in Figure 5-10,
belt grooves for debris, uneven/excessive rib wear or except over the water pump pulley.
exposed belt cords. Inspect the back side of the belt
5. Rotate tensioner in the direction shown in Figure
for glazing (high heat), debris or exposed belt cords.
5-9, then finish installing the belt, routing the belt
Cracks across the width of the belt are acceptable,
over the water pump pulley LAST.
but cracks along the length of the belt intersecting with
cracks across the width must be replaced. 6. Slowly release the tensioner to apply tension to the
drive belt.
To replace the belt:
7. Check the alignment of the belt with the tensioner
1. Turn off engine and block the wheels to prevent
and the rest of the front-end accessory drive.
movement while working on the machine.
8. Start the engine and listen for belt “squeal,”
2. Using a 3/8-inch square drive, rotate tensioner
which indicates belt slippage. If you hear the
in the direction shown in Figure 5-10 to relieve
belt squealing, recheck the routing to ensure it is
pressure on the belt. Remove the belt.
installed correctly on each pulley.
NOTE: The spring-loaded belt tensioner must be
Check the engine belt tensioner, pulley and arm for
pivoted away from the drive belt. Pivoting
cracks every 500 hours. If either component shows
in the wrong direction can damage the
damage, register or log onto the Cummins engine
tensioner.
website for access to additional engine information:
3. Inspect the tensioner, idler and drive pulleys for dirt,
https://quickserve.cummins.com/info/index.html
wear and cracks.
NOTE: Do not confuse build-up road dirt with wear.
Remove any debris from the grooves of the
pulleys, clean, check and reuse all pulleys
if not damaged rather than replacing. If
pulleys are damaged, replace before

Maintenance
Air Filter Be sure to clean the inside of the air

cleaner body before replacing the air filter element.
Turbo-charged engines are especially demanding on air
Be careful not to introduce any contaminants into the
filter performance. The operator should be continually
engine intake tube.
aware of the condition of the air filter system. Inspect
all components for damage, cracked hoses or loose To replace the air filter:
clamps. Replace the air filter every 250 service hours. 1. Open clamps securing the cover on the filter
A lockable access panel is located at the top of the right housing, then remove the cover.
side for convenient access to the air filter. (Figure 5-11)
2. Remove the filter cartridge.
NEVER operate machine without air
filter to prevent destruction of the engine. 3. Replace with the new filter cartridge.
4. Reinstall cover and secure with the clamps.
5. Reset the filter indicator by pressing button on top of
the indicator. (Figure 5-12)
Air Filter
Lockable Radiator
Cover Cap
Figure 5-11. Air Filter

1 - Pre-Cleaner
2 - Indicator
Figure 5-13. Engine Radiator Surge Tank Fill Cap 5
Radiator Coolant
A restriction indicator is
Ensure the radiator is full and that no debris is present
mounted on other side of
that could block the system and cause overheating.
the air filter that should be
(Compressed air can be used to remove any debris
checked often, accessed
from the radiator.) You can access the radiator surge
via the left engine panel.
tank fill cap via a lockable access door on top of the left
(Figure 5-12) As the
rear side of the grader. (Figure 5-13) When the engine
air filter becomes more
is cold, the coolant level should be visible in sight glass
clogged, the air pressure
through left side of the engine cover. If low, fill with a
increases, causing the
solution of 50 percent water and 50 percent ethylene-
indicator to reflect the red
glycol antifreeze. Flush the radiator system every 500
zone. If the red indicator
service hours (see your Engine Operator Manual for
is visible, the air cleaner
more information).
element must be replaced.
Figure 5-12. Air Filter DO NOT remove the radiator surge
Indicator tank cap while the engine is still hot. The radiator is
under pressure and the hot water can cause serious
injury.

Maintenance
Avoid prolonged and repeated skin

contact with used antifreeze as contact can cause
skin disorders or injury. Wash thoroughly after any
contact.
ALWAYS wear eye protection when
using compressed air to prevent injury.
To check the radiator or add coolant: SCR System
1. Open the access compartment to reach the radiator
surge tank cap. (Figure 5-13)
2. Remove the cap to check radiator level ONLY
WHEN UNIT IS COOL. Coolant level should be
DEF Pump
visible.
3. If coolant level is low, add coolant. DO NOT overfill.
DEF Tank
Selective Catalytic Reduction

(SCR) System Figure 5-14. SCR System
The SCR system is an efficient, effective means of

filtering dirt and other contaminates for optimum engine
performance and reducing air pollution from exhaust Diesel Exhaust Fluid (DEF)
emissions. (Figure 5-14) The SCR system precisely System
injects Diesel Exhaust Fluid (DEF) into the engine’s
DEF is a mixture pure urea and de-ionized water
exhaust system to transform those toxic exhaust
that is injected into the exhaust stream by the SCR
gases into harmless water vapor and nitrogen. SCR
system. The DEF system is an efficient, effective means
technology is also cost-effective and fuel-efficient.
of filtering dirt and other contaminates for optimum
It is critical that you prevent contamination machine performance and reducing air pollution from
entering into the SCR system. Even trace amounts exhaust emissions. DEF fluid is available at most truck
of contaminants introduced into the SCR system can stops, diesel engine dealerships, auto supply stores and
cause damage. large gas stations. To find DEF locations in the U.S., go
to http://www.finddef.com/def_map.php.
NEVER tamper with or remove any
emission-related component under penalty of law. DEF contains urea, therefore, wear
eye protection, gloves and appropriate protective
DO NOT pressure wash or steam
clothing when filling the tank and handling DEF.
clean this unit to avoid damaging the components.
Avoid skin contact. Use only with adequate
Use compressed air to remove any loose debris.
ventilation and avoid breathing vapor or mist. DO
NOT get the substance in your eyes. In case of
contact, immediately flush eyes for a minimum of
15 minutes. ALWAYS wash hands thoroughly after
handling DEF.
The DEF tank is located on the right side of the grader
inside the smaller access door behind the operator
station. (Figure 5-15) DEF tanks always have a blue
cap with a smaller fill neck to prevent erroneously filling
with the wrong fluid.

Maintenance
• Always clean around the fill neck and dispensing

nozzle when refilling the DEF tank. If you’re refilling
the DEF tank often, the opportunity for airborne dust
and dirt ingestion is high.
• Be especially careful handling DEF at the job site.
While it’s a good idea to have DEF on hand, especially
in rural areas, the risk of contamination is higher. Be
sure the ambient temperature is within the correct
DEF Tank storage range if bringing DEF to the work site.
Filler Cap A sensor on the DEF tank header monitors the level,
temperature and quality of DEF in the tank. The header
is mounted on top of the DEF tank and provides filtered
DEF supply from the tank to the after treatment DEF
dosing unit. Both the DEF tank header and dosing
Figure 5-15. DEF Tank
unit have serviceable filters that require cleaning or
NOTE: Check the fittings around the DEF tank replacement. (Figure 5-16)
header for leaks or any signs of damage
4
regularly. DEF leaks will leave a white
deposit around the fittings.
Typically, machines will consume DEF fluid equal to
2 - 10 percent of the fuel you burn. Temperature and
humidity affect DEF consumption, with hot and dry 3
climates resulting in greater DEF consumption. DEF 2
freezes at 12° F (-11° C), and should be stored 40 - 80° 1
F (5 - 27° C) to maintain shelf life. Temperatures above
86°F (30° C) causes DEF to break down into ammonia,
reducing shelf life considerably.
DEF may be stored in the machine’s tank up to four
months at the recommended temperature. Keep
container tightly closed and sealed until ready for use.
Always keep the DEF tank full.
5
DO NOT use DEF after its expiration
date. Always dispose of DEF in compliance with
federal and local environmental laws.
• Store DEF in a well-sealed container in a well-
ventilated location away from dust and direct sunlight.
Figure 5-16. DEF Tank Header Assembly
• Keep DEF containers away from fuel and lubricant
containers, and any other source of contamination. 1 - Suction DEF Connector
• Store DEF in a dedicated container that has not been 2 - DEF Connector
used with other fluids, including funnels and hoses. If 3 - Coolant Connectors
using pumps, ensure the seals, O-rings and fittings on
the dispenser is DEF-compatible. 4 - Electrical Connector

Maintenance
The DEF system will automatically purge the fluid To service the DEF tank filter inside the header (Figure
from the system after shutting down the machine and 5-16):
requires no intervention from the operator.
1. Complete Steps 1 - 4 to prepare machine for DEF
Before servicing any component in the DEF system, system maintenance.
allow the DEF system to purge. You will hear the
2. Place a container under the DEF tank as a small
pumping noise as the system completes the purge cycle
amount of DEF may drain from the coolant lines
automatically after shutting down the engine.
when disconnected. (Dispose of the fluid in
1. Shift transmission into neutral. accordance with environmental regulations.) DO
2. Apply the parking brake. NOT flush the coolant.
3. Shut off the engine. Wait at least five minutes after 3. Use a clean, damp cloth to wipe the unit to reduce
shutting down the engine for the after treatment DEF the risk of contamination entering the DEF tank.
dosing unit to complete its automatic purge cycle. Wipe away any spilled DEF while servicing the DEF
tank filter.
DO NOT disconnect battery until the
4. Disconnect the coolant connectors and cap the
purge cycle has completed to prevent damage to the
lines to prevent contamination or DEF leakage.
unit.
Figure 5-16) (You can also use a pair of coolant
4. Place battery master switch in the OFF position. hose pinch-off pliers to clamp the lines. Make sure
(Page 5-21) the tank coolant hose material is flexible enough.)
DO NOT drain the cooling system. DO NOT spill any
It’s important to service the DEF
coolant into the DEF tank.
system in a clean, dust-free environment to prevent
contamination in the DEF tank that can damage the 5. Disconnect the DEF connector.
after treatment DEF dosing unit.
6. Disconnect the suction DEF connector.
7. Disconnect the back-flow DEF connector.
DEF Tank Filter 8. Disconnect the electrical connector by pressing the
top of the fitting.
The DEF tank filter should be cleaned or replaced every
2000 hours, or every two years, whichever is first. The 9. Remove the header from the tank by removing the
filter is the first point of contact with foreign elements. six bolts on the metal ring separating the header
To clean or replace the DEF tank filter, remove the DEF from the tank. Slowly and carefully lift the header
header tank assembly using the following procedures. out of the DEF tank, exposing the filter unit, to avoid
The DEF lines are connected using quick-release damaging the filter or other components.
fittings and must be disconnected in the order 10. Remove the clip, pull the filter cartridge out and
described below. (Figure 5-16) inspect for cracks, damage and contamination
Wear eye protection, gloves and or debris. Clean the filter and reinsert, unless
appropriate protective clothing to avoid injury. The replacing the filter at service interval or if debris or
coolant lines connect to the after treatment dosing damage is evident:
unit are hot and under pressure. DO NOT disconnect • Discard the filter element and O-ring in
while the engine is running or before the system has accordance with environmental regulations and
purged and cooled down after shutting down the replace with a new filter element.
engine. Disconnecting the coolant lines before the
system cools down may cause coolant to spray and • Also inspect the after-treatment DEF dosing unit
burn skin on contact. filter after replacing the tank filter. (Figure 5-17)
NOTE: It is imperative that you disconnect the 11. Lubricate the O-rings with clean DEF fluid and install
plumbing from the header in the exact order the new filter element (O-ring side facing outward) in
described below to prevent accidental DEF its seated notch location.
contamination of the electrical connector. 12. Reinstall the filter cartridge into the DEF tank.
13. Reinstall the tank filter header in reverse order

Maintenance
DEF Dosing Unit Filter FUEL SYSTEM

The DEF dosing unit filter prevents foreign objects that The fuel level is indicated on the PV485 digital
may be suspended in the DEF from entering the dosing display component on the steering column. Proper
system, which draws DEF from the tank, pressurizes maintenance of the fuel system ensures top
it, and delivers the DEF through a dosing valve. Any performance and prevents damage to internal engine
unused DEF is then routed back to the tank. The DEF components. The fuel filler cap and fuel filter are located
dosing unit filter should be replaced every 4500 hours just inside the right engine access panel. (Figure 5-18)
or three years, whichever comes first. It is located on The fuel water separator component is also located at
the left inside the rear access panel on the driver’s side. the right engine access door.
Follow these procedures to replace the dosing unit filter:
1. Follow Steps 1 - 4 on Page 5-18 to prepare machine
for DEF system maintenance.
2. Place a container under the DEF dosing unit as a
small amount of DEF may drain from the lines when
disconnected. (Dispose of the fluid in accordance
with environmental regulations.)
3. Use a clean, damp cloth to wipe the unit to reduce
the risk of contamination entering the DEF system.
Debris can cause permanent damage and
premature failure in the DEF dosing unit.
4. Unscrew the DEF filter cap and remove the Fuel Cap Fuel Filter
equalizing element and filter element. (Figure 5-17) Figure 5-18. Fuel Filler Cap and Fuel Filter
NOTE: Fill the tank to FULL before storing the
motor grader overnight to reduce moisture
accumulation from condensation in the tank. Fuel
contaminated by water promotes the growth of
microbes that can clog fuel filters and lines over
time. 5
The operator should NEVER be on or
near the motor grader while fuel is being added. NO
SMOKING while filling the fuel tank as all fuels for
internal combustion engines are flammable. Fill the
fuel tank only in a designated area where there is
good ventilation and a fire extinguisher available.
1 2 3 NEVER fill the tank, check fuel level

or check for fuel leaks near an open flame or near
Figure 5-17. DEF Dosing Unit Filter equipment that can create sparks.
1 - Filter Cap
Diesel fuel is very flammable. Use
2 - Filter Equalizing Element extra caution and DO NOT spill fuel. DO NOT change
3 - Filter Element the fuel filter while the motor grader is running. DO
NOT change the fuel filter in an area near an open
5. Discard both the filter element and equalizing flame. DO NOT smoke while changing the fuel filter.
element in accordance with environmental
regulations. NEVER loosen a fuel injector line as
contents are under high pressure. DO NOT try to
6. Reinstall the new filter and equalizing element. bleed air by loosening injector lines.
7. Reinstall and tighten the cap.
NOTE: Lubrication on the DEF filter O-ring is not
required.

Maintenance
Fuel Filter
The fuel filter element must be replaced as directed
Fuel Water
in the Engine Operator’s Manual. The fuel filter and Separator
fuel water separator are located inside the left engine
access panel (Figure 5-19).
Replace the fuel filter using the following general
procedures:
1. Stop the engine.
2. Put a container under fuel filters before removing Figure 5-19. Fuel Water Separator Location
the filter elements.
To drain the water separator:
NOTE: Consider the environment when discarding
used filters and do so according to safe and 1. Pull retainer clip from plug to disconnect the
lawful practices. harness. (Figure 5-20)
3. Wipe the area around the fuel filter elements and 2. Unplug the harness, then unscrew the plug.
element mounting heads using a clean, lint-free 3. Drain and reinsert components.
cloth. (Figure 5-19)
4. Use a filter removal wrench to loosen and remove
fuel filter elements by turning in a counterclockwise
direction. Drain and discard the removed elements.
5. Wipe the inside area of the filter heads with a clean, Pump
lint-free cloth. Fill the new fuel filter elements
completely with clean fuel.
6. Put clean fuel onto the element rubber gaskets. Filter
7. Install the new fuel filter elements onto the filter Body
heads. Carefully tighten the elements (by hand
only).
DO NOT overtighten the fuel filter
elements onto the filter heads.
8. Start the engine and check for ANY fuel leaks.
Clip
Fuel Water Separator Plug
Water and dirt that gets into fuel settles into the fuel
water separator. (Figure 5-20) As it collects, a red float Figure 5-20. Water Separator
rises. When the float reaches the line on the separator, To clean the water separator:
an error code will appear on the PV485 digital display.
It is important to drain it immediately. The fuel water 1. Follow the previous steps for draining the water
separator is conveniently located on the right engine separator.
access door. 2. Loosen and remove the filter body and clean it with
If you run out of fuel, it is important light oil.
to pump the water separator to prime fuel injection 3. Reinsert and tighten.
lines. Failure to do so can adversely affect
performance.

Maintenance
ELECTRICAL SYSTEM Batteries contain sulfuric acid and

normally produce explosive gases that can cause
Battery Servicing serious injury. DO NOT allow flames or sparks to
come near the battery.
The motor grader electrical system is a 12-volt negative
ground system. Two batteries are located on the left When charging or working near a
side of the machine in a lockable battery compartment battery, always shield your face and protect your
directly below the engine access panel. (Figure 5-21) eyes. In case of acid contact with skin or eyes,
flush immediately with water for a minimum of 15
minutes and get prompt medical attention. If acid is
swallowed, call a physician immediately.
When replacing the battery, discard the old battery
properly. Before connecting the battery, be sure the
master battery switch is turned off. The switch is located
just inside the left engine access panel. (Figure 5-22)
When servicing the electrical system
or welding on the machine, always turn the Master
Disconnect switch to the OFF position to disconnect
the ground strap from the battery to prevent damage
to the machine electrical system.
Master
Battery
Figure 5-21. Batteries Switch
NOTE: The electrical system is a negative ground
system. Connect the positive (+) cable to
the positive (+) post of the battery. Connect
the ground cable to the negative (-) post of
the battery. It is advisable to disconnect the
Figure 5-22. Master Battery Switch
5
negative (-) cable first and reconnect it last.
Reversed polarity can damage the electrical Be sure to keep the battery fully charged during cold
system. weather to keep it from freezing. Freezing weather has
little effect on a fully charged battery.
Clean terminals and battery posts thoroughly and check
that battery cable terminals are tight. Dirty or loose When connecting a booster battery, if necessary for
connections can create high electrical resistance and cold weather starting, connect one end of the first
permit arcing, which will quickly burn and pit terminals jumper cable to the positive (+) terminal of the dead
and posts. battery and the other end to the positive (+) terminal of
the booster battery. Connect one end of the second
Keep the battery clean by washing it off whenever dirt
jumper cable to the negative (-) terminal of the booster
buildup is excessive. If corrosion is present around
battery and the other end to the frame of the machine
terminal connections, remove them and wash with
with the dead battery.
ammonia solution or a solution consisting of 1/4 lb. (11 kg)
baking soda added to one quart of warm water. Make DO NOT attach the negative (-) cable
certain the vent caps are tight to prevent solution from from the booster battery to the negative (-) post of
entering the cells. After cleaning, pour clean water over the dead battery because a spark could cause an
the battery and surrounding area to wash the solution explosion.
away. Check vent cap breather openings to make sure
they are open.

Maintenance
Alternator Servicing Fuse Boxes

The alternator supplies electrical current for charging The electrical system is protected from overload
the battery that provides electrical power to electronic damage by fuses. If an electrical component fails to
controls. The built-in regulator in the alternator controls operate, check the fuse box panel first to ensure that a
the voltage output. (Figure 5-23) fuse has not “blown.” A blown fuse is an indication that
there is an overload that needs to be corrected.
There are two fuse boxes--one is located on the left
engine access panel door and the other is located
under the main control panel.
• Figure 5-24 shows corresponding fuse information
for the fuse box on the engine access door.
• Figure 5-25 on the following page shows
corresponding fuse information for the main fuse box
under the ain control panel.
Figure 5-23. Alternator

NOTE: Never disconnect the alternator while the
machine is operating. If the wires must be
disconnected from the alternator, be sure to
mark them for proper reconnection.
Use the following precautions to prevent damage to the
alternator for any maintenance performed:
• Always disconnect the battery before disconnecting
or connecting the alternator.
• An alternator should never be polarized. DO NOT
ground any alternator terminals or circuits. Figure 5-24. Engine Door Fuse Panel
• Be certain the wiring is properly connected before If you replace a fuse, but it continues to blow, contact
connecting the battery. your authorized LeeBoy dealer for assistance.
Always replace a blown fuse with
the same rating as specified. Never replace with a
higher amperage rating. Damage to the electrical
system or fire can occur from improper fuse
replacement.

Maintenance
Lighting
Inspect lights for proper operation daily. If a light or If broken wires are found, solder together and cover with
group of lights does not function: a shrink-wrap type of plastic covering (preferred) or
electrician’s tape to prevent contamination of the solder
• Check the fuse box panel for a blown fuse. joint by moisture.
• Examine all visible wiring connections, ensuring they If you make any repairs to the wiring harness on the
are not frayed or damaged, and securely fastened. grader, always replace or repair the protective loom
• Check lighting mounts for proper ground. covering the wiring to prevent future damage to the
wiring harness. Examine the routing of the harness and
• Remove light lens or casing (if applicable) and check ensure it is not subjected to excessive movement, which
bulb. Replace if needed. often causes broken wiring.
• Inspect wiring harness for damage (see Schematics
in Section 6).
10A 10A 10A 10A 10A 10A 15A 15A 15A 15A 20A
FRONT WORK
REAR WORK
FLASHER
AC/HEAT
BEACON/
FRONT
LIGHTS
LIGHTS
LIGHTS
WIPER
WIPER
REAR
BEAM
BEAM
LOW
HIGH
TAIL
FAN
KEY
OPEN
F24 F22 F20 F18 F16 F14 F12 F10 F8 F6 F4 F2

F23 F21 F19 F17 F15 F13 F11 F9 F7 F5 F3 F1
DIAGNOSTICS
STEERING
OUTLET
HORN/
ENGINE
RADIO
DOME
TRAVEL
FLOAT/
WORK/
BRAKE
AWD
PARK
AUX
OPEN OPEN OPEN
10A 10A 10A 10A 10A 10A 10A 10A 10A

5
LOW HIGH WORK/ SEAT AUX

FLASHER TRAVEL SWITCH STEERING
BEAM BEAM
Figure 5-25. Fuse Panel (Under Main Control Panel)

Maintenance
Dielectric Grease To correctly apply dielectric grease:
Dielectric grease is a nonconductive, insulating • Apply a thin, visible, uniform coat using ONLY high-
compound applied to electrical connectors. When quality dielectric grease (Dow Corning 4 or equivalent)
applied correctly, a high-quality dielectric grease across the MALE connector as shown in Figure 5-26.
displaces debris and moisture in the connector. The • Coating too thin may not fill the gaps between
proper application of dielectric grease fills any gaps pins.
between pins or in the connector which prevents debris
• Coating too thick may prevent proper
and moisture from creating corrosion of the electrical
connection or force pins or seals out. (Figure
components.
5-27)
Equipment damage can occur if using • Plug in the male connector.
low-quality, incompatible dielectric grease.
DO NOT force connector to lock if too
If not applied or incorrectly applied, corrosion can result
much grease has been applied.
that causes rapid increase in resistance, intermittent
connections, overheating, and a variety of electrical Excessive grease application does
problems. Numerous electrical issues throughout the not allow a proper connection by preventing the
machine can be avoided by the proper application and plugs from locking into place, and can cause damage
use of dielectric grease. to the connector seals.
Figure 5-27. Incorrect Application of Dielectric

Figure 5-26. Correct Application of Dielectric Grease
Grease

Maintenance
HYDRAULIC SYSTEM Checking Hydraulic Oil Level

The hydraulic system is composed of two major The hydraulic oil tank and sight gauge is located on the
component groups--the hydrostatic drive and the right side of the machine. The hydraulic oil fill cap is
auxiliary hydraulic group. The hydraulic motors and accessed on the right side of the grader just behind the
cylinders use the same hydraulic oil reservoir and operator platform. (Figure 5-28)
hydraulic oil supply. Solenoid valves, flow-control valves, NOTE: Wait 10 minutes after engine has been shut
dividers and other components allow simultaneous down before checking hydraulic oil.
function and control of all hydraulic systems. A
30-gallon hydraulic tank with suction strainers, charge Oil level is determined by sight gauge.
pressure and return filters stores and cleans the Hydraulic oil should be added if the oil level falls
hydraulic fluid. An oil cooler is mounted with the engine below the fill line. Never fill above the black fill line.
radiator to complete the hydraulic system.
Hydraulic
The hydrostatic drive group consists of an axial piston Oil Cap
hydrostatic pump coupled to the rear of the diesel
engine. A hydraulic motor drives the rear axle. The
Fill
auxiliary hydraulic group consists of a two-section
Line
gear pump mounted on the rear of the drive pump. If
equipped with the AWD option, a second axial piston
drive pump is installed and connected to the front wheel
drive motors.
Sight
ALWAYS use an equivalent grade of Gauge
hydraulic fluid. 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
inspecting for leaks in the hydraulic system. Never
use your hands to locate leaks as hydraulic fluid
under pressure can pierce the skin and cause
Figure 5-28. Hydraulic Sight Gauge and Filler Cap
Use extreme caution when removing 5
the filler cap to prevent foreign matter from entering
serious injury and toxic reaction.
the hydraulic tank.
Never attempt makeshift repairs using If hydraulic level is low:
tape, clamps or cements in the hydraulic system.
The system operates under extremely high pressure 1. Clean around the hydraulic oil filler cap before
and such repairs could fail, causing serious injury. removing to add hydraulic oil to the tank.
Inspect the motor grader for hydraulic leaks daily. 2. Fill tank to the black fill line on sight gauge.
Check that all fittings are secure and tight weekly. If 3. Screw the hydraulic oil filler cap back onto the
leaking fluid is found, it is probably on the pressure hydraulic tank.
side of the hydraulic system. DO NOT OPERATE the
machine until the hydraulic leak is repaired.
Leaks on the suction side of the hydraulic system are
more difficult to find and more serious since air or dirt
introduced into the system causes rapid component
wear and eventual failure. Some symptoms of suction
leakage are:
• Hydraulic fluid “foaming.”
• Sluggish system operation.
• Unusual noises in the hydraulic pumps or motors.

Maintenance
Change Hydraulic Oil and Filter 2. Place a drain collection container of sufficient
capacity to collect the hydraulic oil under the
Changing the hydraulic oil removes the accumulation hydraulic tank on the right side of the machine.
of dirt, water and mechanical wear particles from the
hydraulic oil reservoir and system. The chemical 3. Open the hydraulic oil drain valve by turning the
structure of hydraulic oil changes after continuous valve handle up to allow hydraulic oil to drain. (The
use, therefore, new oil is important to ensure correct valve is located just above the DEF tank.) (Figure
operation of the hydraulic system. 5-29)
Never let the hydraulic oil reservoir

tank run dry. Pump damage will occur. Return
Shut-Off
Condensation can also build up in the hydraulic
Valve
system and clog the filter elements. This could lead
to insufficient hydraulic oil at the pump and degrade
performance, causing damage to components.
Change the hydraulic oil and filter after the first 100
hours of use, then every 500 hours or seasonally, Oil Drain
whichever comes first. Also remove and clean the Valve
suction strainer when changing the hydraulic oil at the
2000-hour intervals.
The hydraulic filter is located on the right side of engine
compartment. (Figure 5-29)
Figure 5-30. Hydraulic Shut-Off Valves
Hydraulic 4. Allow all of the hydraulic oil to drain into the

container.
Oil Filter
Cap Strainer
Sight
Gauge
Suction
Strainers
Figure 5-29. Hydraulic Filter Location Diffuser
Use the following procedure to change the hydraulic oil
and filter: Charge
Filter
1. Stop the engine. Allow the hydraulic oil to cool (Tank
until it is at a warm temperature. Slowly loosen and Exterior)
remove the hydraulic oil filler cap. Put a clean, lint- Return Filter
free cloth over the hydraulic tank fill tube opening (Tank Exterior)
and secure in place with tape.
DO NOT drain the hydraulic oil from Figure 5-31. Hydraulic Tank Components
the reservoir when it is HOT. Hot hydraulic oil can
cause serious injury. Drain at a warm temperature
only.

Maintenance
5. Check the hydraulic tank suction strainers in bottom Change Hydraulic Oil Cap
of the hydraulic oil tank. Clean if necessary. (Figure
5-31)
Strainer
6. Close the hydraulic oil drain valve by turning it back The oil strainer is mounted in the hydraulic oil filler
to the original position (shown in Figure 5-30). opening under the filler cap. (Figure 5-31)
7. Unscrew and remove the hydraulic return and DO NOT remove the hydraulic filler
charge oil filters on the exterior of the tank. (Figure cap from the reservoir when it is hot as this can
5-31) cause serious injury. Allow hydraulic oil to cool down
to a warm temperature.
• If equipped with the AWD option, remove the
two bolts on either side of the hydraulic motor To change the hydraulic oil strainer:
panel on the undercarriage. (Figure 5-32) 1. Remove the hydraulic oil filler cap.
The front of the panel can be pivoted to access
the AWD charge filter. Unscrew and remove 2. Remove the six (6) screws securing the strainer,
the AWD charge filter. Reinstall the panel after then remove the strainer and gasket.
replacing the AWD charge filter. 3. Install a new gasket, aligning the six screw holes in
the gasket with the mounting holes on the reservoir.
4. Install the new strainer, aligning the holes in the
strainer with the mounting holes of the gasket and
AWD secure the strainer with the six screws.
Charge 5. Fill the hydraulic oil reservoir with (recommend
Filter Citgo All Weather/All Temperature Multiviscosity
hydraulic oil).
DO NOT overfill the hydraulic oil
reservoir with oil.
6. Check the oil level in the hydraulic oil reservoir. Add
Figure 5-32. AWD Charge Filter oil if needed.
8. Discard filter properly in accordance with
government environmental regulations.
7. Reinstall the hydraulic oil filler cap and tighten
securely. 5
9. Reinstall new hydraulic oil filters.
10. Carefully remove the cloth from the hydraulic oil tank
fill tube opening. Hydraulic Pump and Motor
11. Refill the hydraulic oil tank (Citgo All Weather/ The hydraulic pump and motor generally require no
All Temperature Multiviscosity hydraulic oil is regularly scheduled maintenance. Frequent inspection
recommended for this machine). for leaks will indicate the need for service of these
components. See your authorized dealer for service if
DO NOT overfill the hydraulic oil needed.
reservoir with oil.
12. Check the oil level at the sight gauge and add more
if needed.
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.

Maintenance
Hydraulic Test Ports

The hydraulic test ports provide an easy and convenient NOTE: Ports #2, #3 and #4 shown in the figure
means of checking pressure for the grader’s main and table only apply if equipped with the
hydraulic functions: (Figure 5-33) The test ports are optional AWD (All-Wheel Drive), there are
located inside the panel under the operator’s seat. additional test ports.
Relief pressures are shown at Table 5-3.
Table 5-3. Hydraulic Test Port Relief Pressures
NOTE: Be sure to use the appropriate sized gauge
for pressure PSIs shown. Item
Function PSI Relief / Gauge
No.
To check hydraulic pressure:
1* Charge 350 PSI
1. Run the engine long enough for the hydraulic oil to
2* Forward 3800 PSI with drive at full load.
warm to operating temperature. Set throttle to 1800
RPMs. 3* Reverse 3800 PSI with drive at full load.
1800 PSI with implement
2. Connect the appropriate gauge to the port being 4 Main Manifold
cylinder held at stop.
tested.
Steering/ 2200 PSI with steering held at
3. Start the engine, then check gauge for the proper 5
Brakes lock.
pressure reading.
6 Charge 350 PSI
4. If adjustment is needed, contact your authorized LB
7 Forward 6500 PSI with drive at full load.
Performance service center.
8 Reverse 6500 PSI with drive at full load.
* Optional AWD only.
1 2 3
5 6 7 8
Figure 5-33. Hydraulic Test Ports

Maintenance
CHASSIS The rim and tire assemblies for the

wheels are very heavy and must be supported when
Tires lug nuts are removed.
The tires should be maintained at the proper tire Never exceed the tire manufacturer’s
pressure of 30 - 35 PSI and should be checked daily. maximum recommended inflation pressure.
However, various operating speeds, road conditions, Never cut or weld on inflated tire/rim
material truck size, tire options and other operating assembly. Heat from welding can cause an increase
conditions may require different tire pressure. in pressure and may result in tire explosion.
Use 15-19.5 TL 8PR tires for this machine.
It is recommended that you use a
If a tire appears to be low, measure the pressure to be hydraulic lift if available when raising the vehicle.
sure of proper inflation. Protect tires from exposure to Otherwise, use jack stands on a solid, flat surface
petroleum products and other chemicals. to prevent the machine from tipping when it is
raised. Block the remaining wheels using sturdy
• Use proper tire mounting equipment and experienced
wheel chocks. DO NOT lie under the machine while
personnel for tire repair service.
supported only by a jack. Death or serious injury can
• Carefully inspect any tire and rim assembly for result from improperly supporting a raised machine.
damage before inflating tire. Contact a qualified repair
To replace the tires:
service if needed.
1. Loosen lug nuts.
2. Release any air that remains in the tire.
3. Use a jack or hoist to lift the side of the machine.
4. Place supports under the machine.
5. Attach a sling or other support to the tire.
6. Remove the eight (8) lug nuts from the wheel.
7. Release any air that remains in the tire.
8. Using standard tire removal tools, remove the tire
from the wheel. 5
9. Install new tire on the wheel.
10. Measure PSI using tire pressure gauge and inflate
to the proper PSI.
11. Align the mounting holes with the studs on the hub.
12. Reinstall lug nuts (8 on front and 10 on rear tires).
13. Torque the lug nuts in a diagonal pattern to 300 ft-lb
Figure 5-34. Properly Inflated Tire on front tires and 350 ft-lb on rear tires.
14. Remove supports and lower jack.

Maintenance
Repack Front Wheel Bearings 4. Remove nuts and washers on the axle spindle.
(Figure 5-36)
The wheel bearings secure the wheel and tire to the
vehicle on the drive shaft inside the wheel hub. While 5. Carefully pull the wheel bearing and seal off the axle
wheel bearings are designed to last 100,000 miles, they spindle. Inspect wheel bearing and seal for wear or
can lose lubricity over time. Dirt and debris can also damage.
seep into the wheel bearings. If the wheel bearings • Discard bearing if replacement is needed. It is
aren’t cleaned and repacked, they can wear out and recommended that you discard the seals and
possibly break or damage other wheel components. replace with new ones.
When any of the following symptoms appear, the wheel
• Otherwise, thoroughly clean wheel bearings,
bearing is damaged and should be replaced on both
wheel hub, axle spindle and mounting hardware
wheels of the same axle.
with solvent. Once the excess grease is
• Abnormal and excessive tire wear on the inside or removed, you can spray liberal amounts of
outside edge of tire. brake cleaner inside the wheel bearings and
• Grinding or roaring noise from a tire. This symptom wheel hub for additional cleaning.
indicates metal-on-metal contact and definitely
requires wheel bearing replacement.
• The steering wheel bounces and vibrates at lower
speeds, vibrating more as the machine accelerates.
Cleaning and repacking or replacing
wheel bearings is a messy job. Wear gloves and
have plenty of shop rags and room to work around
the entire wheel hub. Dispose of used grease in
Wheel
accordance with environmental law. Bearing
To clean and repack (or replace) wheel bearings: and Seal
1. Park the grader on a level surface in a designated
area where grease does not touch or run off onto
the ground.
Spindle
2. Using a hydraulic lift (if possible) or raise vehicle
with a pair of jack stands on the same axle to
service wheel bearings. Use wheel chocks on the
other wheels for safety.
Wheel
3. Beginning with one side, remove dust cover and lug Bearing
nuts from wheel, then remove tire and wheel hub,
placing it clearly away from the work area. (Figure Seal
5-35)
Dust Cap Lug Nuts
Nuts/Washers
Figure 5-36. Axle Spindle, Seal and Wheel Bearings
Figure 5-35. Wheel Dust Cap and Lug Nuts

Maintenance
If using compressed air for drying REPLACEMENT PROCEDURES

wheel hub components after cleaning, wear eye
protection! Compressed air can cause serious Batteries
personal injury if misused. Use compressed air at
safe low levels. NEVER point the nozzle at others. Batteries create explosive gases
when charging. DO NOT expose these gases to
6. Work fresh grease into the wheel bearings. You can
sparks or open flame during maintenance. Always
put the wheel bearing and grease into a plastic zip
perform battery service in a well-ventilated area or
lock bag to really work the grease into every small
outside. Serious injury can occur from exploding
wheel and bearing.
batteries.
7. Work fresh grease inside the wheel hub, ensuring
the outer edges are fully covered, and put liberal When installing batteries, always
amounts of grease onto the axle spindle. install the positive cable first followed by the
negative cable. Reversed polarity can damage the
8. Reinsert the wheel bearings ensuring it is oriented electrical system.
as shown in Figure 5-35, then new seal, washers
and nuts. Continue packing grease inside all the 1. Remove the black ground (-) cable from the
parts as you install them. negative (-) battery terminal, followed by the red (+)
cable from the positive (+) battery terminal. (Figure
9. Torque nut to 50 ft lbs. Then loosen the nut one 5-38)
turn.
10. Retighten the nut to 15 ft lbs. To ensure the nut does
not loosen, bend one edge of the washer toward the
outer nut and the other edge side toward the inner
nut. (Figure 5-37)
11. You can spin the hub and rotor to test for noise
and smoothness before reinstalling the wheel and
tire. When packed correctly, the rotor spins freely
without noise.
5
12. Reinstall tire and wheel. Torque lug nuts. (See
Section 2, Torque Specifications)
13. Repeat procedure on the other wheel.
Bend Here
Figure 5-38. Batteries
Figure 5-37. Wheel Dust Cap and Lug Nuts

Maintenance
If the negative cable is grounded Radiator Hoses

during removal, sparks will not occur. If the positive
Radiator hoses should be replaced if worn or frayed.
cable is grounded during removal, sparks will occur
Replacement parts are listed in Section 7, Illustrated
and could ignite explosive gases.
Parts List (IPL).
2. Remove the hold-down bar.
This procedure should only be
3. Inspect the batteries for cracks, wear and damage performed when the equipment is not operating.
that could result in leaks.
DO NOT remove the radiator cap while
4. Carefully remove the batteries from the battery the engine is still hot. The radiator is under pressure.
plate, noting battery position during removal. Removing the cap could cause serious injury.
Allow the batteries and surrounding 1. Turn off ignition, remove key, and allow the engine to
area to dry. DO NOT dry batteries using compressed cool down before proceeding:
air. Battery acid can cause severe injury if blown into
the face or other areas of the body. If injury occurs, 2. Remove the radiator surge tank cap.
seek medical attention immediately. Flush eyes and 3. Drain radiator into a suitable container (5.75 gallons
skin for 30 minutes with clean water. or 22.8 liters).
5. Make sure the battery cells are sealed. Clean the 4. To remove upper hose, loosen the two hose clamps
batteries, battery tray, cables, and brackets with and disconnect. If clamps are not damaged, retain
baking soda and warm water. Allow to air dry. for installation.
6. Place the batteries in proper position in the battery tray. 5. To remove lower hose, loosen the two hose clamps
7. Install hold down bar. Tighten bar to retain battery, and disconnect. If clamps are not damaged, retain
but not so tight as to damage battery. for installation.
8. Install red (+) battery cable to the positive (+) battery 6. Install new hoses in reverse order of procedures
terminal. above.
9. Install the black (-) battery cable to the negative (-)

battery terminal.
10. Reattach the battery box cover and reconnect the
battery box locks.
11. Attach nut and washers to bolts, but do not tighten.
12. Reinstall rear bolts through a washer, then through
the adjusting bolt and mounting hole in the frame.
13. Tighten bolts and torque. (See Section 2, Torque
Specifications)

Maintenance
Moldboard Blade
The frequency for replacing the moldboard blade
depends upon the material you’re working with and
operator’s skill in maneuvering the blade.
For safety, wear a hard hat, gloves and Side-Cut
safety glasses when replacing grader attachments. Edge
To replace or change the blade:
1. Block the front and rear wheels to prevent
movement of the machine. Blade
2. Start the grader with the park brake engaged, then Bolts
lower the moldboard so it just touches the ground
without any down pressure.
3. Turn off the ignition, ensuring the park brake is still
engaged, and dismount the grader.
4. Working on one section at a time, stand so the blade Side-Cut
is turned away from you, and begin with a bolt on Edge Bolts
either end of the blade.
5. Remove the nut and washer, then the bolt. (Figure
Remove
5-39)
nut and
6. Work from one end to the other until all have been washer
removed to CAREFULLY dislodge the blade from
first.
the moldboard.
7. Move used blade safely out of the way and align new
blade. Figure 5-39. Replacing Moldboard Blade
5
8. Working from one end to the other, install bolts,
washers and nuts, then torque. (See Torque
Tables, Section 2) Side-Cut Edges
9. Discard any worn bolts and replace with the same The moldboard side-cut edges can become damaged
size. (See Section 7, Illustrated Parts List) or worn over time, requiring replacement.
Follow the same procedure previously outlined for
removing the bolts to replace the side-cut edges.
(Figure 5-39) There are four bolts on each side-cut
edge.

Maintenance
Moldboard Slide Cylinder 5. Retract the moldboard and shut down the engine.
Hydraulic cylinders function by pressurized hydraulic 6. Disconnect, plug and tag the hydraulic hoses, being
oil. The moldboard slide cylinder moves the moldboard very careful to prevent any contamination when
from side to side. Extensive wear or damage to plugging the hydraulic hose fittings.
the cylinder could cause leaks, resulting in loss of NOTE: Inspect the hydraulic fittings. Replace any
pressure that adversely affects performance. If you damaged or worn fittings.
notice hydraulic oil leaking on the moldboard or loss of
7. Place a block or other means of supporting the
functionality, check the hydraulic hoses and fittings first.
cylinder, then remove the cotter pin and cylinder
If the moldboard slide cylinder needs to replaced: pin from the right side. Carefully slide the cylinder
1. Park the grader on a level surface in a designated away from the moldboard support frame to remove
area where oil does not touch or run off onto the it. Clean the area thoroughly before installing new
ground. cylinder.
2. Engage the park brake and place wheel chocks on 8. Position the new moldboard slide cylinder into
wheels for safety. place.
3. Extend the moldboard left to its limit. 9. Insert the cylinder pin on the stationary side first,
then reconnect that hydraulic hose. Start the grader
4. Remove the cotter pin, then the cylinder pin on the and extend the cylinder rod to align it through the
left side of the slide cylinder. (Figure 5-40) mounting hole.
10. Reinstall cylinder and cotter pins on each side of
the cylinder. (It is recommended that you use new
cotter pins.)
11. Reconnect the hydraulic hoses according to the
tags for correctly reinstalling hoses.
12. Using a grease gun, lubricate the cylinder rod (left
side).
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.
Pin
Cotter Pin
Figure 5-40. Moldboard Slide Cylinder

Maintenance
Moldboard Lift Cylinders 8. Remove the bushing inside from the cylinder pin.
1. Park the grader on a level surface in a designated 9. Remove the bushing inside from the cylinder pin.
area where oil does not touch or run off onto the Carefully remove the lift cylinder from the frame
ground. to remove it. Clean the area thoroughly before
installing new cylinder.
2. Lower the moldboard to the ground.
10. Position the new moldboard lift cylinder into place.
3. Engage the park brake, shut down the engine and
place wheel chocks on wheels for safety. 11. Insert bushing (ensuring the grease fitting is in
place), then position the side plate and secure with
4. Use a sling or other means of supporting the washers and bolts. Torque bolts. (See Torque
moldboard lift cylinders. Tables, Section 2)
5. Disconnect, plug and tag the hydraulic hoses 12. Repeat Steps 4 - 11 on the other lift cylinder if
connected to bottom of one cylinder, being very needed.
careful to prevent any contamination when plugging
the hydraulic hose fittings. 13. Reconnect the hydraulic hoses according to the
tags for correct reconnection.
NOTE: Inspect the hydraulic fittings. Replace any
damaged or worn fittings. 14. Using a grease gun, lubricate the rods on each
cylinder.
6. Use flats on cylinder rod to unthread cylinder rod
from ball joint. If the ball joint needs to be replaced, 15. Start the engine and idle for a few minutes to ensure
separate tapered ball joint stud from turntable and the hydraulic oil has warmed in the system.
remove. (Figure 5-41) 16. Raise and lower the moldboard several times to
7. Remove the four (4) bolts and washers on the front ensure proper operation and check for leaks.
side of the lift cylinder, then the lift cylinder mount
slide plate as shown in Figure 5-41.
Lift
(Front Side
5
Cylinders
of Cylinders)
Cylinder Pin
Bolts
Bushing
Ball Joint
Figure 5-41. Moldboard Lift Cylinders

Maintenance
Moldboard Tilt Cylinders 5. Disconnect, plug and tag the hydraulic hoses, being
very careful to prevent any contamination when
1. Park the grader on a level surface in a designated plugging the hydraulic hose fittings.
area where oil does not touch or run off onto the
ground. NOTE: Inspect the hydraulic fittings. Replace any
damaged or worn fittings.
2. Engage the park brake and place wheel chocks on
wheels for safety. 6. Carefully slide the tilt cylinder from the moldboard
frame to remove it. Clean the area thoroughly
3. Place a block under the moldboard attachment and before installing new cylinder.
lower the moldboard to rest lightly on the block,
extending it forward. Turn off the engine. 7. Position the new moldboard tilt cylinder into place.
4. Remove the cotter and cylinder pins from the right 8. Insert the cylinder and cotter pins. (It is
side. (Figure 5-42) recommended that you use new cotter pins.)
Cotter and
10. Using a grease gun, lubricate the cylinder rod.
Cylinder Pins
(Right Side the hydraulic oil has warmed in the system.
of Tilt
Cylinder) 12. Tilt the moldboard back and forth several times to
ensure proper operation and check for leaks.
Tilt Cylinder
Figure 5-42. Moldboard Tilt Cylinder

Maintenance
Moldboard Angle Cylinder Articulate Cylinders

1. Park the grader on a level surface in a designated Articulated steering is very common for graders and
area where oil does not touch or run off onto the other off-road industrial machines. Slow speeds and
ground. rough terrain make this steering system ideal. An
articulate cylinder on each side of the front “boom”
2. Engage the park brake, shut down the engine, and
connects to swivel pivot joints that connect the boom
place wheel chocks on wheels for safety.
and cab frame together. When the operator turns to the
3. Use a sling or other means of supporting the right or left, pressurized hydraulic oil pushes the cylinder
moldboard angle cylinders. in the corresponding direction, “articulating” the joint.
4. Disconnect, plug and tag the hydraulic hoses, being To replace the articulate cylinders:
1. Park the grader on a level surface in a designated
plugging the hydraulic hose fittings.
NOTE: Inspect the hydraulic fittings. Replace any ground.
5. Remove the cotter and cylinder pins on each side of place wheel chocks on wheels for safety.
one of the angle cylinders, then the other cylinder.
3. Use a sling or other means of supporting the
6. Carefully slide each moldboard angle cylinder from articulate cylinder.
the frame to remove it. Clean the area thoroughly
4. Disconnect, plug and tag the hydraulic hoses, being
before installing new cylinders. (Figure 5-43)
5. Remove the cotter and cylinder pins on each side of
one of the articulate cylinders. (Figure 5-44)
Angle
Cylinders
5
Cylinder
Pin
Cotter
Pin
Figure 5-43. Moldboard Angle Cylinders Articulate
7. Position the new moldboard angle cylinder into Cylinder
place on one side. Insert the cylinder and cotter
pins. (It is recommended that you use new cotter Cylinder
pins.) Pin
8. Complete Step 7 on the other side if needed. Cotter
9. Reconnect the hydraulic hoses according to the Pin
Figure 5-44. Articulate Cylinder
10. Using a grease gun, lubricate the rods on each
cylinder.

Maintenance
6. Carefully slide the articulate cylinder from the frame 5. The cylinder end connectors are a tie rod end
to remove it. Clean the area thoroughly before shaft connected to the tie rod end housing. While
installing new cylinder. supporting the cylinder, remove the mounting nut
and washers, then loosen the jam nut. (Figure
7. Position the new articulate cylinder into
5-45)
place. Insert the cylinder and cotter pins. (It is
recommended that you use new cotter pins.)
8. Complete Steps 3 - 7 on the other side if needed.
cylinder. Steering Cylinder
12. Articulate the boom right and left several times to
Wheel Steering Cylinder Mounting

Nut
The wheel steering cylinder hydraulically turns the front Jam Nut
wheels right and left. The cylinder can be accessed
without jacking up the front end, but working underneath Figure 5-45. Wheel Steering Cylinder
provides better access.
6. Use a ball joint removal tool to remove the end
It is recommended that you use a connectors from the frame mounts.
hydraulic lift if available when raising the vehicle.
Otherwise, use jack stands on a solid, flat surface 7. Carefully slide the wheel steering cylinder from
to prevent the machine from tipping when it is the frame to remove it. Clean the area thoroughly
raised. Block the remaining wheels using sturdy before installing new cylinder.
wheel chocks. DO NOT lie under the machine while 8. Position the new wheel steering cylinder into place.
supported only by a jack. Death or serious injury can
result from improperly supporting a raised machine. 9. Reinstall the mounting nut and washers, then
retighten the jam nut.
To replace the wheel steering cylinder:
1. Park the grader on a level surface in a designated tags for correct reconnection.
ground. 11. Using a grease gun, lubricate the rods on each
cylinder.
place wheel chocks on wheels for safety. 12. Start the engine and idle for a few minutes to ensure
3. Use a block or other means of supporting the
steering cylinder. 13. Turn the steering wheel right and left several times
to ensure proper operation and check for leaks.

Maintenance
Wheel Lean Cylinder Scarifier Lift Cylinder

1. Park the grader on a level surface in a designated 1. Park the grader on a level surface in a designated
area where oil does not touch or run off onto the area where oil does not touch or run off onto the
ground. ground.
2. Ensure the wheel lean cylinder is retracted. Engage 2. Lower the scarifier to the ground. Engage the
the park brake and shut down the engine. park brake, shut down the engine, and place wheel
chocks on wheels for safety.
3. It is recommended that you use a hydraulic lift if
available, or use jack stands on a solid, flat surface 3. Use a sling or other means of supporting the
to raise the front end (enough to tilt axle). Block the scarifier lift cylinder.
remaining wheels using sturdy wheel chocks.
4. Disconnect, plug and tag the hydraulic hoses, being very careful to prevent any contamination when
very careful to prevent any contamination when plugging the hydraulic hose fittings.
NOTE: Inspect the hydraulic fittings. Replace any damaged or worn fittings.
5. Remove the two (2) cotter and cylinder pins on the Scarifier
back side of one of the wheel lean cylinder. (Figure Cylinder
4-46)
Cotter
Pins (2)
Wheel Lean Cylinder Hex Nut

(Rear)
and Bolt
Figure 5-47. Scarifier Cylinder

5
5. Remove the hex nut and bolt from the scarifier lift
cylinder. (Figure 5-47)
6. Carefully slide the cylinder from the frame to remove
Wheel Lean Cylinder it. Clean the area thoroughly before installing new
(Front) cylinder.
Figure 5-46. Wheel Lean Cylinder 7. Position the new scarifier lift cylinder into place and
6. Carefully slide the wheel lean cylinder from the reinstall nut and bolt.
frame to remove it. Clean the area thoroughly 8. Reconnect the hydraulic hoses according to the
before installing new cylinder. tags for correct reconnection.
7. Position the new wheel lean cylinder into 9. Repeat Steps 3 - 8 on the other scarifier lift cylinder.
place. Insert the cylinder and cotter pins. (It is
recommended that you use new cotter pins.)
cylinder.
tags for correct reconnection. Using a grease gun,
lubricate the rods on each cylinder.
12. Raise and lower the scarifier several times to
the hydraulic oil has warmed, check wheel lean
operation, and check for leaks.

Maintenance
Front Blade Lift Cylinder WELDING ON MACHINE

(Option)
If equipped with the optional front blade, use the
following procedure to replace the front blade lift
cylinder:
1. With the front blade component attached, park
the grader on a level surface in a designated area
where oil does not touch or run off onto the ground.
Engage the park brake, shut down the engine, and
place wheel chocks on wheels for safety.
2. Lower the front blade attachment to the ground and
use chocks on each side to prevent the blade from
falling. Use a sling or other means of supporting the
front blade lift cylinder.
very careful to prevent any contamination when Figure 5-49. Welding
plugging the hydraulic hose fittings. If the machine has been damaged or metal parts worn
due to extensive use, minor welding may be necessary
for repair. Welding is very dangerous. Only individuals
who are properly trained should weld in a dedicated
area away from others as even looking at ultraviolet light
from the arcing can cause serious eye injury.
Welding hazards include toxic fumes, harmful dust,
light radiation, burns, combustion from sparks and the
potential for extensive damage to the eye. There is also
a danger of electric shock. If combustible or flammable
materials are nearby, the heat and sparks produced by
welding can cause fires or explosions.
Electrical current can ignite fire, cause an explosion or
Front Blade
damage machine components, therefore it is critical
Cylinder
Bolts and Nuts
to turn off power to the machine. It is also important to
grind off the paint to ensure proper ground on the area
Figure 5-48. Front Blade Lift Cylinder being welded.
4. Remove the hex nut, bolt and cylinder pin from one DO NOT weld on or near fuel tanks.
side, then the other side of the cylinder. (Figure
5-48) DO NOT weld near electrical
components and harnesses. All components should
5. Carefully slide the cylinder from the frame to remove be protect from heat and welding sparks.
it. Clean the area thoroughly before installing new
cylinder.
6. Position the new front blade lift cylinder into place
and reinstall nuts, bolts and pins.
tags for correct reconnection. 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.

Maintenance
Before welding on the machine: WINTERIZING FOR STORAGE

PREPARE:
Perform the following procedures to prepare the
• Clear the area of any fire hazards, flammable liquids machine for winterizing and storage.
and solids, or any items that could catch on fire.
1. Store the machine in a dry, protected area:
• Ensure a fire extinguisher is available to the work area.
• Cover seat with plastic. Place a “DO NOT
• Hang welding blanket(s) around and underneath the OPERATE” tag on the main control panel.
work area.
• Cover all exposed control panels with tarps or
• Paint and rust should be removed from the welding plastic.
area to prevent arcing in other areas or components.
An indirect ground can cause arcing that will damage • Ensure all cab doors and windows are closed
machine components. Only connect the ground to and seal properly.
the component being welded. DO NOT connect the • Ensure the tires are properly inflated.
ground to other bolted assemblies, wheels, bearings,
• Replace worn or damaged decals if needed.
motors, tracks, torque hubs, etc.
2. Inspect the machine thoroughly and repair worn or
DISCONNECT:
damaged parts. Inspect all hoses, couplers, fittings
• Turn the master battery switch to the OFF position. and cylinders. Tighten loose fittings and replace any
• Disconnect the battery positive and negative worn hoses found.
terminals. 3. Lubricate all grease points:
• Disconnect Plus 1 controller(s). • Coat all exposed cylinder shafts with lithium-
• Disconnect engine ECU(s) controller (if equipped). based grease.
• Disconnect engine DEF controller (if equipped). • Ensure all exposed threads are lubricated.
• If machine has truck chassis: Disconnect the battery • Ensure cables are lubricated and move freely.
positive and negative terminals and unplug the ECU(s) • If the machine has high- and low-speed chains,
for the engine, transmission and ABS systems if be sure they are oiled.
5
equipped. Refer to the truck owner manual for any
4. Check air filter. Clean or replace air filter elements if
other recommendations.
needed.
DO NOT MAKE MODIFICATIONS TO THE MACHINE.
5. Check engine oil level and fill if needed.
ONLY weld if needed for repair purposes. Weldment
modifications to the machine can void your warranty. 6. Check hydraulic oil sight gauge and fill if needed.
Hydraulic oil that is contaminated
must be drained, the filter elements replaced and
the hydraulic tank refilled. Failure to perform this
maintenance procedure if needed could result in
premature failure of the pumps or motors.
7. Ensure the fuel tank is full to prevent condensation
in the fuel tank. Add cold-weather additive when
appropriate.
8. If machine is equipped with Diesel Exhaust Fluid
(DEF), ensure the DEF tank is full.
9. If machine is equipped with a citrus tank, ensure the
tank is full to prevent rust.

Maintenance
10. If machine is equipped with water tank(s), the tank Periodic Maintenance in Storage
should be drained. The pump and filter must also be
purged to prevent freezing. If storing the machine more than two months, perform
the 100-Hour routine maintenance procedures for every
11. If machine is equipped with windshield washer 100 hours the machine is stored. (Page 5-5)
bottle, ensure the bottle is full of window washer fluid
with a cold-weather blend. Also be sure to:
12. Perform specific gravity test on engine coolant. • Reinstall the battery to start the engine and allow
Drain and replace or fill with antifreeze mixture to the engine to warm until all machine functions are at
prevent freeze damage if needed. operating temperature at least twice per month.
13. Disconnect battery and store inside in a cool, dry • Keep battery fully charged and check the electrolyte
place. Ensure breakers are in the OFF position. level regularly.
14. Remove steering control boxes and electrical • Check the hydraulic fluid on a regular basis for
cords. Store inside in a cool, dry place. possible moisture contamination. This is especially
important in climates with varying temperatures and
• If equipped with any plugged-in remote sensors humidity as condensation can develop inside the
(i.e., sonic auger sensor), disconnect, remove hydraulic tank.
and store inside in a cool dry place.
15. Cover the exhaust and intake filter. Be sure to seal
the exhaust cover with tape to prevent moisture Removing from Storage
from entering, especially if storing outside.
1. Perform maintenance procedures described above.
16. Lower machine components and attachments (i.e.,
screed, broom, blade, etc.) to the lowest position, 2. Check all fluid levels, belt tensions, and bolt torques.
resting on blocks to prevent ground contact or 3. Replace battery.
pavement damage.
4. Replace alternator belt.
17. Clean the machine, including the undercarriage.
Paint chipped or rusty areas to prevent further 5. Clean any excess grease or rust inhibitor from all
rusting. Lock all lockable panels, cab doors and exposed cylinder rods, seals and O-rings.
spare tire. Remove ignition key and store keys in a 6. Start engine and allow machine to warm before
safe place. driving out of storage.

Maintenance
TROUBLESHOOTING
Hydraulic Motor Start-Up Grease
Shaft
O-Ring
(Required)
Splines
Pre-Start
If the hydraulic system is down as a result of a major
component failure:
1. Drain and clean the tank and system components
(hoses, valves, fittings and cooler) to ensure it is
free from metallic debris and other contamination.
+ +
Failure to do so may result in damage to the pump(s)
and/or other components on start-up.
Capscrew Capscrew
2. Change all the filters. (or Bolt) (or Bolt)
3. Change the fluid. On large systems where the cost
of changing the fluid may be prohibitive, the fluid
should be flushed until a cleanliness level of ISO Figure 5-50. Hydraulic Motor Installation
4406 Code 18/16/13 or better is achieved.
To avoid contamination:
• Remove all matter from around the ports of the
Installation and Start-Up motor and the threads of fittings.
When installing hydraulic motors, it is important that the • Fill the case of the motor being used (piston-type,
mounting flange of the motor makes full contact with the gear motor, gerotor motor, geroller motor or vane
mounting surface of the application. Mounting hardware motor) with clean hydraulic fluid through the highest
of the appropriate grade and size must be used: case drain port and connect the case drain line.
1. Use Grade 8 socket-head capscrews to attach the Failure to do so will result in damage to the motor
motor. through inadequate lubrication on start-up.
2. Install lock washer over capscrew.
3. Apply Loctite 243 (blue) to the capscrew threads.
• Units that are mounted vertically with the shaft up
require special attention to ensure the fluid level in
the case is high enough to lubricate the front shaft
5
4. Install extra thick, hardened H-D thick washers over bearing(s).
the capscrew.
Once all system connections are made, run the motor
5. Install the capscrew-hardened washer and lock 15 - 30 minutes at no-load and half-speed to bleed air
washer in the SAE two-bolt flange. from the hydraulic system.
6. Torque the capscrew to the wet torque value
defined for the capscrew grade and size.
It is CRITICAL to use the correct
mounting hardware.
Hubs, pulleys, sprockets and couplings must be
properly aligned to avoid inducing excessive thrust or
radial loads. Although the output device must fit the
shaft tightly, a hammer should never be used to install
any type of output device onto the shaft. The port
plugs should only be removed from the motor when the
system connections are ready to be made.

Maintenance
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
SYMPTOM CAUSE REMEDY
Defective battery or low battery
Replace or charge battery.
charge.
Insufficient fuel supply. Fill fuel tank.
Use only ULSD (Ultra-Low Sulfur Diesel) fuel with
Wrong grade fuel. a maximum sulfur content of 15 ppm (parts per
million).
Drain small amount of fuel into a clean container.
Debris or dirt in fuel. Inspect for debris. If any is noted, drain and flush
fuel system. Change fuel filter.
Water in fuel Drain fuel. Change fuel filter and refill tank.
Worn piston rings or low compression. See your authorized dealer.
Blown head gasket. See your authorized dealer.
Engine difficult to start Inspect to ensure wires are tight.
or does not start. Faulty wiring.
Repair or replace wiring if needed.
Clean solenoid plunger.
Starter solenoid doesn’t function Replace solenoid coil.
properly or faulty ignition switch. Replace or rebuild starter or solenoid.
Replace ignition switch.
Inspect, clean and remove any debris or foreign
Intake or exhaust system restricted.
objects in system.
Clean battery terminal connections.
Engine cranking speed too low.
Charge or replace battery.
Insufficient fuel supply to injector. Check fuel system. Clean or replace fuel filter.
Check for air leaks in the low-pressure side of the
Air in the fuel system. fuel system.
Prime fuel system.
Low fuel. Add fuel to fuel tank.
Voltage should be 9 volts with the ignition switch
No voltage to fuel shut-off solenoid.
in the ON or START position.
No fuel to injector pump. Check fuel supply system.
Engine turns over but
Fuel filter plugged or restricted. Replace fuel filter.
does not start.
Intake or exhaust system restricted. Check for and remove restrictions.
Loose or dirty connections at Clean battery posts and cable ends. Reinstall
batteries. cables.
Wrong oil weight in low temperatures. Change oil and oil filter.

Maintenance

Electrical wiring fault supplying power
to the fuel solenoid when key is in the Repair wiring.
OFF position.
Faulty diode in engine wire harness at Check diode wire connection and/or replace
alternator. diode.
Injection pump fuel solenoid inopera- Check solenoid for defects or foreign material
Engine doesn’t shut tive. inhibiting proper operations.
off. Engine operating on fumes drawn into
Locate and isolate source of fumes.
air intake.
Low idle set too high. Set idle to specifications.
Repair or replace ignition switch. See your au-
Ignition switch malfunction.
thorized dealer.
Starter pinion gear not disengaging
Repair or replace. See your authorized dealer.
from flywheel.
Excessive load for engine horsepower
Reduce load on unity by reducing ground speed.
rating.
De-rate engine power output for altitudes above
Operating engine at high altitude.
10,000 feet (305 meters).
Air intake piping restricted. Remove restrictions.
Air cleaner element(s) dirty. Clean or replace air cleaner element(s).
Check fuel line for restrictions.
Fuel suction line or filter restricted.
Replace fuel filter.
Engine power output
is low. Poor quality fuel. Verify by operating with a fuel of known quality.
Fuel return system restricted. Correct restricted fuel return system.
Fuel quality poor.
Fuel transfer pump malfunctioning.

Verify by operating with a known fuel quality.
Replace fuel transfer pump.
5
Refer to Engine Operator’s Manual.
Throttle improperly adjusted. Adjust throttle controls.
Replace fuel injector.
Fuel injector malfunctioning.
Refer to Engine Operator’s Manual.
Low engine oil level. Fill engine oil to correct level.
Oil viscosity too low for high ambient
Change oil and oil filter.
temperature.
Loose or worn hydraulic pump drive
Repair or replace damaged coupling.
coupling.
Abnormal engine
Injection pump timing incorrect. See your authorized dealer.
noise (rattle, knock).
Internal engine component wear. Refer to your Engine Owner’s Manual.
Wrong fuel grade. a maximum sulfur content of 15 ppm (parts per
million).
Starter switch or solenoid stuck. 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.

Maintenance

Electrical power not being supplied to
Check fuses.
gauge.
Check for leaks. Add or drain engine oil. Check
Oil level too high or too low.
dipstick calibration.
Oil filter plugged. Change oil and replace oil filter.
Replace fuel injector, fuel transfer pump and/or
Engine oil pressure is Oil diluted with fuel.
injection pump.
low.
Oil pressure sensor or gauge
Replace oil pressure sensor or gauge.
malfunctioning.
Oil viscosity is too low. Change oil and oil filter.
Oil pressure valve faulty. Repair or replace. See your authorized dealer.
Loose oil pump drive gear or worn
See your authorized dealer.
pump housing.
Park brake not fully disengaged. Disengage park brake.
Machine “jerks” when Engine speed set too low. Operate engine at recommended RPMs.
moving forward or Air leaking into hydraulic system. Tight or replace hoses, fittings or filter.
reverse. Hydrostatic pump malfunction. Repair or replace pump.
Low hydraulic oil. Fill hydraulic tank to proper level.
Air entering charge side of fuel Check fuel filter for air bubbles. Tighten fittings
system. and connections. Inspect lines for damage.
Water or debris in fuel. Drain fuel, replace fuel filter and refill.
Fuel filter clogged. Replace filter.
Check fuel lines for kinks, debris or damage.
Return linen from injection pump to
Clean with compressed air. Replace lines if
Engine surges or stalls fuel tank restricted.
needed.
frequently.
Air filter elements clogged. Clean or replace air filter elements.
Fuel transfer pump or nozzles
malfunction.
Leaking head gasket, sticking or
burned valves, valve clearance Refer to your Engine Owner’s Manual.
incorrect, worn or broken piston rings.
Air entering charge side of fuel Check fuel filter for air bubbles. Tighten fittings
system. and connections. Inspect lines for damage.
Drain and flush fuel system. Change fuel filter and
Water or debris in fuel.
Engine misses, refill tank.
operates erratically or Return line from injection pump to tank
Clean and replace cap.
operates poorly at low restricted.
speeds. 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.

Maintenance

Restricted air filter element. Clean or replace air filter elements.
Wrong grade of fuel. a maximum sulfur content of 15 ppm (parts per
Engine emits million).
excessive black or Engine overloaded. Remove load. Run at fast idle to clear the engine.
gray exhaust smoke. Turbocharger gasket leak. Repair or replace. See your authorized dealer.
Incorrect injection pump timing. Repair or replace. See your authorized dealer.
Excessive fuel deliver. Injection pump
or nozzle malfunctions.
Wrong grade of fuel. a maximum sulfur content of 15 ppm (parts per
Engine emits million).
excessive blue or
Injection pump or nozzle malfunctions. See your authorized dealer.
white exhaust smoke.
Excessive oil consumption due to
Refer to your Engine Owner’s Manual.
engine malfunction.
Low coolant level. Refill radiator with correct coolant.
Loose, worn or broken fan belt. Tighten or replace.
Worn pulley grooves allowing engine Replace belt and pulleys. Refer to your Engine
belt slippage. Owner’s Manual.
Radiator dirty or clogged. Clean or replace.
Radiator shroud missing or damaged. See your authorized dealer to replace shroud.
Engine overloaded. Reduce load. Operate in low gear.
Radiator cap doesn’t seal. Replace radiator cap.
Fan damaged. Replace fan.
5
Engine overheats.
Injection pump timing incorrect. See your authorized dealer.
Hydraulic system overheating due to Check for clogged hydraulic oil cooler. See your
internal leakage. authorized dealer.
Thermostats stuck (or missing). Replace thermostats.
Interior of cooling system coated with Flush the cooling system with cleaner. Refill with
lime deposits. water and antifreeze solution.
Water pump leaking. Repair or replace pump.
Excessive fuel delivery or injection
pump malfunctions.
Low hydraulic fluid level. Add hydraulic oil.
Hydraulic tank return filters contain Check filters for contamination and clean or
contamination. replace.
Check relief valve setting. Check relief valve
Steering motor priority relief valve set
Steering is difficult. setting. It should be 2200 PSI. Adjust setting if
incorrectly.
necessary.
Worn hydraulic pump. Repair or replace.
Worn steering orbital motor. Repair or replace.
Worn steering cylinder. Repair or replace.

Maintenance

Loose wiring or fault connection. Tighten or replace loose wiring or connector.
Alternator not Diode at alternator loose or faulty. Tighten connection or replace diode.
charging. Alternator belt loose or broken. Adjust or replace belt.
Alternator malfunctioning. Rebuild or replace alternator.
Remove alternator belt and turn alternator by
Alternator bearings. hand. If pulley turns rough, repair or replace
Noisy alternator. alternator.
Worn drive belt. Replace drive belt.
Alternator malfunction. Repair or replace.
Check alternator charging rate. Repair or
Battery uses too much Battery overcharges.
replace alternator if needed.
water.
Cracked or broken battery case. Replace battery.
Battery hold-down clamps too tight, Replace battery and reinstall (or replace) hold-
loose or missing. down clamps properly.
Cracked battery case.
Keep battery fully charged during winter. If
Frozen batteries.
frozen, replace batteries.
Low water level in battery. Fill with distilled water and charge.
Corroded or loose battery cable
Clean and tighten all connections.
Low battery output. connections.
Broken or loose battery posts. Replace battery.
Loose, slipping alternator belt. Replace belt.
Horn fuse. Replace fuse.
Horn will not sound. Horn ground connection. Check and repair ground connection.
Horn is inoperable. Replace horn.
Batteries not charged or not longer
Charge or replace batteries.
operable.
Battery connections. Clean and tighten all connections.
Listen for the starter solenoid click when key is
Starter motor. placed in the start position. If the solenoid clicks,
repair or replace starter motor.
Check for 12 volts at the small solenoid
Starter solenoid. connections when key is placed in the start
Starter does not
position. If 12 volts are present, replace solenoid.
function.
Check for 12 volts at both sides of the circuit
breaker. If 12 volts is not present on either side,
Starter system circuit breaker.
check wiring. If 12 volts show on only one side,
replace the circuit breaker.
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.

Maintenance

Low hydraulic oil level.
Hydraulic filter clogged.
No hydraulic power. Hydraulic pumps or pump drive Change oil and replace hydraulic filter.
coupling damaged or excessive
leakage in hydraulic system.
Low hydraulic oil level. Add hydraulic oil.
Inspect charge side hoses and fittings to pump
Air in hydraulic oil (foaming). for leakage. Tighten fittings or replace hoses and
Hydraulic system fittings as needed.
functions slowly.
Hydraulic filter clogged. Add oil and replace hydraulic filter.
Extremely low pump flow or excessive
leakage in system.
Low hydraulic oil level. Refill with hydraulic fluid.
Defective temperature gauge or
sensor giving wrong temperature Replace gauge or sensor.
reading.
Hydraulic system
Excessive ambient air temperature Operate broom at slower ground speed and
overheats.
and high-duty cycle. maximum engine RPMs during hot weather.
Clean fins and correct any other problems with
Plugged fins on fluid cooler.
cooling air flow.
Worn hydrostatic pump. Repair or replace.
Low hydraulic oil level. Add hydraulic oil.
Hydraulic functions Hydraulic filter restricted. Change oil and replace hydraulic filter.
make noise. Hydraulic filter relief valve stuck or set
5
too low.
Radiator fins damaged or obstructed
Inspect radiator fins. Clean, repair or replace.
by debris.
Collapsed or restricted radiator hose. Inspect hoses. Replace if needed.
Check belt tension and tighten or replace as
Loose fan drive belt.
needed.
Cooling fan shroud damaged or
Inspect shroud. Repair or replace.
missing.
Coolant temperature Incorrect or malfunctioning radiator
Check radiator cap and replace if needed.
above normal. cap.
Temperature gauge or sensor
Repair or replace.
malfunctioning.
Thermostat stuck in closed position. Test thermostat. Replace if necessary.
Dirt, scale or rust in the cooling
Clean cooling system.
system.
Loose wiring, faulty connection. Repair or replace loose wiring or connectors.
Coolant level too low. Add coolant.
Air filter elements clogged. 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.

Maintenance

Park brake light
Hydraulic pressure has dropped to Check hydrostatic travel system charge
comes on when
1300 PSI or less. pressure.
traveling.
Faulty brake switch. Replace brake switch.
Loose wiring to brake solenoid. Repair/replace wiring.
Park brake won’t Check/adjust charge relief valves on hydrostatic
release. Low charge pressure to brakes (300 pump 350 - 400 PSI in neutral. Engine must be at
PSI or less). maximum RPMs when adjusting charge pressure.
Repair/replace hydrostatic pump if needed.
Faulty switch/wiring. Repair/replace switch or wiring.
Park brake won’t hold.
Faulty brake. Repair/replace brake(s) on rear wheels.
Machine lunges when Traction pump malfunction. See your authorized dealer.
placed in forward,
reverse or neutral,
or there is excessive Differential drive malfunction. See your authorized dealer.
noise in the drive
system.. Transfer case malfunction. See your authorized dealer.
Check all switches and wiring. Replace if
Two-speed valve not receiving signal.
Two-speed won’t shift. needed.
Park brake not set. Set park brake.
Control valve linkage binding. Repair linkage.
Control valve sticks or Broken return spring on control valve.
is hard to operate. Or contamination in valve bore, scored Contact your authorized dealer.
valve bore, or bent valve bore.
Low hydraulic oil level. Check and fill hydraulic tank to proper level.
Traction pump
Traction pump malfunction. 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.

Maintenance
PV485 DIAGNOSTIC TROUBLE CODE (DTC) CHART

LEGEND
SPN: Suspect Parameter Number DPF: Diesel Particulate Filter FMI: Failure Mode Identifier
EGR: Exhaust Gas Recirculation ECU: Engine Control Unit CPU: Central Processing Unit
NE-G: Negative Ground NE: Neutral G: Ground
SCV: Selective Control Valve MAF: Mass Air Flow PM: Particulate Matter
DC: Direct Current IC: Integrated Circuit EBC: Electronic Brake Control
PLV: Pressure Limiting Valve CAN: Controller Area Network CM: Control Module
DDC: Direct Digital Control SW: Switch TSC: Torque Speed Control
ETC: Electronic Throttle Control CCVS: Current Controlled Voltage Source
MPROP: Manifold Pressure Rail Operating Pressure
EEPROM: Electrically Erasable Programmable Read-Only Memory
FAULT
SPN FMI DESCRIPTION
CODE
111 629 12 Engine control module critical internal failure. Bad intelligent device or component.
115 612 2 Engine magnetic speed/position lost both signals. Data erratic, intermittent or incorrect.
122 102 3 Intake manifold 1 pressure sensor circuit. Voltage above normal or shorted to high source.
123 102 4 Intake manifold 1 pressure sensor circuit. Voltage above normal or shorted to low source.
Accelerator pedal or lever position sensor 1 circuit. Voltage above normal or shorted to
131 91 3
high source.
Accelerator pedal or lever position sensor 1 circuit. Voltage above normal or shorted to
132 91 4
low source.
133 974 3
Remote accelerator pedal or lever position sensor 1 circuit. Voltage above normal or
shorted to high source. 5
Remote accelerator pedal or lever position sensor 1 circuit. Voltage above normal or
134 974 4
shorted to low source.
Engine oil rifle pressure. Data valid but below normal operating range. Moderately severe
143 100 18
level.
Engine coolant temperature 1 sensor circuit. Voltage above normal or shorted to high
144 110 3
source.
Engine coolant temperature 1 sensor circuit. Voltage above normal or shorted to low
145 110 4
source.
Engine coolant temperature. Data valid but above normal operating range. Moderately
146 110 16
severe level.
Accelerator pedal or lever position 1 sensor circuit frequency. Data valid but below normal
147 91 1
operational range. Most severe level.
Accelerator pedal or lever position 1 sensor circuit frequency. Data valid but above normal
148 91 0
Engine coolant temperature. Data valid but above normal operational range. Most severe
151 110 0
level.
Intake manifold 1 temperature sensor circuit. Voltage above normal or shorted to high
153 105 3
source.

Maintenance
FAULT
SPN FMI DESCRIPTION
CODE
Intake manifold 1 temperature sensor circuit. Voltage above normal or shorted to low
154 105 4
source.
Intake manifold 1 temperature. Data valid but above normal operational range. Most
155 105 0
severe level.
187 3510 4 Sensor supply 2 circuit. Voltage below normal or shorted to low source.
195 111 3 Coolant level sensor 1 circuit. Voltage above normal or shorted to high source.
196 111 4 Coolant level sensor 1 circuit. Voltage above normal or shorted to high source.
197 111 18 Coolant level sensor 1 circuit. Voltage above normal or shorted to low source.
221 108 3 Barometric pressure sensor circuit. Voltage above normal or shorted to high source.
222 108 4 Barometric pressure sensor circuit. Voltage above normal or shorted to low source.
227 3510 3 Sensor supply 2 circuit. Voltage above normal or shorted to high source.
Engine crankshaft speed/position. Data valid but above normal operational range. Most
234 190 0
severe level.
235 111 1 Coolant level. Data valid but below normal operational range. Most severe level.
238 3511 4 Sensor supply 3 circuit. Voltage below normal or shorted to low source.
239 3511 3 Sensor supply 3 circuit. Voltage above normal or shorted to low source.
241 84 2 Wheel-based vehicle speed. Data erratic, intermittent or incorrect.
Wheel-based vehicle speed sensor circuit tampering has been detected. Abnormal rate
242 84 10
of change.
245 647 4 Fan control circuit. Voltage below normal or shorted to low source.
Engine fuel pump pressurizing assembly 1 circuit. Voltage below normal or shorted to low
271 1347 4
source.
Engine fuel pump pressurizing assembly 1 circuit. Voltage below normal or shorted to high
272 1347 3
source.
Engine fuel pump pressurizing assembly 1 circuit. Mechanical system not responding or
281 1347 7
out of adjustment.
285 639 9 Multiplexing PGN time-out error. Abnormal update rate.
286 639 13 Multiplexing configuration error. Out of calibration.
Multiplexing remote accelerator pedal or lever position sensor system. Received network
288 974 19
date in error.
292 441 14 Auxiliary temperature sensor input 1 special instructions.
Auxiliary temperature sensor input 1 circuit. Voltage above normal or shorted to high
293 441 3
source.
Auxiliary temperature sensor input 1 circuit. Voltage above normal or shorted to low
294 441 4
source.
296 1388 14 Auxiliary pressure sensor input 2 special instructions.
322 651 5 Injector solenoid driver cylinder 1 circuit. Current below normal or open circuit.
Engine control module warning internal hardware failure. Bad intelligent device or
343 629 12
component.

Maintenance
FAULT
SPN FMI DESCRIPTION
CODE
351 3597 12 Injector power supply. Bad intelligent device or component.
Engine oil rifle pressure. Data valid but below normal operational range. Most severe
415 100 1
level.
418 97 15 Water in fuel indicator. Data valid but above normal operating range. Least severe level.
428 97 3 Water in fuel indicator sensor circuit. Voltage above normal or shorted to high source.
429 97 4 Water in fuel indicator sensor circuit. Voltage above normal or shorted to low source.
431 558 2 Accelerator pedal or lever idle validation switch. Data erratic, intermittent or incorrect.
432 558 13 Accelerator pedal or lever idle validation switch circuit out of calibration.
435 100 2 Engine oil rifle pressure. Data erratic, intermittent or incorrect.
441 168 18 Battery 1 voltage data valid but below normal operating range. Moderately severe level.
442 168 16 Battery 1 voltage data valid but below normal operating range. Moderately severe level.
Injector metering rail 1 pressure. Data valid but above normal operational range. Most
449 157 0
severe level.
Injector metering rail 1 pressure sensor circuit voltage above normal or shorted to high
451 157 3
source.
Injector metering rail 1 pressure sensor circuit voltage below normal or shorted to low
452 157 4
source.
523 611 2 Auxiliary intermediate speed switch validation data erratic, intermittent or incorrect.
527 702 3 Auxiliary input/output 2 circuit voltage above normal or shorted to high source.
528 93 2 Auxiliary alternate torque validation switch data erratic, intermittent or incorrect.
529 703 3 Auxiliary input/output 3 circuit voltage above normal or shorted to high source.
Injector metering rail 1 pressure data valid but above normal operating range. Moderately
553
559
157
157
16
18
severe level.
Injector metering rail 1 pressure data valid but below normal operating range. Moderately
5
severe level.
584 677 3 Starter relay driver circuit voltage above normal or shorted to high source.
585 677 4 Starter relay driver circuit voltage below normal or shorted to low source.
599 640 14 Auxiliary commanded dual output shutdown.
649 1378 31 Engine oil change interval condition exists.
689 190 2 Engine crankshaft speed/position data erratic, intermittent or incorrect.
Turbocharger 1 compressor intake temperature circuit voltage above normal or shorted to
691 1172 3
high source.
Turbocharger 1 compressor intake temperature circuit voltage above normal or shorted to
692 1172 4
low source.
697 1136 3 Engine ECU temperature sensor circuit voltage above normal or shorted to high source.
698 1136 4 Engine ECU temperature sensor circuit voltage above normal or shorted to low source.
Engine speed/position camshaft and crankshaft misalignment. Mechanical system not
731 723 7
responding or out of adjustment.
778 723 2 Engine camshaft speed/position sensor data erratic, intermittent or incorrect.
1117 3597 2 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 3
high source.

Maintenance
FAULT
SPN FMI DESCRIPTION
CODE
Accelerator pedal or lever position sensor 2 circuit voltage above normal or shorted to low
1241 2623 4
source.
1242 91 2 Accelerator pedal or lever position sensor 1 data erratic, intermittent or incorrect.
1515 91 19 Multiplexed accelerator pedal or lever sensor system received network data error.
1539 1387 3 Auxiliary pressure sensor input 1 circuit voltage above normal or shorted to high source.
1621 1387 4 Auxiliary pressure sensor input 1 circuit voltage above normal or shorted to high source.
1695 3513 3 Sensor supply 5 voltage above normal or shorted to high source.
1696 3513 4 Sensor supply 5 voltage above normal or shorted to low source.
Water in fuel indicator. Data valid but above normal operating range. Moderately severe
1852 97 16
level.
1866 411 2 Exhaust gas recirculation differential pressure. Data erratic.
Water in fuel indicator data valid but above normal operating range. Moderately severe
1852 97 16
level.
1866 411 2 Exhaust gas recirculation differential pressure data erratic.
1893 2791 9 EGR valve control circuit abnormal update rate.
1896 2791 13 EGR valve controller out of calibration.
2182 1072 4 Engine brake actuator driver 1 circuit voltage above normal or shorted to high source.
2183 1072 4 Engine brake actuator driver 1 circuit voltage above normal or shorted to low source.
2185 3512 3 Sensor supply circuit voltage above normal or shorted to high source.
2186 3512 4 Sensor supply circuit voltage above normal or shorted to low source.
2271 27 3 EGR valve position circuit voltage above normal or shorted to high source.
2272 27 4 EGR valve position circuit voltage above normal or shorted to low source.
Exhaust gas recirculation differential pressure sensor circuit voltage above normal or
2273 411 3
shorted to high source.
Exhaust gas recirculation differential pressure sensor circuit voltage above normal or
2274 411 4
2311 633 31 Electronic fuel injection control valve circuit condition exists.
2321 190 2 Engine crankshaft speed/position data erratic, intermittent or incorrect.
2322 723 2 Engine camshaft speed/position data erratic, intermittent or incorrect.
2351 2791 4 EGR valve control circuit voltage below normal or shorted to low source.
2352 2791 3 EGR valve control circuit voltage below normal or shorted to low source.
Exhaust gas recirculation temperature sensor circuit voltage above normal or shorted to
2375 412 3
high source.
Exhaust gas recirculation temperature sensor circuit voltage above normal or shorted to
2376 412 4
low source.
2377 647 3 Fan control circuit voltage above normal or shorted to high source.
2442 651 13 Injector solenoid driver cylinder 1 out of calibration.
2448 111 17 Coolant level data valid but below normal operating range. Least severe level.

Maintenance
FAULT
SPN FMI DESCRIPTION
CODE
2555 729 3 Engine air intake air heater 1 circuit voltage above normal or shorted to high source.
2556 729 4 Engine air intake air heater 1 circuit voltage above normal or shorted to low source.
2557 697 3 Auxiliary PWM driver 1 circuits voltage above normal or shorted to high source.
2558 697 4 Auxiliary PWM driver 1 circuits voltage above normal or shorted to low source.
Exhaust gas recirculation temperature data valid but above normal operating range. Least
2961 412 15
severe level.
Exhaust gas recirculation temperature data valid but above normal operating range.
2962 412 16
Moderately severe level.
Engine coolant temperature data valid but above normal operating range. Least severe
2963 110 15
level.
Intake manifold 1 temperature data valid but above normal operating range. Least severe
2964 105 15
level.
Engine exhaust gas recirculation outlet pressure sensor circuit voltage above normal or
3136 5019 3
shorted to high source.
Engine exhaust gas recirculation outlet pressure sensor circuit voltage above normal or
3137 5019 4
3186 1623 9 Tachography output shaft speed abnormal update rate.
3213 1623 19 Tachography output shaft speed received network data in error.
3326 91 9 Multiplexed accelerator pedal or lever sensor system abnormal update rate.
3328 191 9 Transmission output shaft speed abnormal update rate.
3418 191 19 Transmission output shaft speed received network data in error.
3525 84 19 Wheel-based vehicle speed received network data in error.
3526
3527
84
558
9
19
Wheel-based vehicle speed abnormal update rate.
Accelerator pedal or lever idle validation switch received network data in error. 5
3528 558 9 Accelerator pedal or lever idle validation switch abnormal update rate.
3555 1081 9 Engine Wait to Start lamp abnormal update rate.
3613 111 9 Coolant level sensor abnormal update rate.
3614 111 19 Coolant level sensor received network data in error.
3641 748 9 Transmission output retarder abnormal update rate.
3697 630 12 Engine control module calibration memory. Bad intelligent device or component.
High pressure common rail fuel pressure relieve valve. Mechanical system not responding
3727 5571 7
or out of adjustment.
3737 1675 31 Engine starter mode over-crank protection condition exists.
High pressure common rail fuel pressure relief valve data valid but above normal
3741 5571 0
4642 97 0 Water in fuel indicator data valid but above normal operating range. Most severe level.
4734 701 14 Auxiliary input/output 1 special instructions.
4789 1639 0 Fan speed data valid but above normal operational range. Most severe level.
4791 1639 1 Fan speed data valid but above below operational range. Most severe level.

Maintenance
PV485 Troubleshooting
Under certain conditions, the PV485 digital display can
become inoperable. If the display screen is completely
black, it must be replaced. If the gauges on the screen Clip
become gray (Figure 5-51), the display panel is not
receiving communication over the CANbus. If this
occurs, check the connector. If the gauges are still gray,
check the ECU powering up.
Figure 5-52. PV485 Main Connector

5. Ensure all the other terminals are locked into the
connector shell.
6. Push the red retaining clip back into the locked
position and ensure terminals are flush with the red
retaining clip. (Figure 5-53)
Figure 5-51. Screen Turns Gray
Check PV485 Connector

1. Ensure the ignition switch is in the OFF position
Figure 5-53. Terminal Seat
before starting the machine.
7. Reinstall connector on to the PV485 panel, making
2. Remove the main connector from the rear of the
sure the connector shell locks into its mate on the
PV485 digital display controller.
display panel.
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 5-52)

Section 6
SCHEMATICS
Page
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Electrical Schematic (1 of 9) . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Rear Harness (1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Rear Harness (2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Front Harness (1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
6
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

Schematics
Hydraulic Schematic (1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . 6-51

6-2
Schematics
ELECTRICAL SCHEMATIC (1 OF 9)
Part # 1017934
Figure 6-1. Electrical Schematic (1 of 9)

Schematics
NOTES

Schematics
Part # 1017934

Schematics
NOTES

Schematics
Part # 1017934

Schematics
NOTES

Schematics
Part # 1017934
CAB
FUNCTIONS

Schematics
NOTES

Schematics
Part # 1017934

Schematics
NOTES

Schematics
Part # 1017934
HEADLIGHTS/
TAILLIGHTS/
TURN SIGNALS

Schematics
NOTES

Schematics
Part # 1017934

Schematics
NOTES

Schematics
Part # 1017934

Schematics
NOTES

Schematics
Part # 1017934

Schematics
NOTES

Schematics
REAR HARNESS (1 OF 2)
Schematic for Part # 1017935
C C
Figure 6-10. Rear Harness (1 of 2)

Schematics
NOTES

Schematics
REAR HARNESS (2 OF 2)
Figure 6-11. Rear Harness (2 of 2)

Schematics
NOTES

Schematics
FRONT HARNESS (1 OF 2)
Figure 6-12. Front Harness (1 of 2)

Schematics
NOTES

Schematics
FRONT HARNESS (2 OF 2)
Figure 6-13. Front Harness (2 of 2)

Schematics
NOTES

Schematics
CAB HARNESS (1 OF 2)
Figure 6-14. Cab Harness (1 of 2)

Schematics
NOTES

Schematics
CAB HARNESS (2 OF 2)
Figure 6-15. Cab Harness (2 of 2)

Schematics
NOTES

Schematics
ENGINE HARNESS (1 OF 2)
Figure 6-16. Engine Harness (1 of 2)

Schematics
NOTES

Schematics
ENGINE HARNESS (2 OF 2)
Figure 6-17. Engine Harness (2 of 2)

Schematics
NOTES

Schematics
STEERING CONSOLE HARNESS (1 OF 2)

Figure 6-18. Steering Console Harness (1 of 2)

Schematics
NOTES

Schematics
STEERING CONSOLE HARNESS (2 OF 2)

Figure 6-19. Steering Console Harness (2 of 2)

Schematics
NOTES

Schematics
CONTROL PANEL (1 OF 5)
Part # 1018235
ITEM
PART NUMBER QTY DESCRIPTION
NO.
1 1018166 1 WELDMENT, CONTROL PANEL, 685D
2 1018170 1 PANEL, INSTRUMENT, 685D
3 39146-14 1 SWITCH,IGN,W/HEAT ST
4 982249 1 SWITCH,PUSH BUTTON
5 73119-CMG 2 SWITCH-WIPER/WASHER
6 1011147 1 LIGHTER, CIGARETTE
7 35812 1 LOCK,WITH OFFSET CAM
1018628-01
8 1018171 1 PANEL, FUSE
HIGH 9 720290 1 SOLENOID,12V,CONSTANT DUTY
BEAM
10 36086 6 BRACKET,RELAY MOUNT
11 36085 5 RELAY,12VDC,SPDT,40 AMP,5 PIN
LOW 12 35136-20 1 PLUG, HOLE, .562 FLUSH MOUNT, PLASTIC
E-STOP BEAM
13 851091608 1 FLASHER,SIGNAL (3 PRONG)
14 685060 1 FUSE BLOCK,18 GANG,ATC
15 36695 1 FUSE BLOCK,6 GANG,ATC
F
16 36341 4 FUSE,15 AMP,ATC
17 36340 16 FUSE,10 AMP,ATC
18 851391 5 SWITCH,TOGGLE,SPST,2-POS
19 851090624 3 SWITCH,TOGGLE,SPDT,2-POS
20 122-#8-32-16F 8 PHMS, CROSS, #8-32 X 1, FT
21 122-#8-32-8F 6 PHMS, CROSS, #8-32 X 0.5, FT
ON ON ON ON FRONT/PARK LOW LOW
22 302-#8 14 WASHER, LOCK, #8
PARK HIGH HIGH
23 209-#8-32 14 NUT,HEX,MACH,#8-32
F
OFF FRONT REAR 24 300-#8 6 WASHER, FLAT, SAE, #8
R
25 300-4 8 WASHER, FLAT, SAE, 1/4
(PUSH FOR WASHER FLUID)
2
S
HIGH
A
TRAVEL ON ON ON 26 100-4-20-12-5F 6 CSHH,1/4-20 X 0.75,GR5,FT
P
E
X 27 204-4-20-5 4 NUT,LOCK,STOVER,1/4-20,GR5
L
E
LOW E WORK AWD FRONT SECONDARY 28 122-#4-40-8F 2 PHMS, CROSS, #4-40 X .375, FT
D
FLOAT STEERING
29 300-#4 2 WASHER, FLAT, SAE, #4
30 302-#4 2 WASHER, LOCK, #4
6
OFF
685D
RUN ON
START
ENGAGE PARK BRAKE
TO START VEHICLE OR
31 209-#4-40 2 NUT, HEX, MACH, #4-40
TO SHIFT DRIVE AXLE 32 1019586 1 RESISTOR, 68 OHM, 25 WATT
P 33 851090613 1 SWITCH,TOGGLE,SPDT,3-POS
FUSE
PANEL
34 1018390 1 SWITCH, DPDT, 3POS, 2NT1-12
ACCESS
1018628-02
35 72086 2 SWITCH,TOGGLE,DPDT,2-POS
36 1010672 1 SWITCH,EMER STOP, 1-NC
37 981916 1 CONN,31-PIN,RECPT,HD34-24-31PT, DEUTSCH
38 1015381 1 CONNECTOR, 31 PIN, HD34-24-31ST
39 981916-01 2 CONN,NUT,24 SHELL
40 981916-02 2 CONN,LOCKWASHER,24 SHELL
41 1018628-02 1 DECAL, OPER, CONTROL PANEL
42 1018628-01 1 DECAL, OPER, CONTROL PANEL, TOP
43 988343 2 INSERT,NUT,.250-20 NC,FIRST GR
44 302-4 2 WASHER, LOCK, 1/4
45 20347712 0.6 TRIM LOK, 100B3X3/16 X 8.000
Figure 6-20. Control Panel (1 of 5)

Schematics
NOTES

Schematics
Part # 1018235
36 42 19 1 36
B
B
SECTION B-B
27
A
25 18 34
26 33 12 5 41
19
17 16
35 17
6 20 23 22 24
14
3
15 6
7 26 25 27
13
2
21 23 22 24
32
11
28 29 30 31
10
26 25 27
SECTION A-A
A 8 9

Schematics
NOTES

Schematics
Part # 1018235

Schematics
NOTES

Schematics
Part # 1018235

Schematics
NOTES

Schematics
Part # 1018235
FUS23 FUS24 10A KEY SWITCH
HORN DOME FUS21 10A FUS22 10A TAILLIGHTS
DIAGNOSTIC FUS19 10A FUS20 10A HAZARD TURN SIG
RADIO FUS17 10A FUS18
FLOAT/AWD FUS15 10A FUS16 10A REAR WORK
AUX STEERING FUS13 10A FUS14 10A FRONT WORK
FUS11 FUS12 10A FAN BEACON
OUTLET FUS9 10A FUS10 15A REAR WIPER
WORK/TRAVEL
REV SW
FUS7 10A FUS8 15A FRONT WIPER
W23
GROUND
6
PARK BRAKE FUS5 10A FUS6 15A LO BEAM WIRES
W24
FUS3 FUS4 15A HI BEAM
FRONT WIPER
REAR WIPER
RADIO
WORK/DOME
FAN
ACC/ECU/DISPLAY FUS1 10A FUS2 10A HEATER RELAY "R" REAR HARNESS
ALTERNATOR CONNECTOR
HD34-24-31ST
"F" FRONT HARNESS

CONNECTOR
HD34-24-31PT

Schematics
NOTES

Schematics
HYDRAULIC SCHEMATIC (1 OF 5)
Part # 1020130
Figure 6-25. Hydraulic Schematic (1 of 5)

Schematics
NOTES

Schematics
Part # 1020130
6
C5

Schematics
NOTES

Schematics
Part # 1020130

Schematics
NOTES

Schematics
Part # 1020130

Schematics
NOTES

Schematics
Part # 1020130
A A
6

Schematics
NOTES

Section 7
ILLUSTRATED PARTS LIST
Page
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Boom Articulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Boom Pivot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Rear Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Front Axle Assembly, 2WD (1 of 3) . . . . . . . . . . . . . . . . . . . . . . 7-10
OPTION-Front Axle Assembly, AWD (1 of 3). . . . . . . . . . . . . . . . . 7-16
MoldboardTurntable Assembly, 11 Ft/12 Ft (1 of 4) . . . . . . . . . . . . . . 7-22
Moldboard Turntable Assembly, 11 Ft/12 Ft (2 of 4). . . . . . . . . . . . . . 7-24
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

Illustrated Parts List
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
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 Scarifier . . . . . . . . . . . . . . . . . . . 7-88
OPTION - Dozer Blade/Blade Scarifier (Cont.) . . . . . . . . . . . . . . . 7-90
OPTION - Front Scarifier . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92
OPTION - Rear Scarifier. . . . . . . . . . . . . . . . . . . . . . . . . . 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

QUICK REFERENCE
FILTERS/STRAINERS ELECTRICAL COMPONENTS
Engine Description Part # Description Part #
Oil Filter 1012474-12 • 10A ATC 36340
Water Separator 1013667-18 • 15A ATC 36341
Fuel Filter 1012474-27
Fuse Block, 18 Gang - ATC 685060
Air Cleaner, Primary 1011263-13
Air Cleaner, Secondary 1012474-25 Fuse Block, 6 Gang - ATC 36695
Hydraulic
Suction Strainer 1014037 Relay, 12V 36085
Suction Strainer 1014027

Charge Filter 290030 TRACK ASSEMBLIES
Charge Filter Head 1017402
Description Part #
Return Filter 1018447
Return Filter Head 1018446 Rear Tire/Wheel Assembly - Right 1010197R
ENGINE COMPONENTS Rear Tire/Wheel Assembly - Left 1010197L
Description Part #
Engine Belt, Non-AC 1017509-08 Front Tire/Wheel Assy, 2WD - Right A120330AL
Engine Belt, w/AC 1017509-12

Front Tire/Wheel Assy, 2WD - Left A120330AR
Alternator 1017509-06
Front Tire/Wheel Assy, AWD - Right 1012240R

Starter 1008650-01
Front Tire/Wheel Assy, AWD - Left 1012240L

AC Compressor 1013772
Specifications and designs may change without prior notice. These

illustrations do not necessarily show the standard versions.

BOOM ARTICULATION
3
4 1
2
7,8,9
Figure 7-1. Boom Articulation

Boom Articulation
Item Part Number Qty Description Remarks
No
REF 1018345 2 Articulation Cylinder Assembly w/Adapters Includes Items 1-4
1 1018413 2 Hydraulic Cylinder, 3.00 x 9.00 x 1.25
2 FS6400-06-06-O 4 Straight Adapter, -6 ORFS/-6 O-Ring
3 210060 4 Clevis Pin, 1.00 x 2.63 w.1.50 Head
4 80338 4 Cotter Pin, .188 x 2.00
5 220360 4 Bushing, 1.00 ID x 1.25 OD x 1.00
6 100071 2 Articulation Clamp Half
7 100-10-18-80-8 8 CSHH, 5/8-18 x 5.00, GR8
8 307-10 8 Washer, Lock, Hi-Collar, 5/8
9 310-10 8 Washer, Hardened, SAE, 5/8

BOOM PIVOT
4 2
3
4
14
17
16
11,12,13
10
15
8
9
14
Figure 7-2. Boom Pivot

Boom Pivot
Item
Part Number Qty Description Remarks
No
1 100141 1 Articulating Shaft Nut
2 100090 2 Articulating Shaft Seal
3 100110 2 Articulating Shaft Bearing Cone
4 100120 2 Articulating Shaft Bearing Cup
5 1018242 1 Articulating Shaft
6 140620 2 Lube Fitting, 90°, 1/4-28
7 131140 4 Hose Clamp, 2 Hole
REF 984411 2 Lift Cylinder Mount
8 100152SRV 2 Trunnion Mount Assembly Includes Item 9
9 100080A 4 Bushing, 1.75 ID x 2.250 OD x 1.50 LG
10 100161 2 Moldboard Trunion Assembly Includes Item 9
11 100-10-11-48-8 8 CSHH, 5/8-11 x 3.00, GR8
12 302-10 8 Washer, Lock, 5/8
13 300-10 8 Washer, Flat, SAE, 5/8
14 140610 8 Lube Fitting, Straight, 1/4-28
15 100170 12 Bushing, 2.008 x 2.505 x 1-1/2
16 858961 4 Washer, 3.000 ID x 2.031 ID x .125
17 80338 2 Cotter Pin, .188 x 2.00

REAR DRIVE ASSEMBLY
22
23
22
3
20
21
24 3
27
28,29,30
17,18,19
16
25,26
10
8
14,15
7
11
1 12 8
9
2 13
4,5,6
2
Figure 7-3. Rear Drive Assembly

Rear Drive Assembly

Item
No
REF 1018341 1 Drive Axle & Motor Assembly w/Adapters
1 1009952SRV 1 Drive Axle Assembly, DANA 150 Bogie
2 1010197R 2 Tire & Wheel Assembly - Right Rear Includes Items 4-6
3 1010197L 2 Tire & Wheel Assembly -Left Rear Includes Items 4-6
REF 100514 4 Tire, 15: x 19.5", 8 PLY
REF 100513 4 Air Valve, 2 pc.
REF 1010198 4 Wheel
4 100-14-14-192-8 8 CSHH, 7/8-14 x 12.00, GR8
5 300-14 16 Washer, Flat, SAE, 7/8
6 95383832 8 Locknut, 7/8-14
7 1011461 1 Hydraulic Motor, 2-Speed, H1-B, 80cc
8 1902-16 2 Split Flange Clamp, Code 62, -16
9 FS1804-16-16-FG 1 Elbow Adapter, 90°, Code 62, -16 ORFS/-16 Flange
10 FS1800-16-16 1 Straight Adapter, Code 62, 16 ORFS/-16 Flange
11 6400-10-12-O 1 Reducer Adapter, -10 O-Ring/-12 O-Ring
12 FS6804-12-12-12-NWO-FG 1 Run Tee Adapter, -12 ORFS/-12 O-Ring/-12 ORFS
13 FS6500-12-12-FG 1 Swivel Elbow Adapter, 90°, -12 ORFS/-12 ORFS
14 102-M14-2-40-8.8F 4 CSSH, M14x2.0 x 40mm, C8.8, FT
15 307-10 4 Washer, Lock, Hi-Collar, 5/8
16 1018374 1 Low Range Switch Bracket
17 100-M14-2-30-8.8F 2 CSHH, M14x2.0 x 30mm, C8.8, FT
18 302-9 2 Washer, Lock, 9/16
19 300-9 2 Washer, Flat, SAE, 9/16
20 1018391 1 Switch, SPDT, Sealed
21 FS7205-06-14-NWO-FG 1 Elbow Adapter, 90°, -6 ORFS/14mm O-Ring
22 FS7640-06-14-O 5 Straight Adapter, -6 ORFS/14mm O-Ring
23 FS2603-06-06-06 2 Union Tee Adapter, -6 ORFS (x3)
24 FS2700-08-08 1 Bulkhead Union Adapter, -8 ORFS
25 FS0306-08 1 Bulkhead Locknut, -8 ORFS
26 FS0304-C-08 1 Cap Adapter, -8 ORFS
27 1010655 1 Oil Drain Bulkhead Bracket
28 100-M16-2-30-8.8F 1 CSHH, M16x2.0 x 30mm, C8.8, FT
7
29 302-10 1 Washer, Lock, 5/8
30 300-10 1 Washer, Flat, SAE, 5/8
REF F387TCJCJ1060606-21 2 Hydraulic Hose Jumper - Front Not Shown
REF F387TCJCJ1060606-17 2 Hydraulic Hose Jumper - Rear Not Shown

FRONT AXLE ASSEMBLY, 2WD (1 OF 3)
9
14,15
16,17 13
12
10
11
18,19,20
1
6
3,4
Figure 7-4. Front Axle Assembly, 2WD (1 of 3)

Front Axle Assembly, 2WD (1 of 3)

Item
No
1 1018076 1 Front Axle Assembly - 2WD See Figure 7-5
2 988328 2 Front Axle Clamp
3 100-10-11-24-8F 4 CSHH, 5/8-11 x 1.50, GR8, FT
4 302-10 4 Washer, Lock, 5/8
5 1018086 1 Front Axle Pin
6 A120330AR 1 Tire/Wheel Assembly - Right
7 A120330AL 1 Tire/Wheel Assembly - Left
REF 110340 2 Tire, 15" x 19.5", 8 Ply Included with 6 & 7
REF 120330B 2 Wheel Included with 6 & 7
REF 20192233 2 Valve Stem Included with 6 & 7
8 1009420 16 Lug Nut
REF 1018364 2 Cover Plate Assembly w/Adapters Includes Items 9-17
9 1018223 2 Cover
10 FS0304-C-06 2 Adapter Cap, -6 ORFS
11 FS2700-06-06 2 Bulkhead Union Adapter, -6 ORFS/-6 ORFS
12 0306-06 2 Bulkhead Lock Nut, -6
13 1018392 2 Connector, 6 Pin,
14 122-#8-32-12F 4 PHMS, Cross, #8-32 x .75, FT
15 300-#8 4 Washer, Flat, SAE, #8
16 302-#8 4 Washer, Lock, #8
17 209-#8-32 4 Nut, Hex, Mach, #8-32
18 100-4-20-16-5 8 CSHH, 1/4-20 x 1.00, GR5
19 302-4 8 Washer, Lock, 1/4
20 300-4 8 Washer, Flat, SAE, 1/4

2
18,19,20,21,22
3
12
1
18
17
7
14
8,9
13
19
5
11
21
22
10
23
12
16
13
18
14
13
19
15
22
20
21
14
13


Item
No
1 1018077 1 Front Axle Weldment Includes Items 2,3
2 984625 2 Front Yoke Bushing
3 984625-1 2 Bushing
4 110161 1 Lean Cylinder Pin,
5 400-6-28 1 Roll Pin, 3/8 x 1.75
6 140615 1 Lube Fitting, 45°, 1/4-28
7 110021 4 Spindle Mount Half Clamp
8 100-10-11-40-5 8 CSHH, 5/8-11 x 2.50, GR5
9 302-10 8 Washer, Lock, 5/8
10 1018248 1 Hydraulic Cylinder, 2.50 x 13.00 x 1.50 Steering
11 FS6802-06-06-NWO-FG 1 Elbow Adapter, 45°, -6 ORFS/-6 ORFS
13 214-20-12-5 4 Nut, Heavy Hex, 1-1/4-12, GR5
14 110210 3 Ball Joint - Right
15 1018097 1 Steering Tie Rod
16 110200 1 Ball Joint - Left
17 1018674 1 Hydraulic Cylinder, 3.50 x 5.00 x 1.50 Front Wheel Lean
19 110141SRV 3 Front Wheel Lean Tie Pin
20 110170 2 Front Wheel Lean Clevis
21 855002 3 Washer, Flat, 1.25 ID x 2.063 OD x .130
22 80338 3 Cotter Pin, .188 x 2.00
23 110182 1 Tie Rod, Wheel Lean

4,5,6
4,5,6
8
7
3
2
10
8
3
3
7
1
14
11
14
15
12
11
13
13
4
5,6
9
4,5,6
20
17
16
21
18
19
23
25
22
24
26
24


Item
No
1 110033SRV 1 Front Spindle Mount - Right
2 110043SRV 2 Front Spindle Mount - Left
3 110130 3 Tie Rod Bushing, 1.25 ID x 1.50 OD x 1.00 LG
4 852827 4 Clamp Half
5 100-10-11-48-5 8 CSHH, 5/8-11 x 3.00, GR5
6 302-10 8 Washer, Lock, 5/8
7 110151 2 Front Wheel Lean Pin
9 1018081 1 Steering Arm with Axle - Right Includes Item 10 (x2)
10 1018080 1 Steering Arm with Axle - Left Includes Item 10 (x2)
11 210190 4 Bearing Cup (x2) Not Shown
12 110101 2 Machined Nut
13 210240 2 Seal
14 210180 2 Bearing Cone
REF 110061 2 Front King Pin
15 110240A 2 Wheel Hub Assembly w/ Studs Includes Items 15-18
16 988911SRV 2 Wheel Hub
17 110250 2 Wheel Hub Inner Bearing Cup
18 610200 2 Wheel Hub Outer Bearing Cup
19 110350A 16 Wheel Stud
20 36830 2 Seal
21 110260 2 Wheel Hub Inner Bearing Cone
22 610210 2 Wheel Hub Outer Bearing Cone
23 110300 2 Front Spindle Thick Washer
24 110310 4 Front Spindle Nut
25 110320 2 Front Spindle Lock Washer
26 110330 2 Dust Cap

OPTION-FRONT AXLE ASSEMBLY, AWD (1 OF 3)
28
31 30
30
32,24,25
29
28
27
28 26
27
22
23,24,25
22
9
18,19
20,21 14
10
11 13
12
1 7
15,16,17
3,4
6
8
Figure 7-7. OPTION-Front Axle Assembly, AWD (1 of 3)

OPTION-Front Axle Assembly, AWD (1 of 3)

Item
No
1 1018102 1 AWD Front Axle Assembly
2 988328 2 Front Axle Clamp
3 100-10-11-24-8F 4 CSHH, 5/8-11 x 1.50, GR8, FT
4 302-10 4 Washer, Lock, 5/8
5 1018086 1 Front Axle Pin
6 1012240R 1 FWD Tire & Wheel Assembly, 15x19.5 - Right
7 1012240L 1 FWD Tire & Wheel Assembly, 15x19.5 - Left
REF 100514 A/R Tire, 15" x 19.5", 8 Ply
8 120350A A/R Lug Nut
9 1018225 2 Cover
10 FS2700-06-06 2 Bulkhead Union Adapter, -6 ORFS, -6 ORFS
12 FS2701-08-08-FG 6 Bulkhead Elbow Adapter, 90°, -8 ORFS/-8 ORFS
13 FS0306-06 6 Bulkhead Lock Nut, -6 ORFS
14 1018392 2 Connector, 6 Pin, DT04-6P-L012
15 100-4-20-16-5 8 CSHH, 1/4-20 x 1.00, GR5
16 302-4 8 Washer, Lock, 1/4
17 300-4 8 Washer, Flat, SAE, 1/4
18 122-#8-32-12F 8 PHMS, Cross, #8-32 x .75, FT
19 300-#8 8 Washer, Flat, SAE, #8
20 302-#8 8 Washer, Lock, #8
21 209-#8-32 8 Nut, Hex, Mach, #8-32
22 12757970 2 Side Cover
23 100-6-16-16-5F 8 CSHH, 3/8-16 x 1.00, GR5, FT
24 302-6 8 Washer, Lock, 3/8
25 300-6 8 Washer, Flat, SAE, 3/8
REF 1018642 1 Equa-Trac Valve Assembly w/Adapters Includes Items 26-31
26 1019685-03 1 Equa-Trac Manifold, AWD
27 1019685-04 4 Spool Stop Adapter Included w/Item 27
29 FS6801-08-08-NWO-FG 1 Elbow Adapter, 90°, -8 ORFS/-8 O-Ring
7
30 FS6602-08-08-08-FG 2 Swivel Runt Tee Adapter, -8 ORFS (x3)
32 100-6-16-12-5F 2 CSHH, 3/8-16 x .75, GR5, FT


18,19,20,21,22
2
3
12
1
23
14
19 18
13
18
17
19
7
22
8,9
21
11
5
21
20
22
10
16
13
12
14
13
15
13
14


Item
No
REF 1018102 1 AWD Front Axle Assembly
1 1018103 1 AWD Front Axle Includes Items 2,3
2 984625 2 Front Yoke Groove Bushing
3 984625-1 2 Bushing
4 110161 1 Lean Cylinder Pin
5 400-6-28 1 Roll Pin, 3/8 x 1.75
6 140615 1 Lube Fitting, 45°, 1/4-28
7 857377 4 Spindle Mounting Clamp - AWD
8 100-10-11-40-5 8 CSHH, 5/8-11 x 2.50, GR5
9 302-10 8 Washer, Lock, 5/8
10 1019767 1 Hydraulic Cylinder, Steering, 2.50 x 12.50 x 1.50 Steering - AWD
13 214-20-12-5 4 Nut, Heavy Hex, 1-1/4-12, GR5
14 110210 3 Ball Joint - Right
15 110192 1 Steering Tie Rod
16 110200 1 Ball Joint - Left
17 1018674 1 Hydraulic Cylinder, 3.50 x 5.00 x 1.50 Front Wheel Lean
19 110141SRV 3 Front Wheel Lean Tie Pin
20 110170 2 Front Wheel Lean Clevis
21 855002 3 Washer, Flat, 1-1/4 ID x 2-1/16 OD
22 80338 3 Cotter Pin, 3/16 x 2.00
23 859375 1 Tie Rod, Wheel Lean

12
11
13
12
4
3
2
4
9,10
4
5
8
11
5
6
9,10
7


Item
No
1 986366SRV 1 AWD Spindle Mount - Right Includes Items 3,4
2 986365SRV 1 AWD Spindle Mount - Left Includes Items 3,4
3 110130 3 Wheel Lean Tie Rod Bushing
4 210040 4 Inner Race Bearing
5 857368 2 AWD Wheel Lean Shaft
6 140610 2 Straight Lube Fitting, 1/4-28
7 1018091 1 AWD Steering Arm Assembly - Right Includes Item 9
8 986363SRV 1 AWD Steering Arm Assembly - Left Includes Item 9
9 101-10-11-32-5 8 CSHH, Heavy, 5/8-11 x 2.00, GR5
10 302-10 8 Washer, Lock, 5/8
11 1019685-01 2 Torque Hub & Casting

MOLDBOARDTURNTABLE ASSEMBLY, 11 FT/12 FT (1 OF 4)

6
7 4
4,6,7 9,10,11,12
9,10,11,12
19
5
18
20
18
27
17
18
21
17,18
16 19,20
13
1
14 15
20 19
24,26,15
18
23
25,26,15
18 22
18
3a/3b
Figure 7-10. Moldboard Turntable Assembly, 11 Ft/12 Ft (1 of 4)

Moldboard Turntable Assembly, 11 Ft/12 Ft (1 of 4)

Item
No
1 130004 1 Turntable & Drawbar Assembly See Figure 7-11
2 130243SRV 1 Moldboard Slide Assembly See Figure 7-12
3a 1018110 1 Moldboard Assembly, 11 Ft. x 21" See Figure 7-13
3b 1018442 1 OPTION - Moldboard Assembly, 121 Ft. x 22" See Figure 7-13
REF 1018346 2 Moldboard Lift Cylinder Assembly w/Fittings Includes Items 4-7
5 130060 2 Ball Joint
7 FS6400-06-06-O X 060 2 Straight Adapter, -6 ORFS/-6 O-Ring, .060 Orifice (Rod End)
8 100080A 4 Bushing, 1.75 ID x 2.25 OD x 1.50 LG
9 100-6-16-16-5F 4 CSHH, 3/8-16 x 1.00, GR5, FT
10 302-6 4 Washer, Lock, 3/8
11 300-6 4 Washer, Flat, SAE, 3/8
12 858953 4 Washer, Flat, 7/16 ID x 2-1/2 OD
13 310-14 2 Washer, Hardened, SAE, 7/8
14 206-14-14-5 2 Nut, Hex, Castle, 7/8-14
15 80338 4 Pin, Cotter, 3/16 x 2.00
16 204-20-7-5 1 Nut, Lock, Stover, 1-1/4-7, GR5
REF 1018347 2 Moldboard Swing Cylinder Assembly w/Fittings Includes Items 17,18
18 FS6801-06-06-NWO-FG 10 Elbow Adapter, 90°, -6 ORFS/-6 O-Ring (2 Per Cylinder)
19 210060 6 Clevis Pin, 1.00 x 2.625 x 1.50 HD
20 80389 6 Cotter Pin, 1/8 x 1.00
21 130031SRV 1 Moldboard Rod w/Ends
REF 1018349 1 Moldboard Slide Cylinder Assembly w/Fittings Includes Items 18,22
22 1018678 1 Hydraulic Cylinder, 3.00 x 36.00 x 1.75 I
REF 1018348 1 Moldboard Tilt Cylinder Assembly w/Fittings Includes Items 18,23
24 1011419SRV 1 Pin, Moldboard Tilt - Long
25 1011420SRV 1 Pin, Moldboard Tilt - Short
26 855002 2 Washer, Flat, 1-1/4 ID x 2-1/16 OD
7
OPT 1018648 1 OPTION - Circle Side Shift
REF 1018414 1 Circle Side Shift Cylinder Assembly w/Adapters Includes Items 18,27
28 1018649 1 Hose Kit - Circle Side Shift Not Shown

MOLDBOARD TURNTABLE ASSEMBLY, 11 FT/12 FT (2 OF 4)
2,3
9,10,11,12
5
13
6 14
21,22,23
15,16
17
14 18
29
30
19,20
31
24
25
26
27,3,28


Item
No
REF 130004 1 Turntable & Drawbar Assembly Includes Items 1-27
REF 130014-1SRV 1 Drawbar Assembly Includes Items 1-20
1 857578 1 Turntable Dust Cover
2 100-6-16-12-5F 4 CSHH, 3/8-16 x .75, GR5, FT
3 300-6 7 Washer, Flat, SAE, 3/8
4 204-20-7-5 1 Nut, Lock, Stover, 1-1/4-7, GR5
5 130060-1 2 Ball Joint Bushing, Small Taper
REF 1019684 1 Moldboard Slide Manifold Assembly w/Adapters Includes Items 7-8
7 1019696 1 Moldboard Slide Manifold
9 100-4-20-24-5 2 CSHH, 1/4-20 x 1.50, GR5
10 300-4 4 Washer, Flat, SAE, 1/4
11 302-4 2 Washer, Lock, 1/4
12 200-4-20-5 2 Nut, Hex, 1/4-20, GR5
13 131140 8 Hose Clamp, 2 Hole - 5/8
14 220360 4 Bushing, 1.00 ID x 1.25 OD x 1.00
15 100-8-13-40-5 6 CSHH, 1/2-13 x 2.50, GR5
16 302-8 6 Washer, Lock, 1/2
17 130101 1 Drawbar Pull Ball Socket Half
18 130106 1 Drawbar Pull Ball
19 200-18-12-5 1 Nut, Hex, 1-1/8-12, GR5
20 302-18 1 Washer, Lock, 1-1/8
21 100-10-11-60-5 6 CSHH, 5/8-11 x 3.75, GR5
22 300-10 6 Washer, Flat, SAE, 5/8
23 204-10-11-5 6 Nut, Lock, Stover, 5/8-11, GR5
24 130224SRV 1 Moldboard Turntable Weldment Includes Items 3,14,25
25 1009981 2 Bushing, Moldboard Tilt
7
26 130083 1 Turntable Bottom Plate
28 35465-06 9 Grommet
29 130103 1 Drawbar Pull Ball Shim - .025
30 130104 1 Drawbar Pull Bar Shim - .030
31 130105 2 Drawbar Pull Bar Shim - .055

9,10
14,15
1
2
16
6
18
17
4
8
3
7
11,10,12
11,10,12
18
13,10
17
16


Item
No
REF 130243SRV 1 Moldboard Slide Assembly
1 130141 2 Moldboard Slide Clamp - Upper
2 130130 6 Moldboard Slide Clamp 3-Hole Shim - Upper
3 130161 2 Moldboard Slide Clamp - Lower
4 130150 6 Moldboard Slide Clamp 4-Hole Shim - Lower
5 130261 1 Moldboard Slide Clamp - Center
6 130251 1 Moldboard Slide Clamp Shim - Center
7 130121 2 Moldboard Shim - Top
8 1009981 2 Moldboard Tilt Bushing
9 100-10-11-24-5F 3 CSHH, 5/8-11 x 1.50, GR5, FT
10 302-10 19 Washer, Lock, 5/8
11 100-10-11-56-5 8 CSHH, 5/8-11 x 3.50, GR5
12 200-10-11-5 8 Nut, Hex, 5/8-11, GR5
13 100-10-11-48-5 8 CSHH, 5/8-11 x 3.00, GR5
14 119-10-11-48 4 Square Head Set Screw, 5/8-11 x 3.00, Flat Point
15 202-10-11-5 4 Nut, Jam, 5/8-11, GR5
16 130231 2 Moldboard Pin
17 130232 2 Cotter Pin, 1/4 x 2.25
18 100250 2 Washer, Flat, 1.50 x 2.50

8
1
4,5,6
2
4,5,6
4,5,6
3
4,5,6
3


Item
No
1 1018110 1 Moldboard Assembly, 11 Ft. x 21" Includes Items 2-6
2 1011670 1 Moldboard Cutting Edge, 11 Ft.
3 130180 4 Moldboard Curved End Bit
4 130220 A/R Plow Bolt, 5/8-11 x 2.00
5 302-10 A/R Washer, Lock, 5/8
6 200-10-11-5 A/R Nut, Hex, 5/8-11, GR5
7 1018442 1 OPTION - Moldboard Assembly, 12 Ft. x 21" Includes Items 3-6,8

8 853860 2 Moldboard Cutting Edge, 6 Ft., Offset Punched

CANOPY ASSEMBLY
11
10
11
11
10
12 14,15
11 14,16 16,17
10
17
13
8,9
18
3 21
4
20
5,6,7
19
2
30
29
1
25 22,23,24
26
27,28
Figure 7-14. Canopy Assembly

Canopy Assembly
Item
No
GRP 1018602 Group - Canopy Detail
1 1018597 1 Canopy
REF 1013610 1 Access Door Assembly Includes Items 2,3
2 1013610-01 1 Access Door Plate
3 980460 1 Lever Latch
- 35560 A/R Replacement Key
4 987639 2 Hinge
5 100-5-18-16-5F 4 CSHH, 5/16-18 x 1.00, GR5, FT
6 300-5 4 Washer, Flat, SAE, 5/16
7 302-5 4 Washer, Lock, 5/16
8 1018603 1 Vandalism Cover - Right
9 35812 1 Lock w/Offset Cam
10 859133 9 Wiring Cover Plate
11 1013307 4 LED Light
12 1019631 1 Vandalism Cover - Display
13 1018609 1 Vandalism Cover Mount - Display
14 100-4-20-12-5F 5 CSHH, 1/4-20 x .75, GR5, FT
15 302-4 3 Washer, Lock, 1/4
16 300-4 5 Washer, Flat, SAE, 1/4
17 200-4-20-5 5 Nut, Hex, 1/4-20, GR5
18 1018858 1 Floor Mat Sound Insulation
19 1017754 1 Cross Member Cover Bracket
20 1010872 1 Seat Box Access Panel
21 1011722 1 Canopy Grab Bar
22 100-8-13-24-5 4 CSHH, 1/2-13 x 1.50, GR5
23 302-8 4 Washer, Lock, 1/2
24 300-8 7 Washer, Flat, SAE, 1/2
25 12754577 4 Cab Isolator Backing Washer
26 12754576 4 Cab Isolation Mount (2 pcs.)
27 100-14-9-80-8 4 CSHH, 7/8-9 x 5.00, GR8
28 204-14-9-5 4 Nut, Lock Stover, 7/8-9, GR5
29
30
1010893
117-5-18-12
2
2
Threshold Plate
CSSBH, 5/16-18 x .75 7

CAB ASSEMBLY - EXTERIOR (1 OF 2)
25
23
24
8 22
21
9,6 25
5,10
20
11,12,13
2
7
3
17,18
1 19
4,5,6
25
14
26
15
27
16 28,29
Figure 7-15. Cab Assembly - Exterior (1 of 2)

Cab Assembly - Exterior (1 of 2)

Item
No
GRP 1017558 Group - Cab Detail
REF 1013610 1 Access Door Assembly Includes Items 1,2
1 1013610-01 1 Access Door
2 980460 1 Lever Latch
- 35560 A/R Replacement Key
3 987639 2 Hinge
4 100-5-18-16-5F 4 CSHH, 5/16-18 x 1.00, GR5, FT
5 302-5 6 Washer, Lock, 5/16
6 300-5 8 Washer, Flat, SAE, 5/16
7 151200 1 Windshield Wiper Washer Tank
8 1011114 1 Washer Bottle Mounting Plate
9 100-5-18-24-5 2 CSHH, 5/16-18 x 1.50, GR5
10 200-5-18-5 2 Nut, Hex, 5/16-18, GR5
11 100-4-20-12-5F 4 CSHH, 1/4-20 x .75, GR5, FT
12 302-4 4 Washer, Lock, 1/4
13 300-4 4 Washer, Flat, SAE, 1/4
14 1010882SRV 2 Door Open Latch
15 1010884SRV 2 Door Open Latch Extension
16 1000835 2 Pull Pin, Spring Loaded
17 100-6-16-12-5F 4 CSHH, 3/8-16 x .75, GR5, FT
18 302-6 4 Washer, Lock, 3/8
19 300-6 4 Washer, Flat, SAE, 3/8
20 151190 1 Windshield Wiper Blade - 20"
21 151180 1 Windshield Wiper Arm
22 852810 1 Windshield Washer Nozzle Kit
23 151170 1 Windshield Wiper Motor
24 81277 1 CSBHS, 1/4-20 x .88, SS
25 1013307 4 LED Light
26 12754577 4 Cab Isolator Backing Washer
27 12754576 4 Cab Isolation Mount (2 pc.)
28 100-14-9-80-8 4 CSHH, 7/8-9 x 5.00, GR8

CAB ASSEMBLY - EXTERIOR (2 OF 2)
20
31
3
5,6,7
29
21
14
15
30
16 2
20
4
28
22
3
27
1
26
24
18
19 25 17
4 23
23
12,7
13
6,7
11
9
5
8a/8b
10
Figure 7-16. Cab Assembly - Exterior (2 of 2)

Cab Assembly - Exterior (2 of 2)

Item
No
1 1018033 1 Cab Door Assembly - Right Includes Items 3-7,8a,9-13
2 1018032 2 Cab Door Assembly - Left Includes Items 3-7,8b,9-13
3 1013591-05 2 Door Glass - Upper
4 1013591-06 2 Door Glass - Lower
5 982415 2 Push Button Door Handle
6 100-M5-0.8-10-8.8F 8 CSHH, M5x0.8 x 10mm, C8.8, FT
7 300-4 14 Washer, Flat, SAE, 1/4
8a 983219-01SRV 1 Rotary Latch - Right
8b 983423-01SRV 1 Rotary Latch - Left
9 981206 2 Latch Mounting Plate
10 123-4-20-12F 8 FHMS, Cross, 1/4-20 x .75, FT
11 980678 2 Door Latch Cover
12 100-4-20-12-5F 6 CSHH, 1/4-20 x .75, GR5, FT
13 851156 2 Round Ball Knob
14 982060 2 Interior Handle
15 117-4-20-12 4 CSSBH, 1/4-20 x .75
16 982416 2 Striker Bolt
17 1010872 1 Seat Box Access Panel Plate
18 1010893 2 Threshold Plate
19 117-5-18-12 4 CSSBH, 5/16-18 x .75
20 1013591-04 2 Side Glass
21 1013591-02 1 Windshield Glass - Rear
22 1013591-01 1 Windshield Glass - Front
23 1013591-03 2 Lower Kick Glass - Front
REF 1018842 1 Cab Insulation Kit Includes Items 24-31
24 1018842-01 1 Floor Mat Sound Insulation
25 1010790-09 1 Bottom Front Sound Insulation - Right
26 1010790-08 1 Bottom Front Sound Insulation - Left
27 1010790-07 1 Front Sound Insulation - Right
28 1010790-06 1 Front Sound Insulation - Left
29 1010790-04 1 Sound Insulation - Left
7
30 1010790-03 1 Sound Insulation - Rear
31 1010790-02 1 Sound Insulation - Headliner

CAB ASSEMBLY - INTERIOR

4
2,3
6
7,8,9,10
11,12
4
13
5
2,3
11,12
4
4
2,3
15,16,17
14
14
Figure 7-17. Cab Assembly - Interior

Cab Assembly - Interior

Item
No
1 1010895 1 Heater & AC Evaporator Unit See Fig. 7-18
2 1011198 4 Louver, Front Panel - 2.7
3 1011199 4 Louver Retainer - 2.7
4 859133 8 Wiring Cover Plate
5 1017571 1 Dome Light Mounting Plate
6 151191 1 Cover Plate (No Rear Wiper)
7 100-4-20-16-5 2 CSHH, 1/4-20 x 1.00, GR5
9 302-4 2 Washer, Lock, 1/4
10 200-4-20-5 2 Nut, Hex, 1/4-20, GR5
11 1010894 2 Diffuser Mounting Plate
12 1011200 2 Louver, Front Panel - 4.0
13 1010873 1 Access Panel Plate
14 1011201 2 Louver, Narrow Frame
15 100-5-18-16-5 3 CSHH, 5/16-18 x 1.00, GR5
16 302-5 3 Washer, Lock, 5/16
17 300-6 3 Washer, Flat, SAE, 5/16

CAB ASSEMBLY - AIR CONDITIONING (1 OF 2)
17
18,19,20
17
18,19,20
16
12,21,11
5 6,7,8,9
2
22
10,11,12
13
15
14
13
Figure 7-18. Cab Assembly - Air Conditioning (1 of 2)

Cab Assembly - Air Conditioning (1 of 2)

Item
No
GRP 1018238 Group - Air Conditioning
1 1013772 1 AC Compressor
2 1017509-12 1 AC/Fan Drive Belt
3 38525-01 1 AC Dryer
4 12755077 1 Condensor Assembly Binary Switch
5 36745-08 1 Dryer Clamp
6 100-4-20-12-5F 6 CSHH, 1/4-20 x .75, GR5, FT
7 300-4 12 Washer, Flat, SAE, 1/4
8 302-4 6 Washer, Lock, 1/4
9 200-4-20-5 6 Nut, Hex, 1/4-20, GR5
10 100-5-18-48-5 1 CSHH, 5/16-18 x 3.00, GR5
11 300-5 5 Washer, Flat, SAE, 5/16
12 200-5-18-5 5 Nut, Hex, 5/16-18, GR5
13 33492 2 Straight Fitting, 08MP-10HB, Crimped
14 32874 1 Ball Valve, 1/2" (Brass)
15 5502-8-8 1 Street Elbow Adapter, 90°, -8 NPTF/-8 NPTF
16 1013712-01 1 AC Condenser
17 1020466 2 AC Condenser Mount
18 122-#10-32-8F 4 PHMS, Cross, #10-32 x .50, FT
19 300-#10 6 Washer, Flat, SAE, #10
20 205-#10-32-5 4 Nut, Lock, Nylon, #10-32, GR5
21 302-5 4 Washer, Lock, 5/16
22 1018240 1 Air Conditioning Hose Kit (4 Hoses)

CAB ASSEMBLY - AIR CONDITIONING (2 OF 2)

6
5 6
8
9
10 11
2
1
Figure 7-19. Cab Assembly - Air Conditioning (2 of 2)

Cab Assembly - Air Conditioning (2 of 2)

Item
No
REF 1010895 1 Heater & A/C Evaporator Unit
1 12755230 Blower Assembly Includes Items 2,3
2 1010895-02 1 Blower Motor
3 1010895-01 1 Blower Fan
4 12755045 1 Evaporator Assembly
5 12755492 3 Evaporator Assembly Knob
6 36745-20 2 Recirculation Filter Knob
7 12755490 1 Recirculation Filter
8 12755496 1 Cold Control
9 36745-18 1 Fan Switch
10 12755494 1 Cable Control Assembly
11 12755168 1 Fresh Air Filter

CANOPY/CAB DETAILS - SEAT
3,4,5
8
T
H
R + 3,4,5,6
)_(
O
T
T
2
L
E
1013789-03
10,11,12
7
Figure 7-20. Canopy/Cab Details - Seat

Canopy/Cab Details - Seat

Item
No
1 1009335 1 Seat Assembly w/Seat Belt
- 1009335-01 A/R Seat Track Set Not Shown
2 1020478 4 Seat Mount Plate
3 100-5-18-16-5 12 CSHH, 5/16-18 x 1.00, GR5
4 300-5 16 Washer, Flat, SAE, 5/16
5 302-5 12 Washer, Lock, 5/16
6 200-5-18-5 4 Nut, Hex, 5/16-18, GR5
7 1018771 1 Throttle Control Mount
8 1013789-03 1 Decal - Throttle Operation
9 1018764 1 Throttle Control Lever
10 100-6-16-12-5F 4 CSHH, 3/8-16 x .75, GR5, FT
11 302-6 4 Washer, Lock, 3/8
12 300-6 4 Washer, Flat, SAE, 3/8

CANOPY/CAB DETAILS - INTERIOR
13
14,15,16
24,25,26,27
20,21
22,23
12
9
6
11
10
17,18,19 5
1,2
7,8
28
1,2
Figure 7-21. Canopy/Cab Details - Interior

Canopy/Cab Details - Interior

Item
No
1 151370 2 Rearview Mirror - Outside
2 10623 2 Mirror Arm
3 720260 1 Rearview Mirror - Inside
4 1007953SRV 1 OPTION -Rear Camera
- 1004617 1 Camera Display
- 1003907 1 Outdoor Color Camera, 12VDC Not Shown
- 1003908 1 Cable Not Shown
- 1016876 1 Adapter, Gemini TC to EC Monitor Not Shown
5 35425 1 Defrost Fan Assembly, 12V
6 38840 1 Dome Light
7 985234-01 1 Manual Case
8 988634 1 Decal - Operator's Manual
REF 1019550 1 Flip-Down Beacon Assembly Includes Items 9-23
9 1010890 1 Beacon Mounting Plate
10 1010889 1 Beacon Mounting Brace
11 38392 1 Bumper
12 41519 1 Handle
13 1013231 1 Beacon, Amber, Strobe, LED
14 122-#10-24-12F 3 PHMS, Cross, #10-24 x .75, FT
15 300-#10 3 Washer, Flat, SAE, #10
16 205-#10-24-5 3 Nut, Lock, Nylon, #10-24, GR5
17 100-4-20-16-5 1 CSHH, 1/4-20 x 1.00, GR5
18 300-4 2 Washer, Flat, SAE, 1/4
19 205-4-20-5 1 Nut, Lock, Nylon, 1/4-20, GR5
20 100-5-18-16-5 2 CSHH, 5/16-18 x 1.00, GR5
21 300-5 4 Washer, Flat, SAE, 5/16
22 302-5 2 Washer, Lock, 5/16
23 200-5-18-5 2 Nut, Hex, 5/16-18, GR5
24 100-6-16-12-5F 2 CSHH, 3/8-16 x .75, GR5, FT
25 300-6 4 Washer, Flat, SAE, 3/8
7
26 302-6 2 Washer, Lock, 3/8
27 200-6-16-5 2 Nut, Hex, 3/8-16, GR5
28 1000705SRV 1 OPTION - Radio w/Speakers & Antenna See Figure 7-47

CONTROLS - 10 STATION (1 OF 3)
9
8
17,18,19
20,21
17,18,19
2
14a
10
11
12
16
22
1018628-03
HIGH
23
6
685D
5
4
5
AWD
4
3
10
13
14a/14b
15
Figure 7-22. Controls - 10 Station (1 of 3)

Controls - 10 Station (1 of 3)
Item
No
GRP 1018087 1 Group - 10 Station Console
1 1018088 1 Console
2 1018090 1 Console Face Panel
REF 1018429 1 Steering Motor Assembly w/Fittings Includes Items 3-5
3 100397 1 Steering Control Unit
6 300040 1 Steering Column, 6.00"
7 115772 1 Steering Wheel, 14.00"
8 300020 1 Nut, Hex, 13/16-20
9 20944062 1 Steering Wheel Cap
10 31985 2 Dash Light - Green
11 1010500 1 Dash Light - White
12 31986 1 Dash Light - Blue
13 31983 1 Dash Light - Red
14a 35136-4 2 Hole Plug, Flush Mount - 1/2" 2WD Option Only
14b 1001625 1 Dash Light - Amber AWD Option Only
15 1018803 1 PV480 Display (w/o throttle)
16 1018628-03 1 Decal - Front Control Panel
17 100-5-18-16-5F 4 CSHH, 5/16-18 x 1.00, GR5, FT
18 302-5 4 Washer, Lock, 5/16
19 300-5 4 Washer, Flat, SAE, 5/16
20 100-6-16-24-5 4 CSHH, 3/8-16 x 1.50, GR5
21 302-6 4 Washer, Lock, 3/8
22 33687 1 Turn Signal w/Hazard
23 1018628-04 1 Decal - Info, Lube Chart

7-48
15,16
11
7 9,10
13
8 12
6 5
17
13
19,20,21
14
4
2

1
3 18,16
11
DANGER PELIGRO DANGER
RUN-AWAY VEHICLE RIESGO DE MOVIMIENTO RISQUE DE PERTE DE

HAZARD! INESPERADO DEL CONTRÔLE DU
VEHICULO! VÉHICULE !
DO NOT shift on hills. NO cambiar de marcha sobre NE PAS changer de vitesse
Machine must be in pendientes. sur les pentes.
27 NEUTRAL and Es necesario colocar la La machine doit être au
Emergency Brake máquina en PUNTO MUERTO
POINT MORT et le frein
applied before y aplicar el freno de
d’urgence doit être serré
estacionamiento antes de
dismounting. avant de quitter la machine.
desocupar la máquina.
Failure to comply will Le non-respect de cette règle
Si no se cumple con esta
result in death or disposición, se causará la entraînera des blessures
serious injury. muerte o lesiones graves. graves, voire mortelles.
983125-21
WARNING ADVERTENCIA AVERTISSEMENT

26 LUNGE HAZARD! ¡RIESGO DE MOVIMIENTO RISQUE DE BOND EN
ABRUPTO! AVANT !
25 Machine will lunge La máquina se moverá La machine fait un bond
unexpectedly if abruptamente si se pisa en avant si la pédale
22 drive pedal is el pedal de mando d'entraînement est
depressed. motriz. enfoncée.
Aplicar el freno de Appliquer le frein de
Apply park brake estacionamiento stationnement avant 28
before exiting.
24 23 antes de salir. de quitter.
Failure to comply Si no se cumple con Le non-respect de cette

esta disposición, se règle risque d’entraîner
988271
could result in death puede causar la muerte des blessures graves,
or serious injury. o lesiones graves. voire mortelles. 1011464
LeeBoy 685D Motor Grader

Item
No
GRP 1018087 1 Group - 10 Station Console
1 1018987 1 Cover Plate
REF 1018370 1 10 Station Valve Assembly w/Adapters Includes Items 2,23-26
2 989177 1 10 Station Valve Assembly
3 140630 4 Lever
4 140630-3 2 Lever, 40°
5 910058 6 Valve Lever Mount Bracket Includes Item 6
6 102-4-20-14-F 12 CSSH, 1/4-20 x .875, FT
7 901010 6 Valve Lever Link Assembly
REF 1006586 4 Valve Lever Assembly Includes items 8-14
8 140560 4 Master Link
9 140551 4 Lever Mounting Block
10 140610 8 Straight Lube Fitting, 1/4-28
11 300-6 10 Washer, Flat, SAE, 3/8
12 140571SRV 4 Valve Lever Pivot Arm Includes Item 10
13 202-8-13-5 8 Nut, Hex, 1/2-13, GR5
14 140531 4 Control Lever
15 100-6-16-28-5 4 CSHH, 3/8-16 x 1.75, GR5
16 302-6 6 Washer, Lock, 3/8
17 920225 4 Ball Knob, ø1-7/8 x 1/2-13
18 31877 2 Wing Nut, 3/8-16
19 100-5-18-48-5 3 CSHH, 5/16-18 x 3.00, GR5
20 302-5 3 Washer, Lock, 5/16
21 200-5-18-5 3 Nut, Hex, 5/16-18, Gr5
26 988271 1 Decal - OPT, Circle Shift
27 1011464 1 Decal - Warning, Lunge Hazard
28 983125-21 1 Decal - Runaway Vehicle

12
1
6
14
2
3
6
9
15
10
13
11
3
4
4
4
7
4
4
8
4
6
9
4
4
16

Item
No
REF 989177 1 Valve Assembly, 10 Section w/Float *Some items not shown for clarity
1 910055 1 Valve Inlet Cover w/Relief Valve

2 901009 1 Main Relief Valve
3 989177-01 2 Float Valve Section
4 910054 6 Spring Return Valve Section
5 910056 1 Valve Outlet Cover w/PB Sleeve
6 910062 A/R Valve Section Seal Kit
7 141010 A/R Dust Boot, V-20 Valve Spool
8 141060 A/R Valve Spool End Clevis
9 910058 A/R Valve Lever Mounting Bracket
10 141020 A/R Anti-Cavitation Valve & Plug
11 910059 A/R Valve Spool Seal Kit
12 141050 2 Float Positioner Kit
13 901014 A/R Valve Spring Center Kit
14 141040 A/R Valve Spool End Spring Cap
15 901007 A/R Valve Spool Detent Kit
16 901002 1 Power Beyond Sleeve
REF 910052 A/R Detent Valve Section Not Shown
REF 910065 A/R Relief Valve Seal Kit Not Shown

CONTROLS - PANEL
4,5 3 2 1
1018628-01
HIGH
BEAM
LOW
E-STOP BEAM
4 4 12 10 10
13 10 10 10 11 9 8 7 7 6
ON ON ON ON FRONT/PARK LOW LOW
PARK HIGH HIGH
OFF FRONT REAR

F
R
(PUSH FOR WASHER FLUID)
2 HIGH TRAVEL ON ON ON
S A
P X
E L
E E WORK
LOW AWD FRONT SECONDARY
D
FLOAT STEERING
OFF
685D
RUN ON
ENGAGE PARK BRAKE
START TO START VEHICLE OR
TO SHIFT DRIVE AXLE
P
FUSE
PANEL
ACCESS
1018628-02
14 12 15 16
17
21 20 19 18
WORK WORK
TAIL LIGHTS LIGHTS BEACON/ WIPER WIPER LOW HIGH AC/
KEY LIGHTS FLASHER REAR FRONT FAN REAR FRONT BEAM BEAM HEAT
10A 10A 10A OPEN 10A 10A 10A 15A 15A 15A 15A 20A
F24 F22 F20 F18 F16 F14 F12 F10 F8 F6 F4 F2
F23 F21 F19 F17 F15 F13 F11 F9 F7 F5 F3 F1
OPEN HORN/ DIAGNO- RADIO FLOAT/ AUX OPEN OUTLET WORK/ PARK OPEN ENGINE
DOME STICS 10A AWD STEERING 10A TRAVEL BRAKE 10A
10A 10A 10A 10A 10A 10A
FLASHER LOW HIGH WORK/ SEAT AUXILARY

BEAM BEAM TRAVEL SWITCH STEERING
22 1018628-05
23
26
25
24
Figure 7-25. Controls - Panel

Controls - Panel
Item
No
REF 1018235 1 Control Panel Assembly
1 1010794 1 Cup Holder
2 1018628-01 1 Decal - Control Panel, Top
3 851090624 3 Toggle Switch, SPDT, 2-POS
4 1010672 1 Emergency Stop Switch, 1-NC
5 1010692 1 Contact Block, 1-NC
6 1018628-02 1 Decal - Control Panel, Front
7 73119-CMG 2 Switch - Wiper/Washer
8 35136-20 1 Hole Plug, .562
9 1018390 1 Toggle Switch, DPDT, 3-POS
10 851090613 1 Toggle Switch, SPDT, 3-POS
11 851391 5 Toggle Switch, SPST, 2-POS
12 72086 2 Toggle Switch, DPST, 2-POS
13 982249 1 Push Button Switch
14 39146-14 1 Ignition Switch
15 35812 1 Lock w/Offset Cam
16 1011147 1 12V Receptacle
17 1018628-05 1 Decal - Fuse Panel
18 685060 1 Fuse Block, 18 Gang, ATC
19 36340 16 Fuse, 10A, ATC
20 36341 3 Fuse, 15A, ATC
21 36695 1 Fuse Block, 6 Gang, ATC
22 36085 5 Relay, 12VDC, SPDT, 40A, 5-PIN
23 851091608 1 Signal Flasher
24 36086 6 Relay Mounting Bracket
25 720290 1 Solenoid, 12V, Constant Duty
26 1019586 1 Resistor, 68 Ohm, 25 Watt

CONTROLS - FOOT
31
1,5
35,36,37 32 2
34
33
27,29 13
4 12
14 14
11
14
3 15 12
38,39,40 30 14 14
6 13
22 7
24 8
25
7 18,19
26 9 10 20,21
23 16
27,28,29
17
Figure 7-26. Controls - Foot

Controls - Foot
Item
No
REF 1010780 1 Forward/Reverse Pedal Assembly Includes Items 1-5
1 1010784 1 Forward/Reverse Pedal Includes Item 5
2 1010785 1 Pivot Pin
3 1010781 1 Pedal Mount
4 113-4-20-4 1 Socket Head Set Screw, Cup, 1/4-20 x .25
5 140620 1 Lube Fitting, 90°, 1/4"-28
6 P72965 1 Ball Joint, Female, 3/8
7 202-6-24-5 2 Nut, Hex, Jam, 3/8-24, GR5
8 1010787 1 Link Arm - RWD Model Only
9 1019450 1 Link Arm - AWD Model Only
10 100500 1 Rod End Ball Joint, 3/8"
11 1012917 1 Foot Pedal Tensioner Bar
12 38245 2 Compression Spring
13 1012918 2 Set Screw Collar, 3/8"
14 300-8 5 Washer, Flat, SAE, 1/2
15 100-8-13-28-5 1 CSHH, 1/2-13 x 1.75, GR5
REF 12757503 1 Back-Up Alarm Switch Assembly Includes Items 16-21
16 12757501 1 Back-Up Alarm Switch
17 12757496 1 Back-Up Alarm Switch Bracket
18 122-#10-24-16F 2 PHMS, Cross, #10-24 x 1.00, FT
19 300-#10 2 Washer, Flat, SAE, #10
20 302-#10 2 Washer, Lock, #10
21 209-#10-24 2 Nut, Hex, Machine, #10-24
REF 1018339 1 Brake Pedal Assembly w/Adapters Includes Items 22-26
22 1010517 1 Brake Pedal Valve
25 6832-06-06-06-NWO-FG 1 Branch Tee Swivel Adapter, -6 O-Ring (x3)
26 1019683 1 Pump Destroke Switch
27 100-6-16-24-5 3 CSHH, 3/8-16 x 1.50, GR5
28 302-6 3 Washer, Lock, 3/8
7
29 300-6 3 Washer, Flat, SAE, 3/8
30 1018989 1 Console Front
31 115715 1 Pedestal Spring Shock
32 115878 1 Nut, M10x1
33 115714 1 Gas Spring Actuator Head
34 1019718 1 Column Tilt Pedal
35 100-5-18-32-5 2 CSHH, 5/16-18 x 2.00, GR5
36 300-5 2 Washer, Flat, 5/16
37 200-5-18-5 2 Nut, Hex, 5/16-18, GR5

HYDRAULICS - TANKS
8
9
1 11,12,6
10
13
25 27,28,29
26
22
24
14
23
18 5,6,7
21
19
15
21
16
17
20 3
44
43 37
31
39 38
30
32
42
4 33
34
37
44
35
45
5,6,7
36
46
40
41
Figure 7-27. Hydraulics - Tanks

Hydraulics - Tanks
Item
No
REF 1018114 1 Hydraulic Tank Assembly w/Adapters - RWD
1 1017531 1 Hydraulic Tank Assembly, 30 Gallon Includes Items 2-7
2 1017534 2 SRC Strap
3 1018053 1 Tank Access Door - Right
4 1018052 1 Tank Access Door - Left
5 100-4-20-12-5F 4 CSHH, 1/4-20 x .75, GR5, FT
6 300-4 16 Washer, Flat, SAE, 1/4
7 200-4-20-5 4 Nut, Hex, 1/4-20, GR5
8 37680 1 Reservoir Filler Breather Cap Assembly Includes Strainer & Gasket
9 128-#10-32-10 6 Screw, HWH, Slotted, #10-32 x 5/8
10 1000206 1 Hydraulic Tank Cover Plate
11 100-4-20-8-5F 8 CSHH, 1/4-20 x .50, GR5, FT
12 302-4 8 Washer, Lock, 1/4
13 500070 1 Hydraulic Oil Sight Level/Temperature Gauge
14 1010402 1 Hydraulic Oil Temperature Sender
15 6806-16-16 NWO 1 Elbow Adapter, 90°, -16 O-Ring/-16 NPTF
16 280210 1 Ball Valve, 1.00"
17 FS2404-16-16 1 Connector Adapter -16 ORFS/-16 NPTF
18 F387TCJCJ9161616-20 1 Hose Assembly, Return Filter to Tank
REF 1017484 1 Charge Filter Assembly Includes Items 19-21
19 1017402 1 Hydraulic Filter Head
20 290030 1 Hydraulic Filter Element, 9 Micron
REF 1018445 1 Return Filter Assembly w/Adapters Includes Items 22-26
22 1018446 1 Hydraulic Return Filter Head
23 1018447 1 Hydraulic Return Filter Element, 10 Micron
24 FS6400-16-20-O 1 Straight Adapter, -16 ORFS/ -20 O-Ring
26 FS2406-20-12 1 Straight Reducer Adapter, -20 FFORX/-12 ORFS
27 100-6-16-12-5F 6 CSHH, 3/8-16 x .75, GR5, FT
28 302-6 6 Washer, Lock, 3/8
29 300-6 6 Washer, Flat, SAE, 3/8
7
31 6405-12-12-O 1 Straight Adapter, -12 O-Ring/-12 NPTF
32 1009089 1 Ball Valve, .75 MNPT-.75FNPT
33 FS2501-16-12-FG 1 Elbow Adapter, 90°, -16 ORFS/-12 NPTF
35 1018448 1 Hydraulic Return Diffuser, -32 SAE O-Ring, 95 GPM
36 6410-20-16-O 1 Reducer Adapter, -20 O-Ring/-16 O-Ring
38 1011971 1 Magnetic Drain Plug, -16 SAE Orb
39 6408-32-O 1 Plug Adapter, -32 O-Ring

HYDRAULICS - TANKS (CONT.)

8
9
1 11,12,6
10
13
25 27,28,29
26
22
24
14
23
18 5,6,7
21
19
15
21
16
17
20 3
44
43 37
31
39 38
30
32
42
4 33
34
37
44
35
45
5,6,7
36
46
40
41
Figure 7-27. Hydraulics - Tanks (Cont.)

Hydraulics - Tanks (Cont.)

Item
No
40 1014027 1 Suction Strainer, 30 GPM, 100 Mesh
43 1014037 1 Suction Strainer, 100 Mesh, O-Ring Seal
44 35812 2 Lock
REF 1018643 1 Hydraulic Tank Assembly w/Adapters - AWD Includes Items 1-38,40-44
45 1014037 1* Suction Strainer, 100 Mesh, O-Ring Seal *Add (1) to Replace Item 39

HYDRAULICS - 2WD
22,19,18,21
5
6
5
7
23,19
18,21
20,19
18,21
1 13,14
15,16
2 9
12
17,18,19
x2
11
10 8
Figure 7-28. Hydraulics - 2WD

Hydraulics - 2WD
Item
No
REF 1019747 1 Articulation Valve Assembly w/Adapters Includes Items 1-3
1 1019746 1 Articulation Lock Check Valve
2 FS6803-06-06-06-NWO-FG 2 Branch Tee Adapter, -6 ORFS/-6 ORFS/-6 O-Ring
3 FS6400-06-06-O X 100 2 Straight Adapter, -6 ORFS/-6 O-Ring, .100 Orifice
REF 1019684 1 Moldboard Manifold Assembly w/Adapters Includes Items 4-5
4 1019696 1 Moldboard Slide Manifold
REF 1018641 1 Moldboard Cushion Valve Assembly w/Adapters Includes Items 5-7
6 122084 1 Circle Turn Cushion Valve
8 1018223 2 Cover Plate
9 1018392 2 Connector, 6-Pin, DT04-6P-L012
12 FS0306-06 2 Bulkhead Lock Nut, -6 ORFS
13 122-#8-32-12F 8 PHMS, Cross, #8-32 x .75, FT
14 300-#8 8 Washer, Flat, #8
15 302-#8 8 Washer, Lock, #8
16 209-#8-32 8 Nut, Hex, Machine Screw, #8-32
17 100-4-20-16-5 8 CSHH, 1/4-20 x 1.00, GR5
18 302-4 14 Washer, Lock, 1/4
19 300-4 18 Washer, Flat, SAE, 1/4
20 100-4-20-32-5 2 CSHH, 1/4-20 x 2.00, GR5
21 200-4-20-5 6 Nut, Hex, 1/4-20, GR5
22 100-4-20-36-5 2 CSHH, 1/4-20 x 2.25, GR5
23 100-4-20-40-5 2 CSHH, 1/4-20 x 2.50, GR5

HYDRAULICS - BRAKE, 2WD/AWD
12
13
14
15
16
7 17
11
1
24,19,20,25
9
18,19,20
8
7 10
4
21,22 6
7
5
23,22 3
Figure 7-29. Hydraulics - Brake, 2WD/AWD

Hydraulics - Brake, 2WD/AWD

Item
No
REF 1018340 1 Brake System Assembly w/Adapters
1 1017529 1 Charge Valve Weldment
2 852720 1 Low Pressure Brake Switch
4 750602 1 Brake Manifold w/Relief
9 852740 1 Brake Charge Valve
12 1010390 1 Brake System Accumulator, 60 CI
13 FS6540-08-08-O 1 Swivel Straight Adapter, -8 ORFS/-8 O-Ring
15 FS6602-06-08-06-FG 1 Swivel Run Tee Adapter, -6 ORFS/-8 ORFS/-6 ORFS
18 100-6-16-20-5 3 CSHH, 3/8-16 x 1.25, GR5
19 302-6 5 Washer, Lock, 3/8
20 300-6 7 Washer, Flat, SAE, 3/8
21 100-4-20-36-5 1 CSHH, 1/4-20 x 2.25, GR5
22 302-4 2 Washer, Lock, 1/4
23 100-4-20-60-5 1 CSHH, 1/4-20 x 3.75, GR5
24 100-6-16-28-5 2 CSHH, 3/8-16 x 1.75, GR5
25 200-6-16-5 2 Nut, Hex, 3/8-16, GR5

HYDRAULICS - VALVE BANK, 2WD/AWD

22
4
23
20
21
18a/18b
4
19
14
14
15
13
1
17,6,7,8
4
10 16
11
12,6,7,8
4
9
2
3
4 29,30,31
5,6,7,8
12,6,7,8
23 32,31,30,33
3
24 3
4 28
27
27
25
26
Figure 7-30. Hydraulics - Valve Bank, 2WD/AWD

Hydraulics - Valve Bank, 2WD/AWD

Item
No
REF 1018344 1 Valve Bank Assembly w/Adapters Includes Items 1-16
1 1017539 1 Manifold & Trans Shift Valve Mount
2 983361 1 Trans Shift Valve
5 102-4-20-28 2 CSSH, 1/4-20 x 1.75
7 302-4 7 Washer, Lock, 1/4
8 200-4-20-5 7 Nut, Hex, 1/4-20, GR5
9 853850 1 FWD/REV Shift Solenoid Valve
10 FS6602-06-06-06-FG 1 Swivel Run Tee Adapter, -6 ORFS (x3)
12 100-4-20-32-5 4 CSHH, 1/4-20 x 2.00, GR5
13 1019697 1 Return Manifold
17 100-4-20-44-5 3 CSHH, 1/4-20 x 2.75, GR5
18a 1019088 1 Remote Test Ports Assembly - 2WD Includes Items 19,20
18b 1019089 1 Remote Test Ports Assembly - AWD Option Includes Items 19-21
19 1019090 1 Test Port Mount
20 1019707 5 Test Port Adapter, -4 ORFS
21 1019707 3 Test Port Adapter, -4 ORFS Option - AWD ONLY
22 1017698 1 Destroke Solenoid Assembly w/Adapters Includes Items4,23

23 1011845 2 Destroke Pump Valve, NO, 2-Way, 2-POS, 12V
24 1018651 1 AWD Filter & Valve Assembly w/Adapters Option - AWD Only
25 1017402 1 Hydraulic Filter Head
26 290030 1 Hydraulic Filter Element, 9 Micron
7
28 1018650 1 AWD Charge Filter Mount
29 100-6-16-16-5F 4 CSHH, 3/8-16 x 1.00, GR5, FT
30 302-6 4 Washer, Lock, 3/8
31 300-6 4 Washer, Flat, SAE, 3/8
32 100-6-16-28-5 2 CSHH, 3/8-16 x 1.75, GR5
33 200-6-16-5 2 Nut, Hex, 3/8-16, GR5

HYDRAULICS - PUMPS, 2WD
28
3
27
2
26
4,5
25
29,30,31
9
22
23
10,11,12,13
24
8
6,7
14
19
16,17,18
32
38,39
20
15
20
21
33
37
34
23
35
22
36
Figure 7-31. Hydraulics - Pumps, 2WD

Hydraulics - Pumps, 2WD

Item
No
1 114308 1 Pump Drive Includes Items 2-7
2 114521 1 Pump Mounting Plate
3 113259 1 Pump Drive Coupling/Flex Plate
4 102-6-16-12-F 8 CSSH, 3/8-16 x .75, FT
6 100-M10-1.5-35-8.8F 12 CSHH, M10x1.5 x 35mm, C8.8, FT
7 302-M10 12 Washer, Lock, M10
9 12757496 1 Switch Bracket
10 102-#10-32-16-F 2 CSSH, #10-32 x 1.00, FT
11 300-#10 2 Washer, Flat, SAE, #10
12 302-#10 2 Washer, Lock, #10
13 209-#10-32 2 Nut, Machine Screw, #10-32
REF 1018342 1 Hydraulic Pumps Assembly w/Adapters Includes Items 14-38
14 1018470 1 Hydraulic Pump, 75cc, 13T, BPAD
15 1018437 1 Pump Lever Plate
16 100-4-20-16-5 2 CSHH, 1/4-20 x 1.00, GR5
17 300-4 2 Washer, Flat, SAE, 1/4
18 205-4-20-5 2 Nut, Lock, Nylon, 1/4-20, GR5
22 FS1804-16-16-FG 2 Code 62 Adapter, 90°, -16 ORFS/-16 Flange
23 1902-16 2 Code 62 Clamp Flange, -16
29 100-8-13-28-5 4 CSHH, 1/2-13 x 1.75, GR5
30 986810 4 Washer, Lock,1/2, Nord Wedge (2 pc.)
31 105571 4 Thick Washer w/Offset Hole
7
32 36808 1 O-Ring, 3.237 ID x .103, SAE 152
33 1018473 1 Hydraulic Double Gear Pump, .93 CIR, 13T, SAE 8
38 100-8-13-24-5F 2 CSHH, 1/2-13 x 1.50, GR5, FT
39 309-8-20-3 2 Washer, Thick, 1/2 x 1.25 x .188

7-68
4,5
10,11,12,13
8
HYDRAULICS - PUMPS, AWD
16,17 6,7
15
18,19,20
21 9 3
2
23 22
1
34 35 24
17
25
22 31,32,33
16,17 37
30
38 22
39 14
Figure 7-32. Hydraulics - Pumps, AWD

25 25
44 24
22 31,32,33
43
40 30
42
36
26 21 25
39
46,47
41 26 27 28
29
45

Hydraulics - Pumps, AWD

Item
No
1 114308 1 Pump Drive Includes Items 2-7
2 114521 1 Pump Mounting Plate
3 113259 1 Pump Drive Coupling/Flex Plate
4 102-6-16-12-F 8 CSSH, 3/8-16 x .75, FT
6 100-M10-1.5-35-8.8F 12 CSHH, M10x1.5 x 35mm, C8.8, FT
7 302-M10 12 Washer, Lock, M10
9 12757496 1 Switch Bracket
10 102-#10-32-16-F 2 CSSH, #10-32 x 1.00, FT
11 300-#10 2 Washer, Flat, SAE, #10
12 302-#10 2 Washer, Lock, #10
13 209-#10-32 2 Nut, Machine Screw, #10-32
REF 1018343 1 Hydraulic Pumps Assembly w/Adapters - AWD Includes Items 14-47
14 1018472 1 Hydraulic Pump, 75cc, 13T, CPAD
15 1018437 1 Pump Lever Plate
16 100500 3 Rod End Ball Joint, 3/8"
17 200-6-16-5 2 Nut, Hex, 3/8-16, GR5
18 100-4-20-16-5 4 CSHH, 1/4-20 x 1.00, GR5
19 300-4 4 Washer, Flat, SAE, 1/4
20 205-4-20-5 4 Nut, Lock, Nylon, 1/4-20, GR5
25 1902-16 4 Code 62 Clamp Flange, -16
31 100-8-13-28-5 8 CSHH, 1/2-13 x 1.75, GR5
7
32 986810 8 Washer, Lock,1/2, Nord Wedge (2 pc.)
33 105571 8 Thick Washer w/Offset Hole
34 1019449 1 Throttle Plate, AWD Pump
35 56B-0692ZI 1 Threaded Rod, 3/8-24 UNF x 11.00
36 1018471 1 Hydraulic Pump, 55cc, 13T, BPAD
40 36808 1 O-Ring, 3.237 ID x .103, SAE 152
41 1018473 1 Hydraulic Double Gear Pump, .93 CIR, 13T,SAE 8

7-70
4,5
10,11,12,13
8
16,17 6,7
15
18,19,20
21 9 3
2
23 22
1
34 35 24
17
HYDRAULICS - PUMPS, AWD (CONT.)
25
22 31,32,33
16,17 37
30
38 22
39 14
25 25
44 24
Figure 7-32. Hydraulics - Pumps, AWD (Cont.)

22 31,32,33
43
40 30
42
36
26 21 25
39
46,47
41 26 27 28
29
45

Hydraulics - Pumps, AWD (Cont.)

Item
No
46 100-8-13-24-5F 2 CSHH, 1/2-13 x 1.50, GR5, FT
47 309-8-20-3 2 Washer, Thick, 1/2 x 1.25 x .188

ENGINE - SHROUD
35 30,16,17,32
33,34,9 28
31,16,17,32 4
27
33,34,9
29 8,9
10
11
1 3
5,6
12,13
15,16,17,18
15,16,17,18 14
2
11
26
24
23
4
19
24
25
3
5,6
24
23
20
21,22,9
Figure 7-33. Engine - Shroud

Engine - Shroud
Item
No
GRP 1017993 Group - Engine Shroud
REF 1017994 1 Engine Shroud Assembly Includes Items 1-18
1 1017995 1 Engine Shroud Weldment
2 1018004 1 Access Door - Left
3 160450 2 Door Latch
4 117-6-16-20 4 CSSBH, 3/8-16 x 1.25
5 122-#10-32-8F 8 PHMS, Cross, #10-32 x .50, FT
6 205-#10-32-5 8 Nut, Lock, Nylon, #10-32, GR5
7 1018005 1 Access Door - Right
9 300-6 18 Washer, Flat, SAE, 3/8
10 1018013 1 Air Cleaner Access Door
11 35812 2 Door Lock
12 117-4-20-12 2 CSSBH, 1/4-20 x .75
13 205-4-20-5 2 Nut, Lock, Nylon, 1/4-20, GR5
14 1001057 4 Lifting Ring, 500#
15 100-4-20-12-5F 10 CSHH, 1/4-20 x.75, GR5, FT
16 302-4 12 Washer, Lock, 1/4
17 300-4 14 Washer, Flat, SAE, 1/4
REF 1018016 1 Radiator Shroud Assembly Includes Items 9,11,14-26
19 1018017 1 Radiator Shroud Weldment
20 1018029 1 Radiator Grill
21 100-6-16-16-5F 4 CSHH, 3/8-16 x 1.00, GR5, FT
22 302-4 4 Washer, Lock, 3/8
REF 1007529 2 Brake Light Assembly Includes Items 23,24
23 1006806 2 Brake Light
24 160030A1 3 Grommet
25 852520 1 Back-Up Alarm Horn
26 1010961 1 Radiator Access Door
27 1018049 1 Intake Pipe
28 1019059 1 Support Bar
7
29 1013857 2 Intake Support Bracket
30 100-4-20-16-5 1 CSHH, 1/4-20 x 1.00, GR5
31 100-4-20-20-5 1 CSHH, 1/4-20 x 1.25, GR5
32 217-4-20 2 Nut, Lock, Flexloc, 1/4-20
33 100-5-18-16-5 8 CSHH, 5/16-18 x 1.00, GR5
34 302-5 8 Washer, Lock, 5/16
35 1019257 1 Engine Top Access Cover

ENGINE - RADIATOR
3
2
1
6
7
14
15
11 14
12 16
11 11
5 12
13
8
8
9 14
14
9 15 17
8
8
14
14
10 18
14
14
17
Figure 7-34. Engine - Radiator

Engine - Radiator
Item
No
1 1017509-01 1 Cooling Unit
2 100165 1 Radiator Cap
3 988986 1 Coolant Level Sensor
6 1017509-09 1 Radiator Brace
7 1010076-08 1 Isolator
8 1014076 4 T-Bolt Clamp (3.09-3.35)
9 1012642 2 Charge Air Hose, Wire Reinforced
10 1017547 1 Charge Air Pipe - Lower
11 1014074 3 T-Bolt Clamp (2.53-2.84)
12 1016121-37 2 CAC Air Intake Hose
13 1017546 1 Charge Air Pipe - Upper
14 1013667-21 8 T-Bolt Clamp (1.87-2.13)
15 1017509-21 2 High Temp Sleeve, 1.75 ID, 45°
16 1017544 1 Coolant Pipe - Upper
17 1017509-22 2 High Temp Sleeve, 2.00 ID, 90°
18 1017545 1 Coolant Pipe - Lower

ENGINE - INTAKE/EXHAUST
23
22
21
19
18
20
19
12
18
11
6,7,8
15
17
14 5
16
13 5 10
4
1
3
Figure 7-35. Engine - Intake/Exhaust

Engine - Intake/Exhaust
Item
No
1 171090 3 T-Bolt Clamp (3.31-3.59)
2 1010076-38 1 Intake Elbow
3 1017548 1 Air Intake Pipe
4 1000834 1 Rubber Elbow, 90°, 4.00 x 3.00 ID
5 953521243 3 T-Bolt Clamp (4.31-4.59)
6 1013667-30 1 Air Filter Assembly
7 1011263-13 1 Air Filter - Primary Not Shown
8 1012474-25 1 Air Filter - Secondary Not Shown
9 39068 1 T-Bolt Clamp (5.28-5.59)
10 72172 1 Rubber Elbow, 90°, 5.00 x 4.00 ID
11 1018049 1 Intake Pipe Weldment
12 1011263-04 1 Pre-Cleaner
13 1009242-06 1 V-Band Clamp, 3.22"
14 1017549 1 Exhaust Pipe Weldment
15 1014098 1 V-Band Clamp, 3.88"
16 1013667-12 1 Gasket
17 1013528-87 1 Decomp Reactor Tube
18 1014101 2 V-Band Clamp, Spherical, 5.13"
19 1013667-11 2 Gasket
20 1017509-25 1 Elbow
21 1017509-24 1 SCR
22 1012526-38 1 Clamp, 4.00
23 1018048 1 Exhaust Pipe, 4.00"

ENGINE - COMPONENTS
33 32 31 30 29 14
40
39
10 13
37,38 11,12
9
15 16
34 35 36
*Lid removed for clarity Connects to rear of
Drive Axle Assembly
(See Figure 7-3)
7 3
8 6 4
5
28 2
19
23,24,25 1
19
18
23,24,25
26 17
27
20
21
26
27
22
Figure 7-36. Engine - Components

Engine - Components
Item
No
1 1017509-04 1 Fan
2 1008650-02 1 Fan Spacer
3 1017509-08 1 Fan Belt w/o AC Option
4 1013528-71 1 Belt Tensioner
5 1017509-06 1 Alternator
6 1017509-07 1 Engine Dipstick
7 1013528-72 1 Alternator Mounting
8 1008650-01 1 Starter, 4.8kW
9 1017509-02 1 ECU
10 1013528-70 1 Oil Filler
11 1012474-10 1 Fuel Filter Head
12 1012474-27 1 Fuel Filter
13 1012474-12 1 Oil Filter
14 1013667-18 1 Fuel/Water Separator Filter
15 7205-08-18-NWO-FG 1 Elbow Adapter, 90°, -8 JIC/M18 O-Ring Included with Engine
16 F387TCJCJ9101010-22 1 Hose Assembly - Engine Oil Pan to Rear Axle Included w/AWD Hyd Hose Kit
17 1017509-11 1 Engine & Radiator Mount - Left
18 1017509-10 1 Engine & Radiator Mount - Right
19 1010196 2 Engine Mounting Bracket
20 1017543 2 Radiator Spacer
21 36048 2 Rubber Mount
22 1009242-34 2 Isolator Mount
23 100-10-18-64-8 4 CSHH, 5/8-18 x 4.00, GR8
24 300-10 8 Washer, Flat, SAE, 5/8
26 1017509-26 4 Rubber Isolation Engine Mount (2 pc.)
27 113683 4 Engine Mount Washer
28 1019668 1 Grid Heater and Relays Assembly Includes Items 29-40
29 1019666 1 Enclosure
30 1019667 1 Panel
31 1013394 1 Relay, 200A
32 36086 6 Relay Mounting Bracket
7
33 36085 6 Relay, 12VDC, SPDT, 40A, 5 Pin
34 985752 2 Mega Fuse Holder
35 1014120 1 Fuse, 175A, AMG
36 1014121 1 Fuse, 250A, AMG
37 1014487 1 Strain Relief, 1-1/2" NPT
38 1014489 1 Locking Nut, 1-1/2" NPT
39 1014358 1 Receptacle Connector, 23-Pin
40 720290 1 Solenoid, 12V Constant Duty

ENGINE - DEF TANK
6,7,8
5
4
5
Figure 7-37. Engine - DEF Tank

Engine - DEF Tank

Item
No
1 1017509-05 1 DEF Tank
2 1013667-03 1 Coolant Control Valve
3 1020604 1 DEF Control Module Mount
4 1012641 1 Supply DEF Module
5 1013924 2 DEF Tank Strap
6 100-5-18-16-5F 4 CSHH, 5/16-18 x 1.00, GR5, FT
7 302-5 4 Washer, Lock, 5/16
8 300-5 4 Washer, Flat, SAE, 5/16

ENGINE - FUEL TANK
7,8,9
4
14,15,16
4
13
5 17
3
5
18
19
18
20
19 18
18
2
10,11,12
Figure 7-38. Engine - Fuel Tank

Engine - Fuel Tank

Item
No
REF 1017535 1 Fuel Tank Assembly, 45 Gallon Includes Items 1-9
1 1017536 1 Fuel Tank, 45 Gallon
3 1695HB-6-4 1 Barb Elbow Fitting, -04 to .375
4 2502-6-6 2 Elbow Adapter, 90°, -6 JIC/-6 NPTF
5 30682-6-6 2 Push Lok Fitting, -6 FJX/-6 Hose
6 1016871 1 Fuel Sending Unit
7 122-#12-24-12F 5 PHMS, Cross, #12-24 x .75, FT
8 302-#12 5 Washer, Lock, #12
9 300-#12 5 Washer, Flat, SAE, #12
10 100-8-13-24-5 4 CSHH, 1/2-13 x 1.50, GR5
11 302-8 4 Washer, Lock, 1/2
12 300-8 4 Washer, Flat, SAE, 1/2
13 140030FL 1 Fuel Tank Cap, Lockable
14 100-4-20-12-5F 2 CSHH, 1/2-13 x 1.50, GR5
15 302-4 2 Washer, Lock, 1/4
16 300-4 2 Washer, Flat, SAE, 1/4
17 1018220 1 Fuel Fill Neck
18 22B-36 4 Hose Clamp, #36
19 1010900 2 Reducer, Rubber, 2.25-2.00
20 1018411 1 Fuel Fill Pipe

ENGINE - BATTERY BOX

22
24
21
23
25
26
2
28
4,5,6
27
3
16,17,18
12,13 20
14,15 7,8,9
11
10 1
19
19
Figure 7-39. Engine - Battery Box

Engine - Battery Box

Item
No
1 1018070 1 Battery Box
2 35812 1 Door Lock
3 1020571 1 Prop Rod Bar
4 100-4-20-16-5 1 CSHH, 1/4-20 x 1.00, GR5
6 205-4-20-5 1 Nut, Lock, Nylon, 1/4-20, GR5
7 100-8-13-24-5F 2 CSHH, 1/2-13 x 1.50, GR5, FT
8 302-8 2 Washer, Lock, 1/2
10 982962 1 Battery Hold-down Assembly
11 36688-55 2 Knob
12 122-#10-24-12F 2 PHMS, Cross, #10-24 x .75, FT
13 300-#10 4 Washer, Flat, SAE, #10
14 302-#10 2 Washer, Lock, #10
15 209-#10-24 2 Nut, Hex, Machine, #10-24
16 100-6-16-152-5 2 CSHH, 3/8-16 x 9.50, GR5
17 302-6 2 Washer, Lock, 3/8
18 300-6 2 Washer, Flat, SAE, 3/8
19 Purchase Locally 2 Battery, 12VDC, 800CCA, Group 24
20 109740 1 Battery Master Disconnect Switch
21 1019672 1 Battery Cable (-), 28", Eye/Eye, 4 AWG
22 1019673 1 Battery Cable (-), 7", Eye/Eye, 4 AWG
23 1019674 1 Battery Cable (-), 18", Eye/Eye, 1/0 AWG
24 1019675 1 Battery Cable (-), 12.5", Eye/Eye, 1/0 AWG
25 1019676 1 Battery Cable (+), 12.5", Eye/Eye, 1/0 AWG
26 1019677 1 Battery Cable (-), 30", Eye/Eye, 1/0 AWG
27 1019678 1 Battery Cable (+), 32", Eye/Eye, 1/0 AWG
28 1019679 1 Battery Cable (+), 13", Eye/Eye, 1/0 AWG

FRAME DETAILS
1
11
8
10
Figure 7-40. Frame Details

Frame Details
Item
No
1 852560 1 Light Kit
2 1018051 1 Headlamp Mount
- 100-6-16-16-5F 2 CSHH, 3/8-16 x 1.00, GR5, FT
- 302-6 2 Washer, Lock, 3/8
- 300-6 2 Washer, Flat, SAE, 3/8
3 1018230 2 Cab Entrance Step Assembly
- 100-8-13-16-5F 4 CSHH, 1/2-13 x 1.00, GR5, FT
- 302-8 4 Washer, Lock, 1/2
4 20190773 1 Low Pitch Horn
- 100-4-20-20-5 1 CSHH, 1/4-20 x 1.25, GR5
- 302-4 1 Washer, Lock, 1/4
- 200-4-20-5 1 Nut, Hex, 1/4-20, GR5
5 1017582 1 Rear Frame Front Guard
- 100-8-13-24-5 4 CSHH, 1/2-13 x 1.50, GR5
- 302-8 4 Washer, Lock, 1/2
6 1018666 1 Hydraulic Motor Access Panel
- 100-8-13-24-5 2 CSHH, 1/2-13 x 1.50, GR5 Front
- 302-8 2 Washer, Lock, 1/2 Front
- 300-8 2 Washer, Flat, SAE, 1/2 Front
- 1019265 2 Shoulder Bolt, 1/2-13, 1.25 LG Rear
- 300-8 10 Washer, Flat, SAE, 1/2 Rear
- 200-8-13-5 2 Nut, Hex, 1/2-13, GR5 Rear
7 12754774 1 Option - SMV Sign Assembly
- 100-6-16-16-5F 2 CSHH, 3/8-16 x 1.00, GR5, FT
- 302-6 2 Washer, Lock, 3/8
8 100180 1 Pintle Hitch
- 100-8-13-40-5 4 CSHH, 1/2-13 x 2.50, GR5
- 302-8 4 Washer, Lock, 1/2
7
- 200-8-13-5 4 Nut, Hex, 1/2-13, GR5
9 1019138 2 Rear Scarifier Access Cover
- 100-6-16-16-5F 4 CSHH, 3/8-16 x 1.00, GR5, FT
- 302-6 4 Washer, Lock, 3/8
10 1010739 2 Axle Mounted Step Plate
- 100-M16-2-40-8.8F 4 CSHH, M16x2 x 40mm, C8.8, FT
- 302-10 4 Washer, Lock, 5/8
11 982560 2 Axle Mounted Step Plate
- 100-M14-2-30-8.8F 4 CSHH, M14x2 x 30mm, C8.8, FT
- 302-9 4 Washer, Lock, 9/16

OPTION - DOZER BLADE/BLADE SCARIFIER

17
26
27,28,29
24 23 32
27,28,29 33
20,21,22 31
30
17
25 1
18,16 14 13
11 19
12 8
9 15,16
15,16
10 15,16
3 17 13
4,5,6
37
39,16,19
36
38
34
40,22
21,41
34
35
Figure 7-41. OPTION - Dozer Blade/Blade Scarifier

OPTION - Dozer Blade/Blade Scarifier

Item
No
GRP 1018831 Group - Dozer Blade
REF 1018828 1 Dozer Assembly, 8 ft. Includes Items 2-19
2 1018830 1 Dozer Blade, 8 Ft.
3 108581 1 Cutting Edge, 8 Ft., Offset Punched
4 130220 10 Plow Bolt, 5/8-11 x 2.00
5 302-10 10 Washer, Lock, 5/8
6 200-10-11-5 10 Nut, Hex, 5/8-11, GR5
REF 12758133SRV 1 Front Attachment Assembly Includes Items 7-19
7 12758118 1 Universal Back Plate
8 12758123 1 Push Arm Linkage - Bottom
9 117706 2 Push Arm Bar - Top
10 107661 2 Push Arm Link Pin - Bottom
11 1012072 2 Push Arm Pivot Pin - Bottom
12 107663 2 Front Blade Link Pin
13 100529 4 Washer, 3.00
14 103127 2 Bushing, 1.25 ID x 1.50 OD x 1.00 LG
15 100-8-13-16-8F 6 CSHH, 1/2-13 x 1.00, GR8, FT
16 302-8 14 Washer, Lock, 1/2
17 140610 A/R Lube Fitting, Straight, 1/4-28
18 101-8-13-22-8F 2 CSHH, Heavy, 1/2-13 x 1.38, GR8, FT
19 300-8 8 Washer, Flat, SAE, 1/2
20 100-12-10-36-5 6 CSHH, 3/4-10 x 2.25, GR5
21 302-12 8 Washer, Lock, 3/4
22 300-12 14 Washer, Flat, SAE, 3/4
REF 1018420 1 Dozer Lift Cylinder Assembly w/Adapters Includes Items 23-24
25 110596 1 Cylinder Mounting Pin - Long
26 110597 1 Cylinder Mounting Pin - Short
27 100-6-16-12-5F 2 CSHH, 3/8-16 x .75, GR5, FT
28 302-6 2 Washer, Lock, 3/8
7
29 300-6 2 Washer, Flat, SAE, 3/8
REF 1018647 1 Dozer Float Valve Assembly w/Adapters
31 100202 1 Solenoid Valve
REF 1018646 1 Hydraulic Hose Kit, Dozer Blade Not Shown
GRP 1018849 Group - Front Blade Scarifier

34 1018850 2 Front Scarifier Weldment

OPTION - DOZER BLADE/BLADE SCARIFIER (CONT.)

17
26
27,28,29
24 23 32
27,28,29 33
20,21,22 31
30
17
25 1
18,16 14 13
11 19
12 8
9 15,16
15,16
10 15,16
3 17 13
4,5,6
37
39,16,19
36
38
34
40,22
21,41
34
35
Figure 7-41. OPTION - Dozer Blade/Blade Scarifier (Cont.)

OPTION - Dozer Blade/Blade Scarifier (Cont.)

Item
No
35 100523 A/R Scarifier Point
36 1018852 1 Front Scarifier Mount - Left Includes Item 38
37 1018853 1 Front Scarifier Mount - Right Includes Item 38
38 1000835 2 Spring Loaded Pull Pin
39 100-8-13-24-5 6 CSHH, 1/2-13 x 1.50, GR5
40 100-12-10-56-5 4 CSHH, 3/4-10 x 3.50, GR5
41 200-12-10-5 4 Nut, Hex, 3/4-10, GR5

OPTION - FRONT SCARIFIER

22
15
23,24,25
13 12
31
23,24,25 32
30
19,20,21 18
14 17
16
11
1 28,27 9
7 29
10 5
26,27
8
26,27
4
6 26,27
9
Figure 7-42. OPTION - Front Scarifier

OPTION - Front Scarifier

Item
No
GRP 1018880 Group - Front Scarifier
1 1018879 1 Front Scarifier Weldment
2 132040 5 Scarifier Shank w/Tooth
3 132050 A/R Scarifier Tooth
4 1020476 5 Scarifier Shank Lock Pin
5 12758123SRV 1 Bottom Pusharm Linkage Weldment
6 107661 2 Pusharm Link Pin - Bottom
7 1012072 2 Pusharm Pivot Pin - Bottom
8 117706 2 Pusharm Bar - Top
9 100529 4 Washer, 3.00
REF 107663 2 Front Blade Link Pin
10 103127 2 Bushing, 1.25 ID x 1.50 OD x 1.00 LG
11 1018420 1 Dozer Lift Cylinder Assembly w/Adapters Includes Items 10,11
14 110596 1 Cylinder Mounting Pin - Long
15 110597 1 Cylinder Mounting Pin - Short
16 12758118 1 Universal Backplate
19 100-12-10-36-5 6 CSHH, 3/4-10 x 2.25, GR5
20 302-12 6 Washer, Lock, 3/4
21 300-12 6 Washer, Flat, SAE, 3/4
22 140610 A/R Lube Fitting, Straight, 1/4-28
23 100-6-16-12-5F 2 CSHH, 3/8-16 x .75, GR5, FT
24 302-6 2 Washer, Lock, 3/8
25 300-6 2 Washer, Flat, SAE, 3/8
26 100-8-13-16-8F 6 CSHH, 1/2-13 x 1.00, GR8, FT
27 302-8 8 Washer, Lock, 1/2
28 101-8-13-22-8F 2 CSHH, Heavy, 1/2-13 x 1.38, GR8, FT
REF 300-8 2 Washer, Flat, SAE, 1/2
REF 1018647 1 Dozer Float Valve Assembly w/Adapters
7
30 100202 1 Solenoid Valve
REF 1018646 1 Hydraulic Hose Kit, Dozer Blade Not Shown

OPTION - REAR SCARIFIER
17
16
18
16 17
13,14
1
12
6 2
8,9,10
7
3
5
11,9,10
Figure 7-43. OPTION - Rear Scarifier

OPTION - Rear Scarifier

Item
No
GRP 1018098 Group - Rear Scarifier Includes Items 1-15
1 1018099 1 Rear Scarifier Weldment
2 132040 9 Scarifier Shank w/Tooth Includes Item 3
3 132050 9 Scarifier Tooth
4 1020476 9 Locking Shank, Scarifier Tooth
REF 1018352 2 Scarifier Cylinder Assembly w/Adapters Includes Items 4-6
5 1014284SRV 2 Hydraulic Cylinder, 2.50 x 12.00 x 1.00
8 100-16-8-88-8 2 CSHH, 1-8 x 5.50, GR8
9 300-16 4 Washer, Flat, SAE, 1
10 204-16-8-5 4 Nut Lock, Stover, 1-8, GR5
11 100-16-8-120-8 2 CSHH, 1-8 x 7.50, GR8
12 1010773SRV 2 Scarifier Pin
13 100-6-16-16-5F 2 CSHH, 3/8-16 x 1.00, GR5, FT
14 302-6 2 Washer, Lock, 3/8
15 1018640 1 Hydraulic Hose Kit, Rear Scarifier Not Shown
16 FS2700-06-06 4 Bulkhead Union Adapter, -6 ORFD/-6 ORFS

17 0306-06 4 Bulkhead Lock Nut, -6

OPTION - REAR WIPER
7,8
Figure 7-44. OPTION - Rear Wiper

OPTION - Rear Wiper

Item
No
OPT 982106 1 OPTION - Rear Window Wiper/Washer
1 151170 1 Windshield Wiper Motor
2 151180 1 Windshield Wiper Arm
3 151190 1 Windshield Wiper Blade, 20"
4 73119-CMG 1 Wiper/Washer Switch
5 852810 1 Windshield Washer Nozzle Kit
6 1011124 1 Wiper Motor Cover Plate
7 100-6-16-16-5F 2 CSHH, 3/8-16 x 1.00, GR5, FT
8 301-6 2 Washer, Flat, USS, 3/8
9 81277 1 CSBHS, 1/4-20 x .88, SS
10 35550 5 Windshield Washer Hose, .188 ID (per foot) Not Shown
11 300-6 2 Washer, Flat, SAE, 3/8 Not Shown

OPTION - COLD WEATHER START
Figure 7-45. OPTION - Cold Weather Start

OPTION - Cold Weather Start

Item
No
OPT 1016450 1 OPTION - Cold Weather Package
1 121057 1 Engine Heater Cable
2 1016451 1 Engine Heater

OPTION - DEAD ENGINE STEERING
3,4,5
18
3,4,5 17
6 16
7
8 15
6 1
10
9
7
11
8
12
13
14
Figure 7-46. OPTION - Dead Engine Steering

OPTION - Dead Engine Steering

Item
No
OPT 1019630 1 OPTION - Dead Engine Steering
REF 1019626 1 Dead Engine Steering Unit Assembly w/Adapter Includes Items 1-12
1 685020 1 Dead Engine Steering Motor & Pump
2 1019627 1 Dead Engine Steering Unit Mount
3 100-6-16-12-5F 4 CSHH, 3/8-16 x .75, GR5, FT
4 302-6 4 Washer, Lock, 3/8
6 FS2501-08-06-FG 2 Elbow Adapter, 90°, -8 ORFS/-6 NPTF
7 FS6565-08-08 2 Double Swivel Union Adapter, -8 ORFS/-8 ORFS
8 1019694 2 Check Valve, 5 PSI, 8 GMP, -8 ORFS
11 8 G65L-S 1 Straight Adapter, -8 ORFS/-8 O-Ring
12 1019693 1 Pressure Switch, Dead Engine Steering
REF 1019628 1 Dead Engine Steering Hose Kit
13 F387TCJCJ9060606-36 1 Hose Assembly
14 F387TCJCJC060606-39 1 Hose Assembly
17 FS6803-20-20-20-NWO-FG 1 Branch Tee Adapter, -20 ORFS/-20 ORFS/-20 O-Ring

OPTION - STEREO W/ANTENNA
10,9,11
8,9
2
4,5,6,7
Figure 7-47. OPTION - Stereo w/Antenna

OPTION - Stereo w/Antenna

Item
No
GRP 1016867 OPTION - Radio/CD w/Speakers & Antenna
1 1011314 1 Radio, AM/FM/CD w/Auxiliary Input and Speakers
2 1008092 1 Mount, Weldment, Radio/Speaker
3 1002021 1 Antenna, AM/FM, Flexible
4 122-#10-24-12F 8 PHMS, Cross, #10-24 x .75, FT
5 300-#10 8 Washer, Flat, SAE, #10
6 303-#10 8 Washer, Lock, External Tooth, #10
7 209-#10-24 8 Nut, Hex, Machine, #10-24
8 100-4-28-12-5F 2 CSHH, 1/4-28 x .75, GR5, FT
9 302-4 3 Washer, Lock, 1/4
10 200-4-20-5 1 Nut, Hex, 1/4-20, GR5
11 300-4 1 Washer, Flat, SAE, 1/4
REF 35136-6 1 Plug, Hole, ø.75, Flush Mount, Plastic Not Shown

Hydraulic Hose Index
HYDRAULIC HOSE INDEX

Hose
Qty. Part Number Description
No.
1018254 Hydraulic Hose Kit - 2WD
1 2 F387TCJCJ1060606-21 BOGIE AXLE REAR JUMPER
2 2 F387TCJCJ1060606-17 BOGIE AXLE FRONT JUMPER
3 1 F387TCJCJC060606-36 FWD/REV VALVE 2 TO BOGIE AXLE REAR
4 1 F387TCJCJ9060606-24 2 SPEED VALVE A TO BOGIE SHIFTER FRONT
5 1 F387TCJCJ5060606-25 2 SPEED VALVE B TO BOGIE SHIFTER REAR
6 1 F387TCJCJ9040404-14 LP SWITCH TO CHARGE VALVE TEE
7 1 F387TCJCJ7080808-29 RELIEF VALVE T TOP CHARGE VALVE
8 1 F387TCJCJ9080808-28 RELIEF VALVE OUT TO CHARGE VALVE P
9 1 F387TCJCJC080808-45 GEAR PUMP TO BRAKE SYSTEM RELIEF VALVE
10 1 F387TCJCJ7080808-54 10 STATION VALVE PBR TO RETURN MANIFOLD
11 1 F387TCJCJ7080808-54 10 SECTION VALVE T TO RETURN MANIFOLD
12 1 F387TCJCJC080808-71 GEAR PUMP TO 10 SECTION VALVE P
13 1 F387TCJCJ7080808-54 10 SECTION VALVE D TO RETURN MANIFOLD
14 1 F387TCJCJ9080808-81 BRAKE CHARGE VALVE TO STEERIING MOTOR
15 1 F387TCJ5J7080808-66-0 STEERING MOTOR TO RETURN MANIFOLD
20 1 F797TCJCJC161616-23 RWD PUMP A TO DRIVE MOTOR A
21 1 F797TCJCJC161616-58 RWD PUMP B TO DRIVE MOTOR B
22 1 F387TCJCJC060606-15 RWD PUMP DESTROKE TOP TO VALVE
23 1 F387TCJCJC060606-18 RWD PUMP DESTROKE BOTTOM TO VALVE
24 1 F387TCJ9J9060606-27-90 TRANS SHIFT VALVE P TO BRAKE VALVE 3
25 1 F387TCJ9J9060606-23-0 TRANS SHIFT VALVE T TO BRAKE VALVE 1
26 1 F387TCJCJC060606-41 RWD PUMP FILTER AUX TO BRAKE VALVE 1
27 1 F387TCJCJ9060606-62 BRAKE VALVE 3 TO TANK
28 1 K811HTJSJS202020-60 TANK TO RWD PUMP SUCTION
29 1 K811HTJSJS242424-36 TANK TO GEAR PUMP SUCTION
30 1 F387TCJCJC121212-61 DRIVE MOTOR CASE DRAIN TO TANK
31 1 F387TCJCJ5121212-65 RWD PUMP CASE DRAIN TO TANK
32 1 F387TCJCJ9080808-23 BRAKE RELIEF VALVE TO RETURN MANIFOLD
33 1 F387TCJCJC121212-91 RADIATOR BOTTOM TO RETURN MANIFOLD
34 1 F387TCJCJC121212-45 RADIATOR TOP TO RETURN FILTER
35 1 F387TCJCJ7101010-35 RWD PUMP FILTER AUX TO CHARGE FILTER OUT
36 1 F387TCJCJ7101010-38 RWD PUMP FILTER AUX TO CHARGE FILTER IN
37 1 F387TCJCJ9101010-22 ENGINE OIL PAN TO REMOTE FITTING ON AXLE
38 1 F387TCJCJC060606-206 WHEEL LEAN VALVE A TO CYLINDER ROD END
39 1 F387TCJCJC060606-198 WHEEL LEAN VALVE B TO CYLINDER CAP END
40 1 F387TCJCJC060606-170 DOZER LIFT VALVE A TO LH BULKHEAD
41 1 F387TCJCJC060606-173 DOZER LIFT VALVE B TO RH BULKHEAD
42 1 F387TCJCJC060606-210 STEERING MOTOR TO CYLINDER ROD END
43 1 F387TCJCJ5060606-201 STEERING MOTOR TO CYLINDER CAP END

Hose
No.
44 1 F387TCJCJC060606-161 MOLDBOARD SWING VALVE B TO CUSHION VALVE TOP
45 1 F387TCJCJC060606-164 MOLDBOARD SWING VALVE A TO CUSHION VALVE BOTTOM
46 1 F387TCJCJC060606-123 MOLDBOARD LIFT VALVE B TO LH LIFT CYLINDER, TOP
47 1 F387TCJCJC060606-123 MOLDBOARD LIFT VALVE A TO LH LIFT CYLINDER, BOTTOM
48 1 F387TCJCJC060606-121 MOLDBOARD LIFT VALVE B TO RH LIFT CYLINDER, TOP
49 1 F387TCJCJC060606-121 MOLDBOARD LIFT VALVE A TO RH LIFT CYLINDER, BOTTOM
50 1 F387TCJCJC060606-260 MOLDBOARD TILT VAVLE B TO CYLINDER CAP END
51 1 F387TCJCJC060606-279 MOLDBOARD SLIDE VALVE A TO CYLINDER CAP END
52 1 F387TCJCJC060606-270 MOLDBOARD SLIDE VALVE B TO CYLINDER ROD END
53 1 F387TCJCJC060606-265 MOLDBOARD TILT VALVE A TO CYLINDER ROD END
54 1 F387TCJCJC060606-38 ARTICULATION VALVE A TO MANIFOLD V2
55 1 F387TCJCJC060606-38 ARTICULATION VALVE B TO MANIFOLD V1
56 1 F387TCJCJC060606-20 ARTICULATION VALVE C1 TO LH CYLINDER ROD END
57 1 F387TCJCJC060606-20 ARTICULATION VALVE C2 TO LH CYLINDER CAP END
58 1 F387TCJCJC060606-20 ARTICULATION VALVE C1 TO RH CYLINDER CAP END
59 1 F387TCJCJC060606-20 ARTICULATION VALVE C2 TO RH CYLINDER ROD END
60 1 F387TCJCJ9060606-36 SWING MANIFOLD LH BOTTOM TO CYLINDER CAP END
61 1 F387TCJCJ9060606-28 SWING MANIFOLD LH TOP TO CYLINDER ROD END
62 1 F387TCJCJ9060606-28 SWING MANIFOLD RH BOTTOM TO CYLINDER ROD END
63 1 F387TCJCJ9060606-36 SWING MANIFOLD TOP TO CYLINDER CAP END
64 1 F387TCJCJC060606-30 BRAKE PEDAL P TO BRAKE PRESSURE SWITCH
65 1 F387TCJCJ9060606-49 BRAKE PEDAL T TO TANK
66 1 F387TCJCJC060606-46 BRAKE PEDAL OUT TO AXLE FRONT TEE
70 1 F387TCJCJ9161616-20 RETURN FILTER TO TANK
71 1 F387TCJCJ9060606-38 CUSHION VALVE LOWER TO MANIFOLD LOWER
72 1 F387TCJCJ9060606-39 CUSHION VALVE UPPER TO MANIFOLD UPPER
73 1 F387TCJCJC060606-133 REAR SCARIFIER VALVE B TO REAR TEE
74 1 F387TCJCJC060606-129 REAR SCARIFIER VALVE A TO FRONT TEE
75 2 F387TCJ9J9060606-56-0 REAR SCARIFIER R-L JUMPER

Hose
No.
1018478 Hydraulic Hose Kit - AWD
1 2 F387TCJCJ1060606-21 BOGIE AXLE REAR JUMPER
2 2 F387TCJCJ1060606-17 BOGIE AXLE FRONT JUMPER
3 1 F387TCJCJC060606-36 FWD/REV VALVE 2 TO BOGIE AXLE REAR
4 1 F387TCJCJ9060606-24 2 SPEED VALVE A TO BOGIE SHIFTER FRONT
5 1 F387TCJCJ5060606-25 2 SPEED VALVE B TO BOGIE SHIFTER REAR
6 1 F387TCJCJ9040404-14 LP SWITCH TO CHARGE VALVE TEE
7 1 F387TCJCJ7080808-29 RELIEF VALVE T TOP CHARGE VALVE
8 1 F387TCJCJ9080808-28 RELIEF VALVE OUT TO CHARGE VALVE P
9 1 F387TCJCJC080808-42 GEAR PUMP TO BRAKE SYSTEM RELIEF VALVE
10 1 F387TCJCJ7080808-54 10 SECTION VALVE PBR TO RETURN MANIFOLD
11 1 F387TCJCJ7080808-54 10 SECTION VALVE T TO RETURN MANIFOLD
12 1 F387TCJCJC080808-67 GEAR PUMP TO 10 SECTION VALVE P
13 1 F387TCJCJ7080808-54 10 SECTION VALVE D TO RETURN MANIFOLD
14 1 F387TCJCJ9080808-81 BRAKE CHARGE VALVE TO STEERIING MOTOR
15 1 F387TCJ5J7080808-66-0 STEERING MOTOR TO RETURN MANIFOLD
20 1 F797TCJCJC161616-23 RWD PUMP A TO DRIVE MOTOR A
21 1 F797TCJCJC161616-58 RWD PUMP B TO DRIVE MOTOR B
22 1 F387TCJCJC060606-15 RWD PUMP DESTROKE TOP TO VALVE
23 1 F387TCJCJC060606-18 RWD PUMP DESTROKE BOTTOM TO VALVE
24 1 F387TCJ9J9060606-27-90 TRANS SHIFT VALVE P TO BRAKE VALVE 3
25 1 F387TCJ9J9060606-23-0 TRANS SHIFT VALVE T TO BRAKE VALVE 1
26 1 F387TCJCJC060606-41 RWD PUMP FILTER AUX TO BRAKE VALVE 3
27 1 F387TCJCJ9060606-62 BRAKE VALVE 1 TO TANK
28 1 K811HTJSJS202020-60 TANK TO RWD PUMP SUCTION
29 1 K811HTJSJS242424-38 TANK TO GEAR PUMP SUCTION
30 1 F387TCJCJC121212-61 DRIVE MOTOR CASE DRAIN TO TANK
31 1 F387TCJCJ5121212-65 RWD PUMP CASE DRAIN TO TANK
32 1 F387TCJCJ9080808-23 BRAKE RELIEF VALVE TO RETURN MANIFOLD
33 1 F387TCJCJC121212-91 RADIATOR BOTTOM TO RETURN MANIFOLD
34 1 F387TCJCJC121212-45 RADIATOR TOP TO RETURN FILTER
35 1 F387TCJCJ7101010-35 RWD PUMP FILTER OUT TO CHARGE FILTER
36 1 F387TCJCJ7101010-38 RWD PUMP FILTER TO CHARGE FILTER IN
37 1 F387TCJCJ9101010-22 ENGINE OIL PAN TO REMOTE FITTING ON AXLE
38 1 F387TCJCJC060606-206 WHEEL LEAN VALVE A TO CYLINDER ROD END
39 1 F387TCJCJC060606-198 WHEEL LEAN VALVE B TO CYLINDER CAP END
40 1 F387TCJCJC060606-170 DOZER LIFT VALVE A TO LH BULKHEAD
41 1 F387TCJCJC060606-173 DOZER LIFT VALVE B TO RH BULKHEAD
42 1 F387TCJCJC060606-210 STEERING MOTOR TO CYLINDER ROD END
43 1 F387TCJCJ5060606-201 STEERING MOTOR TO CYLINDER CAP END
44 1 F387TCJCJC060606-161 MOLDBOARD SWING VALVE B TO CUSHION VALVE TOP
45 1 F387TCJCJC060606-164 MOLDBOARD SWING VALVE A TO CUSHION VALVE BOTTOM
46 1 F387TCJCJC060606-123 MOLDBOARD LIFT VALVE B TO LH LIFT CYLINDER, TOP
47 1 F387TCJCJC060606-123 MOLDBOARD LIFT VALVE A TO LH LIFT CYLINDER, BOTTOM

Hose
No.
48 1 F387TCJCJC060606-121 MOLDBOARD LIFT VALVE B TO RH LIFT CYLINDER, TOP
49 1 F387TCJCJC060606-121 MOLDBOARD LIFT VALVE A TO RH LIFT CYLINDER, BOTTOM
50 1 F387TCJCJC060606-260 MOLDBOARD TILT VAVLE B TO CYLINDER CAP END
51 1 F387TCJCJC060606-279 MOLDBOARD SLIDE VALVE A TO CYLINDER CAP END
52 1 F387TCJCJC060606-270 MOLDBOARD SLIDE VALVE B TO CYLINDER ROD END
53 1 F387TCJCJC060606-265 MOLDBOARD TILT VALVE A TO CYLINDER ROD END
54 1 F387TCJCJC060606-38 ARTICULATION VALVE A TO MANIFOLD V2
55 1 F387TCJCJC060606-38 ARTICULATION VALVE B TO MANIFOLD V1
56 1 F387TCJCJC060606-20 ARTICULATION VALVE C1 TO LH CYLINDER ROD END
57 1 F387TCJCJC060606-20 ARTICULATION VALVE C2 TO LH CYLINDER CAP END
58 1 F387TCJCJC060606-20 ARTICULATION VALVE C1 TO RH CYLINDER CAP END
59 1 F387TCJCJC060606-20 ARTICULATION VALVE C2 TO RH CYLINDER ROD END
60 1 F387TCJCJ9060606-36 SWING MANIFOLD LH BOTTOM TO CYLINDER CAP END
61 1 F387TCJCJ9060606-28 SWING MANIFOLD LH TOP TO CYLINDER ROD END
62 1 F387TCJCJ9060606-28 SWING MANIFOLD RH BOTTOM TO CYLINDER ROD END
63 1 F387TCJCJ9060606-36 SWING MANIFOLD TOP TO CYLINDER CAP END
64 1 F387TCJCJC060606-30 BRAKE PEDAL P TO BRAKE PRESSURE SWITCH
65 1 F387TCJCJ9060606-49 BRAKE PEDAL T TO TANK
66 1 F387TCJCJC060606-46 BRAKE PEDAL OUT TO AXLE FRONT TEE
70 1 F387TCJCJ9161616-20 RETURN FILTER TO TANK
71 1 F387TCJCJ9060606-38 CUSHION VALVE LOWER TO MANIFOLD LOWER
72 1 F387TCJCJ9060606-39 CUSHION VALVE UPPER TO MANIFOLD UPPER
101 1 K811HTJSJS202020-45 TANK TO AWD PUMP SUCTION
102 1 F387TCJCJC121212-53 AWD PUMP CASE DRAIN TO TANK
103 1 F387TCJCJC101010-46 AWD PUMP TO CHARGE FILTER IN
104 1 F387TCJCJC101010-52 CHARGE FILTER OUT TO AWD PUMP
105 1 F387TCJCJC060606-48 AWD PUMP DESTROKE TOP TO VALVE
106 1 F387TCJCJC060606-46 AWD PUMP DESTROKE BOTTOM TO VALVE
107 1 F487TCJCJC121212-178 AWD PUMP A TO EQUA-TRAC R
108 1 F487TCJCJC121212-178 AWD PUMP B TO EQUA-TRAC F
109 1 F387TCJCJ9080808-190 EQUA-TRAC F TO TANK
110 1 F787TCJCJC080808-29 EQUA-TRAC L LEFT TO RH BULHEAD CENTER
111 1 F787TCJCJ9080808-31 EQUA-TRAC R LEFT TO RH BULKHEAD REAR
112 1 F787TCJCJC080808-32 EQUA-TRAC F TO RH BULKHEAD FRONT
113
114
115
1
1
1
F787TCJCJC080808-29
F787TCJCJC080808-30
F787TCJCJC080808-33
EQUA-TEAC L RIGHT TO LH BULKHEAD CENTER
EQUA-TRAC R LEFT TO LH BULKHEAD REAR
EQUA-TRAC F TO LH BULKHEAD FRONT
7
116 1 F787TCJCJ7080808-38 RH BULKHEAD CENTER TO AWD HUB FRONT
117 1 F787TCJCJ7080808-40 RH BULKHEAD REAR TO AWD HUB REAR
118 1 F787TCJCJC080808-38 RH BULKHEAD FRONT TO AWD HUB CENTER
119 1 F787TCJCJ7080808-38 LH BULKHEAD CENTER TO AWD HUB FRONT
120 1 F787TCJCJ7080808-40 LH BULKHEAD REAR TO AWD HUB REAR
121 1 F787TCJCJC080808-38 LH BULKHEAD FRONT TO AWD HUB CENTER

Hose
No.
1018640 Hydraulic Hose kit - Rear Scarifier
4 2 F387TCJCJ9060606-18 SCARIFIER REAR BULKHEAD TO CYLINDER CAP END
5 2 F387TCJCJ9060606-34 SCARIFIER FRONT BULKHEAD TO CYLINDER ROD END
Hose
No.
1018646 Hydraulic Hose kit - Dozer/Front Scarifier
1 1 F387TCJCJ9060606-18 DOZER FLOAT VALVE 2 TO LH BULKHEAD
2 1 F387TCJCJ9060606-18 DOZER FLOAT VALVE 1 TO RH BULKHEAD
3 1 F387TCJCJ9060606-34 DOZER LH BULKHEAD TO CYLINDER ROD END
4 1 F387TCJCJ9060606-34 DOZER RH BULKHEAD TO CYLINDER CAP END
Hose
No.
1018649 Hydraulic Hose kit - Circle Side Shift
1 1 F387TCJCJC060606-72 CIRCLE SHIFT VALVE A TO CYLINDER CAP END
2 1 F387TCJCJC060606-80 CIRCLE SHIFT VALVE B TO CYLINDER ROD END
Hose
No.
1019628 Hydraulic Hose kit - Dead Engine Steering
1 1 F387TCJCJC060606-39 GEAR PUMP OUT TO DES PUMP CHECK VALVE
2 1 F387TCJCJ9060606-36 GEAR PUMP SUCTION TO DES PUMP SUCTION

NOTES

Decal Index
DECAL INDEX
Part Number Description Qty.
1018628 Decal Kit - Safety & Operations

1018628-04 DECAL, INFO, LUBE CHART 1
856579-04 DECAL, CAUTION, MOLDBOARD 2
856579-05 DECAL, CAUTION, KEEP CLEAN 1
856579-06 DECAL, WARNING, ENGINE EXHAUST 1
856579-07 DECAL, CAUTION, BURN HAZARD 1
856579-08 DECAL, WARNING, CONTENTS UNDER PRESSURE 1
856579-09 DECAL, DANGER, EXPLOSION HAZARD 1
856579-10 DECAL, DANGER, FLAMMABLE 1
856579-12 DECAL, DANGER, PINCH POINT 10
856607 DECAL, OPER, TIE DOWN 2
856625 DECAL, DANGER, FALL/CRUSH, HAZARD 2
983125-04 DECAL, INFO, DOOR RELEASE 2
856539 DECAL, WARNING, READ OPERATOR'S MANUAL 1
39141-05 DECAL, CAUTION, HYDRAULIC OIL 1
1013275 DECAL, NOTICE, HYDRAULIC DYE 1
1005474 DECAL, NO UNATTENDED 1
39141-19 DECAL, CAUTION, ALARM 1
983125-10 DECAL, WARNING, SEVER HAZARD, FAN 4
1010091 DECAL, CERTIFIED EMISSION ENGINE INSTALLATION 1
1010090 DECAL, ULTRA LOW SULFUR FUEL ONLY 1
1010089 DECAL, CJ-4 OIL ONLY 1
988634 DECAL, NOTICE OPERATOR'S MANUAL 1
1018628-03 DECAL, OPER, CONTROL PANEL, FRONT 1
988271 DECAL, OPTION CIRCLE SHIFT, VALVE FUNCTION 1
1011223 DECAL, OPER, CONSOLE TILT 1
1011464 DECAL, WARNING, LUNGE HAZARD 1
983125-21 DECAL, GRADER, RUNAWAY VEHICLE 1
1018628-05 DECAL, FUSE PANEL, 685D 1
73824 DECAL, WARNING, WEAR SEATBELT 1
1018628-08 DECAL, INFO, TEST PORTS 1
1018628-06 DECAL, TEST PORTS, GRADER 1
1018628-07 DECAL, INFO, DEF TANK 1
940002 DECAL, DECO, FLAG 2
1013789-03 DECAL, OPER, THROTTLE 1

Decal Index
Part Number Description Qty.
1018627 Decal Kit - Decorative

1018627-01 DECAL, DECO, RIGHT SIDE, REAR, 685D 1
1018627-02 DECAL, DECO, LEFT SIDE, REAR, 685D 1
1018627-03 DECAL, DECO, BOOM, RH, 685D 1
1018627-04 DECAL, DECO, BOOM, LH, 685D 1
1018627-05 DECAL, DECO, 685D 5
1018627-06 DECAL, DECO, REAR STRIPE, 685D 1

Alphabetical Parts Index
ALPHABETICAL PARTS INDEX

Item Figure
Description Part No.
No. No.
10 Station Valve Assembly 989177 2 7-23
10 Station Valve Assembly w/Adapters 1018370 REF 7-23
12V Receptacle 1011147 16 7-25
-A-
AC Compressor 1013772 1 7-18
AC Condenser 1013712-01 16 7-18
AC Condenser Mount 1020466 17 7-18
AC Dryer 38525-01 3 7-18
AC/Fan Drive Belt 1017509-12 2 7-18
Access Door 1013610-01 1 7-15
Access Door - Left 1018004 2 7-33
Access Door - Right 1018005 7 7-33
Access Door Assembly 1013610 REF 7-14
Access Door Assembly 1013610 REF 7-15
Access Door Plate 1013610-01 2 7-14
Access Panel Plate 1010873 13 7-17
Adapter Cap, -6 ORFS FS0304-C-06 10 7-4
Adapter, Gemini TC to EC Monitor 1016876 - 7-21
Air Cleaner Access Door 1018013 10 7-33
Air Conditioning Hose Kit 1018240 REF 7-18
Air Filter - Primary 1011263-13 7 7-35
Air Filter - Secondary 1012474-25 8 7-35
Air Filter Assembly 1013667-30 6 7-35
Air Intake Pipe 1017548 3 7-35
Air Valve, 2 pc. 100513 REF 7-3
Alternator 1017509-06 5 7-36
Alternator Mounting 1013528-72 7 7-36
Antenna, AM/FM, Flexible 1002021 3 7-47
Anti-Cavitation Valve & Plug 141020 10 7-24
Articulating Shaft 1018242 5 7-2
Articulating Shaft Bearing Cone 100110 3 7-2
Articulating Shaft Bearing Cup 100120 4 7-2
Articulating Shaft Nut 100141 1 7-2
Articulating Shaft Seal 100090 2 7-2
Articulation Clamp Half 100071 6 7-1

Item Figure
No. No.
Articulation Cylinder Assembly w/Adapters 1018345 REF 7-1
Articulation Lock Check Valve 1019746 1 7-28
Articulation Valve Assembly w/Adapters 1019747 REF 7-28
AWD Charge Filter Mount 1018650 28 7-30
AWD Filter & Valve Assembly w/Adapters 1018651 24 7-30
AWD Front Axle 1018103 1 7-8
AWD Front Axle Assembly 1018102 1 7-7
AWD Front Axle Assembly 1018102 REF 7-8
AWD Spindle Mount - Left 986365SRV 2 7-9
AWD Spindle Mount - Right 986366SRV 1 7-9
AWD Steering Arm Assembly - Left 986363SRV 8 7-9
AWD Steering Arm Assembly - Right 1018091 7 7-9
AWD Wheel Lean Shaft 857368 5 7-9
Axle Mounted Step Plate 1010739 10 7-40
Axle Mounted Step Plate 982560 11 7-40
-B-
Back-Up Alarm Horn 852520 25 7-33
Back-Up Alarm Switch 12757501 16 7-26
Back-Up Alarm Switch Assembly 12757503 REF 7-26
Back-Up Alarm Switch Bracket 12757496 17 7-26
Ball Joint 130060 5 7-10
Ball Joint - Left 110200 16 7-5
Ball Joint - Left 110200 16 7-8
Ball Joint - Right 110210 14 7-5
Ball Joint - Right 110210 14 7-8
Ball Joint Bushing, Small Taper 130060-1 5 7-11
Ball Joint, Female, 3/8 P72965 6 7-26
7
Ball Knob, ø1-7/8 x 1/2-13 920225 17 7-23
Ball Valve, .75 MNPT-.75FNPT 1009089 32 7-27
Ball Valve, 1.00" 280210 16 7-27
Ball Valve, 1/2" (Brass) 32874 14 7-18
Barb Elbow Fitting, -04 to .375 1695HB-6-4 3 7-38
Battery Box 1018070 1 7-39
Battery Cable (-), 12.5", Eye/Eye, 1/0 AWG 1019675 24 7-39
Battery Cable (-), 18", Eye/Eye, 1/0 AWG 1019674 23 7-39
Battery Cable (-), 28", Eye/Eye, 4 AWG 1019672 21 7-39

Item Figure
No. No.
Battery Cable (-), 30", Eye/Eye, 1/0 AWG 1019677 26 7-39
Battery Cable (-), 7", Eye/Eye, 4 AWG 1019673 22 7-39
Battery Cable (+), 12.5", Eye/Eye, 1/0 AWG 1019676 25 7-39
Battery Cable (+), 13", Eye/Eye, 1/0 AWG 1019679 28 7-39
Battery Cable (+), 32", Eye/Eye, 1/0 AWG 1019678 27 7-39
Battery Hold-down Assembly 982962 10 7-39
Battery Master Disconnect Switch 109740 20 7-39
Battery, 12VDC, 800CCA, Group 24 Purchase Locally 19 7-39
Beacon Mounting Brace 1010889 10 7-21
Beacon Mounting Plate 1010890 9 7-21
Beacon, Amber, Strobe, LED 1013231 13 7-21
Bearing Cone 210180 14 7-6
Bearing Cup 210190 11 7-6
Belt Tensioner 1013528-71 4 7-36
Blower Assembly 12755230 1 7-19
Blower Fan 1010895-01 3 7-19
Blower Motor 1010895-02 2 7-19
Bottom Front Sound Insulation - Left 1010790-08 26 7-16
Bottom Front Sound Insulation - Right 1010790-09 25 7-16
Bottom Pusharm Linkage Weldment 12758123SRV 5 7-42
Brake Charge Valve 852740 9 7-29
Brake Light 1006806 23 7-33
Brake Light Assembly 1007529 REF 7-33
Brake Manifold w/Relief 750602 4 7-29
Brake Pedal Assembly w/Adapters 1018339 REF 7-26
Brake Pedal Valve 1010517 22 7-26
Brake System Accumulator, 60 CI 1010390 12 7-29
Brake System Assembly w/Adapters 1018340 REF 7-29
Branch Tee Adapter, -20 ORFS/-20 ORFS/-20 O-Ring FS6803-20-20-20-NWO-FG 17 7-46
Branch Tee Adapter, -6 ORFS/-6 ORFS/-6 O-Ring FS6803-06-06-06-NWO-FG 2 7-28
Branch Tee Swivel Adapter, -6 O-Ring (x3) 6832-06-06-06-NWO-FG 25 7-26
Bulkhead Elbow Adapter, 90°, -8 ORFS/-8 ORFS FS2701-08-08-FG 12 7-7
Bulkhead Lock Nut, -6 0306-06 12 7-4
Bulkhead Lock Nut, -6 0306-06 17 7-43
Bulkhead Lock Nut, -6 ORFS FS0306-06 13 7-7
Bulkhead Lock Nut, -6 ORFS FS0306-06 12 7-28
Bulkhead Locknut, -8 ORFS FS0306-08 25 7-3
Bulkhead Union Adapter, -6 ORFD/-6 ORFS FS2700-06-06 16 7-43
Bulkhead Union Adapter, -6 ORFS, -6 ORFS FS2700-06-06 10 7-7

Item Figure
No. No.
Bulkhead Union Adapter, -6 ORFS/-6 ORFS FS2700-06-06 11 7-4
Bulkhead Union Adapter, -8 ORFS FS2700-08-08 24 7-3
Bumper 38392 11 7-21
Bushing 984625-1 3 7-5
Bushing 984625-1 3 7-8
Bushing, 1.00 ID x 1.25 OD x 1.00 220360 5 7-1
Bushing, 1.00 ID x 1.25 OD x 1.00 220360 14 7-11
Bushing, 1.25 ID x 1.50 OD x 1.00 LG 103127 14 7-41
Bushing, 1.25 ID x 1.50 OD x 1.00 LG 103127 10 7-42
Bushing, 1.75 ID x 2.25 OD x 1.50 LG 100080A 8 7-10
Bushing, 1.75 ID x 2.250 OD x 1.50 LG 100080A 9 7-2
Bushing, 2.008 x 2.505 x 1-1/2 100170 15 7-2
Bushing, Moldboard Tilt 1009981 25 7-11
-C-
Cab Door Assembly - Left 1018032 2 7-16
Cab Door Assembly - Right 1018033 1 7-16
Cab Entrance Step Assembly 1018230 3 7-40
Cab Insulation Kit 1018842 REF 7-16
Cab Isolation Mount (2 pc.) 12754576 27 7-15
Cab Isolation Mount (2 pcs.) 12754576 26 7-14
Cab Isolator Backing Washer 12754577 25 7-14
Cab Isolator Backing Washer 12754577 26 7-15
Cable 1003908 - 7-21
Cable Control Assembly 12755494 10 7-19
CAC Air Intake Hose 1016121-37 12 7-34
Camera Display 1004617 - 7-21
7
Canopy 1018597 1 7-14
Canopy Grab Bar 1011722 21 7-14
Cap Adapter, -16 ORFS FS0304-C-16 34 7-27
Charge Air Hose, Wire Reinforced 1012642 9 7-34
Charge Air Pipe - Lower 1017547 10 7-34
Charge Air Pipe - Upper 1017546 13 7-34

Item Figure
No. No.
Charge Filter Assembly 1017484 REF 7-27
Charge Valve Weldment 1017529 1 7-29
Check Valve, 5 PSI, 8 GMP, -8 ORFS 1019694 8 7-46
Circle Side Shire Cylinder Assembly w/Adapters 1018414 REF 7-10
Circle Turn Cushion Valve 122084 6 7-28
Clamp Half 852827 4 7-6
Clamp, 4.00 1012526-38 22 7-35
Clevis Pin, 1.00 x 2.625 x 1.50 HD 210060 19 7-10
Clevis Pin, 1.00 x 2.63 w.1.50 Head 210060 3 7-1
Code 62 Adapter, 90°, -12 ORFS/-16 Flange FS1804-12-16-FG 39 7-32
Code 62 Clamp Flange, -16 1902-16 23 7-31
Code 62 Clamp Flange, -16 1902-16 25 7-32
Cold Control 12755496 8 7-19
Column Tilt Pedal 1019718 34 7-26
Compression Spring 38245 12 7-26
Condenser Assembly Binary Switch 12755077 4 7-18
Connector Adapter -16 ORFS/-16 NPTF FS2404-16-16 17 7-27
Connector, 6 Pin, 1018392 13 7-4
Connector, 6 Pin, DT04-6P-L012 1018392 14 7-7
Connector, 6-Pin, DT04-6P-L012 1018392 9 7-28
Console 1018088 1 7-22
Console Face Panel 1018090 2 7-22
Console Front 1018989 30 7-26
Contact Block, 1-NC 1010692 5 7-25
Control Lever 140531 14 7-23
Control Panel Assembly 1018235 REF 7-25
Coolant Control Valve 1013667-03 2 7-37
Coolant Level Sensor 988986 3 7-34
Coolant Pipe - Lower 1017545 18 7-34
Coolant Pipe - Upper 1017544 16 7-34
Cooling Unit 1017509-01 1 7-34
Cotter Pin, .188 x 2.00 80338 4 7-1
Cotter Pin, .188 x 2.00 80338 17 7-2
Cotter Pin, .188 x 2.00 80338 22 7-5
Cotter Pin, 1/4 x 2.25 130232 17 7-12
Cotter Pin, 1/8 x 1.00 80389 20 7-10
Cotter Pin, 3/16 x 2.00 80338 22 7-8

Item Figure
No. No.
Cover 1018223 9 7-4
Cover 1018225 9 7-7
Cover Plate 1018987 1 7-23
Cover Plate 1018223 8 7-28
Cover Plate (No Rear Wiper) 151191 6 7-17
Cover Plate Assembly w/Adapters 1018364 REF 7-4
Cross Member Cover Bracket 1017754 19 7-14
CSBHS, 1/4-20 x .88, SS 81277 24 7-15
CSBHS, 1/4-20 x .88, SS 81277 9 7-44
CSHH, 1/2-13 x 1.00, GR5, FT 100-8-13-16-5F - 7-40
CSHH, 1/2-13 x 1.00, GR8, FT 100-8-13-16-8F 15 7-41
CSHH, 1/2-13 x 1.00, GR8, FT 100-8-13-16-8F 26 7-42
CSHH, 1/2-13 x 1.50, GR5 100-8-13-24-5 22 7-14
CSHH, 1/2-13 x 1.50, GR5 100-8-13-24-5 10 7-38
CSHH, 1/2-13 x 1.50, GR5 100-4-20-12-5F 14 7-38
CSHH, 1/2-13 x 1.50, GR5 100-8-13-24-5 - 7-40
CSHH, 1/2-13 x 1.50, GR5 100-8-13-24-5 - 7-40
CSHH, 1/2-13 x 1.50, GR5 100-8-13-24-5 39 7-41
CSHH, 1/2-13 x 1.50, GR5, FT 100-8-13-24-5F 38 7-31
CSHH, 1/2-13 x 1.50, GR5, FT 100-8-13-24-5F 46 7-32
CSHH, 1/2-13 x 1.50, GR5, FT 100-8-13-24-5F 7 7-39
CSHH, 1/2-13 x 1.75, GR5 100-8-13-28-5 15 7-26
CSHH, 1/2-13 x 1.75, GR5 100-8-13-28-5 29 7-31
CSHH, 1/2-13 x 1.75, GR5 100-8-13-28-5 31 7-32
CSHH, 1/2-13 x 2.50, GR5 100-8-13-40-5 15 7-11
CSHH, 1/2-13 x 2.50, GR5 100-8-13-40-5 - 7-40
CSHH, 1/4-20 x .50, GR5, FT 100-4-20-8-5F 11 7-27
CSHH, 1/4-20 x .75, GR5, FT 100-4-20-12-5F 14 7-14
7
CSHH, 1/4-20 x .75, GR5, FT 100-4-20-12-5F 11 7-15
CSHH, 1/4-20 x .75, GR5, FT 100-4-20-12-5F 12 7-16
CSHH, 1/4-20 x .75, GR5, FT 100-4-20-12-5F 6 7-18
CSHH, 1/4-20 x .75, GR5, FT 100-4-20-12-5F 5 7-27
CSHH, 1/4-20 x 1.00, GR5 100-4-20-16-5 18 7-4
CSHH, 1/4-20 x 1.00, GR5 100-4-20-16-5 15 7-7
CSHH, 1/4-20 x 1.00, GR5 100-4-20-16-5 7 7-17
CSHH, 1/4-20 x 1.00, GR5 100-4-20-16-5 17 7-21
CSHH, 1/4-20 x 1.00, GR5 100-4-20-16-5 17 7-28

Item Figure
No. No.
CSHH, 1/4-20 x 1.00, GR5 100-4-20-16-5 16 7-31
CSHH, 1/4-20 x 1.00, GR5 100-4-20-16-5 18 7-32
CSHH, 1/4-20 x 1.00, GR5 100-4-20-16-5 30 7-33
CSHH, 1/4-20 x 1.00, GR5 100-4-20-16-5 4 7-39
CSHH, 1/4-20 x 1.25, GR5 100-4-20-20-5 31 7-33
CSHH, 1/4-20 x 1.25, GR5 100-4-20-20-5 - 7-40
CSHH, 1/4-20 x 1.50, GR5 100-4-20-24-5 9 7-11
CSHH, 1/4-20 x 2.00, GR5 100-4-20-32-5 20 7-28
CSHH, 1/4-20 x 2.00, GR5 100-4-20-32-5 12 7-30
CSHH, 1/4-20 x 2.25, GR5 100-4-20-36-5 22 7-28
CSHH, 1/4-20 x 2.25, GR5 100-4-20-36-5 21 7-29
CSHH, 1/4-20 x 2.50, GR5 100-4-20-40-5 23 7-28
CSHH, 1/4-20 x 2.75, GR5 100-4-20-44-5 17 7-30
CSHH, 1/4-20 x 3.75, GR5 100-4-20-60-5 23 7-29
CSHH, 1/4-20 x.75, GR5, FT 100-4-20-12-5F 15 7-33
CSHH, 1/4-28 x .75, GR5, FT 100-4-28-12-5F 8 7-47
CSHH, 1-8 x 5.50, GR8 100-16-8-88-8 8 7-43
CSHH, 1-8 x 7.50, GR8 100-16-8-120-8 11 7-43
CSHH, 3/4-10 x 2.25, GR5 100-12-10-36-5 20 7-41
CSHH, 3/4-10 x 2.25, GR5 100-12-10-36-5 19 7-42
CSHH, 3/4-10 x 3.50, GR5 100-12-10-56-5 40 7-41
CSHH, 3/8-16 x .75, GR5, FT 100-6-16-12-5F 32 7-7
CSHH, 3/8-16 x .75, GR5, FT 100-6-16-12-5F 2 7-11
CSHH, 3/8-16 x .75, GR5, FT 100-6-16-12-5F 17 7-15
CSHH, 3/8-16 x .75, GR5, FT 100-6-16-12-5F 10 7-20
CSHH, 3/8-16 x .75, GR5, FT 100-6-16-12-5F 24 7-21
CSHH, 3/8-16 x .75, GR5, FT 100-6-16-12-5F 27 7-27
CSHH, 3/8-16 x .75, GR5, FT 100-6-16-12-5F 27 7-41
CSHH, 3/8-16 x .75, GR5, FT 100-6-16-12-5F 23 7-42
CSHH, 3/8-16 x .75, GR5, FT 100-6-16-12-5F 3 7-46
CSHH, 3/8-16 x 1.00, GR5, FT 100-6-16-16-5F 23 7-7
CSHH, 3/8-16 x 1.00, GR5, FT 100-6-16-16-5F 9 7-10
CSHH, 3/8-16 x 1.00, GR5, FT 100-6-16-16-5F 29 7-30
CSHH, 3/8-16 x 1.00, GR5, FT 100-6-16-16-5F 21 7-33
CSHH, 3/8-16 x 1.00, GR5, FT 100-6-16-16-5F - 7-40
CSHH, 3/8-16 x 1.00, GR5, FT 100-6-16-16-5F - 7-40
CSHH, 3/8-16 x 1.00, GR5, FT 100-6-16-16-5F - 7-40
CSHH, 3/8-16 x 1.00, GR5, FT 100-6-16-16-5F 13 7-43
CSHH, 3/8-16 x 1.00, GR5, FT 100-6-16-16-5F 7 7-44

Item Figure
No. No.
CSHH, 3/8-16 x 1.25, GR5 100-6-16-20-5 18 7-29
CSHH, 3/8-16 x 1.50, GR5 100-6-16-24-5 20 7-22
CSHH, 3/8-16 x 1.50, GR5 100-6-16-24-5 27 7-26
CSHH, 3/8-16 x 1.75, GR5 100-6-16-28-5 15 7-23
CSHH, 3/8-16 x 1.75, GR5 100-6-16-28-5 24 7-29
CSHH, 3/8-16 x 1.75, GR5 100-6-16-28-5 32 7-30
CSHH, 3/8-16 x 9.50, GR5 100-6-16-152-5 16 7-39
CSHH, 5/16-18 x 1.00, GR5 100-5-18-16-5 15 7-17
CSHH, 5/16-18 x 1.00, GR5 100-5-18-16-5 3 7-20
CSHH, 5/16-18 x 1.00, GR5 100-5-18-16-5 20 7-21
CSHH, 5/16-18 x 1.00, GR5 100-5-18-16-5 33 7-33
CSHH, 5/16-18 x 1.00, GR5, FT 100-5-18-16-5F 5 7-14
CSHH, 5/16-18 x 1.00, GR5, FT 100-5-18-16-5F 4 7-15
CSHH, 5/16-18 x 1.00, GR5, FT 100-5-18-16-5F 17 7-22
CSHH, 5/16-18 x 1.00, GR5, FT 100-5-18-16-5F 6 7-37
CSHH, 5/16-18 x 1.50, GR5 100-5-18-24-5 9 7-15
CSHH, 5/16-18 x 2.00, GR5 100-5-18-32-5 35 7-26
CSHH, 5/16-18 x 3.00, GR5 100-5-18-48-5 10 7-18
CSHH, 5/16-18 x 3.00, GR5 100-5-18-48-5 19 7-23
CSHH, 5/8-11 x 1.50, GR5, FT 100-10-11-24-5F 9 7-12
CSHH, 5/8-11 x 1.50, GR8, FT 100-10-11-24-8F 3 7-4
CSHH, 5/8-11 x 1.50, GR8, FT 100-10-11-24-8F 3 7-7
CSHH, 5/8-11 x 2.50, GR5 100-10-11-40-5 8 7-5
CSHH, 5/8-11 x 2.50, GR5 100-10-11-40-5 8 7-8
CSHH, 5/8-11 x 3.00, GR5 100-10-11-48-5 5 7-6
CSHH, 5/8-11 x 3.00, GR5 100-10-11-48-5 13 7-12
CSHH, 5/8-11 x 3.00, GR8 100-10-11-48-8 11 7-2
CSHH, 5/8-11 x 3.50, GR5 100-10-11-56-5 11 7-12
CSHH, 5/8-11 x 3.75, GR5 100-10-11-60-5 21 7-11
CSHH, 5/8-18 x 4.00, GR8 100-10-18-64-8 23 7-36
7
CSHH, 5/8-18 x 5.00, GR8 100-10-18-80-8 7 7-1
CSHH, 7/8-14 x 12.00, GR8 100-14-14-192-8 4 7-3
CSHH, 7/8-9 x 5.00, GR8 100-14-9-80-8 27 7-14
CSHH, 7/8-9 x 5.00, GR8 100-14-9-80-8 28 7-15
CSHH, Heavy, 1/2-13 x 1.38, GR8, FT 101-8-13-22-8F 18 7-41
CSHH, Heavy, 1/2-13 x 1.38, GR8, FT 101-8-13-22-8F 28 7-42
CSHH, Heavy, 5/8-11 x 2.00, GR5 101-10-11-32-5 9 7-9
CSHH, M10x1.5 x 35mm, C8.8, FT 100-M10-1.5-35-8.8F 6 7-31
CSHH, M10x1.5 x 35mm, C8.8, FT 100-M10-1.5-35-8.8F 6 7-32

Item Figure
No. No.
CSHH, M14x2 x 30mm, C8.8, FT 100-M14-2-30-8.8F - 7-40
CSHH, M14x2.0 x 30mm, C8.8, FT 100-M14-2-30-8.8F 17 7-3
CSHH, M16x2 x 40mm, C8.8, FT 100-M16-2-40-8.8F - 7-40
CSHH, M16x2.0 x 30mm, C8.8, FT 100-M16-2-30-8.8F 28 7-3
CSHH, M5x0.8 x 10mm, C8.8, FT 100-M5-0.8-10-8.8F 6 7-16
CSSBH, 1/4-20 x .75 117-4-20-12 15 7-16
CSSBH, 1/4-20 x .75 117-4-20-12 12 7-33
CSSBH, 3/8-16 x 1.25 117-6-16-20 4 7-33
CSSBH, 5/16-18 x .75 117-5-18-12 30 7-14
CSSBH, 5/16-18 x .75 117-5-18-12 19 7-16
CSSH, #10-32 x 1.00, FT 102-#10-32-16-F 10 7-31
CSSH, #10-32 x 1.00, FT 102-#10-32-16-F 10 7-32
CSSH, 1/4-20 x .875, FT 102-4-20-14-F 6 7-23
CSSH, 1/4-20 x 1.75 102-4-20-28 5 7-30
CSSH, 3/8-16 x .75, FT 102-6-16-12-F 4 7-31
CSSH, 3/8-16 x .75, FT 102-6-16-12-F 4 7-32
CSSH, M14x2.0 x 40mm, C8.8, FT 102-M14-2-40-8.8F 14 7-3
Cup Holder 1010794 1 7-25
Cutting Edge, 8 Ft., Offset Punched 108581 3 7-41
Cylinder Mounting Pin - Long 110596 25 7-41
Cylinder Mounting Pin - Long 110596 14 7-42
Cylinder Mounting Pin - Short 110597 26 7-41
Cylinder Mounting Pin - Short 110597 15 7-42
-D-
Dash Light - Amber 1001625 14b 7-22
Dash Light - Blue 31986 12 7-22
Dash Light - Green 31985 10 7-22
Dash Light - Red 31983 13 7-22
Dash Light - White 1010500 11 7-22
Dead Engine Steering Hose Kit 1019628 REF 7-46
Dead Engine Steering Motor & Pump 685020 1 7-46
Dead Engine Steering Unit Assembly w/Adapter 1019626 REF 7-46
Dead Engine Steering Unit Mount 1019627 2 7-46
Decal - Control Panel, Front 1018628-02 6 7-25
Decal - Control Panel, Top 1018628-01 2 7-25
Decal - Front Control Panel 1018628-03 16 7-22
Decal - Fuse Panel 1018628-05 17 7-25
Decal - Info, Lube Chart 1018628-04 23 7-22

Item Figure
No. No.
Decal - Operator's Manual 988634 8 7-21
Decal - OPT, Circle Shift 988271 26 7-23
Decal - Runaway Vehicle 983125-21 28 7-23
Decal - Throttle Operation 1013789-03 8 7-20
Decal - Warning, Lunge Hazard 1011464 27 7-23
Decomp Reactor Tube 1013528-87 17 7-35
DEF Control Module Mount 1020604 3 7-37
DEF Tank 1017509-05 1 7-37
DEF Tank Strap 1013924 5 7-37
Defrost Fan Assembly, 12V 35425 5 7-21
Destroke Pump Valve, NO, 2-Way, 2-POS, 12V 1011845 23 7-30
Destroke Solenoid Assembly w/Adapters 1017698 22 7-30
Detent Valve Section 910052 REF 7-24
Diffuser Mounting Plate 1010894 11 7-17
Dome Light 38840 6 7-21
Dome Light Mounting Plate 1017571 5 7-17
Door Glass - Lower 1013591-06 4 7-16
Door Glass - Upper 1013591-05 3 7-16
Door Latch 160450 3 7-33
Door Latch Cover 980678 11 7-16
Door Lock 35812 11 7-33
Door Lock 35812 2 7-39
Door Open Latch 1010882SRV 14 7-15
Door Open Latch Extension 1010884SRV 15 7-15
Double Swivel Union Adapter, -8 ORFS/-8 ORFS FS6565-08-08 7 7-46
Dozer Assembly, 8 ft. 1018828 REF 7-41
Dozer Blade, 8 Ft. 1018830 2 7-41
Dozer Float Valve Assembly w/Adapters 1018647 REF 7-41
Dozer Float Valve Assembly w/Adapters 1018647 REF 7-42
Dozer Lift Cylinder Assembly w/Adapters 1018420 REF 7-41
7
Dozer Lift Cylinder Assembly w/Adapters 1018420 11 7-42
Drawbar Assembly 130014-1SRV REF 7-11
Drawbar Pull Ball 130106 18 7-11
Drawbar Pull Ball Shim - .025 130103 29 7-11
Drawbar Pull Ball Socket Half 130101 17 7-11
Drawbar Pull Bar Shim - .030 130104 30 7-11
Drawbar Pull Bar Shim - .055 130105 31 7-11
Drive Axle & Motor Assembly w/Adapters 1018341 REF 7-3
Drive Axle Assembly, DANA 150 Bogie 1009952SRV 1 7-3

Item Figure
No. No.
Dryer Clamp 36745-08 5 7-18
Dust Boot, V-20 Valve Spool 141010 7 7-24
Dust Cap 110330 26 7-6
-E-
ECU 1017509-02 9 7-36
Elbow 1017509-25 20 7-35
Elbow Adapter, 45°, -12 ORFS/-12 O-Ring FS6802-12-12-NWO-FG 38 7-32
Elbow Adapter, 45°, -6 ORFS/-6 ORFS FS6802-06-06-NWO-FG 11 7-5
Elbow Adapter, 90°, -16 ORFS/-12 NPTF FS2501-16-12-FG 33 7-27
Elbow Adapter, 90°, -16 O-Ring/-16 NPTF 6806-16-16 NWO 15 7-27
Elbow Adapter, 90°, -6 JIC/-6 NPTF 2502-6-6 4 7-38
Elbow Adapter, 90°, -6 ORFS/14mm O-Ring FS7205-06-14-NWO-FG 21 7-3

Item Figure
No. No.
Elbow Adapter, 90°, -8 JIC/M18 O-Ring 7205-08-18-NWO-FG 15 7-36
Elbow Adapter, 90°, -8 ORFS/-6 NPTF FS2501-08-06-FG 6 7-46
Elbow Adapter, 90°, Code 62, -16 ORFS/-16 Flange FS1804-16-16-FG 9 7-3
Emergency Stop Switch, 1-NC 1010672 4 7-25
Enclosure 1019666 29 7-36
Engine & Radiator Mount - Left 1017509-11 17 7-36
Engine & Radiator Mount - Right 1017509-10 18 7-36
Engine Dipstick 1017509-07 6 7-36
Engine Heater 1016451 2 7-45
Engine Heater Cable 121057 1 7-45
Engine Mount Washer 113683 27 7-36
Engine Mounting Bracket 1010196 19 7-36
Engine Shroud Assembly 1017994 REF 7-33
Engine Shroud Weldment 1017995 1 7-33
Engine Top Access Cover 1019257 35 7-33
Equa-Trac Manifold, AWD 1019685-03 26 7-7
Equa-Trac Valve Assembly w/Adapters 1018642 REF 7-7
Evaporator Assembly 12755045 4 7-19
Evaporator Assembly Knob 12755492 5 7-19
Exhaust Pipe Weldment 1017549 14 7-35
Exhaust Pipe, 4.00" 1018048 23 7-35
7
-F-
Fan 1017509-04 1 7-36
Fan Belt 1017509-08 3 7-36
Fan Spacer 1008650-02 2 7-36
Fan Switch 36745-18 9 7-19
FHMS, Cross, 1/4-20 x .75, FT 123-4-20-12F 10 7-16
Flip-Down Beacon Assembly 1019550 REF 7-21
Float Positioner Kit 141050 12 7-24
Float Valve Section 989177-01 3 7-24

Item Figure
No. No.
Floor Mat Sound Insulation 1018858 18 7-14
Floor Mat Sound Insulation 1018842-01 24 7-16
Foot Pedal Tensioner Bar 1012917 11 7-26
Forward/Reverse Pedal 1010784 1 7-26
Forward/Reverse Pedal Assembly 1010780 REF 7-26
Fresh Air Filter 12755168 11 7-19
Front Attachment Assembly 12758133SRV REF 7-41
Front Axle Assembly - 2WD 1018076 1 7-4
Front Axle Clamp 988328 2 7-4
Front Axle Clamp 988328 2 7-7
Front Axle Pin 1018086 5 7-4
Front Axle Pin 1018086 5 7-7
Front Axle Weldment 1018077 1 7-5
Front Blade Link Pin 107663 12 7-41
Front Blade Link Pin 107663 REF 7-42
Front King Pin 110061 REF 7-6
Front Scarifier Mount - Left 1018852 36 7-41
Front Scarifier Mount - Right 1018853 37 7-41
Front Scarifier Weldment 1018850 34 7-41
Front Scarifier Weldment 1018879 1 7-42
Front Sound Insulation - Left 1010790-06 28 7-16
Front Sound Insulation - Right 1010790-07 27 7-16
Front Spindle Lock Washer 110320 25 7-6
Front Spindle Mount - Left 110043SRV 2 7-6
Front Spindle Mount - Right 110033SRV 1 7-6
Front Spindle Nut 110310 24 7-6
Front Spindle Thick Washer 110300 23 7-6
Front Wheel Lean Clevis 110170 20 7-5
Front Wheel Lean Clevis 110170 20 7-8
Front Wheel Lean Pin 110151 7 7-6
Front Wheel Lean Tie Pin 110141SRV 19 7-5
Front Wheel Lean Tie Pin 110141SRV 19 7-8
Front Yoke Bushing 984625 2 7-5
Front Yoke Groove Bushing 984625 2 7-8
Fuel Fill Neck 1018220 17 7-38
Fuel Fill Pipe 1018411 20 7-38
Fuel Filter 1012474-27 12 7-36
Fuel Filter Head 1012474-10 11 7-36
Fuel Sending Unit 1016871 6 7-38

Item Figure
No. No.
Fuel Tank Assembly, 45 Gallon 1017535 REF 7-38
Fuel Tank Cap, Lockable 140030FL 13 7-38
Fuel Tank, 45 Gallon 1017536 1 7-38
Fuel/Water Separator Filter 1013667-18 14 7-36
Fuse Block, 18 Gang, ATC 685060 18 7-25
Fuse Block, 6 Gang, ATC 36695 21 7-25
Fuse, 10A, ATC 36340 19 7-25
Fuse, 15A, ATC 36341 20 7-25
Fuse, 175A, AMG 1014120 35 7-36
Fuse, 250A, AMG 1014121 36 7-36
FWD Tire & Wheel Assembly, 15x19.5 - Left 1012240L 7 7-7
FWD Tire & Wheel Assembly, 15x19.5 - Right 1012240R 6 7-7
FWD/REV Shift Solenoid Valve 853850 9 7-30
-G-
Gas Spring Actuator Head 115714 33 7-26
Gasket 1013667-12 16 7-35
Gasket 1013667-11 19 7-35
Grid Heater and Relays Assembly 1019668 28 7-36
Grommet 35465-06 28 7-11
Grommet 160030A1 24 7-33
Group - 10 Station Console 1018087 GRP 7-22
Group - 10 Station Console 1018087 GRP 7-23
Group - Air Conditioning 1018238 GRP 7-18
Group - Cab Detail 1017558 GRP 7-15
Group - Canopy Detail 1018602 GRP 7-14
Group - Dozer Blade 1018831 GRP 7-41
Group - Engine Shroud 1017993 GRP 7-33
7
Group - Front Blade Scarifier 1018849 GRP 7-41
Group - Front Scarifier 1018880 GRP 7-42
Group - Rear Scarifier 1018098 GRP 7-43
-H-
Handle 41519 12 7-21
Headlamp Mount 1018051 2 7-40
Heater & A/C Evaporator Unit 1010895 REF 7-19
Heater & AC Evaporator Unit 1010895 1 7-17

Item Figure
No. No.
High Temp Sleeve, 1.75 ID, 45° 1017509-21 15 7-34
High Temp Sleeve, 2.00 ID, 90° 1017509-22 17 7-34
Hinge 987639 4 7-14
Hinge 987639 3 7-15
Hole Plug, .562 35136-20 8 7-25
Hole Plug, Flush Mount - 1/2" 35136-4 14a 7-22
Hose Assembly F387TCJCJ9060606-36 13 7-46
Hose Assembly F387TCJCJC060606-39 14 7-46
Hose Assembly - Engine Oil Pan to Rear Axle F387TCJCJ9101010-22 16 7-36
Hose Assembly, Return Filter to Tank F387TCJCJ9161616-20 18 7-27
Hose Clamp, #36 22B-36 18 7-38
Hose Clamp, 2 Hole 131140 7 7-2
Hose Clamp, 2 Hole - 5/8 131140 13 7-11
Hose Kit - Circle Side Shift 1018649 28 7-10
Hydraulic Cylinder, 2.50 x 12.00 x 1.00 1014284SRV 5 7-43
Hydraulic Cylinder, 2.50 x 13.00 x 1.50 1018248 10 7-5
Hydraulic Cylinder, Steering, 2.50 x 12.50 x 1.50 1019767 10 7-8
Hydraulic Double Gear Pump, .93 CIR, 13T, SAE 8 1018473 33 7-31
Hydraulic Double Gear Pump, .93 CIR, 13T,SAE 8 1018473 41 7-32
Hydraulic Filter Element, 9 Micron 290030 20 7-27
Hydraulic Filter Element, 9 Micron 290030 26 7-30
Hydraulic Filter Head 1017402 19 7-27
Hydraulic Filter Head 1017402 25 7-30
Hydraulic Hose Jumper - Front F387TCJCJ1060606-21 REF 7-3
Hydraulic Hose Jumper - Rear F387TCJCJ1060606-17 REF 7-3
Hydraulic Hose Kit, Dozer Blade 1018646 REF 7-41
Hydraulic Hose Kit, Dozer Blade 1018646 REF 7-42
Hydraulic Hose Kit, Rear Scarifier 1018640 15 7-43
Hydraulic Motor Access Panel 1018666 6 7-40

Item Figure
No. No.
Hydraulic Motor, 2-Speed, H1-B, 80cc 1011461 7 7-3
Hydraulic Oil Sight Level/Temperature Gauge 500070 13 7-27
Hydraulic Oil Temperature Sender 1010402 14 7-27
Hydraulic Pump, 55cc, 13T, BPAD 1018471 36 7-32
Hydraulic Pump, 75cc, 13T, BPAD 1018470 14 7-31
Hydraulic Pump, 75cc, 13T, CPAD 1018472 14 7-32
Hydraulic Pumps Assembly w/Adapters 1018342 REF 7-31
Hydraulic Pumps Assembly w/Adapters - AWD 1018343 REF 7-32
Hydraulic Return Diffuser, -32 SAE O-Ring, 95 GPM 1018448 35 7-27
Hydraulic Return Filter Element, 10 Micron 1018447 23 7-27
Hydraulic Return Filter Head 1018446 22 7-27
Hydraulic Tank Assembly w/Adapters - AWD 1018643 REF 7-27
Hydraulic Tank Assembly w/Adapters - RWD 1018114 REF 7-27
Hydraulic Tank Assembly, 30 Gallon 1017531 1 7-27
Hydraulic Tank Cover Plate 1000206 10 7-27
- I, J, K, L-
Ignition Switch 39146-14 14 7-25
Inner Race Bearing 210040 4 7-9
Intake Elbow 1010076-38 2 7-35
Intake Pipe 1018049 27 7-33
Intake Pipe Weldment 1018049 11 7-35
Intake Support Bracket 1013857 29 7-33
Interior Handle 982060 14 7-16
Isolator 1010076-08 7 7-34
Isolator Mount 1009242-34 22 7-36
Knob 36688-55 11 7-39
Latch Mounting Plate 981206 9 7-16
Lean Cylinder Pin 110161 4 7-8
Lean Cylinder Pin, 110161 4 7-5
7
LED Light 1013307 11 7-14
LED Light 1013307 25 7-15
Lever 140630 3 7-23
Lever Latch 980460 3 7-14
Lever Latch 980460 2 7-15
Lever Mounting Block 140551 9 7-23
Lever, 40° 140630-3 4 7-23
Lift Cylinder Mount 984411 REF 7-2
Lifting Ring, 500# 1001057 14 7-33

Item Figure
No. No.
Light Kit 852560 1 7-40
Link Arm - AWD Model Only 1019450 9 7-26
Link Arm - RWD Model Only 1010787 8 7-26
Lock 35812 44 7-27
Lock w/Offset Cam 35812 9 7-14
Lock w/Offset Cam 35812 15 7-25
Locking Nut, 1-1/2" NPT 1014489 38 7-36
Locking Shank, Scarifier Tooth 1020476 4 7-43
Locknut, 7/8-14 95383832 6 7-3
Louver Retainer - 2.7 1011199 3 7-17
Louver, Front Panel - 2.7 1011198 2 7-17
Louver, Front Panel - 4.0 1011200 12 7-17
Louver, Narrow Frame 1011201 14 7-17
Low Pitch Horn 20190773 4 7-40
Low Pressure Brake Switch 852720 2 7-29
Low Range Switch Bracket 1018374 16 7-3
Lower Kick Glass - Front 1013591-03 23 7-16
Lube Fitting, 45°, 1/4-28 140615 6 7-5
Lube Fitting, 45°, 1/4-28 140615 6 7-8
Lube Fitting, 90°, 1/4"-28 140620 5 7-26
Lube Fitting, 90°, 1/4-28 140620 6 7-2
Lube Fitting, Straight, 1/4-28 140610 14 7-2
Lug Nut 1009420 8 7-4
Lug Nut 120350A 8 7-7
-M-
Machined Nut 110101 12 7-6
Magnetic Drain Plug, -16 SAE Orb 1011971 38 7-27
Main Relief Valve 901009 2 7-24
Manifold & Trans Shift Valve Mount 1017539 1 7-30
Manual Case 985234-01 7 7-21
Master Link 140560 8 7-23
Mega Fuse Holder 985752 34 7-36

Item Figure
No. No.
Mirror Arm 10623 2 7-21
Moldboard Assembly, 11 Ft. x 21" 1018110 3a 7-10
Moldboard Assembly, 11 Ft. x 21" 1018110 1 7-13
Moldboard Curved End Bit 130180 3 7-13
Moldboard Cushion Valve Assembly w/Adapters 1018641 REF 7-28
Moldboard Cutting Edge, 11 Ft. 1011670 2 7-13
Moldboard Cutting Edge, 6 Ft., Offset Punched 853860 8 7-13
Moldboard Lift Cylinder Assembly w/Fittings 1018346 REF 7-10
Moldboard Manifold Assembly w/Adapters 1019684 REF 7-28
Moldboard Pin 130231 16 7-12
Moldboard Rod w/Ends 130031SRV 21 7-10
Moldboard Shim - Top 130121 7 7-12
Moldboard Slide Assembly 130243SRV 2 7-10
Moldboard Slide Assembly 130243SRV REF 7-12
Moldboard Slide Clamp - Center 130261 5 7-12
Moldboard Slide Clamp - Lower 130161 3 7-12
Moldboard Slide Clamp - Upper 130141 1 7-12
Moldboard Slide Clamp 3-Hole Shim - Upper 130130 2 7-12
Moldboard Slide Clamp 4-Hole Shim - Lower 130150 4 7-12
Moldboard Slide Clamp Shim - Center 130251 6 7-12
Moldboard Slide Cylinder Assembly w/Fittings 1018349 REF 7-10
Moldboard Slide Manifold 1019696 7 7-11
Moldboard Slide Manifold 1019696 4 7-28
Moldboard Slide Manifold Assembly w/Adapters 1019684 REF 7-11
Moldboard Swing Cylinder Assembly w/Fittings 1018347 REF 7-10
Moldboard Tilt Bushing 1009981 8 7-12
Moldboard Tilt Cylinder Assembly w/Fittings 1018348 REF 7-10
Moldboard Trunnion Assembly 100161 10 7-2
Moldboard Turntable Weldment 130224SRV 24 7-11
Mount, Weldment, Radio/Speaker 1008092 2 7-47
-N-
Nut Lock, Stover, 1-8, GR5
Nut, Heavy Hex, 1-1/4-12, GR5
204-16-8-5
214-20-12-5
10
13
7-43
7-5
7
Nut, Heavy Hex, 1-1/4-12, GR5 214-20-12-5 13 7-8
Nut, Hex, 1/2-13, GR5 202-8-13-5 13 7-23
Nut, Hex, 1/2-13, GR5 200-8-13-5 - 7-40
Nut, Hex, 1/2-13, GR5 200-8-13-5 - 7-40
Nut, Hex, 1/4-20, GR5 200-4-20-5 12 7-11

Item Figure
No. No.
Nut, Hex, 1/4-20, GR5 200-4-20-5 17 7-14
Nut, Hex, 1/4-20, GR5 200-4-20-5 10 7-17
Nut, Hex, 1/4-20, GR5 200-4-20-5 9 7-18
Nut, Hex, 1/4-20, GR5 200-4-20-5 7 7-27
Nut, Hex, 1/4-20, GR5 200-4-20-5 21 7-28
Nut, Hex, 1/4-20, GR5 200-4-20-5 8 7-30
Nut, Hex, 1/4-20, GR5 200-4-20-5 - 7-40
Nut, Hex, 1/4-20, GR5 200-4-20-5 10 7-47
Nut, Hex, 1-1/8-12, GR5 200-18-12-5 19 7-11
Nut, Hex, 13/16-20 300020 8 7-22
Nut, Hex, 3/4-10, GR5 200-12-10-5 41 7-41
Nut, Hex, 3/8-16, GR5 200-6-16-5 27 7-21
Nut, Hex, 3/8-16, GR5 200-6-16-5 25 7-29
Nut, Hex, 3/8-16, GR5 200-6-16-5 33 7-30
Nut, Hex, 3/8-16, GR5 200-6-16-5 17 7-32
Nut, Hex, 5/16-18, GR5 200-5-18-5 10 7-15
Nut, Hex, 5/16-18, GR5 200-5-18-5 12 7-18
Nut, Hex, 5/16-18, GR5 200-5-18-5 6 7-20
Nut, Hex, 5/16-18, GR5 200-5-18-5 23 7-21
Nut, Hex, 5/16-18, Gr5 200-5-18-5 21 7-23
Nut, Hex, 5/16-18, GR5 200-5-18-5 37 7-26
Nut, Hex, 5/8-11, GR5 200-10-11-5 12 7-12
Nut, Hex, 5/8-11, GR5 200-10-11-5 6 7-13
Nut, Hex, 5/8-11, GR5 200-10-11-5 6 7-41
Nut, Hex, Castle, 7/8-14 206-14-14-5 14 7-10
Nut, Hex, Jam, 3/8-24, GR5 202-6-24-5 7 7-26
Nut, Hex, Mach, #8-32 209-#8-32 17 7-4
Nut, Hex, Mach, #8-32 209-#8-32 21 7-7
Nut, Hex, Machine Screw, #8-32 209-#8-32 16 7-28
Nut, Hex, Machine, #10-24 209-#10-24 21 7-26
Nut, Hex, Machine, #10-24 209-#10-24 15 7-39
Nut, Hex, Machine, #10-24 209-#10-24 7 7-47
Nut, Jam, 5/8-11, GR5 202-10-11-5 15 7-12
Nut, Lock Stover, 7/8-9, GR5 204-14-9-5 28 7-14
Nut, Lock, Flexloc, 1/4-20 217-4-20 32 7-33
Nut, Lock, Nylon, #10-24, GR5 205-#10-24-5 16 7-21
Nut, Lock, Nylon, #10-32, GR5 205-#10-32-5 20 7-18
Nut, Lock, Nylon, #10-32, GR5 205-#10-32-5 6 7-33
Nut, Lock, Nylon, 1/4-20, GR5 205-4-20-5 19 7-21

Item Figure
No. No.
Nut, Lock, Nylon, 1/4-20, GR5 205-4-20-5 18 7-31
Nut, Lock, Nylon, 1/4-20, GR5 205-4-20-5 20 7-32
Nut, Lock, Nylon, 1/4-20, GR5 205-4-20-5 13 7-33
Nut, Lock, Nylon, 1/4-20, GR5 205-4-20-5 6 7-39
Nut, Lock, Stover, 1/4-20, GR5 204-4-20-5 18 7-33
Nut, Lock, Stover, 1-1/4-7, GR5 204-20-7-5 16 7-10
Nut, Lock, Stover, 1-1/4-7, GR5 204-20-7-5 4 7-11
Nut, M10x1 115878 32 7-26
Nut, Machine Screw, #10-32 209-#10-32 13 7-31
Nut, Machine Screw, #10-32 209-#10-32 13 7-32
-O, P, Q-
Oil Drain Bulkhead Bracket 1010655 27 7-3
Oil Filler 1013528-70 10 7-36
Oil Filter 1012474-12 13 7-36
OPTION - Circle Side Shift 1018648 OPT 7-10
OPTION - Cold Weather Package 1016450 OPT 7-45
OPTION - Dead Engine Steering 1019630 OPT 7-46
OPTION - Moldboard Assembly, 12 Ft. x 21" 1018442 7 7-13
OPTION - Moldboard Assembly, 121 Ft. x 22" 1018442 3b 7-10
OPTION - Radio w/Speakers & Antenna 1000705SRV 28 7-21
OPTION - Radio/CD w/Speakers & Antenna 1016867 GRP 7-47
OPTION - Rear Window Wiper/Washer 982106 OPT 7-44
Option - SMV Sign Assembly 12754774 7 7-40
OPTION -Rear Camera 1007953SRV 4 7-21
7
O-Ring, 3.237 ID x .103, SAE 152 36808 32 7-31
O-Ring, 3.237 ID x .103, SAE 152 36808 40 7-32
Outdoor Color Camera, 12VDC 1003907 - 7-21
Panel 1019667 30 7-36
Pedal Mount 1010781 3 7-26
Pedestal Spring Shock 115715 31 7-26
PHMS, Cross, #10-24 x .75, FT 122-#10-24-12F 14 7-21
PHMS, Cross, #10-24 x .75, FT 122-#10-24-12F 12 7-39
PHMS, Cross, #10-24 x .75, FT 122-#10-24-12F 4 7-47

Item Figure
No. No.
PHMS, Cross, #10-24 x 1.00, FT 122-#10-24-16F 18 7-26
PHMS, Cross, #10-32 x .50, FT 122-#10-32-8F 18 7-18
PHMS, Cross, #10-32 x .50, FT 122-#10-32-8F 5 7-33
PHMS, Cross, #12-24 x .75, FT 122-#12-24-12F 7 7-38
PHMS, Cross, #8-32 x .75, FT 122-#8-32-12F 14 7-4
PHMS, Cross, #8-32 x .75, FT 122-#8-32-12F 18 7-7
PHMS, Cross, #8-32 x .75, FT 122-#8-32-12F 13 7-28
Pin, Cotter, 3/16 x 2.00 80338 15 7-10
Pin, Moldboard Tilt - Long 1011419SRV 24 7-10
Pin, Moldboard Tilt - Short 1011420SRV 25 7-10
Pintle Hitch 100180 8 7-40
Pivot Pin 1010785 2 7-26
Plow Bolt, 5/8-11 x 2.00 130220 4 7-13
Plow Bolt, 5/8-11 x 2.00 130220 4 7-41
Plug Adapter, -32 O-Ring 6408-32-O 39 7-27
Plug, Hole, ø.75, Flush Mount, Plastic 35136-6 REF 7-47
Power Beyond Sleeve 901002 16 7-24
Pre-Cleaner 1011263-04 12 7-35
Pressure Switch, Dead Engine Steering 1019693 12 7-46
Prop Rod Bar 1020571 3 7-39
Pull Pin, Spring Loaded 1000835 16 7-15
Pump Destroke Switch 1019683 26 7-26
Pump Drive 114308 1 7-31
Pump Drive 114308 1 7-32
Pump Drive Coupling/Flex Plate 113259 3 7-31
Pump Drive Coupling/Flex Plate 113259 3 7-32
Pump Lever Plate 1018437 15 7-31
Pump Lever Plate 1018437 15 7-32
Pump Mounting Plate 114521 2 7-31
Pump Mounting Plate 114521 2 7-32
Push Arm Bar - Top 117706 9 7-41
Push Arm Link Pin - Bottom 107661 10 7-41
Push Arm Linkage - Bottom 12758123 8 7-41
Push Arm Pivot Pin - Bottom 1012072 11 7-41
Push Button Door Handle 982415 5 7-16
Push Button Switch 982249 13 7-25

Item Figure
No. No.
Push Lok Fitting, -6 FJX/-6 Hose 30682-6-6 5 7-38
Pusharm Bar - Top 117706 8 7-42
Pusharm Link Pin - Bottom 107661 6 7-42
Pusharm Pivot Pin - Bottom 1012072 7 7-42
PV480 Display (w/o throttle) 1018803 15 7-22
-R-
Radiator Access Door 1010961 26 7-33
Radiator Brace 1017509-09 6 7-34
Radiator Cap 100165 2 7-34
Radiator Grill 1018029 20 7-33
Radiator Shroud Assembly 1018016 REF 7-33
Radiator Shroud Weldment 1018017 19 7-33
Radiator Spacer 1017543 20 7-36
Radio, AM/FM/CD w/Auxiliary Input and Speakers 1011314 1 7-47
Rear Frame Front Guard 1017582 5 7-40
Rear Scarifier Access Cover 1019138 9 7-40
Rear Scarifier Weldment 1018099 1 7-43
Rearview Mirror - Inside 720260 3 7-21
Rearview Mirror - Outside 151370 1 7-21
Receptacle Connector, 23-Pin 1014358 39 7-36
Recirculation Filter 12755490 7 7-19
Recirculation Filter Knob 36745-20 6 7-19
Reducer Adapter, -10 O-Ring/-12 O-Ring 6400-10-12-O 11 7-3
Reducer Adapter, -20 O-Ring/-16 O-Ring 6410-20-16-O 36 7-27
Reducer, Rubber, 2.25-2.00 1010900 19 7-38
Relay Mounting Bracket 36086 24 7-25
Relay Mounting Bracket 36086 32 7-36
Relay, 12VDC, SPDT, 40A, 5 Pin 36085 33 7-36
Relay, 12VDC, SPDT, 40A, 5-PIN 36085 22 7-25
7
Relay, 200A 1013394 31 7-36
Relief Valve Seal Kit 910065 REF 7-24
Remote Test Ports Assembly - 2WD 1019088 18a 7-30
Remote Test Ports Assembly - AWD Option 1019089 18b 7-30
Replacement Key 35560 - 7-14
Replacement Key 35560 - 7-15
Reservoir Filler Breather Cap Assembly 37680 8 7-27
Resistor, 68 Ohm, 25 Watt 1019586 26 7-25
Return Filter Assembly w/Adapters 1018445 REF 7-27

Item Figure
No. No.
Return Manifold 1019697 13 7-30
Rod End Ball Joint, 3/8" 100500 10 7-26
Rod End Ball Joint, 3/8" 100500 16 7-32
Roll Pin, 3/8 x 1.75 400-6-28 5 7-5
Roll Pin, 3/8 x 1.75 400-6-28 5 7-8
Rotary Latch - Left 983423-01SRV 8b 7-16
Rotary Latch - Right 983219-01SRV 8a 7-16
Round Ball Knob 851156 13 7-16
Rubber Elbow, 90°, 4.00 x 3.00 ID 1000834 4 7-35
Rubber Elbow, 90°, 5.00 x 4.00 ID 72172 10 7-35
Rubber Isolation Engine Mount (2 pc.) 1017509-26 26 7-36
Rubber Mount 36048 21 7-36
Run Tee Adapter, -12 ORFS/-12 O-Ring/-12 ORFS FS6804-12-12-12-NWO-FG 12 7-3
-S-
Scarifier Cylinder Assembly w/Adapters 1018352 REF 7-43
Scarifier Pin 1010773SRV 12 7-43
Scarifier Point 100523 35 7-41
Scarifier Shank Lock Pin 1020476 4 7-42
Scarifier Shank w/Tooth 132040 2 7-42
Scarifier Shank w/Tooth 132040 2 7-43
Scarifier Tooth 132050 3 7-42
Scarifier Tooth 132050 3 7-43
SCR 1017509-24 21 7-35
Screw, HWH, Slotted, #10-32 x 5/8 128-#10-32-10 9 7-27
Seal 210240 13 7-6
Seal 36830 20 7-6
Seat Assembly w/Seat Belt 1009335 1 7-20
Seat Box Access Panel 1010872 20 7-14
Seat Box Access Panel Plate 1010872 17 7-16
Seat Mount Plate 1020478 2 7-20
Seat Track Set 1009335-01 - 7-20
Set Screw Collar, 3/8" 1012918 13 7-26
Shoulder Bolt, 1/2-13, 1.25 LG 1019265 - 7-40
Side Cover 12757970 22 7-7
Side Glass 1013591-04 20 7-16
Signal Flasher 851091608 23 7-25

Item Figure
No. No.
Socket Head Set Screw, Cup, 1/4-20 x .25 113-4-20-4 4 7-26
Solenoid Valve 100202 31 7-41
Solenoid Valve 100202 30 7-42
Solenoid, 12V Constant Duty 720290 40 7-36
Solenoid, 12V, Constant Duty 720290 25 7-25
Sound Insulation - Headliner 1010790-02 31 7-16
Sound Insulation - Left 1010790-04 29 7-16
Sound Insulation - Rear 1010790-03 30 7-16
Spindle Mount Half Clamp 110021 7 7-5
Spindle Mounting Clamp - AWD 857377 7 7-8
Split Flange Clamp, Code 62, -16 1902-16 8 7-3
Spool Stop Adapter 1019685-04 27 7-7
Spring Loaded Pull Pin 1000835 38 7-41
Spring Return Valve Section 910054 4 7-24
Square Head Set Screw, 5/8-11 x 3.00, Flat Point 119-10-11-48 14 7-12
SRC Strap 1017534 2 7-27
Starter, 4.8kW 1008650-01 8 7-36
Steering Arm with Axle - Left 1018080 10 7-6
Steering Arm with Axle - Right 1018081 9 7-6
Steering Column, 6.00" 300040 6 7-22
Steering Control Unit 100397 3 7-22
Steering Motor Assembly w/Fittings 1018429 REF 7-22
Steering Tie Rod 1018097 15 7-5
Steering Tie Rod 110192 15 7-8
Steering Wheel Cap 20944062 9 7-22
Steering Wheel, 14.00" 115772 7 7-22
Straight Adapter, -10 ORFS/-10 O-Ring FS6400-10-10-O 25 7-31
7
Straight Adapter, -12 O-Ring/-12 NPTF 6405-12-12-O 31 7-27
Straight Adapter, -16 ORFS/ -20 O-Ring FS6400-16-20-O 24 7-27

Item Figure
No. No.
Straight Adapter, -6 ORFS/14mm O-Ring FS7640-06-14-O 22 7-3
Straight Adapter, -6 ORFS/-6 O-Ring, .060 Orifice FS6400-06-06-O X 060 7 7-10
Straight Adapter, -6 ORFS/-6 O-Ring, .100 Orifice FS6400-06-06-O X 100 3 7-28
Straight Adapter, -8 ORFS/-8 O-Ring 8 G65L-S 11 7-46
Straight Adapter, Code 62, 16 ORFS/-16 Flange FS1800-16-16 10 7-3
Straight Fitting, 08MP-10HB, Crimped 33492 13 7-18
Straight Lube Fitting, 1/4-28 140610 6 7-9
Straight Lube Fitting, 1/4-28 140610 10 7-23
Straight Reducer Adapter, -12 FFORX/-8 ORFS FS2406-12-08 15 7-46
Strain Relief, 1-1/2" NPT 1014487 37 7-36

Item Figure
No. No.
Street Elbow Adapter, 90°, -8 NPTF/-8 NPTF 5502-8-8 15 7-18
Striker Bolt 982416 16 7-16
Suction Strainer, 100 Mesh, O-Ring Seal 1014037 43 7-27
Suction Strainer, 100 Mesh, O-Ring Seal 1014037 45 7-27
Suction Strainer, 30 GPM, 100 Mesh 1014027 40 7-27
Supply DEF Module 1012641 4 7-37
Support Bar 1019059 28 7-33
Switch - Wiper/Washer 73119-CMG 7 7-25
Switch Bracket 12757496 9 7-31
Switch Bracket 12757496 9 7-32
Switch, SPDT, Sealed 1018391 20 7-3
Swivel Elbow Adapter, 90°, -12 ORFS/-12 ORFS FS6500-12-12-FG 13 7-3
Swivel Run Tee Adapter, -08 ORFS (x3) FS6602-08-08-08-FG 35 7-31
Swivel Run Tee Adapter, -6 ORFS/-6 ORFS/-6 ORFS FS6602-06-06-06-FG 30 7-41
Swivel Runt Tee Adapter, -8 ORFS (x3) FS6602-08-08-08-FG 30 7-7
Swivel Straight Adapter, -8 ORFS/-8 O-Ring FS6540-08-08-O 13 7-29
-T-
Tank Access Door - Left 1018052 4 7-27
7
Tank Access Door - Right 1018053 3 7-27
T-Bolt Clamp (1.87-2.13) 1013667-21 14 7-34
T-Bolt Clamp (2.53-2.84) 1014074 11 7-34
T-Bolt Clamp (3.09-3.35) 1014076 8 7-34
T-Bolt Clamp (3.31-3.59) 171090 1 7-35
T-Bolt Clamp (4.31-4.59) 953521243 5 7-35
T-Bolt Clamp (5.28-5.59) 39068 9 7-35
Test Port Adapter, -4 ORFS 1019707 20 7-30
Test Port Adapter, -4 ORFS 1019707 21 7-30

Item Figure
No. No.
Test Port Mount 1019090 19 7-30
Thick Washer w/Offset Hole 105571 31 7-31
Thick Washer w/Offset Hole 105571 33 7-32
Threaded Rod, 3/8-24 UNF x 11.00 56B-0692ZI 35 7-32
Threshold Plate 1010893 29 7-14
Threshold Plate 1010893 18 7-16
Throttle Control Lever 1018764 9 7-20
Throttle Control Mount 1018771 7 7-20
Throttle Plate, AWD Pump 1019449 34 7-32
Tie Rod Bushing, 1.25 ID x 1.50 OD x 1.00 LG 110130 3 7-6
Tie Rod, Wheel Lean 110182 23 7-5
Tie Rod, Wheel Lean 859375 23 7-8
Tire & Wheel Assembly - Right Rear 1010197R 2 7-3
Tire & Wheel Assembly -Left Rear 1010197L 3 7-3
Tire, 15" x 19.5", 8 Ply 110340 REF 7-4
Tire, 15" x 19.5", 8 Ply 100514 REF 7-7
Tire, 15: x 19.5", 8 PLY 100514 REF 7-3
Tire/Wheel Assembly - Left A120330AL 7 7-4
Tire/Wheel Assembly - Right A120330AR 6 7-4
Toggle Switch, DPDT, 3-POS 1018390 9 7-25
Toggle Switch, DPST, 2-POS 72086 12 7-25
Toggle Switch, SPDT, 2-POS 851090624 3 7-25
Toggle Switch, SPDT, 3-POS 851090613 10 7-25
Toggle Switch, SPST, 2-POS 851391 11 7-25
Torque Hub & Casting 1019685-01 11 7-9
Trans Shift Valve 983361 2 7-30
Trunnion Mount Assembly 100152SRV 8 7-2
Turn Signal w/Hazard 33687 22 7-22
Turntable & Drawbar Assembly 130004 1 7-10
Turntable & Drawbar Assembly 130004 REF 7-11
Turntable Bottom Plate 130083 26 7-11
Turntable Dust Cover 857578 1 7-11
-U, V-
Union Tee Adapter, -6 ORFS (x3) FS2603-06-06-06 23 7-3
Universal Back Plate 12758118 7 7-41
Universal Backplate 12758118 16 7-42
Valve Assembly, 10 Section w. Float 989177 REF 7-24
Valve Bank Assembly w/Adapters 1018344 REF 7-30

Item Figure
No. No.
Valve Inlet Cover w/Relief Valve 910055 1 7-24
Valve Lever Assembly 1006586 REF 7-23
Valve Lever Link Assembly 901010 7 7-23
Valve Lever Mount Bracket 910058 5 7-23
Valve Lever Mounting Bracket 910058 9 7-24
Valve Lever Pivot Arm 140571SRV 12 7-23
Valve Outlet Cover w/PB Sleeve 910056 5 7-24
Valve Section Seal Kit 910062 6 7-24
Valve Spool Detent Kit 901007 15 7-24
Valve Spool End Clevis 141060 8 7-24
Valve Spool End Spring Cap 141040 14 7-24
Valve Spool Seal Kit 910059 11 7-24
Valve Spring Center Kit 901014 13 7-24
Valve Stem 20192233 REF 7-4
Vandalism Cover - Display 1019631 12 7-14
Vandalism Cover - Right 1018603 8 7-14
Vandalism Cover Mount - Display 1018609 13 7-14
V-Band Clamp, 3.22" 1009242-06 13 7-35
V-Band Clamp, 3.88" 1014098 15 7-35
V-Band Clamp, Spherical, 5.13" 1014101 18 7-35
-W, X, Y, Z-
Washer Bottle Mounting Plate 1011114 8 7-15
Washer, 3.00 100529 13 7-41
Washer, 3.00 100529 9 7-42
Washer, 3.000 ID x 2.031 ID x .125 858961 16 7-2
Washer, Flat, #8 300-#8 14 7-28
Washer, Flat, 1.25 ID x 2.063 OD x .130 855002 21 7-5
Washer, Flat, 1.50 x 2.50 100250 18 7-12
Washer, Flat, 1-1/4 ID x 2-1/16 OD 855002 26 7-10
7
Washer, Flat, 1-1/4 ID x 2-1/16 OD 855002 21 7-8
Washer, Flat, 5/16 300-5 36 7-26
Washer, Flat, 7/16 ID x 2-1/2 OD 858953 12 7-10
Washer, Flat, SAE, #10 300-#10 19 7-18
Washer, Flat, SAE, #10 300-#10 15 7-21
Washer, Flat, SAE, #10 300-#10 19 7-26
Washer, Flat, SAE, #10 300-#10 11 7-31
Washer, Flat, SAE, #10 300-#10 11 7-32
Washer, Flat, SAE, #10 300-#10 13 7-39

Item Figure
No. No.
Washer, Flat, SAE, #10 300-#10 5 7-47
Washer, Flat, SAE, #12 300-#12 9 7-38
Washer, Flat, SAE, #8 300-#8 15 7-4
Washer, Flat, SAE, #8 300-#8 19 7-7
Washer, Flat, SAE, 1 300-16 9 7-43
Washer, Flat, SAE, 1/2 300-8 24 7-14
Washer, Flat, SAE, 1/2 300-8 14 7-26
Washer, Flat, SAE, 1/2 300-8 12 7-38
Washer, Flat, SAE, 1/2 300-8 9 7-39
Washer, Flat, SAE, 1/2 300-8 - 7-40
Washer, Flat, SAE, 1/2 300-8 - 7-40
Washer, Flat, SAE, 1/2 300-8 - 7-40
Washer, Flat, SAE, 1/2 300-8 - 7-40
Washer, Flat, SAE, 1/2 300-8 19 7-41
Washer, Flat, SAE, 1/2 300-8 REF 7-42
Washer, Flat, SAE, 1/4 300-4 20 7-4
Washer, Flat, SAE, 1/4 300-4 17 7-7
Washer, Flat, SAE, 1/4 300-4 10 7-11
Washer, Flat, SAE, 1/4 300-4 16 7-14
Washer, Flat, SAE, 1/4 300-4 13 7-15
Washer, Flat, SAE, 1/4 300-4 7 7-16
Washer, Flat, SAE, 1/4 300-4 8 7-17
Washer, Flat, SAE, 1/4 300-4 7 7-18
Washer, Flat, SAE, 1/4 300-4 18 7-21
Washer, Flat, SAE, 1/4 300-4 6 7-27
Washer, Flat, SAE, 1/4 300-4 19 7-28
Washer, Flat, SAE, 1/4 300-4 6 7-30
Washer, Flat, SAE, 1/4 300-4 17 7-31
Washer, Flat, SAE, 1/4 300-4 19 7-32
Washer, Flat, SAE, 1/4 300-4 17 7-33
Washer, Flat, SAE, 1/4 300-4 16 7-38
Washer, Flat, SAE, 1/4 300-4 5 7-39
Washer, Flat, SAE, 1/4 300-4 - 7-40
Washer, Flat, SAE, 1/4 300-4 11 7-47
Washer, Flat, SAE, 3/4 300-12 22 7-41
Washer, Flat, SAE, 3/4 300-12 21 7-42
Washer, Flat, SAE, 3/8 300-6 25 7-7
Washer, Flat, SAE, 3/8 300-6 11 7-10
Washer, Flat, SAE, 3/8 300-6 3 7-11

Item Figure
No. No.
Washer, Flat, SAE, 3/8 300-6 19 7-15
Washer, Flat, SAE, 3/8 300-6 12 7-20
Washer, Flat, SAE, 3/8 300-6 25 7-21
Washer, Flat, SAE, 3/8 300-6 11 7-23
Washer, Flat, SAE, 3/8 300-6 29 7-26
Washer, Flat, SAE, 3/8 300-6 29 7-27
Washer, Flat, SAE, 3/8 300-6 20 7-29
Washer, Flat, SAE, 3/8 300-6 31 7-30
Washer, Flat, SAE, 3/8 300-6 5 7-31
Washer, Flat, SAE, 3/8 300-6 5 7-32
Washer, Flat, SAE, 3/8 300-6 9 7-33
Washer, Flat, SAE, 3/8 300-6 18 7-39
Washer, Flat, SAE, 3/8 300-6 - 7-40
Washer, Flat, SAE, 3/8 300-6 - 7-40
Washer, Flat, SAE, 3/8 300-6 - 7-40
Washer, Flat, SAE, 3/8 300-6 29 7-41
Washer, Flat, SAE, 3/8 300-6 25 7-42
Washer, Flat, SAE, 3/8 300-6 11 7-44
Washer, Flat, SAE, 3/8 300-6 5 7-46
Washer, Flat, SAE, 5/16 300-5 6 7-14
Washer, Flat, SAE, 5/16 300-5 6 7-15
Washer, Flat, SAE, 5/16 300-6 17 7-17
Washer, Flat, SAE, 5/16 300-5 11 7-18
Washer, Flat, SAE, 5/16 300-5 4 7-20
Washer, Flat, SAE, 5/16 300-5 21 7-21
Washer, Flat, SAE, 5/16 300-5 19 7-22
Washer, Flat, SAE, 5/16 300-5 8 7-37
Washer, Flat, SAE, 5/8 300-10 13 7-2
Washer, Flat, SAE, 5/8 300-10 30 7-3
Washer, Flat, SAE, 5/8 300-10 22 7-11
7
Washer, Flat, SAE, 5/8 300-10 24 7-36
Washer, Flat, SAE, 7/8 300-14 5 7-3
Washer, Flat, SAE, 9/16 300-9 19 7-3
Washer, Flat, USS, 3/8 301-6 8 7-44
Washer, Hardened, SAE, 5/8 310-10 9 7-1
Washer, Hardened, SAE, 7/8 310-14 13 7-10
Washer, Lock, #10 302-#10 20 7-26
Washer, Lock, #10 302-#10 12 7-31
Washer, Lock, #10 302-#10 12 7-32

Item Figure
No. No.
Washer, Lock, #10 302-#10 14 7-39
Washer, Lock, #12 302-#12 8 7-38
Washer, Lock, #8 302-#8 16 7-4
Washer, Lock, #8 302-#8 20 7-7
Washer, Lock, #8 302-#8 15 7-28
Washer, Lock, 1/2 302-8 16 7-11
Washer, Lock, 1/2 302-8 23 7-14
Washer, Lock, 1/2 302-8 11 7-38
Washer, Lock, 1/2 302-8 8 7-39
Washer, Lock, 1/2 302-8 - 7-40
Washer, Lock, 1/2 302-8 - 7-40
Washer, Lock, 1/2 302-8 - 7-40
Washer, Lock, 1/2 302-8 - 7-40
Washer, Lock, 1/2 302-8 16 7-41
Washer, Lock, 1/2 302-8 27 7-42
Washer, Lock, 1/4 302-4 19 7-4
Washer, Lock, 1/4 302-4 16 7-7
Washer, Lock, 1/4 302-4 11 7-11
Washer, Lock, 1/4 302-4 15 7-14
Washer, Lock, 1/4 302-4 12 7-15
Washer, Lock, 1/4 302-4 9 7-17
Washer, Lock, 1/4 302-4 8 7-18
Washer, Lock, 1/4 302-4 12 7-27
Washer, Lock, 1/4 302-4 18 7-28
Washer, Lock, 1/4 302-4 22 7-29
Washer, Lock, 1/4 302-4 7 7-30
Washer, Lock, 1/4 302-4 16 7-33
Washer, Lock, 1/4 302-4 15 7-38
Washer, Lock, 1/4 302-4 - 7-40
Washer, Lock, 1/4 302-4 9 7-47
Washer, Lock, 1-1/8 302-18 20 7-11
Washer, Lock, 3/4 302-12 21 7-41
Washer, Lock, 3/4 302-12 20 7-42
Washer, Lock, 3/8 302-6 24 7-7
Washer, Lock, 3/8 302-6 10 7-10
Washer, Lock, 3/8 302-6 18 7-15
Washer, Lock, 3/8 302-6 11 7-20
Washer, Lock, 3/8 302-6 26 7-21
Washer, Lock, 3/8 302-6 21 7-22

Item Figure
No. No.
Washer, Lock, 3/8 302-6 16 7-23
Washer, Lock, 3/8 302-6 28 7-26
Washer, Lock, 3/8 302-6 28 7-27
Washer, Lock, 3/8 302-6 19 7-29
Washer, Lock, 3/8 302-6 30 7-30
Washer, Lock, 3/8 302-4 22 7-33
Washer, Lock, 3/8 302-6 17 7-39
Washer, Lock, 3/8 302-6 - 7-40
Washer, Lock, 3/8 302-6 - 7-40
Washer, Lock, 3/8 302-6 - 7-40
Washer, Lock, 3/8 302-6 28 7-41
Washer, Lock, 3/8 302-6 24 7-42
Washer, Lock, 3/8 302-6 14 7-43
Washer, Lock, 3/8 302-6 4 7-46
Washer, Lock, 5/16 302-5 7 7-14
Washer, Lock, 5/16 302-5 5 7-15
Washer, Lock, 5/16 302-5 16 7-17
Washer, Lock, 5/16 302-5 21 7-18
Washer, Lock, 5/16 302-5 5 7-20
Washer, Lock, 5/16 302-5 22 7-21
Washer, Lock, 5/16 302-5 18 7-22
Washer, Lock, 5/16 302-5 20 7-23
Washer, Lock, 5/16 302-5 34 7-33
Washer, Lock, 5/16 302-5 7 7-37
Washer, Lock, 5/8 302-10 12 7-2
Washer, Lock, 5/8 302-10 29 7-3
Washer, Lock, 5/8 302-10 4 7-4
Washer, Lock, 5/8 302-10 9 7-5
Washer, Lock, 5/8 302-10 6 7-6
Washer, Lock, 5/8 302-10 4 7-7
7
Washer, Lock, 5/8 302-10 9 7-8
Washer, Lock, 5/8 302-10 10 7-9
Washer, Lock, 5/8 302-10 10 7-12
Washer, Lock, 5/8 302-10 5 7-13
Washer, Lock, 5/8 302-10 - 7-40
Washer, Lock, 5/8 302-10 5 7-41
Washer, Lock, 9/16 302-9 18 7-3
Washer, Lock, 9/16 302-9 - 7-40
Washer, Lock, External Tooth, #10 303-#10 6 7-47

Item Figure
No. No.
Washer, Lock, Hi-Collar, 5/8 307-10 8 7-1
Washer, Lock, Hi-Collar, 5/8 307-10 15 7-3
Washer, Lock, M10 302-M10 7 7-31
Washer, Lock, M10 302-M10 7 7-32
Washer, Lock,1/2, Nord Wedge (2 pc.) 986810 30 7-31
Washer, Lock,1/2, Nord Wedge (2 pc.) 986810 32 7-32
Washer, Thick, 1/2 x 1.25 x .188 309-8-20-3 39 7-31
Washer, Thick, 1/2 x 1.25 x .188 309-8-20-3 47 7-32
Wheel 1010198 REF 7-3
Wheel 120330B REF 7-4
Wheel Hub 988911SRV 16 7-6
Wheel Hub Assembly w/ Studs 110240A 15 7-6
Wheel Hub Inner Bearing Cone 110260 21 7-6
Wheel Hub Inner Bearing Cup 110250 17 7-6
Wheel Hub Outer Bearing Cone 610210 22 7-6
Wheel Hub Outer Bearing Cup 610200 18 7-6
Wheel Lean Tie Rod Bushing 110130 3 7-9
Wheel Stud 110350A 19 7-6
Windshield Glass - Front 1013591-01 22 7-16
Windshield Glass - Rear 1013591-02 21 7-16
Windshield Washer Hose, .188 ID (per foot) 35550 10 7-44
Windshield Washer Nozzle Kit 852810 22 7-15
Windshield Washer Nozzle Kit 852810 5 7-44
Windshield Wiper Arm 151180 21 7-15
Windshield Wiper Arm 151180 2 7-44
Windshield Wiper Blade - 20" 151190 20 7-15
Windshield Wiper Blade, 20" 151190 3 7-44
Windshield Wiper Motor 151170 23 7-15
Windshield Wiper Motor 151170 1 7-44
Windshield Wiper Washer Tank 151200 7 7-15
Wing Nut, 3/8-16 31877 18 7-23
Wiper Motor Cover Plate 1011124 6 7-44
Wiper/Washer Switch 73119-CMG 4 7-44
Wiring Cover Plate 859133 10 7-14
Wiring Cover Plate 859133 4 7-17

500 Lincoln County Parkway Ext.
Lincolnton, North Carolina 28092
Phone: (704) 966-3300 - Fax Sales: (704) 483-5802
www.LeeBoy.com
Printed in the U.S.A.

LeeBoy Motor Grader 685D Manual WEB

Uploaded by

Copyright:

Available Formats

LeeBoy Motor Grader 685D Manual WEB

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

LeeBoy Motor Grader 685D Manual WEB

Uploaded by

Copyright:

Available Formats

Operations, Service, and Parts Manual

LEEBOY 685D MOTOR GRADER

iv LeeBoy 685D Motor Grader

LeeBoy 685D Motor Grader v

Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

vi LeeBoy 685D Motor Grader

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

LeeBoy 685D Motor Grader vii

Circle Side Shift. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

viii LeeBoy 685D Motor Grader

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

LeeBoy 685D Motor Grader ix

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

x LeeBoy 685D Motor Grader

Boom Pivot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

LeeBoy 685D Motor Grader xi

Engine - Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78

xii LeeBoy 685D Motor Grader

VT LeeBoy, Inc. is proud to be ISO 9001 certified. The International Standards

VT LeeBoy, Inc., is also proud to be an accredited ANAB manufacturer,

LeeBoy 685D Motor Grader xiii

xiv LeeBoy 685D Motor Grader

LeeBoy 685D Motor Grader 1-1

1-2 LeeBoy 685D Motor Grader

LeeBoy 685D Motor Grader 1-3

The safety messages that follow have CAUTION level

• Ensure that the work area is adequately illuminated.

1-4 LeeBoy 685D Motor Grader

Fire and Explosion Hazard

Modification Hazard Fire Hazard

LeeBoy 685D Motor Grader 1-5

Never operate the machine while under the

1-6 LeeBoy 685D Motor Grader

LeeBoy 685D Motor Grader 1-7

Refueling Precautions • DO NOT bypass the grader neutral-start system.

1-8 LeeBoy 685D Motor Grader

• Be alert for hazards and obstructions such as ditches, Snow Removal

LeeBoy 685D Motor Grader 1-9

Tire Precautions • DO NOT try to seat rings or other components by

1-10 LeeBoy 685D Motor Grader

(Both Sides and

Figure 1-1. Safety Labels and Safety Label Locations

LeeBoy 685D Motor Grader 1-11

Cab Option Safety Decals

(Panel Under Seat)

Figure 1-2. Cab Option Additional Safety Decals

Safety Decals Care

1-12 LeeBoy 685D Motor Grader

INFORMATION AND SPECIFICATIONS

LeeBoy 685D Motor Grader 2-1

ONE YEAR LIMITED WARRANTY

Limited Warranty Exclusions and Limitations

Exclusion of Other Warranties/Limitation of Liability

2-2 LeeBoy 685D Motor Grader

Machine Model Number:

Figure 2-1. Nameplate Location

LeeBoy 685D Motor Grader 2-3

Table 2-1. Machine Dimensions

Table 2-2. Engine Specifications

2-4 LeeBoy 685D Motor Grader