LeeBoy Motor Grader 685C Manual WEB

LEEBOY MODEL 685C MOTOR GRADER
Manual No. 1011484-01

This manual applies
to serial number and
above: 103234
Thumb Index
SAFETY 1
INFORMATION 2
COMPONENT LOCATION 3
OPERATION 4
MAINTENANCE 5
SCHEMATICS 6
ILLUSTRATED PARTS LIST (IPL) 7
LeeBoy Model 685C Motor Grader i

Disclaimer And Copyright

Disclaimer:
All information, illustrations and specifications in this manual are based on the latest information available at the time
of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover,
because of our continuous product improvement policy, we may modify information, illustrations and/or specifications
to explain and/or exemplify a product, service or maintenance improvement. We reserve the right to make any
change at any time without notice. VT LeeBoy, Inc., VT LeeBoy, LeeBoy, and Rosco are all the same entity and are
used interchangeably.
©2014 VT LeeBoy, Inc.
LeeBoy reserves all copyright and other rights in this manual and the manual’s content. No part of this manual may
be reproduced or used in any way without the written permission of LeeBoy, except as necessary to operate LeeBoy
equipment.
ii LeeBoy Model 685C Motor Grader

TABLE OF CONTENTS
Page
Table Of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Label Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Limited Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Items Not Covered. . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Other Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Contact Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Record of Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Machine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Specifications Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Inch Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Metric Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Full Torque Nut Coupling Installation . . . . . . . . . . . . . . . . . 2-17
Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operator’s Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Steering Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
LeeBoy Model 685C Motor Grader iii

Table Of Contents

Forward/Neutral/Reverse (FNR) Pedal/Primary Brake Pedal . . . . . . . . 3-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Operating Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Stopping Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Receiving The Motor Grader . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Preliminary Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Adjusting Steering Console. . . . . . . . . . . . . . . . . . . . . . 4-5
Adjusting Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Cab Option Only. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Recirculated Air Control. . . . . . . . . . . . . . . . . . . . . . . . 4-6
Lights4-8
Break-In Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Pre-start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Driving The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Directional Control . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Travel Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Operating The Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Moldboard Lift Control. . . . . . . . . . . . . . . . . . . . . . . . 4-13
Moldboard Side-shift Control . . . . . . . . . . . . . . . . . . . . . 4-13
Moldboard Pitch Control. . . . . . . . . . . . . . . . . . . . . . . 4-13
Moldboard Angle Control . . . . . . . . . . . . . . . . . . . . . . . 4-13
Wheel Lean Control . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Optional Front Traction Assist Control. . . . . . . . . . . . . . . . 4-14
Scarifier Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Articulation and Steering Control. . . . . . . . . . . . . . . . . . . 4-15
Front Blade Control (Option). . . . . . . . . . . . . . . . . . . . . 4-15
iv LeeBoy Model 685C Motor Grader

Table Of Contents
Spreading Piles . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Vee Ditching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Ditch Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Road Crowning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Bank Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Slope Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Cul-De-Sacs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Motor Grader Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
General Information . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Machine Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Preparing Machine for Maintenance . . . . . . . . . . . . . . . . . 5-8
10 Hour or Daily Routine Maintenance . . . . . . . . . . . . . . . . . 5-8
After The First 50 Hours and Weekly Routine Maintenance . . . . . . 5-9
100 Hour or Monthly Routine Maintenance . . . . . . . . . . . . . . 5-9
250 Hour or Quarterly Routine Maintenance . . . . . . . . . . . . . 5-9
500 Hour or Semi-Annual Routine Maintenance . . . . . . . . . . . 5-9
1000 Hour or Annual Routine Maintenance . . . . . . . . . . . . . . 5-10
2000 Hour Routine Maintenance . . . . . . . . . . . . . . . . . . . 5-10
Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Checking Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Checking Oil Lines and Fittings . . . . . . . . . . . . . . . . . . . . 5-10
Checking Air Intake Hoses . . . . . . . . . . . . . . . . . . . . . . 5-10
Checking Window Washer Fluid Reservoir Level . . . . . . . . . . . 5-10
Checking the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Checking and Adjusting Moldboard Blade Side-Shift Assembly . . . . 5-11
Checking Drawbar Ball and Socket . . . . . . . . . . . . . . . . . . 5-11
Checking and Adjusting Toe-In . . . . . . . . . . . . . . . . . . . . 5-12
Checking Gearbox Breathers . . . . . . . . . . . . . . . . . . . . 5-12
Cleaning, Packing, and Adjusting the Front Wheel Bearings . . . . . 5-12
LeeBoy Model 685C Motor Grader v

Table Of Contents
Checking Neutral Start System . . . . . . . . . . . . . . . . . . . . 5-13

Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Master Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . 5-13
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Cleaning and Tightening Battery Terminal Connections/Terminals . . 5-14
Checking Battery Electrolyte Level . . . . . . . . . . . . . . . . . . 5-15
Tire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Filling Tire with Air . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Changing Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Checking the Engine Lubrication Oil Level . . . . . . . . . . . . . . 5-17
Changing the Engine Oil and Replacing Filter . . . . . . . . . . . . . 5-17
Transfer Case Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Checking Transfer Case Oil Level . . . . . . . . . . . . . . . . . . 5-19
Radiator and Coolant System . . . . . . . . . . . . . . . . . . . . . . . 5-19
Checking Radiator and Coolant Level . . . . . . . . . . . . . . . . 5-19
Cleaning Engine Ventilation Tube (Blow-By Tube) . . . . . . . . . . 5-21
Checking Engine Speed . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Checking and Cleaning Fuel Filler Cap . . . . . . . . . . . . . . . . 5-23
Checking Engine Air Cleaner Assembly . . . . . . . . . . . . . . . 5-23
Replacing Engine Air Filter Elements . . . . . . . . . . . . . . . . . 5-24
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . 5-25
Changing Hydraulic Charge Filter. . . . . . . . . . . . . . . . . . 5-26
Checking and Cleaning Hydraulic Oil Reservoir Filler Cap . . 5-27
Draining, Flushing, and Filling Hydraulic Oil Reservoir. . . . . . . . . 5-27
Rear Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Checking Rear Axle Oil Level . . . . . . . . . . . . . . . . . . . . 5-28
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Fuses And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . 5-29
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . 5-30
Replacing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
vi LeeBoy Model 685C Motor Grader

Table Of Contents
Replacing Scarifier Tooth Shank. . . . . . . . . . . . . . . . . . . 5-31

Replacing Scarifier Tooth. . . . . . . . . . . . . . . . . . . . . . . 5-31
Replacing Articulate Cylinders . . . . . . . . . . . . . . . . . . . . 5-32
Replacing Wheel Steering Cylinder . . . . . . . . . . . . . . . . . 5-33
Replacing Wheel Lean Cylinder. . . . . . . . . . . . . . . . . . . 5-34
Replacing Front Blade Lift Cylinder . . . . . . . . . . . . . . . . . 5-35
Replacing Scarifier Lift Cylinder . . . . . . . . . . . . . . . . . . . 5-35
Replacing Moldboard Slide Cylinder . . . . . . . . . . . . . . . . . 5-36
Replacing Moldboard Tilt Cylinders . . . . . . . . . . . . . . . . . 5-37
Replacing Moldboard Angle Cylinders . . . . . . . . . . . . . . . . 5-37
Replacing Moldboard Lift Cylinder . . . . . . . . . . . . . . . . . . 5-38
Replacing Moldboard Blade . . . . . . . . . . . . . . . . . . . . . 5-38
Replacing Hydraulic Charge Filter. . . . . . . . . . . . . . . . . . 5-39
Replacing Radiator/Oil Cooler Assembly. . . . . . . . . . . . . . . 5-40
Replacing Control Valve Assembly . . . . . . . . . . . . . . . . . . 5-41
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Preparing Machine For Long-Term Storage . . . . . . . . . . . . . 5-42
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Electrical 1 of 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Cab: Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Electrical 2 of 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Cab: Instrument Panel (Cont.) . . . . . . . . . . . . . . . . . . . . . 6-5
Electrical 3 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Electrical 4 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Canopy: Instrument Panel . . . . . . . . . . . . . . . . . . . . . . 6-9
Electrical 5 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Canopy: Instrument Panel (Cont.). . . . . . . . . . . . . . . . . . . 6-11
Electrical 6 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Electrical 7 of 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Secondary Instrument Panel. . . . . . . . . . . . . . . . . . . . . 6-15
Electrical 8 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
One-Line Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
LeeBoy Model 685C Motor Grader vii

Table Of Contents
Hydraulic 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Overall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Hydraulic 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Hydraulic 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Front Wheel Assist. . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Hydraulic 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Illustrated Parts List (IPL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Replacement Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Tire Assembly And Axles (W/Out AWD). . . . . . . . . . . . . . . . . . . 7-10
Front Blade Assembly (With Boom And Front Axle). . . . . . . . . . . . . 7-12
Wheels And Front Axle, AWD (Option) . . . . . . . . . . . . . . . . . . . . 7-14
Rear Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Front Axle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Front Wheel Assist / Awd (Option) Assembly . . . . . . . . . . . . . . . . 7-22
Boom, 10’ Turntable Moldboard Assembly (W/Out AWD). . . . . . . . . . . 7-26
Moldboard Drawbar Assembly (W/Out AWD) . . . . . . . . . . . . . . . . 7-28
Moldboard Lift Assembly (In All Models) . . . . . . . . . . . . . . . . . . 7-30
Turntable Assembly (In All Models) . . . . . . . . . . . . . . . . . . . . . 7-32
Moldboard Assembly (10’) . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Turntable Moldboard Assembly (12’) . . . . . . . . . . . . . . . . . . . . 7-36
Front Dozer Blade Assembly (Option) . . . . . . . . . . . . . . . . . . . 7-38
Scarifier Assembly (Option). . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Cab And Canopy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Cab (Option) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Canopy Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Motor, Windshield Wiper And Misc.. . . . . . . . . . . . . . . . . . . . . 7-50
Vandalism Assembly (Option). . . . . . . . . . . . . . . . . . . . . . . . 7-52
Heater And A/C Evaporator Unit. . . . . . . . . . . . . . . . . . . . . . . 7-54
A/C Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Engine Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Battery Box And Battery Assembly. . . . . . . . . . . . . . . . . . . . . 7-62
viii LeeBoy Model 685C Motor Grader

Table Of Contents
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64

Radiator And Hydraulic Oil Cooler Assembly. . . . . . . . . . . . . . . . 7-66
Hydraulic Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Engine, Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Steering Wheel, Seat And Pedals. . . . . . . . . . . . . . . . . . . . . . 7-72
Steering Wheel and Control Console Assembly. . . . . . . . . . . . . . . 7-74
Steering Wheel and Control Console Assembly (Cont.) . . . . . . . . . . . 7-76
Dead Engine Steering (Option) Assembly. . . . . . . . . . . . . . . . . . 7-78
Instrument Panels (Canopy And Cab). . . . . . . . . . . . . . . . . . . . 7-80
Instrument Panel (Canopy Only). . . . . . . . . . . . . . . . . . . . . . . 7-82
Hydraulic Valve Bank (Block 10 Stack) . . . . . . . . . . . . . . . . . . . 7-84
Hydraulic Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-86
Alphabetical Parts Index (API) . . . . . . . . . . . . . . . . . . . . . . . . 7-88
LeeBoy Model 685C Motor Grader ix

Table Of Contents
NOTES
x LeeBoy Model 685C Motor Grader

Introduction
INTRODUCTION
Thank you for purchasing the 685C Motor Grader. We This manual provides information for use by the
wish you many years of safe and efficient operation of equipment operator under the following headings:
your motor grader. Safety—See Section 1 for important safety guidelines
READ THIS MANUAL PRIOR TO OPERATING the unit. information.
This manual is an important part of the motor grader Information—See Section 2 for important warranty,
and should be kept with the motor grader at all times in contact, and nameplate information and all major system
the dedicated storage container on the motor grader. specifications and typical torque value tables.
Even though you may be familiar with similar equipment,
you MUST read and understand this manual before Component Location—See Section 3 for general
operating this motor grader. Reading the manual will overview of controls and major components.
help you and others avoid injury and help prevent any Operation—See Section 4 for control functionality and
damage to the motor grader. If this manual becomes normal equipment operation.
lost or damaged, contact your authorized LeeBoy
Dealer immediately to order a replacement (Contact Maintenance—See Section 5 for basic preventive
Information on page 2-4). maintenance, repair and troubleshooting procedures.
This manual is intended as a guide for the safe and Schematics—See Section 6 for schematic diagrams of
efficient use of the motor grader. This manual covers the electrical wiring.
procedures for proper operation and maintenance of Illustrated Parts List (IPL)—See Section 7 for
the motor grader. This manual contains information that illustrations, descriptions and part numbers of available
was available at the time of printing and are subject to service parts.
change without notice.
This manual should be used with all related
supplemental books, engine and transmission manuals,
and parts books. Related Service Bulletins should be
reviewed to provide information regarding some of the
recent changes.
If any questions arise concerning this publication or
others, contact your local LeeBoy Dealer for the latest
available information.
LeeBoy Model 685C Motor Grader xi

Introduction
NOTES
xii LeeBoy Model 685C Motor Grader

1
Section 1
SAFETY
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Label Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
LeeBoy Model 685C Motor Grader 1-1

Safety
NOTES
1-2 LeeBoy Model 685C Motor Grader

Safety
This manual provides important information to familiarize

you with safe operating and maintenance procedures.
Even though you may be familiar with similar equipment, Indicates a hazardous situation which, if not avoided, will
you MUST read and understand this manual before result in death or serious injury.
operating the LeeBoy Model 685C Motor Grader and
follow its instructions when operating the grader.
Safety is everyone’s business and is our top concern. Indicates a hazardous situation which, if not avoided,
Knowing the guidelines covered in this section and in could result in death or serious injury.
Section 1 will help ensure your safety, the safety of those
around you and the grader’s proper operation.
LOOK FOR THESE SYMBOLS WHICH POINT OUT Indicates a hazardous situation which, if not avoided,
ITEMS OF EXTREME IMPORTANCE TO THE SAFETY could result in minor or moderate injury.
OF YOU AND YOUR COWORKERS. READ AND
UNDERSTAND THOROUGHLY. HEED THE WARNING
AND FOLLOW THE INSTRUCTIONS.
Indicates a situation which can cause damage to the
Keep safety labels in good condition. If safety labels
equipment, personal property and/or the environment,
become missing or damaged, replacement safety labels
or cause the LeeBoy 685C Motor Grader to operate
are available from your LeeBoy Dealer (see Contact
improperly.
Information on page 2-4 and Figure 1-1. Safety
Labels and Safety Label Locations on page 1-7). NOTE: Indicates a procedure, practice, or condition
that should be followed in order for the grader
or component to function in the manner
intended.

Safety
SAFETY PRECAUTIONS
The safety messages that follow have WARNING
level hazards.
The safety messages that follow have CAUTION level
hazards. Crush Hazard
Pre-Operation Hazard Keep bystanders away from work area before and
during operation.
Read and understand this Operation Manual
before operating or servicing the engine to
ensure that safe operating practices and Modification Hazard
maintenance procedures are followed.
Never modify the LeeBoy machine without written
• Never permit anyone to service or operate the LeeBoy consent of LeeBoy. Any modification can affect the safe
machine without proper training. operation of the grader and may cause personal injury
• Safety signs and labels are additional reminders for or death.
safe operating and maintenance techniques.
• Contact LeeBoy or an authorized LeeBoy Dealer for
additional training.
Exposure Hazard
• Make sure you are aware of all laws and regulations Always wear personal protective equipment,
that are in effect where the grader is operated. Make including appropriate clothing, gloves, work
sure you have all necessary licenses to operate the shoes, and eye and hearing protection, as
grader. required by the task at hand.
Explosion Hazard
While the engine is running or the battery is
Indicates a hazardous situation which, if not avoided, charging, hydrogen gas is being produced
will result in death or serious injury. and can be easily ignited. Keep the area
around the battery well-ventilated and keep
Electrocution Hazard sparks, open flame and any other form of
If your machine comes in contact with ignition out of the area.
electric power lines, observe the following: • Always disconnect the negative (-) battery cable
• Stay in the operators seat. before servicing the grader.
• Warn other workers to stay away and do not touch any • Do not start the engine by shorting the starter circuit
control or any part of the machine. or any other starting method not stated in this manual.
Only use the starting procedure as described in this
• If contact can be broken, drive the machine away from manual to start the engine.
the danger zone.
• Never charge a frozen battery. Always slowly warm the
• If contact cannot be broken, stay in the operators seat battery to room temperature before charging.
until told that power is off.
• Failure to observe this admonishment could result in
electrocution or death.
Suffocation Hazard
Never operate the internal combustion
engine on this machine in an enclosed area
with poor ventilation. Failure to do so could result in
carbon monoxide poisoning or death.

Safety
Fire and Explosion Hazard If the engine must be serviced while it is

operating, remove all jewelry, tie back long
• Diesel fuel is flammable and explosive under certain
hair and keep hands, other body parts and
conditions.
clothing away from moving/rotating parts.
• Never use a shop rag to catch the fuel.
• Always stop the engine before beginning service.
• Wipe up all spills immediately.
• Verify that all grader guards and covers are attached
• Never refuel with the engine running. properly to the grader before starting the engine. Do
not start the engine if any guards or covers are not
• Store any containers containing fuel in a well-
properly installed on the grader.
ventilated area, away from any combustibles or
sources of ignition. • If you must run the engine during maintenance
procedures, make sure you have a helper to keep
Fire Hazard bystanders clear of the grader and make observations
Have appropriate safety equipment of moving parts as requested by the operator.
available. Have all fire extinguishers • Always turn the start switch to the OFF position after
checked periodically for proper operation operation is complete and remove the key from the
and/or readiness. switch. Keep the key in your possession when the
• Always read and follow safety-related precautions grader is not operating.
found on containers of hazardous substances • Attach a “Do Not Operate” tag near the key switch
like parts cleaners, primers, sealants and sealant while performing maintenance on the equipment.
removers.
• Never operate the engine while wearing a headset to
• Undersized wiring systems can cause an electrical listen to music or radio because it will be difficult to
fire. hear the warning signals.
• Always start the engine or operate the controls while
you are seated in the operators seat.
The safety messages that follow have WARNING Alcohol and Drug Hazard
level hazards.
Never operate the engine while under the
Exhaust Hazard influence of alcohol or drugs, or when ill
All internal combustion engines create
carbon monoxide gas during operation and
special precautions are required to avoid Piercing Hazard
carbon monoxide poisoning: Avoid skin contact with high-pressure
• Never block windows, vents or other means of hydraulic fluid or diesel fuel spray caused
ventilation if the LeeBoy machine is operating in an by a hydraulic or fuel system leak such as a
enclosed area. broken hydraulic hose or fuel injection line.
High-pressure hydraulic fluid or fuel can
• Always ensure that all connections are tightened to
penetrate your skin and result in serious injury. If you are
specifications after repair is made to the exhaust
exposed to high-pressure hydraulic fluid or fuel spray,
system.
obtain prompt medical treatment.
• Never check for a hydraulic fluid or fuel leak with your
Entanglement/Sever Hazard hands. Always use a piece of wood or cardboard.
Have your authorized LeeBoy Dealer or distributor
Verify there are no people, obstacles or repair the damaged parts.
other equipment near the machine before
starting the engine. Sound the horn as a
warning before starting the engine.

Safety
Flying Object Hazard

Always wear eye protection when cleaning
the LeeBoy Model 685C Motor Grader The safety messages that follow have NOTICE level
Motor Grader with compressed air or hazards.
high-pressure water. Dust, flying debris,
Any part which is found defective as a result of
compressed air, pressurized water or steam
inspection or any part whose measured value does not
may injure your eyes.
satisfy the standard or limit must be replaced.
Coolant Hazard Always tighten components to the specified torque.

Wear eye protection and rubber gloves Loose parts can cause LeeBoy machine damage or
when handling engine coolant. If contact cause it to operate improperly.
with the eyes or skin should occur, flush
eyes and wash immediately with clean
Only use replacement parts approved by LeeBoy. Other
water.
replacement parts may affect warranty coverage.
Burn Hazard
Some of the grader surfaces become Follow the guidelines of the EPA or other governmental
very hot during operation and shortly after agencies for the proper disposal of
shutdown. hazardous materials such as engine oil,
• Keep hands and other body parts away from hot diesel fuel and engine coolant. Consult
grader surfaces. the local authorities or reclamation facility.
• Handle hot components with heat-resistant gloves.

Clean all accumulated dirt and debris away from the
body of the grader and its components before you
inspect the grader or perform preventive maintenance
The safety messages that follow have CAUTION level procedures or repairs. Operating a grader with
hazards. accumulated dirt and debris will cause premature wear
of grader components. Accumulated dirt and debris also
Poor Lighting Hazard hinders effective grader inspection.
Ensure that the work area is adequately illuminated.
Always install wire cages on portable safety lights.
Retrieve any tools or parts that may have dropped inside
of the grader to avoid improper grader operation.
Tool Hazard
Always use tools appropriate for the task at hand and Dispose of hazardous materials in accordance with
use the correct size tool for loosening or tightening all applicable laws and regulations. Never dispose of
LeeBoy machine parts. hazardous materials by dumping them into a sewer, on
the ground, or into groundwater or waterways.
If any alert indicator illuminates during grader operation,

stop the engine immediately. Determine the cause and
repair the problem before continuing to operate the
grader.

Safety
SAFETY LABEL LOCATIONS A description of location is provided below for each

safety label. For additional instructions, contact your
If your LeeBoy machine has been repainted, it is dealer.
extremely important that all the decals referring to NOTE: It is the responsibility of the owner and operator
CAUTION, WARNING, and DANGER be replaced in their to make sure that all safety labels are readable
proper locations. The illustrations on this page will aid and located on grader as designated by
you in determining the proper locations; for additional LeeBoy.
help, you should refer to the parts listing in the parts
section of this manual and note the description column.
WARNING DANGER PELIGRO DANGER
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
Do not operate or tow unit before reading operators manual.
Failure to comply could result in death or serious injury.
ADVERTENCIA
El vapor de escape de los motores diesel y algunos de sus componentes son RUN-AWAY VEHICLE RIESGO DE MOVIMIENTO RISQUE DE PERTE DE
conocidos por el Estado de California como causantes de cáncer, defectos HAZARD! INESPERADO DEL CONTRÔLE DU
congénitos y otros daños al sistema reproductivo. VEHICULO! VÉHICULE !
No usar ni remolcar la máquina sin antes haber leído el manual del operador. DO NOT shift on hills.
NO cambiar de marcha sobre NE PAS changer de vitesse
Si no se cumple con esta disposición, se puede causar la muerte o lesiones graves.
Machine must be in pendientes. sur les pentes.
AVERTISSEMENT
NEUTRAL and Es necesario colocar la La machine doit être au
Emergency Brake máquina en PUNTO MUERTO
POINT MORT et le frein
L’état de Californie a déterminé que les gaz d’échappement des moteurs diesel et applied before y aplicar el freno de
d’urgence doit être serré
estacionamiento antes de
certains de leurs éléments constitutifs sont à l’origine de cancers, de malformations dismounting.
WARNING CONTENTS UNDER PRESSURE!
avant de quitter la machine.
congénitales et d’autres lésions des organes reproducteurs. desocupar la máquina.
Ne pas faire fonctionner ni remorquer la machine avant de lire le manuel Failure to comply will Si no se cumple con esta
Le non-respect de cette règle
ADVERTENCIA ¡ CONTENIDO BAJO PRESION! d’opérations.

Le non-respect de cette règle risque d’entraîner des blessures graves, voire mortelles.
result in death or
serious injury.
disposición, se causará la
muerte o lesiones graves.
entraînera des blessures
graves, voire mortelles.
AVERTISSEMENT CONTENU SOUS PRESSION !

856579-06 983125-21
856579-08 Rev 1
CAUTION BURN HAZARD!

PRECAUCION ¡ RIESGO DE QUEMADURAS!
ATTENTION RISQUE DE BRÛLURES ! 856579-07 Rev 1
856579-03 DANGER PINCH POINT

PUNTO DE
INSIDE CANOPY PELIGRO APRIETE
DANGER POINT DE
PINCEMENT 856579-12
983125-10
CAUTION
Hydraulic fluid filter
Change when RED
DANGER
PRECAUCION
Filtro de aceite hidráulico
Cambiar si está ROJO
ATTENTION
Filtre à fluide hydraulique
856565 Rev 1 Changer au ROUGE
CRUSH HAZARD!
STAY BACK!
PELIGRO
¡RIESGO DE APLASTAMIENTO!
¡MANTENERSE ALEJADO!
DANGER EXPLOSION HAZARD! DANGER

¡RIESGO DE EXPLOSION! RISQUE D'ÉCRASEMENT !
FALL AND NE PAS S'APPROCHER !
856626
856579-09
RISQUE D’EXPLOSION !
CRUSH HAZARD! ON BATTERY BOX
DO NOT stand on or near
CAUTION
machine while in operation. KEEP CLEAN DANGER PINCH POINT
PUNTO DE
Failure to comply will result PRECAUCION PELIGRO APRIETE
in death or serious injury. MANTENER LIMPIO
856625
DANGER POINT DE
PINCEMENT
ATTENTION
856579-12
MAINTENIR PROPRE
856579-05
WARNING ADVERTENCIA AVERTISSEMENT

LUNGE HAZARD! ¡RIESGO DE MOVIMIENTO RISQUE DE BOND EN
ABRUPTO! AVANT !
Machine will lunge La máquina se moverá La machine fait un bond
unexpectedly if abruptamente si se pisa en avant si la pédale
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
before exiting. 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
could result in death puede causar la muerte des blessures graves,
or serious injury. o lesiones graves. voire mortelles. 1011464
DANGER PINCH POINT

PUNTO DE
PELIGRO APRIETE
DANGER POINT DE
PINCEMENT 856579-12
856579-03
Figure 1-1. Safety Labels and Safety Label Locations

Safety
NOTES

INFORMATION
Section 2
2
Page
Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Limited Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Items Not Covered. . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Other Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Contact Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Record of Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Machine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Hydraulic System. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Specifications Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Inch Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Metric Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Full Torque Nut Coupling Installation . . . . . . . . . . . . . . . . . 2-17

Information
LIMITED WARRANTY POLICY Limitations

LeeBoy has no obligation for:
Warranty
Any defects caused by misuse, misapplication,
Subject to the limitations, exclusions, and claims negligence, accident or failure to maintain or use
procedures set forth herein, LeeBoy warrants [to the in accordance with the most current operating
first retail purchaser] that this product will be free from instructions.
[substantial] defects in materials and workmanship
during the warranty period. Unauthorized alterations.
If a defect in material or workmanship is found, your Defects or failures caused by any replacement parts
authorized LeeBoy Dealer is to be notified during the or attachments not manufactured by or approved by
warranty period. LeeBoy and its authorized Dealer will LeeBoy.
repair or replace any part or component of the unit Failure to conduct normal maintenance and operating
or part that fails to conform to the warranty during the service including, without limitation, providing lubricants,
warranty period. coolant, fuel, tune-ups, inspections or adjustments.
The warranty period will begin on the initial start-up, Unreasonable delay, as established by LeeBoy, in
training and delivery of the unit by the Dealer to the making the applicable units or parts available upon
customer, and will expire after twelve (12) months notification of a service notice ordered by same.
following the delivery of the grader to the first retail
Warranty Responsibility: The warranty responsibility on
purchaser. (See Dealer for additional warranty.)
all engines rests with the manufacturer of the engine.
Manufacturers’ Warranties: Engines are warranted by
Warranty and Parts Support: LeeBoy may have support
their manufacturers and may have warranty coverage
agreements with some engine manufacturers for
that differs from that of LeeBoy. LeeBoy does not
warranty and parts support. However, LeeBoy does not
warrant any engine.
warrant the engine.
Replacement parts furnished by LeeBoy are covered
This Limited Warranty sets forth your sole remedy in
for the remainder of the warranty period applicable
connection with the sale or use of the LeeBoy product
to the unit or component in which such parts are
covered by this Limited Warranty.
installed.
This Limited Warranty extends only to the first retail
LeeBoy has the right to repair any component or part
purchaser, and is not transferable.
before replacing it with a new one.
In the event any portion of this Limited Warranty shall
All new replacement parts purchased by a LeeBoy
be determined to be invalid under any applicable law,
Dealer will carry a six-month warranty.
such provision shall be deemed null and void and the
This Limited Warranty is governed by the laws of the remainder of the Limited Warranty shall continue in full
State of North Carolina. force and effect.
THE FOREGOING WARRANTY IS EXCLUSIVE AND
IN LIEU OF ALL OTHER EXPRESSED, STATUTORY
AND IMPLIED WARRANTIES APPLICABLE TO
UNITS, ENGINES, OR PARTS INCLUDING WITHOUT
LIMITATION, ALL IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR USE OR PURPOSE OR AGAINST
INFRINGEMENT.

Information
Items Not Covered Other Limitations

LeeBoy is not responsible for the following: IN NO EVENT, WHETHER AS A RESULT OF BREACH
OF CONTRACT OR WARRANTY OR ALLEGED
All used units or used parts of any kind.
NEGLIGENCE OR LIABILITY WITHOUT FAULT, SHALL
Repairs due to normal wear and tear or brought about LEEBOY BE LIABLE FOR SPECIAL, INCIDENTAL OR
by abuse or lack of maintenance of the Machine. CONSEQUENTIAL DAMAGES INCLUDING, WITHOUT
Attachments not manufactured or installed by LeeBoy. LIMITATION, LOSS OF PROFIT OR REVENUE, COST
OF CAPITAL, COST OF SUBSTITUTED EQUIPMENT,
Liability for incidental or consequential damages of any FACILITIES OR SERVICES, DOWNTIME COSTS,
type including, but not limited to, lost profits or expenses LABOR COSTS OR CLAIMS OF CUSTOMERS,
of acquiring replacement equipment. PURCHASERS OR LESSEES FOR SUCH DAMAGES.
Liability for incidental or consequential damages of any IN NO EVENT WILL WARRANTY COMPENSATION,
type including, but not limited to, lost profits or expenses OR OTHER DAMAGES AVAILABLE FROM LEEBOY,
of acquiring replacement equipment. EXCEED THE PURCHASE PRICE OF THE PRODUCT.

Information
CONTACT INFORMATION If you have a persistent problem your dealer is unable to

resolve, contact LeeBoy directly.
For information regarding parts and repairs about your Record dealer information in the space provided.
LeeBoy product, first contact the dealer you purchased For additional information about LeeBoy, please visit:
your product from. www.leeboy.com.
Sales Representative:
Dealership Name:
Dealership Address:
Dealership Phone:
RECORD OF OWNERSHIP
Please fill out the following information and use it
when you need to contact LeeBoy for service, parts or
literature.
Grader Model Number:
Grader Serial Number:
Date of Purchase:
NAMEPLATE
The nameplate (Figure 2-1) contains the specific
model number and serial number used to identify the
components for any parts or service information.
VT LEEBOY, INC.
Lincolnton, NC 28092
Year
Model
Serial No.
Motor No.
ON SIDE OF STEERING CONSOLE
Figure 2-1. Nameplate Location

Information
MACHINE DESCRIPTION 1
The description and specifications given in this section
are applicable to the Model 685C Motor Grader.
This section contains a description of how the major
components operate. It also includes the hydraulic,
electrical, performance, and fluid specifications and
torque values for both standard and metric fasteners
used on this machine.
Engine 2
The 685C Motor Grader uses a Cummins QSB4.5
Tier 3 four-cylinder diesel engine to drive the hydraulic
traction pump, and function/steering pump. The engine
is mounted to the rear of the operating platform and
accessible through doors in the engine cover.
A fuel lift pump mounted on the engine draws diesel fuel 3
from the fuel tank. The fuel tank is mounted under the
engine. 4
An air cleaner mounted on the right side of the engine
Figure 2-2. Air Cleaner Assembly
filters intake air before use by the engine. The air
cleaner (Figure 2-2,3) removes fine particles such as 1 - Precleaner
dust, sand, chaff and lint from the air. 2 - Air Cleaner
3 - Air Cleaner Access Clamp
4 - Evacuator/Drain
A pre-cleaner (Figure 2-2,1) mounted on top of the air
cleaner assembly removes larger particles of dirt and
debris before the air enters the air filter elements.
The pre-cleaner relieves the load on the air filter
elements and allows longer intervals between servicing.
The materials trapped by the pre-cleaner are deposited
in the pre-cleaner bowl.
As air is taken into the air cleaner assembly (Figure
2-2,2), a cyclone type action deposits some of the fine
particles in the evacuator (Figure 2-2,4) mounted on
the bottom of the air cleaner housing. The evacuator is
held closed during engine operation by suction. When
the engine is shut off, the weight of the debris helps
to open the rubber flaps allowing the debris to fall out.
The rubber flaps can also be squeezed together for
cleaning.

Information
A fuel filter removes contaminants from the diesel fuel

before the fuel flows to the injection pump for injection
into the engine combustion chamber. See Figure 2-3
and Figure 2-4 for location of engine fuel and oil filters.
Figure 2-4. Engine Oil Filter Location

1 - Engine Oil Filter
A radiator mounted at the rear of the grader cools the
engine. As coolant flows through the radiator, airflow
from the engine-driven fan (Figure 2-5,1) removes heat
from the coolant.
Refer to the engine owner’s Operation and Maintenance
Manual for a complete description of the engine.
Figure 2-3. Fuel Filter Location 1

1 - Fuel Filter Figure 2-5. Radiator Fan Location
1 - Radiator Fan

Information
Electrical System The battery charge rate can be monitored using the
voltmeter mounted on the operator’s control panel. See
The electrical system is powered by a two 12-volt battery Figure 2-7.
system. Two 12-volt batteries are mounted in the battery
compartment located on the right side of the machine.
See Figure 2-6.
l l l l l l 1
l 12 14
l l
VOLTS
l
ll 10 16
l
l l l
l l
8 18
ll
l
Figure 2-7. Operator’s Control Panel
1 1 - Voltmeter
Figure 2-6. 12-Volt System
1 - Two 12-Volt Batteries
The batteries are connected in parallel, producing 12
volts DC and maintaining 950 cold cranking amperes
(CCA). An engine-mounted alternator capable of 105
amperes charging capacity keeps the batteries charged
during normal operation.

Information
Hydraulic System Drive System

The hydraulic system includes two hydraulic pumps The model 685C Motor Grader drive system includes a
driven by the engine. A traction pump (Figure 2-8,1) hydrostatic traction pump (Figure 2-8,1), variable speed
driven directly by the engine is mounted with an adapter hydraulic motor, two-speed transfer case, rear axle
plate at the rear engine output shaft. This pump is carrier assembly, and gear drive assembly.
described in detail in the section entitled Drive System. The hydrostatic traction pump (Figure 2-8,1) is a
variable piston-type pump. A swash plate controls the
direction and flow of hydraulic drive pressure. A forward/
neutral/reverse (FNR) pedal (Figure 3-4,1) and linkage
in the operator’s compartment and pump controller
mounted on the pump are used to control the direction
of travel and output pressure by tilting the swash plate.
The variable drive motor also uses a swash plate to
control machine speed. A work/auto switch (Figure
3-2,19) located on the operator’s control panel in the
operator’s compartment is used to control swash plate
tilt and piston stroke. In WORK mode, the swash plate
1 goes to maximum displacement which generates the
maximum torque. In AUTO mode, the swash plate is
Figure 2-8. Traction Pump pressure compensated and will adjust to maximize
1 - Traction Pump the efficiency of the motor. The swash plate varies
automatically in AUTO mode.
The function/steering pump (Figure 2-9,1) is mounted
on the rear of the traction pump and driven by the A two-speed transfer case mounted between the drive
traction pump output shaft. This gear-type pump motor and rear axle carrier provides high and low gear
provides hydraulic pressure and flow to operate all the selection.
hydraulic cylinders used to control the grader functions A 2-speed hi/low switch (Figure 3-2,20) located on the
and to operate the steering cylinder. operator’s control panel in the operator’s compartment
allows the operator to shift gears.
NOTE: When shifting the 2-speed hi/lo switch (Figure
3-2,20) from low to high (or high to low) make
sure the park brake (Figure 3-2,18) is engaged.
2-speed hi/lo switch must be in LO or
HI at all times. When shifting 2-speed hi/lo switch
from LO to HI or HI to LO the machine must be
stopped on level ground, the brake must be engaged
and the moldboard must be on the ground. Switch
must be in LO or HI at all times.
The rear axle carrier assembly is used to convert input
rotation to axle shaft output rotation. The left and right
axle shafts drive the gear drive assembly.
1 The gear drive assembly uses axle shaft rotation to drive
the gears.
Figure 2-9. Function/Steering Pump
The pump draws hydraulic oil from the reservoir. The
pressurized oil flows to the hydraulic control valve and
to the steering motor mounted in the steering console
located in the operator’s platform.

Information
Brakes The articulate lever (Figure 2-10,3) controls the flow

of hydraulic oil to the articulate cylinders. The articulate
Machine braking is controlled by the flow of hydraulic oil cylinders are mounted between the mainframe
in the drive system. When the forward/neutral/reverse assembly and the boom assembly. The boom assembly
(FNR) pedal (Figure 3-4,1) is returned to neutral from is mounted on the main frame using an articulator
the forward or reverse position, the flow of hydraulic oil shaft and bearing assembly. The assembly allows
to the drive motor stops rotating the rear axle carrier the machine to pivot right and left when the articulate
assembly allowing the machine to slow and stop. cylinders are actuated.
The primary brake is controlled by a foot pedal that The steering can be controlled using one or all of the
releases stored pressure from the accumulator to the steering systems.
rear axle. The brakes are wet disc and are internal of the
axle. An optional dead engine steering system is available,
which allows steering if the engine will not run or certain
The engine must be running to release the park brake hydraulic failures occur. The system includes an electric
(Figure 3-2,18). The fail-safe brake is actuated by motor and traction hydraulic pump combination. When
spring pressure and requires constant hydraulic activated, the traction hydraulic pump provides hydraulic
pressure for release. If the engine is not running or a pressure for steering.
hydraulic failure occurs, the park brake can be manually
released as described in the section entitled Motor 2
Grader Towing on page 4-19 .
Steering
The 685C Motor Grader can be steered using the
steering wheel (Figure 2-10,2) and motor, the wheel
lean lever (Figure 2-10,1), or the articulate lever (Figure
2-10,3).
The steering wheel controls (Figure 2-10,2) the
steering motor, which controls the flow of hydraulic oil to
the steering cylinder. The steering cylinder is mounted
between the front axle support and the right hand
spindle. The left and right spindles are connected by a
3
tie rod, which forces the left wheel to turn when the right
wheel is actuated.
1
988271
The wheel lean lever (Figure 2-10,1) controls the flow of

hydraulic oil to the wheel lean cylinder. The wheel lean
Figure 2-10. Steering Console
cylinder is mounted between the front axle support and
the right hand spindle support. The left and right spindle 1 - Wheel Lean Lever
supports are connected by a tie rod, which forces the 2 - Steering Wheel
left wheel to lean when the right wheel is actuated.
3 - Articulate Lever
The moldboard assembly will contact
the drive wheels during articulation. Make sure the
turning radius and moldboard position do not result
in drive wheel damage caused by improper steering.

Information
Moldboard Scarifier
The moldboard assembly is mounted underneath The scarifier assembly is mounted underneath the
the boom assembly and supported by a drawbar and mainframe assembly. Five replaceable teeth and tooth
turntable assembly. The moldboard is the primary tool supports are used to penetrate the grading surface.
used to move grading materials. The tooth supports are adjustable and secured with pin
The moldboard position is controlled by hydraulic locks inserted between the support frame slot and tooth
cylinders, which allow the moldboard to be tilted from support.
front to rear, tilted from side to side, raised for transport, The scarifier is raised and lowered using a hydraulic lift
rotated, and lowered for penetration. The moldboard cylinders.
assembly can also be side-shifted up to three feet.
1 1
Figure 2-11. Moldboard

1 - Moldboard
Figure 2-12. Scarifier

1 - Rear Scarifier

Information
OPTIONS
The Model 685C Motor Grader can be equipped with
the following options:
• Front blade assembly
• Front-mount scarifier
• Circle side shift
• Front traction assist, allowing the operator to actuate
hydraulic front drive hubs for additional traction during
work
• Dead engine steering, allowing machine steering
during steering pressure failure
• 12 ft. moldboard
• Full fabricated cab with heater, air conditioner and
light package
• Rear wiper and washer (cab model)
• Radio/CD/speaker (cab model)
• Cold weather engine package (block heat and glow
plugs)

Information
dimensions, performance, and torque values for both

SPECIFICATIONS CHARTS metric and standard inch fasteners.
The specifications provided in this section are Replace original equipment only with
applicable to the LeeBoy 685C Motor Grader. Included LeeBoy approved components.
in this section are specifications for grader weights,
Table 2-1. Machine Dimensions

ITEM SPECIFICATION
Overall Length 23 ft. 4 in. (7112 mm)
Overall Height 9 ft. 7 in. (2908 mm
Overall Width 7 ft. 8 in. (2337 mm)
Overall Weight 17,680 lb (7711 kg)
Wheelbase (Front Tire to Mid-tandem) 16 ft. 1 in. (4902 mm)
Front Axle Ground Clearance 12 in. (305 mm)
Refer to Figure 2-13 for diagram showing the overall dimensions of the grader.
Figure 2-13. Machine Dimensions

Table 2-2. Engine Specifications
ITEM SPECIFICATION
Model Cummins QSB 4.5L Turbo Diesel Tier 3
Horsepower 110 HP @ 2100 RPM (82 kW)
Displacement 238 cubic inches (3.9L)
Table 2-3. Electrical Specifications

ITEM SPECIFICATION
Batteries 2 - 12 VDC Maintenance Free
Cold Cranking Amps (CCA) 900 CCA
System Voltage 12 VDC, 105 Amps

Information
Table 2-4. Moldboard Specifications

ITEM SPECIFICATION
Width 10 ft. (3 m)
Height 18 in. (457 mm)
Side Shift 3 ft. (914 mm)
Tilt 30°
Raised Clearance 13 in. (330 mm)
Penetration 14 in. (356 mm)
Rotation 64°
Table 2-5. Front Blade Specification

ITEM SPECIFICATION
Width 7 ft. (2.1 m)
Height 18 in. (457 mm)
Raised Clearance 12 in. (330 mm)
Penetration 6 in. (76 mm)
Table 2-6. Rear Scarifier Specification

ITEM SPECIFICATION
Width 6 ft. (1.8 m)
Numbered Teeth Standard 5; Maximum 9
Raised Clearance 11.539 in. (293 mm) low; 13.714 in. (348.3 mm) high
Penetration 8.5 in. (216 mm) low; 6.0 in. (152.4) high
Table 2-7. Steering Specifications

ITEM SPECIFICATION
Steering Hydraulic
Articulation 24°
Wheel Lean 30°
NOTE: Refer to the tire manufacturer’s brochures for additional information on tire size and requirements.
Table 2-8. Hydraulic Specifications
ITEM SPECIFICATION
Traction Pump Variable Piston Type 4.58 cu. in./rev. (75 cu. cm/rev.)
Function Pump Gear Type 0.6 cu. in./rev. (9.5 cu. cm/rev.)
Steering Pump Gear Type 0.8 cu. in./rev. (13.8 cu. cm/rev.)
Drive Motor Variable Volume 4.8 cu. in./rev. (80 cu. cm/rev.)
Operating Pressure 0 - 6000 PSI (414 Bar)
Hydraulic Filters Remote Pressure Filter
Oil Cooler Radiator/Oil Cooler, Engine Fan Cooling

Information
Table 2-9. Drive System Specifications

ITEM SPECIFICATION
Drive Hydraulic
Transfer Case 2-Speed, 0 - 20 MPH (32 KPH)
Differential Dana Spicer
Final Drive Gear Box
Tires 15/19.5, TL, G-2, 8-Ply Pneumatic
NOTE: Refer to the tire manufacturer’s brochures for additional information on tire size and requirements.
Table 2-10. Machine System Capacity Specifications
ITEM SPECIFICATION
Fuel 31 U.S. Gallons (117 L)
Engine Lubrication Oil 11.6 Quarts (11 L)
Total System Capacity 13.7 (13 L) Quarts
Coolant 5.5 U.S. Gallons (21 L)
Hydraulic Oil Reservoir 27.5 U.S. Gallons (104L)
Transfer Case (2-Speed) 0.92 U.S. Gallon (3.5 L)
Tandem Gear Box 2.32 U.S. Gallons (8.8 L), each side
Differential Oil 2.22 U.S. Gallons (8.4 L)l
Table 2-11. Fuel and Lubricant Specifications

ITEM SPECIFICATION
Engine Oil 15W-40
Hydraulic Oil 5W20 AWAT OIL
Coolant Ethylene/Glycol or Propylene Glycol
Fuel Diesel, Local Low-sulphur Blend
Transfer Case (2-Speed) 90 WT Motor Oil
Tandem Gear Box 90 WT Motor Oil
Differential Oil 90 WT Motor Oil
Grease Shell Avania EP Grease or Equivalent
Table 2-12. Pressure Specifications

ITEM SPECIFICATION
Accumulator (Pre-Charge) 600 PSI
Accumulator 2300 PSI
Relief Valve (750602) 3000 PSI
Charge Valve To Accumulator 2300 PSI
Charge Valve To Orbital 2465 PSI At Relief
10 Section Valve 1900 PSI
Main Drive Pump 6000 PSI
Charge Pressure 350 PSI ± 25 PSI
Park Brake Release 350 PSI ± 25 PSI
Accumulator Low Pressure Switch 1300 PSI (When Light Is On)
Tire Pressure 35 PSI

Information
TORQUE SPECIFICATIONS and machined surfaces. Values are based on

physical limitations of clean, plated and lubricated
Inch Fasteners hardware. In all cases, when an individual torque
value is specified, it should be followed instead of
The following Table lists torque values values given in this table.
for standard hardware and are intended as a guide
for average application involving typical stresses Replace original equipment with
hardware of equal grade.
Table 2-13. Torque Specifications For Standard Inch Fasteners

CAPSCREWS: SAE GRADE 5 CAPSCREWS: SAE GRADE 8
SIZE THREAD TORQUE FT. LBS. TORQUE N•m TORQUE FT. LBS. TORQUE N•m
Dry Lubed Dry Lubed Dry Lubed Dry Lubed
1/4 20 UNC 8 6 11 9 12 9 16 12
28 UNF 10 7 13 10 14 10 19 14
5/16 18 UNC 17 13 24 18 25 18 33 25
24 UNF 19 14 26 20 27 20 37 28
3/8 16 UNC 31 23 42 31 44 33 59 44
24 UNF 35 26 47 36 49 37 67 50
7/16 14 UNC 49 37 67 50 70 52 95 71
20 UNF 55 41 75 56 78 58 105 79
1/2 13 UNC 75 57 100 77 105 80 145 110
20 UNF 85 64 115 86 120 90 165 120
9/16 12 UNC 110 82 145 110 155 115 210 155
18 UNF 120 91 165 125 170 130 230 175
5/8 11 UNC 150 115 205 155 210 160 285 215
18 UNF 170 130 230 175 240 180 325 245
3/4 10 UNC 265 200 360 270 375 280 510 380
16 UNF 295 225 405 300 420 315 570 425
7/8 9 UNC 430 320 580 435 605 455 820 615
14 UNF 475 355 640 480 670 500 905 680
1 8 UNC 645 485 875 655 910 680 1230 925
14 UNF 720 540 980 735 1020 765 1380 1040
1-1/8 7 UNC 795 595 1080 805 1290 965 1750 1310
12 UNF 890 670 1210 905 1440 1080 1960 1470
1-1/4 7 UNC 1120 840 1520 1140 1820 1360 2460 1850
12 UNF 1240 930 1680 1260 2010 1500 2730 2050
1-3/8 6 UNC 1470 1100 1990 1490 2380 1780 3230 2420
12 UNF 1670 1250 2270 1700 2710 2040 3680 2760
1-1/2 6 UNC 1950 1460 2640 1980 3160 2370 4290 3210
12 UNF 2190 1650 2970 2230 3560 2670 4820 3620

Information
Metric Fasteners physical limitations of clean, plated and lubricated

hardware. In all cases, when an individual torque
The following Table lists torque values value is specified, it should be followed instead of
for standard hardware and are intended as a guide values given in this table.
for average application involving typical stresses
and machined surfaces. Values are based on Replace original equipment with
hardware of equal grade.
Table 2-14. Torque Specifications For Metric Fasteners

CLASS 8.8 [GRADE 5 EQUIVALENT] CLASS 10.9 [GRADE 8 EQUIVALENT]
NOMINAL SIZE TORQUE FT. LBS. TORQUE N•m TORQUE FT. LBS. TORQUE N•m
& PITCH Dry Lubed Dry Lubed Dry Lubed Dry Lubed
M4 x 0.7 2.27 1.70 3.07 2.30 2.27 2.31 4.17 3.13
M5 x 0.8 4.58 3.43 6.20 4.65 6.22 4.67 8.43 6.33
M6 x 1 7.75 5.83 10.5 7.90 10.60 7.97 14.3 10.8
M8 x 1.25 18.89 14.17 25.6 19.2 18.95 19.26 34.8 26.1
M10 x 1.25 39.11 29.52 53.0 40.1 53.87 40.59 73.0 55.0
M12 x 1.75 64.94 48.71 88.0 66.0 88.56 66.42 120.0 90.0
M14 x 2 103.32 77.49 140.0 105.0 140.22 107.01 190.0 145.0
M16 x 2 162.36 121.77 220.0 165.0 221.40 166.05 300.0 225.0
M20 x 2.5 317.34 236.16 430.0 320.0 428.04 321.03 580.0 435.0
M24 x 3 516.12 409.59 740.0 555.0 754.38 557.19 1010.0 755.0
M27 x 3 797.04 597.78 1080.0 810.0 1084.86 811.80 1470.0 1100.0
M30 x 3.5 1084.86 811.80 1470.0 1100.0 1476.00 1107.00 2000.0 1500.0

Information
Hydraulic Fittings 4. To prevent twisting the tube(s), use two wrenches.

Place one wrench on the connector body and with
Tightening Flare Type Tube Fittings the second, tighten the swivel nut to the torque
shown in Table 2-15.
1. Check the flare and flare seat for defects that might
cause leakage. NOTE: The torque values shown are based on lubri-
cated connections as in assembly.
2. Align tube with fitting before tightening.
3. Lubricate connection and hand tighten swivel nut
until snug.
Table 2-15. Torque Specifications For Flare Type Tube Fittings
NUT SIZE RECOMMENDED TURNS TO
TUBE SIZE OD (ACROSS TORQUE VALUE TIGHTEN (AFTER FINGER
FLATS) TIGHTENING)
(in) (in) (N•m) (Lb-Ft) (N•m) (Lb-Ft)
3/16 7/16 8 6 1 1/6
1/4 9/16 12 9 1 1/6
5/16 5/8 16 12 1 1/6
3/8 11/16 24 15 1 1/6
1/2 7/8 46 34 1 1/6
5/8 1 62 46 1 1/6
3/4 1 1/4 102 75 3/4 1/8
7/8 1 3/8 122 90 3/4 1/8
Full Torque Nut Coupling 6. Calculate the correct torque wrench setting.
Installation NOTE: The most straight forward method of determin-
ing the correct torque setting is to multiply the
The only completely reliable method of creating a desired torque by the length of the wrench
consistent leak free, long lasting connection is to ensure from the center of the handle to the center of
that the coupling is brought to the proper torque. the drive (L) divided by the length of the wrench
The best method of ensuring a coupling is brought from the center of the handle to the crowfoot
to the proper torque is to use a torque wrench with center (LA), see Figure 2-14.
crowfoot. To ensure the proper torque is met, use the LA
flats method of torque verification. Flats method may L
be used alone in situations where a torque wrench is
inaccessible or unavailable.
There are seven steps involved in proper coupling
installation: Figure 2-14. Torque Wrench - Crowfoot
5. Determine the correct torque value for your NOTE: Torque Wrench Setting = Desired Torque * L /
coupling. LA
NOTE: Only use the torque values specified from the 7. Ensure that the seal face and threads are clean
manufacturer, do not use SAE torque recom- and in good condition. Do not lubricate coupling
mendations. threads.
The minimum torque values are adequate for

sealing in most applications, and the maximum
torque values should never be exceeded.

Information
NOTE: O-Rings should be lubricated with light oil, but

threads should be completely dry unless mak- 1
ing pipe thread connections (interference seal).
ATTACH the male end of the hose onto the
equipment first, since it may be necessary to
rotate the entire hose assembly to tighten the
male threads. Then route the hose into position
while avoiding twisting the hose.
8. Hand tighten the connection by bringing seal face in
contact and rotating the nut by hand until it stops.
NOTE: By definition hand tight is 0.3 – 1 ft.-lb. or when
the seal faces are touching and with the threads
engaged the hex can no longer be rotated by
2
hand.
9. Mark a line across the coupling nut and backup
Figure 2-15. Flats Method Tightening
hex for flats method verification of coupling torque
(Figure 2-15). 1 - Mark Line on Nut
10. Apply a wrench to the backup hex to prevent the 2 - Example 2 Flats difference
coupling and hose from moving while tightening the
11. If a torque wrench cannot fit into the coupling area
nut with a torque wrench.
or if it is unavailable, flats method may be used to
Failure to retain the backup hex during ensure that the coupling is properly tightened, as
installation will also result in additional clamp load shown in Figure 2-15.
force that could cause damage to the seal face. NOTE: The mark placed on the nut and backup hex
NOTE: The coupling nut must be in motion for an accu- after hand tightening should have rotated 1 to 1.5
rate torque reading. If the nut is stopped before flats during final tightening. At this point in time, if
final torque value is achieved, it must be loos- desired, the nut and backup hex may be marked
ened and retightened until the torque is attained to indicate if the coupling loosens over time.
while the nut is in motion.

Information
Table 2-16. Torque Specifications For US Style Coupling Terminations

JIC, SAE 45°, ORFS, O-RING BOSS, GATES ADAPTERLESS AND MEGASEAL
Dash JIC 37°, SAE 45° JIC 37°, SAE 45° Flat Face O-Ring SAE O-Ring Boss SAE O-Ring Boss
Size & Mega-Seal & Mega-Seal Seal (Steel) (Steel) & Gates (Steel) & Gates
(steel) (steel) Adapterless ≤ Adapterless >
4000 PSI 4000 PSI
1/16 Ft-Lb Ft-Lb Ft-Lb Ft-Lb Ft-Lb
Inch Min Max Min Max Min Max Min Max Min Max
-3 8 10
-4 10 11 5 6 10 12 14 16 14 16
-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 2-17. Torque Specifications For DIN 24, DIN Table 2-18. Torque Specifications For 4-Bolt
60, and Inverted Cone Style Coupling Terminations Flange Connections
DIN 24, DIN 60, AND INVERTED CONE 4-BOLT FLANGES
Size Torque Dash Size Bolt Size Torque
mm Ft-Lb 1/16 Inch Inch Ft-Lb
Light Heavy Min Max -8 0.31 17
Series Series -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 finger tighten bolts before
14 12 26 37
applying final torque in a pattern. The seal faces
15 14 30 52 must be parallel with even bolt tension to seal
16 30 52 properly.
18 20 44 74 2. Torque values apply to bolts which 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

Information
Table 2-19. Torque Specifications For SAE Male Table 2-21. Torque Specifications For BSP 30°
Flareless Assembly (MFA) Inverted Cone and JIS Coupling Terminations
SAE MALE FLARELESS ASSEMBLY (MFA) BSP 30° INVERTED CONE AND JIS
After hand tight rotate nut one full turn (8 flats) Dash Size Torque
mm Ft-Lb
Table 2-20. Torque Specifications For NPTF Dry
Seal Pipe Threads 1/16 Inch Min Max
NPTF -2 7 9
Dash Size Max Torque -4 11 18
1/16 Inch Ft-Lb -6 19 28
-2 20 -8 30 36
-4 25 -10 37 44
-6 35 -12 50 60
-8 45 -16 79 95
-12 55 -20 127 152
-16 65 -24 167 190
-20 80 -32 262 314
-24 95 Table 2-22. Flats Method Values For Selected

-32 120 Terminations
1. The torque values obtained from tightening pipe FLATS METHOD VALUES
threads can vary considerably depending on Termination Dash Size Flats
thread condition. Adequate sealing can occur at Type
values much lower than the maximum values listed
1/16 Inch
above. Only enough torque to achieve adequate
sealing should be used. JIC 4 1.5 - 1.75
2. When using a male tapered pipe thread with a JIC 6 1.0 - 1.5
female straight or parallel pipe thread, maximum JIC 8 1.5 - 1.75
values are 50% of those listed in the table.
JIC 10 1.0 - 1.5
3. If thread sealant is used, maximum values shown
JIC 12 1.0 - 1.5
should be decreased by 25%.
JIC 16 .75 - 1.0
JIC 20 .75 - 1.0
JIC 24 .75 - 1.0
JIC 32 .75 - 1.0
JIS 4 .5 - 1.5
1. Seal faces must be in contact and the fitting fully
hand tightened before marking flats.
2. Flats method is most accurate for the first
assembly cycle, for multiple disassembly/
assembly cycles torque values are more reliable.
3. Tightening 2 flats or more is analogous to sever
over torque and may damage seal faces.

Information
Determining Torque Setting Equations

There are several methods of determining the correct Equation 1
setting on the torque wrench when using a crowfoot. All Torque setting if the crowfoot is placed in line with
of the methods involve making the setting proportional respect to the wrench:
to the effective change in length of the wrench multiplied
by the desired final torque. TS = TD * L / LA
L OR
TS = TD * L / (L+E)
Equation 2
Torque setting if the crowfoot is placed at 90° with
E respect to the wrench
TS = TD * L / LH
OR
TS = TD * L / √(L2 + E2)
LA Equation 3
To estimate the crowfoot size (E)
E = Drive Size * 0.5 + Distance between Drive &
Open End + Wrench Size * 0.5774
LH
Figure 2-16. Measurements Needed

L = Distance from center of torque wrench handle to the
center of socket drive
E = Distance from center of socket drive to the center of
crowfoot
LA = Distance from center of torque wrench handle to
the center of crowfoot
LH = Distance from center of torque wrench handle to
the center of crowfoot, when mounted at 90°
TD = Desired torque at the fitting
TS = Torque setting indicated on wrench

Information
NOTES

Section 3
COMPONENT LOCATION
Page
Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3
Steering Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Forward/Neutral/Reverse (FNR) Pedal/Primary Brake Pedal . . . . . . . . 3-10

Component Location
685C Motor Grader
10
17 11
8
20
18
21 23
12
19
13
14
15
7
16
22
4
1
5
2
9
Figure 3-1. 685C Motor Grader (Shown With Optional Cab)

1 - Scarifier 12 - Beacon Light
2 - Engine Access 13 - Precleaner
3 - Hydraulic Oil Reservoir Access 14 - Air Cleaner
4- Step (LH and RH) 15 - Muffler
5 - Moldboard 16 - Rear Tie Downs (LH and RH)
6 - Front Tie Down 17 - Starter Access
7 - Head Lights 18 - Battery Compartment
8 - Forward/Neutral/Reverse (FNR) Pedal 19 - Tow (Pintle) Hitch
9 - Washer Fluid Reservoir Access 20 - Hydraulic Oil Level/Temperature Gauge
10 - Steering Console 21 - Hydraulic Supply Line Gate Valves Access
11 - Operator’s Control Panel 22 - Mid Tie Downs
23 - Work Lights
Component Location
Table 3-1. 685C Motor Grader

ITEM
CONTROL NAME FUNCTION
NO.
1 Scarifier Used to penetrate the grading surface. Mounted underneath mainframe
assembly. Five replaceable teeth and tooth supports.
2 Engine Access Used to access engine. Located on RH side of grader.
3 Hydraulic Oil Reservoir Used to access hydraulic oil reservoir. Located on RH side of grader below air
Access cleaner.
4 Step (LH and RH) Used to enter and exit grader cab.
5 Moldboard Used to move grading materials. Mounted underneath the boom assembly and
supported by a drawbar and turntable assembly.
6 Front Tie Down Used to attach tie-down chains to fasten grader to transport vehicle.
7 Head Lights Used to illuminate the road or area in front of the machine during operation or
transport.
8 Forward/Neutral/ Used to control forward and reverse operation and variable speed of the traction
Reverse (FNR) Pedal pump. (See Figure 3-4 on page 3-10 and Table 3-4 on page 3-11.)
9 Washer Fluid Reservoir Used to access washer fluid reservoir. Located on RH side of grader cab.
Access
10 Steering Console Group includes wheel lean lever, front blade lever, moldboard blade angle lever,
moldboard slide lever, directional indicator, right steer/left steer wheel, horn,
moldboard lift levers, front traction assist lever, articulate lever, scarifier, and
moldboard tilt lever. (See Figure 3-3 on page 3-8 and Table 3-3 on page
3-9.)
11 Operator’s Control Group includes ignition switch, temperature gauge, throttle switch, fan switch,
Panel dome light switch, wiper knobs, head light knob, work light switch, oil pressure
gauge, beacon light switch, circuit breaker reset buttons, tachometer gauge,
voltmeter gauge, fuel gauge, park brake auto/work switch, 2-speed switch, fan
switch and brake pressure light. (Refer to Figure 3-2 on page 3-4 and Table
3-2 on page 3-5.)
12 Beacon Light Used to alert surrounding vehicles and pedestrians of the LeeBoy Model 685C
Motor Grader location.
13 Precleaner Used to remove larger particles of dirt and debris before the air enters the air
filter elements.
14 Air Cleaner Filters intake air before use by the engine. Removes fine particles.
15 Muffler Reduces amount of noise emitted by the exhaust of the engine.
16 Rear Tie Downs (RH Used to attach tie-down chains to fasten grader to transport vehicle.
and LH)
17 Starter Access Used to access starter. Located on LH side of grader.
18 Battery Compartment Houses the electrical system’s two 12-volt batteries. Located on LH side of
grader.
19 Tow (Pintle) Hitch Used to tow attachments.
20 Hydraulic Oil Level/ Used to check level and temperature of hydraulic oil.
Temperature Gauge
21 Hydraulic Supply Line Used to turn on and off hydraulic supply lines.
Gate Valves Access
22 Mid Tie Downs Used to attach tie-down chains to fasten grader to transport vehicle.
23 Work Lights Used to illuminate the work area when working at night.

Component Location
OPERATOR’S CONTROL PANEL
19 20 21 22
PUSH TO AUTO 2-SPEED FAN BRAKE
APPLY HI HI PRESSURE
18
PARK
BRAKE WORK LO LO
1011106-03
7 8 9 10 11 12 13
OFF OFF
LOW LOW
HI LIGHTS HI
6 WIPER
WASHER
WIPER
WASHER
THROTTLE DOME FRONT HEAD WORK REAR BEACON

5 LIGHT WIPER LIGHT LIGHT WIPER LIGHT
25
14
25
3
25
2
25
HEAT OFF RUN
25
START
25
685C 1011106-01
17 16 15
1 - Ignition Switch (Optional Cold Weather 12 - Rear Wiper Off/Low/Hi Switch (Option)
Start-up)
13 - Beacon Light Switch
2 - Wait-to-Start Indicator Light
14 - Circuit Breaker Reset Buttons
3 - Check Engine Indicator Light
15 - Tachometer Gauge
4 - Stop Indicator Light
16 - Voltmeter Gauge
5 - Temperature Gauge
17 - Fuel Gauge
6 - Throttle Switch
18 - Park Brake Button
7 - Dome Light Switch (Option)
19 - Work/Auto Switch
8 - Front Wiper Off/Low/Hi Knob
20 - 2-Speed Hi/Lo Switch
9 - Head Light Knob
21 - Fan Hi/Lo Switch
10 - Work Light Switch
22 - Brake Pressure Light
11 - Oil Pressure Gauge

Component Location
Table 3-2. Operator’s Control Panel

ITEM
NO.
1 Ignition Switch (Optional Controls starting, running and shutting down machine. To start machine, insert
Cold Weather Start-up) key and turn key clockwise (CW) to START position.
Cold Weather Start-Up: To start machine, turn key counterclockwise (CCW) to
HEAT position. The wait-to-start indicator light (Item No. 2) will illuminate. When
wait-to-start indicator light (Item No. 2) turns off, turn key clockwise (CW) to
START position.
To shut down machine, turn key counterclockwise (CCW) to the OFF position and
remove key.
2 Wait-to-Start Indicator Indicates machine is warming up (during cold weather start-up) when illuminated.
Light Wait to start machine until light turns off indicating machine warm-up is complete.
(Refer to Item No. 1 above.)
3 Check Engine Indicator Indicates engine fault when illuminated.
Light
Do not operate machine if check engine indicator light is
illuminated. Refer to an authorized LeeBoy Dealer and engine operator’s
manual.
4 Stop Indicator Light Indicates a system failure when illuminated.
Operation Hazard! Do not operate machine if stop indicator
light is illuminated. Contact an authorized LeeBoy Dealer.
5 Temperature Gauge Displays engine coolant temperature.
6 Throttle Switch Controls engine speed (RPM). Pull switch up to increase engine speed (RPM).
Push switch down to decrease engine speed (RPM).
7 Dome Light Switch Controls operation of the optional cab interior light.
(Option)
8 Front Wiper Off/Low/Hi Controls operation of the windshield wipers. Turn clockwise (CW) to LOW
Knob position for low wiper speed. Turn clockwise (CW) to HI position for high wiper
speed. Push in for wiper washer fluid.
9 Head Light Knob Controls operation of the head lights. These lights are used to illuminate the road
or area in front of the machine during operation or transport. Turn clockwise (CW)
to turn on.
10 Work Light Switch Controls operation of the four (4) work lights mounted on the canopy or optional
cab. These lights are used to illuminate the work area when working at night. Pull
switch up to turn on work lights. Push switch down to turn off work lights.
11 Oil Pressure Gauge Displays engine oil pressure in pounds per square inch (PSI).
12 Rear Wiper Off/Low/Hi Controls operation of the optional cab rear window wiper motor. Turn clockwise
Switch (Option) (CW) to LOW position or low wiper speed. Turn clockwise (CW) to HI position for
high wiper speed. Push in for wiper washer fluid.
13 Beacon Light Switch Controls operation of the safety flashing light on top of the canopy or optional
cab. This light warns traffic of slow moving equipment. Pull switch up to turn on
beacon light. Push switch down to turn off beacon light.
14 Circuit Breaker Reset Resets ignition circuit breaker after circuit breaker is tripped. Push button(s) to
Buttons reset breaker(s).

Component Location
OPERATOR’S CONTROL PANEL
19 20 21 22
PUSH TO AUTO 2-SPEED FAN BRAKE
APPLY HI HI PRESSURE
18
PARK
BRAKE WORK LO LO
1011106-03
7 8 9 10 11 12 13
OFF OFF
LOW LOW
HI LIGHTS HI
6 WIPER
WASHER
WIPER
WASHER

5 LIGHT WIPER LIGHT LIGHT WIPER LIGHT
25
14
25
3
25
2
25
HEAT OFF RUN
25
START
25
685C 1011106-01
17 16 15
Figure 3-2. Operator’s Control Panel (Cont.)
1 - Ignition Switch (Optional Cold Weather 12 - Rear Wiper Off/Low/Hi Switch (Option)
Start-up)
2 - Wait-to-Start Indicator Light
14 - Circuit Breaker Reset Buttons
3 - Check Engine Indicator Light
15 - Tachometer Gauge
4 - Stop Indicator Light
16 - Voltmeter Gauge
5 - Temperature Gauge
17 - Fuel Gauge
6 - Throttle Switch
18 - Park Brake Button
7 - Dome Light Switch (Option)
19 - Work/Auto Switch
20 - 2-Speed Hi/Lo Switch
9 - Head Light Knob
21 - Fan Hi/Lo Switch
10 - Work Light Switch
22 - Brake Pressure Light
11 - Oil Pressure Gauge

Component Location
Table 3-2. Operator’s Control Panel (Cont.)
ITEM
NO.
15 Tachometer Gauge Displays engine speed in revolutions per minute (RPM).
16 Voltmeter Gauge Displays the condition of the battery charging system.
17 Fuel Gauge Displays fuel level in the diesel fuel tank.
18 Park Brake Button Applies park brake. Also use in an emergency to stop machine. Push to apply
park brake. Pull up to release park brake.
19 Work/Auto Switch Controls maximum engine RPM at full throttle. (Maximum RPM increased to 2100
RPM.)
20 2-Speed Hi/Lo Switch Controls 2-speed transfer case shifting.
Operation Hazard! Shift lever must be in low or high at all
times. Machine must be on level ground and at full stop when shifting.
NEVER shift the low to high lever on any incline.
21 Fan/Hi/Lo Switch Controls operation of the cab fan. Pull switch up to HI position for high speed.
Push switch down to LO position for low speed.
22 Brake Pressure Light Indicates low brake pressure when illuminated.
Operation Hazard! Do not operate machine if brake pressure
indicator light is illuminated. Refer to an authorized LeeBoy Dealer.

Component Location
STEERING CONSOLE
UP
ELEVAR
RELEVÉ
GROUND
7
NIVELAR
SOL
IN MM
3 76
8
6 152
9 228
856566
16
15 9
5 10
6
4 11
17
3
12
2
13
1
14
988271

1 - Wheel Lean Lever - Right/Left 10 - Moldboard Right Lift Lever
2 - Front Blade Lever (Option) 11 - Front Traction Assist Switch (Option)
3 - Circle Sideshift (Option) 12 - Articulate Lever
4 - Moldboard Blade Angle Lever 13 - Scarifier Lever
5 - Moldboard Slide Lever 14 - Moldboard Tilt Lever
6 - Directional Indicator 15 - Rear Scarifier Depth Gauge
7 - Steering Wheel 16 - Console Tilt Lock Button
8 - Horn 17 - Front Traction Assist Light (Option)
9 - Moldboard Left Lift Lever

Component Location
Table 3-3. Steering Console

ITEM
NO.
1 Wheel Lean Lever- Pull lever to rotate top of tire clockwise (CW). Push lever to make tires rotate
Right/Left counterclockwise (CCW).
2 Front Blade Lever Raises/lowers front blade. Pull lever to raise front blade. Push to lower front
(Option) blade.
3 Circle Sideshift (Option) Shifts drawbar to the side. Pull lever to shift drawbar left. Push lever to shift
drawbar right.
4 Moldboard Blade Angle Rotates moldboard. Pull lever toward operator to rotate moldboard
Lever counterclockwise (CCW). Push lever to rotate clockwise (CW).
5 Moldboard Slide Lever Shifts moldboard right/left. Pull lever toward operator to shift moldboard toward
left. Push lever to shift moldboard to right.
6 Directional Indicator Controls operation of the right and left turn signals.
7 Steering Wheel Controls right and left steering function of the front wheels.
8 Horn Sounds the horn when pressed.
9 Moldboard Left Lift Raises/lowers end of moldboard. Pull lever toward operator to raise left end of
Lever moldboard. Push lever away to lower left end of moldboard. Put lever in detent to
float on left.
10 Moldboard Right Lift Raises/lowers end of moldboard. Pull lever to raise right end of moldboard. Push
Lever lever to lower right end of moldboard. Put lever in detent to float on right side.
11 Front Traction Assist Controls operation of the optional front traction motors.
Switch (Option)
12 Articulate Lever Rotates boom. Pull lever to turn boom clockwise (CW). Push lever to turn boom
counterclockwise (CCW).
13 Scarifier Lever Raises/lowers scarifier. Pull lever to lower scarifier. Push lever to raise scarifier.
14 Moldboard Tilt Lever Tilts moldboard. Pull lever to rotate top of moldboard forward. Push lever to
rotate top of moldboard back.
15 Rear Scarifier Depth Displays depth of scarifier in inches/millimeters.
Gauge
16 Console Tilt Lock Locks/unlocks console for adjustment.
Button
17 Front Traction Assist Indicates front traction assist is engaged when illuminated.
Light (Option)

Component Location
FORWARD/NEUTRAL/REVERSE (FNR) PEDAL/PRIMARY BRAKE

PEDAL
Figure 3-4. Forward/Neutral/Reverse (FNR) Pedal and Primary Brake

1 - Forward/Neutral/Reverse (FNR) Pedal
2 - Primary Brake Pedal

Component Location
Table 3-4. Forward/Neutral/Reverse (FNR) Pedal and Primary Brake Pedal

ITEM
NO.
1 Forward/Neutral/Reverse Controls forward and reverse shifting and braking of machine. Push forward
(FNR) Pedal to move machine forward. Pull backward to move machine backward. Place
in neutral (center position) to reduce speed.
2 Primary Brake Pedal Foot-actuated brake used for quickly stopping machine. Push forward to
activate brake.

Component Location
NOTES

Section 4
OPERATION
Page
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Operating Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4
Stopping Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Receiving The Motor Grader . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Preliminary Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Adjusting Steering Console. . . . . . . . . . . . . . . . . . . . . . 4-5
Adjusting Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Cab Option Only. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Recirculated Air Control. . . . . . . . . . . . . . . . . . . . . . . . 4-6
Lights4-8
Break-In Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Pre-start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Driving The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Directional Control . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Travel Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Operating The Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Moldboard Lift Control. . . . . . . . . . . . . . . . . . . . . . . . 4-13

Operation
Moldboard Side-shift Control . . . . . . . . . . . . . . . . . . . . . 4-13

Moldboard Pitch Control. . . . . . . . . . . . . . . . . . . . . . . 4-13
Moldboard Angle Control . . . . . . . . . . . . . . . . . . . . . . . 4-13
Wheel Lean Control . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Optional Front Traction Assist Control. . . . . . . . . . . . . . . . 4-14
Scarifier Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Drive System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Articulation and Steering Control. . . . . . . . . . . . . . . . . . . 4-15
Front Blade Control (Option). . . . . . . . . . . . . . . . . . . . . 4-15
Spreading Piles . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Vee Ditching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Ditch Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Road Crowning . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Bank Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Slope Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Cul-De-Sacs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Motor Grader Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Operation
GENERAL INFORMATION SAFETY

This section provides the Operating instructions for OPERATING SAFETY
the Model 685C Motor Grader. It is important to read,
understand, and follow all “Precautions, Operating • Wear OSHA required safety equipment when running
Instructions, and Warnings” written in this manual before the motor grader.
starting or operating the machine.
• ALWAYS be seated in the operator’s seat with the
Failure to observe the “Operating seat belt on when operating the equipment.
Precautions” and “WARNING Instructions” provided
• ALWAYS make sure no person or object is in your line
in this manual can cause serious injury or death.
of travel BEFORE starting.
Only authorized personnel, who are fully trained in
the machine operation can operate the Model 685C • WORK slowly in tight areas.
Motor Grader. • DO NOT run engine in a closed building for long
This machine should be kept in good mechanical periods of time.
condition at all times. • AVOID steep hills and sharp turns if possible.
4
Do not operate a machine needing • REDUCE speed before turning or swinging loads.
repair. Put an information tag on the instrument panel
that says “DO NOT OPERATE”. Remove the key from • ALWAYS look BEFORE changing your direction of
the ignition switch. Repair all damage at once. Minor travel.
damage can result in major system failures. • DO NOT leave the engine running without operator
Do not start or operate the Model 685C present.
Motor Grader before reading, understanding, and • ALWAYS lower moldboard, scarifier, and front blade
following all information given in this section and when leaving the machine unattended.
shown on the machine. The operator must read and
• DO NOT start engine by shorting across starter
understand the function of all controls, indicators
terminals. Machine will start in gear if normal circuitry
and gauges before starting the engine. Serious
is bypassed.
injury or death can result if these procedures are not
followed. • NEVER start engine while standing on the ground.
Start engine only from operator’s seat, with forward/
Refer to Section 3 for a list of controls and a description
neutral/reverse (FNR) pedal (Figure 3-4,1) in
of their functions.
NEUTRAL.
• NEVER shift the low to high lever on any incline.
• CHECK the park brake to make sure it is operating
properly (see Checking Park Brake on page 5-10).
Shift lever must be in LOW or HIGH at
all times. Machine must be on level ground and at full
stop when shifting.

Operation
Stopping Safety RECEIVING THE MOTOR

• ALWAYS park the grader on solid, level ground. If this GRADER
is not possible, always park the grader at a right angle
to the slope. The motor grader was inspected thoroughly at the
factory. However, road hazards or vandalism may
• ALWAYS lower moldboard, scarifier, and front blade (if occur during transport and result in damage. Inspect
equipped) when leaving the machine unattended. the machine as outlined below and perform necessary
• ALWAYS engage park brake. (Push park brake button repairs before placing the machine in service.
(Figure 3-2,18) to apply park brake.) 1. Check engine oil level as shown in the engine
• USE proper flags, barriers and warning devices manufacturer’s operation and maintenance manual.
especially when parking in areas of traffic. 2. Check fuel tank, cooling system, chain boxes,
engine oil, and hydraulic reservoir for proper levels
Maintenance Safety and contaminants. If contaminants are suspected,
• NEVER work on the grader with the engine flush and fill the system.
running. 3. Check all axle fluid locations for proper amount of
• NEVER fill the fuel tank with the engine running. oil (see Checking Rear Axle Oil Level on page
5-28).
• DO NOT change the engine governor settings.
4. Read this manual and understand the contents.
• ALWAYS replace damaged or lost decals.
5. Check all hydraulic functions and repair or adjust
• DISCONNECT battery cables when working on the
as necessary. Have any repairs or adjustments
electrical system or when welding on the unit.
performed by a qualified mechanic or consult local
• IF battery needs a charge, be sure battery charger is dealer.
off when making connections.
6. Check for missing parts. If parts are missing or
• BE SURE the correct battery polarity is observed motor grader is damaged, consult the local LeeBoy
[negative (-) to negative (-) and positive (+) to positive dealer.
(+)], when connecting a battery charger or jumper
7. Check the park brake to make sure it is operating
cable.
properly (see Checking Park Brake on page
• DO NOT use hands to find hydraulic leaks. High 5-10).
pressure fluid can penetrate the skin causing severe
8. Check the seat belt to make sure it is operating
injury.
properly.
• DO NOT service or repair the grader blades, scarifier,
or moldboard in a raised position unless supported by
approved jacks and jack stands.

Operation
PRELIMINARY PROCEDURES Adjusting Seat

Always adjust the seat belt and use
Adjusting Steering Console it during operation of the motor grader. The seat
To adjust the steering console position, press and hold belt is designed to provide safe operator retention
the console tilt lock button (Figure 4-1,1) located on if the machine is involved in an accident or rollover
RH side of the console, tilt console into comfortable incident.
position, then release console tilt lock button to lock The seat can be adjusted for individual comfort. The seat
console into new position. suspension provides operator comfort by absorbing
some of the machine movements during operation. The
1 seat position lever (Figure 4-2,1) allows the operator
to move the seat from front to rear for easy access to
the steering wheel and hydraulic controls. The comfort
control knob (Figure 4-2,2) can be adjusted from soft
ride to firm ride as needed for variable operational
situations. The seat belt provides safe operator
retention if the machine is involved in an accident or
rollover incident. Adjust the seat belt for comfortable
machine operation.

1 - Console Tilt Lock Button
1
2 3
Figure 4-2. Operator’s Seat
1 - Seat Position Lever
2 - Comfort Control Knob
3 - Seat Belt

Operation
Cab Option Only Recirculated Air Control

Cab Door Release To control the amount of recirculated air, open or close
the louver plate on the console located on LH side of the
To open the door from outside the cab: cab.
1. Clasp door handle, push door handle button and pull To unlock the louver plate:
door out.
1. Turn the two louver plate knobs (Figure 4-5,4)
To open the door from inside the cab: counterclockwise (CCW).
1. Pull out the RH or LH door release lever (Figure To open the louver plate:
4-3,1) located below the seat and push door out.
1. Pull the two louver plate knobs (Figure 4-5,4)
towards the operator’s seat then turn the louver
plate knobs (Figure 4-5,4) clockwise to lock the
louver plate.
To close the louver plate:
1. Release the two louver plate knobs (Figure 4-5,4)
and push them away from the operator’s seat then
tighten the louver plate knobs (Figure 4-5,4) to lock
the louver plate.
Defroster
1 To turn on defrost:
Turn heater knob (Figure 4-5,3) clockwise (CW) to
Figure 4-3. Door Release Lever Location
HEAT position and air conditioning knob (Figure 4-5,1)
1 - Door Release Lever clockwise (CW) to A/C position then turn fan blower
speed knob (Figure 4-5,2) clockwise (CW) to LO posi-
Climate Control System tion for low speed fan setting; continue turning clock-
The heater and A/C evaporator unit are installed in the wise (CW) to MED position for medium fan speed setting
console located on LH side of the cab. Louvered vents and HI position for high speed fan setting.
for heat and A/C are located on the posts on LH and RH
sides of the cab and above the front windshield (Figure Heater
4-4). To turn on heater:
1. Turn heater knob (Figure 4-5,3) clockwise (CW)
to HEAT position. Continue turning clockwise (CW)
to increase heater temperature (MAX position is
warmest heater temperature setting).
2. Adjust cab vent louvers for desired air flow.
To turn off heater:
1. Turn heater knob (Figure 4-5,3) counterclockwise
(CCW) to OFF position.
Figure 4-4. Heat and A/C Vent Locations

Operation
Air Conditioning (A/C) Front Wiper

To turn on air conditioning (A/C): 1
1. Turn air conditioning knob (Figure 4-5,1) clockwise OFF
(CW) to A/C position. Continue turning clockwise LOW
HI LIGHTS
(CW) to increase air conditioning (A/C) temperature WIPER
WASHER
(MAX position is coldest air conditioning THROTTLE DOME FRONT HEAD WORK
LIGHT WIPER LIGHT LIGHT
temperature setting).
2. Adjust cab vent louvers as needed.
To turn off air conditioning (A/C):
1. Turn air conditioning knob (Figure 4-5,1)
counterclockwise (CW) to OFF position. To turn on front wiper:
Fan 1. Turn front wiper off/low/hi knob (Figure 4-6,1)
clockwise
HEAT OFF RUN (CW) to LOW position for low wiper
To turn on fan: speed. For high speed, continue turning clockwise
START
1. Turn fan blower speed knob (Figure 4-5,2) (CW) to HI position.

clockwise (CW) to LO position for low speed fan
685C
To turn off front wiper:
setting. Continue turning clockwise (CW) to MED
position for medium fan speed setting and HI 1. Turn front wiper off/low/hi knob (Figure 4-6,1)
position for high speed fan setting. counterclockwise (CCW) to OFF position.
To turn off fan: Front Wiper Washer Fluid

1. Turn fan blower speed knob (Figure 4-5,2) 1. Push in front wiper off/low/hi knob (Figure 4-6,1) for
counterclockwise (CW) to OFF position wiper washer fluid.
4 Rear Wiper
1
OFF OFF
LOW LOW
WIPER
HI LIGHTS WIPER
HI
WASHER WASHER

LIGHT WIPER LIGHT LIGHT WIPER LIGHT
3 Figure 4-7. Operator’s Control Panel 25
1 - Rear Wiper Off/Low/Hi Knob

25
To turn on rear wiper:

25
Figure 4-5. Cab Heater/Air Conditioning (A/C) 1. Turn rear wiper off/low/hi knob (Figure 4-7,1)
1 2 clockwise (CW) to LOW position for low wiper
25
1 - Air Conditioning Knob

OFF speed. For high speed, continue turning clockwise
HEAT RUN
(CW) to HI position.
25
2 - Fan Blower Speed Knob

START
3 - Heater Knob To turn off rear wiper:

25
685C
4 - Louver Plate Knobs 1. Turn rear wiper off/low/hi knob (Figure 4-7,1)
counterclockwise (CW) to OFF position.
1011106-01
Rear Wiper Washer Fluid

For wiper washer fluid:
1. Push in rear wiper off/low/hi knob (Figure 4-7,1) for
wiper washer fluid.

Operation
Lights Work Lights

1
Head Lights
1 OFF OFF
LOW LOW
OFF WIPER
OFF
HI LIGHTS WIPER
HI
LOW WASHER LOW WASHER
WIPER
HI LIGHTS THROTTLE DOME FRONT WIPER
HEAD
HI WORK REAR BE
WASHER LIGHT WIPER WASHER LIGHT LIGHT WIPER L
LIGHT WIPER LIGHT LIGHT WIPER LIGHT
25
Figure 4-8. Operator’s Control Panel Figure 4-10. Operator’s Control Panel
25
1 - Head Light Knob 1 - Work Light Switch
The head light knob (Figure 4-8,1) has three positions: The work light switch (Figure 4-10,1) operates the work
25
first position: running lights, second position: head lights lights mounted on the canopy or optional cab. These
HEAT OFF lights are used to illuminate the work area when working
RUN
25
and third position: high beams. START
OFF
RUN at night.
To turnHEAT
on the three head light positions:
25
START
To turn on work lights:
685C
1. Pull head light knob (Figure 4-8,1) out to turn on
1. Push work light switch (Figure 4-10,1) up (on
25
running lights, continue to pull knob out to turn on
685C
head lights, continue to pull out to turn on high beam position).
lights. To turn off work lights: 1011106-01
To turn off the three head light positions:

1. Pull work light switch (Figure 4-10,1) down (off
1. Push head light knob (Figure 4-8,1) in to turn off position).
running lights, continue to push knob in to turn off
Dome Light
head lights, continue to push in to turn off high beam 1
lights.
Beacon Light OFF
1 LOW
HI LIGHTS
WIPER
WASHER
OFF THROTTLE DOME FRONT HEAD WORK

LOW LIGHT WIPER LIGHT LIGHT
GHTS WIPER
HI
WASHER
EAD WORK REAR BEACON

IGHT LIGHT WIPER LIGHT Figure 4-11. Operator’s Control Panel
1 - Dome Light Button
25
Figure 4-9. Operator’s Control Panel The dome light is located on the top RH side behind the
operator’s seat.
25

To turnHEAT
onOFF
theRUN
dome light:
The beacon light switch (Figure 4-9,1) operates the
25
START
safety flashing light on top of the canopy or optional cab. 1. Push the dome light button (Figure 4-11,1) up (on
position).
25
This light warns traffic of slow moving equipment.
685C
To turn on beacon light: To turn off the dome light:
25
1. Push beacon light switch (Figure 4-9,1) up (on 1. Push the dome light button (Figure 4-11,1) down (off
position). position).
25
1.
685C
To turn off beacon light:
Pull beacon light switch (Figure 4-9,1) down (off
1011106-01
position).

Operation
• CHECK engine, transmission, and hydraulic oil levels.

BREAK-IN PROCEDURES Fill to the correct level as necessary.
NOTE: Make every effort to become familiar with the • FILL the fuel tank with the engine off. NEVER fill fuel
feel and sound of the machine. tank near an open flame or when smoking.
1. Observe engine operation carefully. • CHECK for frayed or worn electrical wires and loose
2. Check the engine oil and coolant frequently. or corroded connections.
3. Operate engine at normal loads. • CHECK tires for wear, cuts, and damage. CHECK air
pressure. INSPECT wheels for loose, damaged, or
4. Check indicators and gauges frequently during missing hardware.
operation.
• CHECK pedals and levers for freedom of movement.
5. Avoid excessive engine idling. MAKE SURE operator’s compartment is free of debris.
6. Perform 10 hour or daily service. • CHECK steps and supports for damage. Repair as
7. Watch for fluid leaks and repair immediately. necessary.
8. Lubricate pivots every 10 hours for first 100 hours. • CHECK protective devices, cab, ROPS, canopy,
shields and seat belt for wear or damage.
9. Check and tighten wheel lug nuts. Tighten to
360 ft. lbs. (488 N•m). • MAKE SURE all protective devices operate correctly.
10. Perform service intervals as shown in Maintenance • ALWAYS be seated in the operator’s seat with the
section. seat belt on when operating the equipment.
11. Change the engine oil and filter after 100 hours of
engine operation (refer to Maintenance section).
ENGINE OPERATION
12. Check engine manufacturer’s operation and Starting the Engine
maintenance manual for additional information of
engine break-in. Preliminary
13. Check the park brake to make sure it is operating NOTE: Refer to engine manufacturer’s operation and
properly (see Checking Park Brake on page maintenance manual for instructions when
5-10). starting engine for the first time. Follow engine
manufacturer’s recommendations for fuel and oil.
PRE-START INSPECTION Before starting the engine:
NOTE: Refer to Maintenance section for maintenance 1. Check the fuel level.
procedures.
2. Check the fuel lines and tank for leaks.
• INSPECT machine. Have any malfunctioning, broken
or missing parts repaired or replaced before using the 3. Check the engine oil level.
grader. Failure to maintain correct engine oil
• CHECK hydraulic hoses daily for wear and leaks level is the greatest single cause of engine failures.
Replace if damaged. 4. Check the hydraulic oil level (see Checking
• CHECK that all the instruction and safety labels are Hydraulic Oil Level on page 5-25).
in place and readable. These are as important as any 5. Fasten seat belt (Figure 4-2,3).
other equipment on the machine.
6. Place forward/neutral/reverse (FNR) pedal (Figure
• CHECK parking brake to insure it’s working properly. 3-4,1) in NEUTRAL (center position).
• READ and FOLLOW all instruction decals. 7. Push park brake button (Figure 3-2,18) to apply
• WEAR OSHA required safety equipment when park brake.
running the motor grader.

Operation
Engine Start-up Cold Weather Engine Start-up: Glow

Plugs Package (Option)
Forward/Neutral/Reverse (FNR) Pedal
(Figure 3-4,1) must be in NEUTRAL (center) position
and Park Brake (Figure 3-2,18) applied before
starting engine.
2
Do not operate the starter longer than
20 seconds. If the engine does not start, allow the HEAT OFF RUN
starter to cool for 2 to 3 minutes. START
1
1. Insert key into the ignition switch (Figure 3-2,1) and 3
turn clockwise (CW) to START position. Release key
when engine starts.
2. Run engine for 30 seconds. Figure 4-12. Ignition Switch - Glow Plug Option
3. Check indicator and gauge operation. 1 - Heat Position
Engine Warm-up 2- Wait-to-Start Indicator Light
Allow engine and hydraulic oil to warm 3 - Start Position
up before activating components. 1. To start machine, turn key counterclockwise (CCW)
1. Start engine and run for several minutes. Do not to HEAT position (Figure 4-12,1). The wait-to-start
accelerate rapidly during warm-up. indicator light (Figure 4-12,2) will illuminate.
2. Operate engine at less-than-normal loads and 2. When wait-to-start indicator light (Figure 4-12,2)
speeds until engine reaches normal operating turns off, turn key clockwise (CW) to START position
temperatures. (Figure 4-12,3).
Cold Weather Engine Start-up Cold Weather Engine Warm-up (40°F

or below)
The improper use of starting aids
(starting fluid) can cause severe engine damage In cold weather, it is extremely
and personal injury. Read and understand the important to allow engine and hydraulic oil to warm
engine manufacturer’s operation and maintenance up before activating components.
manual before attempting to start the engine using
1. Run engine for five minutes.
cold weather starting aids. Engines equipped with
glow plugs and some turbocharged engines will 2. Operate all hydraulic functions before moving machine.
be damaged when using starting fluid for starting
purposes.
Using Booster Batteries - 12 Volt
System
NOTE: See engine manufacturer’s operation and
maintenance manual for information about 1. Make sure the forward/neutral/reverse (FNR) pedal
cold weather starting, aids, and other engine (Figure 3-4,1) is in NEUTRAL (center position)
operation information. before using booster batteries to start the engine.
2. Push park brake button (Figure 3-2,18) to apply
park brake.
Charging batteries produces explosive
gases. Keep flames and sparks away from battery
area. Charge batteries in a well ventilated area.
The electrical system is 12 Volts
with negative (-) ground. Use only 12-Volt booster
batteries.

Operation
Improperly connected jumper cables Adjusting Engine for High Elevation

can produce sparks and explosion. Make sure Do not change engine settings to
negative terminals are connected and positive compensate for elevation. An authorized service
terminals are connected. Never connect negative dealer must service the injection pump.
terminal to a positive terminal. Do not allow vehicles
to touch. Refer to the engine manufacturer’s operation and
maintenance manual for information on engine
3. Connect the positive (red) jumper cable to the specifications and settings. See the local authorized
positive battery post on the booster battery and dealer for engine settings and modifications.
machine batteries.
4. Connect the negative jumper cable to the booster DRIVING THE MACHINE
battery negative post and a good ground (frame, Before driving on public roads, check state and local
bracket or support) away from the battery and laws that may apply to tractors, self-propelled machines,
moving engine components. and towed equipment. Additional lights, mirrors, SMV
5. After starting, remain in the operator’s seat and emblems, or reflectors may be required.
have a helper remove the jumper cables from the
machine. Directional Control
The Model 685C Motor Grader is equipped with
Stopping the Engine a forward/reverse variable speed, hydrostatic
1. Park machine on a level surface. transmission and variable hydraulic motor. The
transmission and hydraulic motor are controlled
2. Place forward/neutral/reverse (FNR) pedal (Figure separately. A directional forward/neutral/reverse (FNR)
3-4,1) in NEUTRAL (center position). pedal (Figure 3-4,1) controls the hydraulic flow and
3. Lower all equipment to ground level. direction of flow through the hydrostatic transmission.
The forward/neutral/reverse (FNR) pedal (Figure
3-4,1) is used to control forward/reverse movement,
park brake.
acceleration, and braking.
Turbocharged engines may be To move machine forward or reverse:
damaged if engine is not shut down properly.
1. Pull park brake button (Figure 3-2,18) up to release
5. Run engine at 1/2 speed without load for 3 to 5 the park brake.
minutes.
2. Advance throttle to working speed (RPM).
6. Push throttle switch (Figure 3-2,6) in LOW (down
position). 3. a. To move machine forward:
7. Turn ignition switch key (Figure 3-2,1) Push the forward/neutral/reverse (FNR) pedal
counterclockwise (CCW) to the OFF position and (Figure 3-4,1) forward.
remove ignition switch key. b. To move machine in reverse:
Push the forward/neutral/reverse (FNR) pedal
Emergency Stopping (Figure 3-4,1) back.
1. In an emergency, place forward/neutral/reverse
(FNR) pedal (Figure 3-4,1) in NEUTRAL (center
position).
2. Reduce engine speed to slow idle.
3. Push the park brake button (Figure 3-2,18) to apply
park brake.
NOTE: After using the park brake button (Figure
3-2,18) for emergency stopping, check park
brake operation (see Checking Park Brake on
page 5-10).
4. Lower components to the ground if engine is
running.

Operation
Travel Speeds NOTE: Check the park brake daily to make sure it
is functioning properly (see Checking Park
To increase travel speed: Brake on page 5-10).
1. Push throttle switch (Figure 3-2,6) up to high NOTE: After using the park brake for emergency
position. stopping, check the park brake to make sure
2. Push work/auto switch (Figure 3-2,19) up to AUTO it is functioning properly (see Checking Park
position. Brake on page 5-10).
2-speed hi/lo switch must be in LO or Park Brake
HI at all times. When shifting 2-speed hi/lo switch
from LO to HI or HI to LO the machine must be A fail-safe hydraulic park brake mounted to the right of
stopped on level ground, the brake must be engaged the operator’s seat uses a button (Figure 3-2,18) to
and the moldboard must be on the ground. Switch engage the park brake.
must be in LO or HI at all times. In an emergency, apply the park brake by pushing down
3. Engage park brake by pressing park brake button on the park brake button.
(Figure 3-2,18) down. To engage the park brake:
4. Push 2-speed hi/lo switch (Figure 3-2,20) up to HI 1. Push the park brake button (Figure 3-2,18) down.
position.
To release the park brake:
5. Disengage park brake by pulling park brake button
1. Pull the park brake button (Figure 3-2,18) up.
(Figure 3-2,18) up.
NOTE: Check the park brake daily to make sure it
Throttle Control is functioning properly (see Checking Park
NOTE: The 685C Motor Grader hydraulic drive system Brake on page 5-10).
is designed to operate between 0 to 6000 PSI NOTE: After using the park brake for emergency
(0 to 414 Bar). When the hydraulic operating stopping, check the park brake to make sure
pressure exceeds 6000 PSI (414 Bar), the relief it is functioning properly (see Checking Park
valve remains open causing excessive heat Brake on page 5-10).
resulting in damage and wear.
A throttle switch (Figure 3-2,6) is located on the
Parking the Machine
operator’s control panel. The switch is used to control Before leaving the operator’s seat, perform the following
the speed (RPM) of the engine. A tachometer (Figure procedures:
3-2,15) located on the operator’s control panel provides
an indication of engine speed. 1. Park machine on a level surface.
To increase engine speed (RPM): 2. Return forward/neutral/reverse (FNR) pedal (Figure

3-4,1) to NEUTRAL (center position).
1. Push the throttle switch (Figure 3-2,6) up to high
position. 3. Lower all equipment to ground level.
To decrease engine speed (RPM): 4. Push the park brake button (Figure 3-2,18) to apply
park brake.
2. Pull the throttle switch (Figure 3-2,6) down to
decrease engine speed (RPM). 5. Idle engine for 3 - 5 minutes at 1/2 speed (RPM).
6. Pull throttle switch (Figure 3-2,6) down to LOW
Braking position.
To brake, return the forward/neutral/reverse (FNR) 7. Turn ignition switch key (Figure 3-2,1)
pedal (Figure 3-4,1) to the NEUTRAL (center) position. counterclockwise (CCW) to OFF position and
This is preferred for slowing the machine down. To remove key.
quickly bring the machine to a complete stop, the
primary brake pedal (Figure 3-4,2) can be used.
In an emergency, apply the park brake by pushing down
on the park brake button (Figure 3-2,18).

Operation
OPERATING THE MACHINE the front of the machine toward the toe of the blade. The
toe of the blade is the end of the moldboard closest to
NOTE: Refer to Section 3 for location and illustration the front of the machine.
of controls and uses.
Counteract side thrust of the machine by leaning the top
This manual does not attempt to teach actual grading of the wheels toward the heel (discharge side) of the
techniques. A qualified motor grader operator trained blade. Articulate the machine slightly toward blade toe to
in all types of grading applications should do the help control side thrust.
grading. The operator must thoroughly understand the
mechanical characteristics of the motor grader and Moldboard Pitch Control
varying elements and terrain for safe operation.
The moldboard can be tilted using the moldboard
Moldboard Lift Control tilt lever (Figure 3-3,9,14) mounted on the hydraulic
control valve.
The moldboard can be raised and lowered using
To tilt the moldboard forward:
the moldboard left and right control levers (Figure
3-3,9,10). The levers are mounted on the hydraulic 1. Push the moldboard tilt lever (Figure 3-3,14)
control valve. forward.
To lower the moldboard: To tilt the moldboard to the rear:
1. Push the moldboard left and right lift levers (Figure 1. Pull the moldboard tilt lever (Figure 3-3,14) back.
3-3,9,10) forward Tilting the moldboard changes the moldboard blade to
To raise the moldboard: provide varying cutting angles.
1. Pull the moldboard left and right lift levers (Figure For normal grading, use the blade in the upright position.
3-3,9,10) back. The blade should be positioned with the top vertical or
slightly ahead of the bottom edge.
The float position allows the moldboard to “float” over
hard surfaces. The moldboard float position can be When greater cutting action is needed, use backward
used to remove snow, remove loose material from a pitch on the moldboard causing the blade to suck in.
hard-packed surface, and to match loose material to a Dirt can build up and contact the circle due to a lack of
hard-packed surface. rolling action. Adjust blade as necessary.
To place the moldboard in the float position: For better mixing and rolling action, pitch the moldboard
ahead of vertical position. When spreading material or
1. Push the left and right lift levers (Figure 3-3,9,10)
maintaining roads, moldboard should be tipped forward.
all the way forward.
This tends to compact material and fill low spots. Use
To release the float detent: only as much forward tip as needed for compacting or
1. Pull the left and right lift levers (Figure 3-3,9,10) filling.
back.
Moldboard Angle Control
Moldboard Side-shift Control The angle of the moldboard can be changed using the
The moldboard can be shifted up to 3 ft. from left to right. moldboard blade angle lever (Figure 3-3,4).
Use the moldboard slide lever (Figure 3-3,5) mounted To angle the moldboard right:
on the hydraulic control valve to move the moldboard
1. Pull the moldboard blade angle lever (Figure 3-3,4)
right and left.
back.
To shift the moldboard to the left:
To angle the moldboard left:
1. Pull the moldboard slide lever (Figure 3-3,5) back.
1. Push the moldboard blade angle lever (Figure
To move the moldboard to the right 3-3,4) forward.
1. Push the moldboard slide lever (Figure 3-3,5) The moldboard discharges material from the side of the
forward. moldboard closest to the rear of the machine.
When the machine is pushing a load with the moldboard
set at an angle, the movement of the load tends to swing

Operation
Wheel Lean Control High/Low Transfer Case

The steering wheels can be leaned for material 2-speed hi/lo switch must be in LO or
movement control and shorter turning radius. The HI at all times. When shifting 2-speed hi/lo switch
wheel can be leaned using the wheel lean lever (Figure from LO to HI or HI to LO the machine must be
3-3,9,1). stopped on level ground, the brake must be engaged
and the moldboard must be on the ground. Switch
To lean the wheels to the right:
must be in LO or HI at all times.
1. Pull the wheel lean lever (Figure 3-3,9,1) back.
The 2-speed hi/lo switch (Figure 3-2,20) allows the
To lean the wheels to the left: driver to operate in two speed ranges.
1. Push the wheel lean lever (Figure 3-3,9,1) forward. To place the machine in high gear:
Lean the wheels toward the windrow when making a 1. Push the 2-speed hi/lo switch (Figure 3-2,20) up.
heavy cut. Lean the wheels to make a shorter turn.
To place the machine in low gear:
Optional Front Traction Assist 1. Pull the 2-speed hi/lo switch (Figure 3-2,20) down.
Control Drive System
Optional front traction drive motors can be engaged When grading:
using the front traction assist switch mounted on the
moldboard right lift lever (Figure 3-3,11). The front 1. Engage park brake by pressing park brake button
traction motors are designed to assist traction in heavy (Figure 3-2,18) down.
materials. (The front traction assist light [green] (Figure 2. Put the machine in low gear by pulling 2-speed hi/lo
3-3,17) will illuminate when front traction assist is switch (Figure 3-2,20) down to LO.
engaged.)
3. Throttle to desired RPM.
Scarifier Control 4. Place auto/work switch (Figure 3-2,19) in AUTO or
The scarifier is used to break up packed surfaces. WORK:
The support teeth should penetrate the surface. Do
not allow the teeth to drag the surface, which creates a. In AUTO the machine works at its fastest speed
excessive wear on the teeth. The scarifier can be raised for the amount of torque needed, varying the
and lowered using the scarifier lever (Figure 3-3,13) speed as needed.
mounted on the hydraulic control valve. b. In WORK the machine will stay at maximum
To lower the scarifier: torque with the speed staying constant to that of
the forward/neutral/reverse (FNR) pedal (Figure
1. Push the scarifier lever (Figure 3-3,13) forward. 3-4,1).
To raise the scarifier: 5. Release park brake by pulling park brake button
1. Pull the scarifier lever (Figure 3-3,13) back. (Figure 3-2,18) up.
When driving on highway:
1. Engage park brake by pressing park brake button
(Figure 3-2,18) down.
2. Put the machine in high gear by pushing 2-speed hi/
lo switch (Figure 3-2,20) up to HI position.
3. Throttle to desired RPM.
4. Push auto/work switch (Figure 3-2,19) up to AUTO
position.
5. Release park brake by pulling park brake button
(Figure 3-2,18) up.

Operation
Articulation and Steering Backfilling

Control Positioning the moldboard to discharge a pile into a trench
and placing the rear wheels over the filled trench backfills
Do not articulate the motor grader the trench and compacts the material at the same time.
when operating on steep slopes. Machine could roll
over. Severe personal injury or death could occur. Vee Ditching
Steering the motor grader is accomplished using a 1. First Pass: Center moldboard (Figure 3-1,5), place
combination of devices. The steering wheel (Figure toe of moldboard blade just outside edge of front
3-3,7) is used for general steering. The articulation lever tire, tilt blade pitch forward until top of blade is in line
(Figure 3-3,12) mounted on the hydraulic control valve with center of front tire, and raise heel of blade just
is used to articulate the front section of the machine for ahead of rear wheels so dirt will spill out between
tighter turns. The steering wheel and articulation can be the rear tires.
used with the wheel lean lever (Figure 3-3,1) for tight
2. Lean front wheels slightly toward discharge end of
turns. Articulation is also used to maintain a straight path
blade.
when working with a windrow.
3. Traveling in low gear, make first pass very light in
To move the front end to the left:
order to establish line of ditch.
1. Push the articulation lever (Figure 3-3,12) forward.
4. Second Pass: Position wheels in vee ditch made in
To move the front end to the right: first pass to compensate for side thrust. This allows
1. Pull the articulation lever (Figure 3-3,12) back. the machine to make a deeper cut at higher speeds
during second pass.
Front Blade Control (Option) 5. Clean-Up Pass: As the dirt builds up between the
The optional front blade is used for moving materials rear tires, a clean-up pass must be made as follows:
and backfilling. The front blade lever (Figure 3-3,2) is a. Side-shift moldboard blade toward ditch and
mounted on the hydraulic control valve. position front wheels outside windrow.
To lower the front blade: b. Set blade at an angle with heel between rear
1. Push the front blade lever (Figure 3-3,2) forward. wheels and blade pitched slightly forward.
To raise the front blade: c. Position toe of blade well beyond windrow to
minimize spillage back into vee ditch.
1. Pull the front blade lever (Figure 3-3,2) back.
d. Articulate machine slightly to deposit windrow
Spreading Piles between rear tires.
By using articulation (offsetting front wheels to edge of 6. Use straight-frame position to spread windrow left
pile) and positioning drive wheels behind moldboard from cleanup pass. Position circle and moldboard
(Figure 3-1,5), piles of material or large windrows can to deposit material evenly. Use material to establish
be easily spread or moved without having to run front roadbed and shoulder.
wheels into the material.
7. Cut the back slope as follows:
NOTE: The amount of material spread in each pass
a. Side shift moldboard blade toward bank.
will be limited by the power and traction of the
machine. b. Position heel of blade in centerline of rear tire
and pitch blade slightly forward.
1. Shift moldboard toward pile.
c. Blade angle is toward direction of travel,
2. Set moldboard nearly square to direction of travel
depending upon degree and height of slope.
and side shift toward pile.
d. Drive wheels of machine in established vee
3. Lean front wheels slightly away from pile and tilt
ditch. The dirt will be deposited from back slope
moldboard slightly forward.
slightly up onto shoulder slope where a cleanup
4. Position moldboard high enough above surface to pass will put the dirt onto roadbed for spreading.
obtain desired depth.
8. To finish the vee ditch, pull windrow up from
shoulder slope, clean away from edge of ditch and
spread dirt.

Operation
Ditch Cleaning Slope Work

1. If ditch is soft and will not support full weight of 1. If possible, make a first pass from above slope to
machine or if ditch is wet, offset rear wheels to allow establish angle as follows:
the tires to ride on shoulder of road. Lift material
a. Side-shift moldboard toward slope.
from ditch and discharge to the outside of the rear
wheels. b. Set blade angle slightly toward rear of machine
with a slight forward tilt.
2. By articulating rear wheels on road and front wheels
into ditch, back machine up until toe of blade is at c. Position blade as far down slope as
end of culvert. possible¬and make first pass.
3. Start the cut, windrowing material onto shoulder or NOTE: The machine can be straight frame or articu-
roadbed. lated for extra reach.
4. When filling washouts on existing back slopes, the 2. On second pass, lean front wheels toward slope
moldboard can be angled back and side-shifted and position upper front wheel above windrow to
enough for material to roll up slope. prevent front end from drifting down. Articulate rear
wheels down slope to increase stability of machine.
Road Crowning 3. Position toe of blade forward and angled so
1. Blade material inward from shoulder of ditches. Cut materials are spilled off heel slightly between rear
top of crown with blade at 0° angle, or at a slight wheels. Set blade pitch ahead of vertical plane and
angle, to cast material to the side needing fill. side shift toward the uphill side. Repeat procedure
until dirt is deposited at toe of slope.
2. Spread windrows by placing blade 10° to 25° toward
center. Keep blade above graded surface to avoid 4. Establish toe of slope by cleaning windrow away
solid objects such as rocks in roadbed. from bottom.
3. Perform crowning operation at relatively high speed. 5. When working on steep slopes, a rollover with the
Increased speed throws loose material from the machine articulated is unlikely; however, extreme
blade, feathers the material, and blends the top. caution should be used when working on slopes
steeper than three to one.
4. Any ridges left in the center can be spread at high
speed with a straight blade. Cul-De-Sacs
Bank Cutting 1. Articulate machine to inside, shift moldboard to
outside, and side shift blade slightly to inside.
1. Make a first pass at base of bank to level and
smooth a platform for the machine. 2. Tilt blade forward 5° to 10°.
2. Shift top of blade forward and place heel in front of 3. Travel in low gear; fast idle with front wheels leaned
rear wheel center. toward direction of turn.
3. Tilt blade forward and lean wheels slightly toward 4. After curb is poured, backfill against the outside of
bank. curb for support.
4. Position machine frame straight with all wheels at 5. For finish grading as turns become shorter, the
base of bank or, if more reach is needed, articulate moldboard can be shifted toward the center. Any
slightly to position front inside wheel on bank. excess material deposited in the center can be
removed.
NOTE: There are three methods for setting depth of
cut: maneuvering lift cylinders, changing blade
pitch, and leaning wheels.
5. After first bank cut, clean any loose material from
bottom of bank.

Operation
TRANSPORTING 5. Engage towing vehicle park brake.

6. Install chocks or blocks against truck and trailer
When transporting the machine on a flat bed vehicle, the
wheels.
vehicle must be capable of carrying the machine safely
in all driving situations. 7. Load machine on the flat bed. Block motor grader
wheels in both directions to prevent rolling.
1. Thoroughly clean the machine using a pressure
washer. Remove all loose gravel, mud or debris 8. Position moldboard as shown in Figure 4-13.
from moldboard, tires or frame. 9. Lower moldboard, scarifier and, if equipped,
2. Make sure the combined height of the truck, trailer front blade to flat bed surface. Secure machine
and loaded grader meet height restrictions for with chains strong enough to prevent machine
the local area including bridges, overpasses, and movement without failure.
overhead obstructions. 10. Idle engine at 1/2 speed (RPM) for 3 to 5 minutes.
3. Park transport vehicle on a level surface. 11. Push throttle switch (Figure 3-2,6) down to idle.
4. Place forward/neutral/reverse (FNR) pedal (Figure 12. Turn ignition switch key (Figure 3-2,1)
3-4,1) in NEUTRAL (center position). counterclockwise (CCW) to the OFF position and
remove ignition switch key.
685C
Figure 4-13. Motor Grader on Transport

Operation
Fasten chains or cables to machine 16. Lower the moldboard length under the motor grader
frame. Do not place chains or cables over or against onto wooden blocks to protect trailer bed. Do not
hydraulic line, hoses or electrical harness. Use apply down pressure.
chains, cables and binders of sufficient capacity to 17. Lower all attachments, such as scarifier and, if
secure the motor grader without breaking, shifting or equipped, front blade.
slipping.
18. Shut down the motor grader by turning ignition
13. Obey all local laws concerning local laws switch key (Figure 3-2,1) counterclockwise (CCW)
concerning loading, unloading, and transport of to the OFF position and removing ignition switch
equipment. key.
NOTE: Keep the trailer bed clean. 19. Apply park brake by pushing down park brake
14. Use a ramp or loading dock. Make sure the ramp button (Figure 3-2,18).
weight capacity will support the grader and has a 20. Cover the exhaust opening with heavy gauge plastic
low angle of rise to the trailer bed. to prevent dust and moisture entering the engine.
15. Load the machine on the trailer bed by driving Remove the plastic cover from the
straight on and centered on the trailer. The motor exhaust before operating the motor grader.
grader centerline must be over the centerline of the
trailer. 21. Secure motor grader to the trailer with tie-down
cables or chains at tie down locations (Figure
4-14,1,2,3).
Figure 4-14. Tie Down Locations

1 - Rear Tie Downs
2 - Mid Tie Downs
3 - Front Tie Down

Operation
MOTOR GRADER TOWING 5. Find center position to disengage gears for towing.
6. On the bottom of the rear axle, locate the brake
It is recommended that all towing operations be release screw (Figure 4-16,1) (the screw with a
performed by a professional towing service. If the square head).
machine must be towed for loading or clearing a work
area the machine can be towed as follows:
Improper towing methods and
equipment can result in severe personal injury or
death. Read and understand towing instructions and
precautions.
The operator must be in the operator’s
seat to control steering and brakes. Steering, brakes,
and transmission may be operational depending on
type of failure and options available.
Wheel must be blocked from moving
while preparing machine for towing.
NOTE: Do not tow machine faster than 5 MPH (8 km/h) 1
Towing or pushing cannot start the engine. Figure 4-16. Brake Release Screw
Do not tow grader long distance. Transport the 1 - Brake Release Screw
machine instead.
7. Using a caliper, measure the exact extension of the
1. Block machine to prevent machine from moving. screw and record measurement.
2. Lift and secure the scarifier, moldboard and, if 8. Turn the screw all the way in to release the brakes
equipped, front blade. for towing the machine.
3. Using a screwdriver or small pry bar, manually pull 9. Fasten a chain or tow bar to the machine.
shifting valve (Figure 4-15,1) all the way out.
NOTE: Some state and local laws prohibit or limit the
use of tow chains on highways. Check state and
local regulations.
10. Run the engine for steering and braking power, if
possible.
11. Activate all warning lights, including hazards and
revolving lights.
The towing vehicle must have sufficient
braking to stop the towed vehicle. If the towed
vehicle cannot be braked, use a tow bar or two tow
vehicles. If using two tow vehicles, position one in
1 front and one behind the towed vehicle for braking.
Stay clear of a tow chain or cable
when tension is applied. Do not allow bystanders to
Figure 4-15. Shifting Valve
enter the path between towing vehicles. Protect the
1 - Shifting Valve operators from broken chains or cables. A broken
4. Now push shift valve (Figure 4-15,1) all the way in. chain or cable can cause severe injury or death.
Make sure the towline, chain or tow bar is in good
condition and strong enough to tow the machine.
Mark the center of the towline with a flag or brightly
colored cloth.

Operation
Make sure a SMV (Slow Moving

Vehicle) plate is attached to the rear of the grader.
Make sure the towline angle is less than 20 degrees
with respect to horizontal plane.
Do not allow the towline to contact any grader
components.
12. Remove any wheel chocks or blocking. Slowly apply
tension to the tow chain or bar. Sudden machine
movement can cause the towline, chain or tow bar
to break.
13. When turning, keep the tow angle and speed to a
minimum.
To return the machine from the
towing condition to normal operation
proceed as follows:
1. Adjust square head screw to the exact position
measured in Step 7 in Motor Grading Towing.

Section 5
MAINTENANCE
Page
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Routine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Machine Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5
Preparing Machine for Maintenance . . . . . . . . . . . . . . . . . 5-8
10 Hour or Daily Routine Maintenance . . . . . . . . . . . . . . . . . 5-8
After The First 50 Hours and Weekly Routine Maintenance . . . . . . 5-9
100 Hour or Monthly Routine Maintenance . . . . . . . . . . . . . . 5-9
250 Hour or Quarterly Routine Maintenance . . . . . . . . . . . . . 5-9
500 Hour or Semi-Annual Routine Maintenance . . . . . . . . . . . 5-9
1000 Hour or Annual Routine Maintenance . . . . . . . . . . . . . . 5-10
2000 Hour Routine Maintenance . . . . . . . . . . . . . . . . . . . 5-10
Checks and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Checking Park Brake. . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Checking Oil Lines and Fittings . . . . . . . . . . . . . . . . . . . . 5-10
Checking Air Intake Hoses . . . . . . . . . . . . . . . . . . . . . . 5-10
Checking Window Washer Fluid Reservoir Level . . . . . . . . . . . 5-10
Checking the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Checking and Adjusting Moldboard Blade Side-Shift Assembly . . . . 5-11
Checking Drawbar Ball and Socket . . . . . . . . . . . . . . . . . . 5-11
Checking and Adjusting Toe-In . . . . . . . . . . . . . . . . . . . . 5-12
Checking Gearbox Breathers . . . . . . . . . . . . . . . . . . . . 5-12
Cleaning, Packing, and Adjusting the Front Wheel Bearings . . . . . 5-12

Maintenance
Checking Neutral Start System . . . . . . . . . . . . . . . . . . . . 5-13

Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Master Disconnect Switch. . . . . . . . . . . . . . . . . . . . . . 5-13
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Cleaning and Tightening Battery Terminal Connections/Terminals . . 5-14
Checking Battery Electrolyte Level . . . . . . . . . . . . . . . . . . 5-15
Tire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Filling Tire with Air . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Changing Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Checking the Engine Lubrication Oil Level . . . . . . . . . . . . . . 5-17
Changing the Engine Oil and Replacing Filter . . . . . . . . . . . . . 5-17
Transfer Case Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Checking Transfer Case Oil Level . . . . . . . . . . . . . . . . . . 5-19
Radiator and Coolant System . . . . . . . . . . . . . . . . . . . . . . . 5-19
Checking Radiator and Coolant Level . . . . . . . . . . . . . . . . 5-19
Cleaning Engine Ventilation Tube (Blow-By Tube) . . . . . . . . . . 5-21
Checking Engine Speed . . . . . . . . . . . . . . . . . . . . . . . 5-21
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Checking and Cleaning Fuel Filler Cap . . . . . . . . . . . . . . . . 5-23
Checking Engine Air Cleaner Assembly . . . . . . . . . . . . . . . 5-23
Replacing Engine Air Filter Elements . . . . . . . . . . . . . . . . . 5-24
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . 5-25
Changing Hydraulic Charge Filter. . . . . . . . . . . . . . . . . . 5-26
Checking and Cleaning Hydraulic Oil Reservoir Filler Cap . . 5-27
Draining, Flushing, and Filling Hydraulic Oil Reservoir. . . . . . . . . 5-27
Rear Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Checking Rear Axle Oil Level . . . . . . . . . . . . . . . . . . . . 5-28
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Fuses And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . 5-29
Component Replacement Procedures . . . . . . . . . . . . . . . . . . . 5-30
Replacing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

Maintenance
Replacing Scarifier Tooth Shank. . . . . . . . . . . . . . . . . . . 5-31

Replacing Scarifier Tooth. . . . . . . . . . . . . . . . . . . . . . . 5-31
Replacing Articulate Cylinders . . . . . . . . . . . . . . . . . . . . 5-32
Replacing Wheel Steering Cylinder . . . . . . . . . . . . . . . . . 5-33
Replacing Wheel Lean Cylinder. . . . . . . . . . . . . . . . . . . 5-34
Replacing Front Blade Lift Cylinder . . . . . . . . . . . . . . . . . 5-35
Replacing Scarifier Lift Cylinder . . . . . . . . . . . . . . . . . . . 5-35
Replacing Moldboard Slide Cylinder . . . . . . . . . . . . . . . . . 5-36
Replacing Moldboard Tilt Cylinders . . . . . . . . . . . . . . . . . 5-37
Replacing Moldboard Angle Cylinders . . . . . . . . . . . . . . . . 5-37
Replacing Moldboard Lift Cylinder . . . . . . . . . . . . . . . . . . 5-38
Replacing Moldboard Blade . . . . . . . . . . . . . . . . . . . . . 5-38
Replacing Hydraulic Charge Filter. . . . . . . . . . . . . . . . . . 5-39
Replacing Radiator/Oil Cooler Assembly. . . . . . . . . . . . . . . 5-40
Replacing Control Valve Assembly . . . . . . . . . . . . . . . . . . 5-41
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Preparing Machine For Long-Term Storage . . . . . . . . . . . . . 5-42
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Maintenance
NOTES

Maintenance
General Information Routine Maintenance

This section gives the necessary procedures for General Information
routine and general maintenance on the Model 685C
Motor Grader. MAINTENANCE must be a planned program that
includes periodic machine inspection and lubrication
Follow all the Maintenance Schedules and Maintenance
procedures.
Procedures to maintain the machine in top operating
order. The MAINTENANCE program must be done, based on
the machine “Operating Hours”, recorded on the hour
meter, or based on the “Periodic Schedule’’, which is
done at time intervals of weekly, monthly, quarterly,
semi-annually, or yearly.
Machine Lubrication
Proper lubrication is necessary to maintain the machine
at top efficiency. Refer to the lubrication information in
Table 5-1. All lubrication points are shown in Figure 5-1.

Maintenance
Lubrication Points
17
9
8
2 7
14 16
13
3
18 4
1
11
6
10 5
15 9
12
Figure 5-1. Lubrication Points

Maintenance
Table 5-1. Lubrication Chart

ITEM
TYPE LUBE DESCRIPTION AND LOCATION INTERVAL
NO.
1 A ARTICULATED JOINT (Until grease escapes from the upper and Monthly
lower joints)
2 A ARTICULATED CYLINDER (Until grease escapes from the clevis Weekly
joints)
3 A GEAR BOX Monthly
4 B DOOR HANDLES, CAB Monthly
5 A DRAWBAR BALL (Until grease escapes from the ball joint) Daily
6 A DRIVE PEDAL (Until grease escapes from the pedal joint) Weekly
7 A FRONT AXLE JOINTS Weekly
8 A FRONT BLADE CYLINDER Weekly
9 A FRONT BLADE JOINTS Weekly
10 A MOLDBOARD LIFT CYLINDERS Daily
11 A MOLDBOARD LIFT TRUNION Daily
12 A MOLDBOARD MOUNTING PINS Weekly
5
13 A MOLDBOARD STABILIZER Weekly
14 A MOLDBOARD SWING CYLINDERS Daily
15 A MOLDBOARD TILT CYLINDERS Weekly
16 A STEERING CYLINDERS Daily
17 A TURN TABLE Weekly
18 A VALVE HANDLES Monthly
LEGEND
A Grease with Shell Avania EP Grease or Equivalent
B Spray with oil or chain lubricant

Maintenance
Maintenance Schedule 4. Push park brake button (Figure 3-2,18) to apply

park brake.
General Information 5. Run engine at 1/2 speed (RPM) without load for 3 to
5 minutes.
The Maintenance Schedule lists the recommended time
intervals between machine maintenance inspections 6. Reduce engine speed (RPM) to slow idle.
and lubrication procedures. Figure 5-1 gives inspection 7. Turn ignition switch key (Figure 3-2,1)
and lubrication information for the Model 685C Motor counterclockwise (CCW) in the OFF position.
Grader. If maintenance must be performed with engine
The “Hour” and “Periodic” time periods list most service running, do not leave machine unattended.
intervals. The maintenance schedule begins with ten
hours, or daily, maintenance intervals and continues 10 Hour or Daily Routine
through the 1,000 hours, or annual, maintenance Maintenance
schedule intervals.
1. Check the fuel level. Keep the fuel tank full to keep
NOTE: If the machine is operated more than ten condensation from forming. Fill at end of day.
hours per day, follow the “Hour” schedule. If the
machine is operated less than ten hours per 2. Perform engine preventative maintenance as
day, follow the “Periodic” schedules, where they described in your engine operator’s manual. Any
apply. engine preventative maintenance should always
begin with an engine oil check.
Preventive maintenance on the 685C Motor Grader
will provide years of trouble-free operation. Adjustment 3. Check the hydraulic oil level (see Checking
can be performed in the field with ordinary hand tools. Hydraulic Oil Level on page 5-25) and fill as
Engine preventative maintenance, other than oil, air, and required.
fuel filter changes, is not covered in this section. Refer to 4. Check the radiator coolant level and fill as required
engine operator’s manual for engine service information. (see Checking Radiator and Coolant Level on
page 5-19).
The changing of oil and cleaning of the
grader should only be done in a designated area that 5. Lubricate the following parts (see Figure 5-1 and
can contain the oil and chemicals involved in any Table 5-1).
maintenance requirement. These by-products should
a. Drawbar ball
be discarded in accordance with environmental
regulations. b. Steering rods and tie rods
Do not substitute fasteners of any kind c. Lift trunions and trunion housing
unless the fasteners are equal in size and grade as 6. Check for damaged, loose, or missing decals.
original equipment. Replace decals as required.
NOTE: When performing any routine maintenance, 7. Check lights for burned out bulbs. Replace bulbs as
such as 50, 100, 250, 500, 1000 or 2000 hours, required.
always include previous routine maintenance
hours to the higher hourly schedule. 8. Check battery cables and connections.
9. Check for loose, damaged, missing or corroded
Preparing Machine for parts. Repair or replace as required.
Maintenance 10. Check tires and wheels for low air pressure, cuts,
Before performing maintenance, perform the following bubbles, damaged rims, or missing lug bolts or nuts.
steps before leaving the operator’s seat unless the 11. Check the park brake daily to make sure it is
maintenance procedure contains additional instructions. operating properly (see Checking Park Brake on
1. Park the machine on a flat even surface. page 5-10).
2. Lower all attachments to ground level.

3-4,1) in NEUTRAL.

Maintenance
After The First 50 Hours and 250 Hour or Quarterly Routine

Weekly Routine Maintenance Maintenance
1. Lubricate the following parts (see Figure 5-1 and Do not smoke when observing battery
Table 5-1). electrolyte level. The fumes can explode. Electrolyte
a. Hydraulic cylinder ends (all) is an acid that can burn if it contacts skin or eyes. If
contact is made, flush area immediately with water.
b. Forward/neutral/reverse (FNR) pedal
1. Check battery electrolyte level (see Checking
c. Front blade pivots, moldboard pivot pins, and Battery Electrolyte Level on page 5-15). Check
axle pivot battery terminals for corrosion. Perform battery
d. Stabilizer rod ends maintenance as required (see Cleaning and
Tightening Battery Terminal Connections/
e. Turntable Terminals on page 5-14).
f. Control levers 2. Change engine oil and replace oil filter (see
Do not smoke when observing battery Changing the Engine Oil and Replacing Filter
electrolyte level. The fumes can explode. Electrolyte on page 5-17). To assure complete removal of
is an acid that can burn if it contacts skin or eyes. If contaminants in the oil, perform the oil change while
contact is made, flush area immediately with water. engine is warm.
2. Check all battery connections and remove any 3. Replace engine air filters (see Replacing Engine
corrosion that is present (see Cleaning and Air Filter Elements on page 5-24).
Tightening Battery Terminal Connections/
Terminals on page 5-14).
3. Perform 50-hour and weekly engine preventative
4.
5.
Check rear drive housing oil level and fill as required
(see Checking Rear Axle Oil Level on page 5-28).
Perform the 250-hour preventative maintenance as
5
maintenance as described in the engine operator’s described in the engine operator’s manual.
manual.
500 Hour or Semi-Annual
100 Hour or Monthly Routine
Routine Maintenance
Maintenance 1. Change fuel filters.
1. Check air filters. Clean or replace as required (see
Replacing Engine Air Filter Elements on page 2. Change hydraulic charge filter (see Changing
5-24). Hydraulic Charge Filter on page 5-26).
2. Check gearbox breathers (see Checking Gearbox 3. Check fuses and circuit breakers. Replace if
Breathers on page 5-12). Replace as required required (see Fuses And Circuit Breakers on page
5-29).
3. Check transfer case oil level and fill as required (see
Checking Transfer Case Oil Level on page 5-19). 4. Check neutral start system. Repair as required (see
Checking Neutral Start System on page 5-13).
4. Lubricate the following parts (see Figure 5-1 and
Table 5-1). 5. Adjust blade side-shift guides.
a. Articulate joint 6. Check drawbar ball and socket for damage. Repair
or replace as required (see Checking Drawbar
b. Chain box pivots Ball and Socket on page 5-11).
c. Door handles and door hinges 7. Check and adjust toe-in as required (see Checking
d. King pin bearings and Adjusting Toe-In on page 5-12).
5. Perform 100-hour or monthly engine preventative 8. Check park brake operation (see Checking Park
maintenance as described in the engine operator’s Brake on page 5-10).
manual. Hydraulic oil under pressure can
cause serious personal injury. Check for oil leaks
with a piece of cardboard. Do not expose hands to
possible high-pressure oil. Shut down engine before
attempting to tighten oil lines and fittings.

Maintenance
9. Check oil lines and fittings for leakage or damage

(see Checking Oil Lines and Fittings on page
Checks and Adjustments
5-10). Replace parts as required.
Checking Park Brake
10. Perform the 500-hour preventative maintenance as
described in the engine operator’s manual. To check park brake:
1. Park the machine on an incline.
1000 Hour or Annual Routine
2. Push park brake button (Figure 3-2,1) to apply park
Maintenance brake.
1. Clean engine ventilation tube (see Cleaning Engine 3. If brake is functioning correctly, the machine will not
Ventilation Tube (Blow-By Tube) on page 5-21). move.
2. Check engine speed (see Checking Engine Speed
on page 5-21). Checking Oil Lines and Fittings
3. Clean, pack and adjust front wheel bearings (see 1. Refer to Preparing Machine for Maintenance on
Cleaning, Packing, and Adjusting the Front Wheel page 5-8 and park machine.
Bearings on page 5-12). 2. Check the machine for indications of oil leakage
4. Check air intake hoses for damage (see Checking around oil lines, hoses, and fittings.
Air Intake Hoses on page 5-10). Replace 3. Tighten fittings as necessary. Replace hoses and
damaged parts. fittings as needed.
5. Clean and check fuel filler cap (see Checking and
Cleaning Fuel Filler Cap on page 5-23). Checking Air Intake Hoses
6. Clean and check hydraulic reservoir filler cap (see 1. Refer to Preparing Machine for Maintenance on
Checking and Cleaning Hydraulic Oil Reservoir page 5-8 and park machine.
Filler Cap on page 5-27). 2. Check air intake hoses from the engine to the air
7. Drain, flush, and fill transfer case with oil (see cleaner assembly and from the air cleaner assembly
Checking Transfer Case Oil Level on page 5-19). to the precleaner.
3. Check for cracked, dry rotted, loose, worn, or
2000 Hour Routine Maintenance damaged hoses, tubes, and clamps.
1. Drain, flush, and fill gear boxes with oil (see 4. Tighten, repair, or replace parts as needed.
Draining, Flushing, and Filling Hydraulic Oil
Reservoir on page 5-27). Checking Window Washer Fluid
2. Drain, flush, and fill rear drive housing with oil (see Reservoir Level
Checking Rear Axle Oil Level on page 5-28)
To check the washer fluid reservoir level:
3. Drain, flush, and fill hydraulic reservoir with oil (see
Draining, Flushing, and Filling Hydraulic Oil 1. Open the washer fluid reservoir access panel door
Reservoir on page 5-27). (Figure 3-1,9) located on the RH side of grader.
4. Drain, flush, and fill engine coolant system with 2. Remove the cap from the reservoir and add new
coolant. washer fluid.
3. Replace the cap.
4. Close the access panel door.
NOTE: During the cold season, make sure there is
freeze-protected washer fluid in the reservoir.

Maintenance
Checking the Drive Belt Checking and Adjusting Moldboard

Belt drive systems equipped with automatic (spring) Blade Side-Shift Assembly
belt tensioners cannot be adjusted or repaired. The
1. Lower the moldboard (Figure 5-3,1) to rest lightly
automatic belt tensioner is designed to maintain proper
on ground.
belt tension over the life of the belt. If tensioner spring
tension is not within specifications, replace tensioner
assembly.
NOTE: Refer to the engine manufacturer’s operation
and maintenance manual for information on
checking tensioner spring and for additional
information on checking and adjusting drive
belts. 1
1. Refer to Preparing Machine for Maintenance on Figure 5-3. Moldboard
page 5-8 and park machine.
1 - Moldboard
2. Inspect the belt frequently and replace the belt if
stretched, cracked, or dry rotted (refer to Figure 2. Raise and lower blade slightly to check guide
7-29). tightness. Blade should slide easily.
3. Check belt tension (Figure 5-2,1). See the engine 3. Remove the upper and lower clamps (Figure
manufacturer’s operation and maintenance manual 7-13,11,12).
5
for tension specifications. 4. Add or remove shims as needed.
5. Install clamps.
Checking Drawbar Ball and

Socket
1. Lower moldboard (Figure 5-3,1) to ground.
2. Check the drawbar and socket assembly for wear
and damage (Figure 5-4,2).
3. Move moldboard lift cylinders (Figure 5-4,1; see
also Figure 5-44,1) without load. Ball should move
freely.
1 4. Check for excessive movement in ball and socket.
Figure 5-2. Fan Belt Tension Check

1 - Belt Tension
4. If belt is not within specifications, replace the belt.
1
2
Figure 5-4. Moldboard Lift Cylinder
1 - Moldboard Lift Cylinder (2 Total, RH Shown)
2 - Drawbar and Socket
5. Add or remove shims as necessary.
Maintenance
Checking and Adjusting Toe-In Cleaning, Packing, and Adjusting

1. Park machine on a flat, even surface. the Front Wheel Bearings
2. Straighten front wheels to vertical position. NOTE: Refer to Figure 7-5 for an illustration of the front
wheel and bearing assembly.
3. Lower moldboard enough to raise front wheels
slightly. 1. Refer to Preparing Machine for Maintenance on
4. Block front axle.
2. Raise and block machine.
5. Allow engine to run at 1/2 speed (RPM) for 3 to 5
minutes. 3. Remove the grease dust cap (Figure 7-1,23) from
the center of the wheel hub.
6. Reduce engine speed to slow idle.
4. Remove lock nuts (Figure 7-7,21) and locking
washer (Figure 7-7,22).
3-4,1) in NEUTRAL (center position).
5. Remove flat washer (Figure 7-7,20) and outer cone
bearing (Figure 7-7,19).
park brake.
6. Pull the wheel hub (Figure 7-7,16), with inner
9. Turn ignition switch key (Figure 3-2,1)
bearing and seal, off the axle spindle (Figure 7-7,
counterclockwise (CCW) to the OFF position.
2,3) assembly.
10. Mark the center of the tire tread front and rear left
7. Remove the seal (Figure 7-7,18) from the hub.
and right tires.
8. Remove the inner bearing (Figure 7-7,17) from the
11. Measure distance between marks on the front of
hub.
tires.
12. Measure distance between marks on rear of tires. Wear eye protection and chemical
resistant gloves when using solvent for cleaning
13. If distance between front tire marks and rear tire purposes. Some solvent can cause skin irritation and
marks is more or less than 1/8 inch (3.2 mm), loosen eye damage.
the tie rod jam nuts. Turn the tie rod center tube to
adjust toe-in to 1/8 inch (3.2 mm). Tighten jam nuts. Wear eye protection when using
compressed air for drying or cleaning components.
14. Turn wheels completely left and right and check Never point the nozzle at another individual. Use
for binding or obstruction. Repair or adjust as a safety reduction valve to reduce air pressure to
necessary. a safe level. Compressed air can cause serious
personal injury if misused.
Checking Gearbox Breathers
9. Using solvent, thoroughly clean the wheel hub
1. Check the gearbox breathers mounted on each (Figure 7-7,16), bearings (Figure 7-7,17,19), cap
side of the engine compartment for dirt. (Figure 7-7,23), and mounting hardware. Dry using
compressed air.
10. Inspect the wheel bearings and cups for pitting,
scoring, wear, and damage. Inspect bearing for
loose or damaged cage. Replace as necessary.
11. Using clean wheel bearing grease, pack the
Figure 5-5. Gearbox Breather bearings. Apply grease to the inner hub and cup
2. If clogged with dirt, clean or replace as necessary. areas.
12. Place the inner bearing in the inner cup. Carefully
install seal over inner bearing.
13. Install hub over spindle and insert outer bearing.
Secure bearing with flat washer and one mounting
nut.

Maintenance
14. Refer to Preparing Machine for Maintenance on When servicing batteries, always
page 5-8 and install tire and wheel assembly. disconnect the negative (-) (ground) cable first and
Using all precautions, inflate tire to 40 PSI. connect it last. Generally, if the negative cable is
15. Tighten mounting nut while rotating wheel assembly. grounded during removal, sparks will not occur. If the
When wheel becomes hard to turn, back nut off 1/6 positive cable is grounded during removal, sparks
of a turn. Secure wheel with locking washer and will occur and could ignite explosive gases.
other mounting nut. NOTE: The electrical system is a negative ground
16. Install bearing cap. system. Connect the positive (+) cable to the
positive (+) post of both batteries. Connect the
17. Tighten the wheel lug nuts alternately in a star
ground (-) cable to the negative (-) post of both
pattern 360 ft. lbs. (488 N•m).
batteries.
18. Raise machine and remove blocking. Lower
NOTE: When replacing the batteries, discard the old
machine.
batteries properly.
Checking Neutral Start System Master Disconnect Switch
When servicing the electrical system
park brake.
or welding on the machine, always turn the master
2. Place forward/neutral/reverse (FNR) pedal (Figure disconnect switch (Figure 5-6) to the OFF position to
3-4,1) in the FORWARD or REVERSE position. disconnect the ground from the batteries to prevent
damage to the machine’s electrical system.
5
3. Turn ignition switch key (Figure 3-2,1) clockwise
(CW) to the START position. Starter must not crank 1. Open the starter access panel (Figure 3-1,17)
the engine. If starter cranks engine, release key. Do located on the LH side of machine to locate
not operate machine. the master disconnect switch (Figure 5-6).
4. Repeat test with the forward/neutral/reverse (FNR)
pedal (Figure 3-4,1) in the opposite direction.
Do not operate machine if starter
cranks engine with forward/neutral/reverse (FNR)
pedal in any gear except neutral. See local dealer for
neutral start system troubleshooting and repair.
3-4,1) in NEUTRAL and turn ignition switch key
(Figure 3-2,1) clockwise (CW) to the START
position. Starter should crank engine.
Battery Maintenance
Batteries contain sulfuric acid and
normally produce explosive gases that can cause
serious injury. Therefore, do not allow flames or
sparks to come near the battery.
When charging or working near a
battery, always shield your face and protect your Figure 5-6. Master Disconnect Switch
eyes. In case of acid contact with skin or eyes, flush
2. Turn the master disconnect switch (Figure 5-6)
immediately with water for a minimum of 15 minutes
counterclockwise (CCW) to the OFF position.
and get prompt medical attention.
If acid is swallowed, get medical
attention immediately.

Maintenance
Alternator Cold Weather Starting

The alternator supplies electrical current for charging Be sure to keep the battery fully
the battery and ample electrical power to the electronic charged during cold weather to keep it from freezing.
controls. The built-in regulator in the alternator controls Freezing weather has little effect on a fully charged
the voltage output. If for any reason the wires must be battery.
disconnected from the alternator, mark them so that
If a booster battery is necessary for cold weather
they can be reconnected properly.
starting:
1. Connect one end of the first jumper cable to the
positive (+) terminal of the dead battery and the
other end to the positive (+) terminal of the booster
battery.
2. Connect one end of the second jumper cable to the
negative (-) terminal of the booster battery and the
other end to the frame of the machine with the dead
battery.
Cleaning and Tightening Battery

Terminal Connections/Terminals
Be certain that the terminals and
battery posts are thoroughly cleaned and that the
battery cable terminals are tight. Dirty or loose
1 connections can create high electrical resistance
and permit arcing, which will quickly burn and pit
Figure 5-7. Alternator terminals and posts.
1 - Alternator Keep the battery clean by washing it off whenever dirt
Use the following precautions to build-up is excessive. If corrosion is present around
prevent damage to the alternator and/or regulator: terminal connections, remove them and wash with
ammonia solution or a solution consisting of 1/4 lb. (0.11
• An alternator is never to be polarized. Never kg) baking soda added to one quart of warm water.
ground any alternator terminals or circuits. Make certain the vent caps are tight to prevent solution
• Always disconnect the battery before from entering the cells. After cleaning, pour clean water
disconnecting or connecting the alternator. Never over the battery and surrounding area to wash the
disconnect the alternator with it operating. Be solution away. Check vent cap breather openings to
certain the wiring is properly connected before make sure they are open.
connecting the battery. 1. Unhook battery box locks (Figure 5-8,1) on the
• Always connect a booster battery in the proper battery compartment and remove cover (Figure
polarity [negative (-) to negative (-) and positive (+) 5-8,2).
to positive (+)]. 2. Disconnect battery clamps (Figure 5-8,3),
grounded (black) clamp first.

Maintenance
Checking Battery Electrolyte

Level
1. Unhook battery box locks (Figure 5-8,1) and
remove cover (Figure 5-8,2).
1 NOTE: If water is added to batteries during freezing
weather the battery must be charged
2 immediately to prevent freezing. Charge battery
using a battery charger or by running the
engine.
2. If using serviceable batteries, fill each cell to
3 specified range with distilled water. Do not overfill.
3. Check battery charge and charging rate.
4. Shut down machine by turning ignition switch key
(Figure 3-2,1) counterclockwise (CCW) to the OFF
position.
4 5. Using a multimeter, check the battery charge by
placing the positive (red) multimeter lead on the
positive (+) battery terminal and the negative (black)
5
Figure 5-8. 12-Volt System multimeter lead on the grounded (-) battery terminal.
With the multimeter set at the 12 VDC setting the
1 - Battery Box Lock battery must show a charge of at least 12 volts. If
2 - Battery Box Cover necessary, charge the battery or perform a load
test.
3 - Battery Clamps
6. Start the engine. With an operator in the operator’s
4 - Battery Terminals seat, check the battery charge level. The multimeter
3. Clean terminals with a stiff brush or battery service should read at least 13.5 volts. If multimeter does
tool. not indicate minimum charge, check the machine
charging system.
4. Apply grease at the base of the battery terminals
(Figure 5-8,4) to prevent gas from escaping.
5. Install and tighten battery clamps (Figure 5-8,3),
grounded (black) clamp last.
6. Attach battery box cover (Figure 5-8,2) and hook
battery box locks (Figure 5-8,1).

Maintenance
Tire Maintenance 1 2
Filling Tire with Air

Explosive separation of a tire and rim
parts can cause serious injury or death.
Never cut or weld on inflated tire/rim assembly. Heat
from welding can cause an increase in pressure and
may result in tire explosion.
NOTE: Use proper tire mounting equipment and
experienced personnel for tire repair service.
If equipment and qualified personnel are not
available, contact a qualified repair service.
NOTE: Carefully inspect any tire and rim assembly run
flat or severely under-inflated before inflating Figure 5-9. Wheel
tire. The tire and rim may have damage. Contact
the local distributor or qualified repair service to 1 - Valve Stem
inspect the tire and rim. 2 - Wheel Lug Nuts (10)
NOTE: Use an accurate gauge to check tire pressure. 4. Turn on air supply. Stand to one side of tire during
Use a gauge with 1-PSI (0.07 bar, 6.9 kPa) inflation.
graduations.
5. After proper inflation (40 PSI) release chuck or
1. Shut off air supply to air hose. stand off gauge.
2. Limit air pressure for tire inflation to proper level. 6. Inspect tire for bulges, bubbles, cracks, and other
3. Install lock on air chuck or stand off gauge on valve damage. If damaged, deflate tire immediately.
stem (Figure 5-9,1). 7. When installing the tire on the machine, tighten lug
nuts (Figure 5-9,2) alternately in a star pattern to
360 ft. lbs. (488 N•m).
Changing Tires
Explosive separation of a tire and rim
parts can cause serious injury or death.
Never cut or weld on inflated tire/rim assembly. Heat
from welding can cause an increase in pressure and
may result in tire explosion.
8. Loosen, but do not remove, the wheel lug nuts
(Figure 5-9,2).
9. Raise and block the machine.
10. Remove lug nuts (Figure 5-9,2) and tire.
11. Install replacement tire on the machine; tighten lug
nuts (Figure 5-9,2) alternately in a star pattern 360
ft. lbs. (488 N•m).

Maintenance
Engine Maintenance 1
General Information
The following engine maintenance information will cover
engine general maintenance procedures most often
required.
For additional, very specific, engine maintenance
information, see the current Cummins diesel engine
operation and maintenance manual.
Checking the Engine Lubrication

Oil Level
NOTE: The engine lubrication oil must be kept at a level
above the “ADD” mark, but not above the “FULL”
mark, on the engine lubrication oil dipstick.
Stop the engine before checking the
engine lubrication oil level. With the engine running,
hot oil can be thrown causing serious injury. Figure 5-11. Engine Oil Filler Cap Location
5
1. To accurately check the engine lubrication oil level, 1 - Engine Oil Filler Cap
put the machine in a “level” position and stop the NOTE: The above procedure will help to remove the
engine. possibility of filling the engine with too much
2. Clean the area around the engine lubrication lubrication oil, by allowing the oil to return to the
oil dipstick (Figure 5-10,1) before removing the oil pan.
dipstick from the engine.
Changing the Engine Oil and
Replacing Filter
The engine lubrication oil must be changed according to
the interval given in the current Cummins Diesel engine
“Operation and Maintenance Manual”.
NOTE: The color of the engine lubrication oil cannot be
used as an indication of the need for an engine
lubrication oil change. The use of engine lubri-
cation oil “analysis service” is the only alternate
reason for not following the required engine
lubrication oil change schedule.
1
Do not change the engine lubrication
Figure 5-10. Engine Lubrication Oil Level Dipstick oil with the engine “running”. Serious engine damage,
or failure will occur. Clean the area around the
1 - Engine Lubrication Oil Level Dipstick
engine lubrication oil dipstick and oil filler cap before
3. Wait five minutes, after engine shutdown, before removing the dipstick, or oil filler cap.
removing the dipstick (Figure 5-10,1) from the
Refer to the engine manufacturer’s operation and
engine and checking the oil level.
maintenance manual for additional information on
4. Remove the engine oil filler cap (Figure 5-11,1) and engine service. Use manufacturer’s recommendations
add oil as necessary. for engine oil and filter replacement.
NOTE: If fuel sulfur content exceeds 0.5 percent,
change engine oil at one-half normal interval.

Maintenance
1. Run engine to warm oil. 9. Tighten filter a 1/2 to 3/4 additional turn.
2. Before leaving operator’s seat, refer to Preparing 10. Remove engine oil filler cap (Figure 5-14,1). Fill
Machine for Maintenance on page 5-8 and park engine with oil (approximately 11.6 quarts [10.9 L]).
the machine. Install filler cap.
3. Remove the oil pan drain plug (Figure 5-12,1) 1
located underneath the machine the and drain oil
into a suitable container. Dispose of oil properly.
Figure 5-12. Oil Pan Drain Plug Location

1 - Oil Pan Drain Plug
4. Clean area surrounding filter and filter head.
Figure 5-14. Engine Oil Filler Cap Location

1 - Engine Oil Filler Cap
NOTE: Before starting engine after a filter change,
disconnect fuel shut-off solenoid wire and crank
engine for 10 seconds to fill filter element and
pre-lube turbocharger if equipped.
11. Turn ignition switch key (Figure 3-2,1) clockwise
(CW) to the ON position. If maintenance must
be performed with engine running, do not leave
machine unattended.
12. Run engine at slow idle.
1 13. Check filter for leaks. Tighten or replace to stop
leaks.
Figure 5-13. Engine Oil Filter
5. Turn filter (Figure 5-13) counterclockwise (CCW) to (Figure 3-2,1) counterclockwise (CCW) to the OFF
remove filter. Clean mounting surface. position. Check oil level. Add oil as needed.
6. Fill replacement filter with clean engine oil.
7. Apply clean engine oil lightly to replacement filter
seal.
8. Install new filter. Turn filter clockwise (CW) until
gasket contacts mounting surface.

Maintenance
Transfer Case Oil Radiator and Coolant

Checking Transfer Case Oil System
Level Checking Radiator and Coolant
Remove the transfer case fill plug (Figure 5-15,1). Level
The transfer case is full when oil runs from the fill plug
opening. Add oil as necessary. Check the coolant freeze protection
level before the start of cold weather. Check with
Draining, Flushing, and Filling the local authorized dealer for information of freeze
Transfer Case protection.
1. Refer to Preparing Machine for Maintenance on Hot engine coolant can cause serious
page 5-8 and park the machine. personal injury. Shut off engine. Remove radiator
filler cap when cool enough to touch with bare
2. Allow the transfer case to cool. Remove the transfer
hands. Slowly loosen filler cap to first stop to relieve
case oil drain plug (Figure 5-15,2) and drain oil into
pressure before removing cap completely.
a suitable container. Dispose of oil properly.
1. Refer to Preparing Machine for Maintenance on
3. Remove the transfer case oil level/fill plug (Figure
page 5-8 and park the machine.
5-15,1).
2. Shut down engine and allow radiator to cool.
5
3. Open the engine access panel door (Figure 3-1,2)
located on LH side of machine.
4. Check coolant level in radiator recovery reservoir
(Figure 5-16,1).
1 3
2
Figure 5-15. Transfer Case
1 - Transfer Case Oil Level/Fill Plug
2 - Transfer Case Oil Drain Plug
Wear eye protection and chemical
resistant gloves when using solvent for cleaning
purposes. Some solvents can cause skin irritation
and eye damage. 1
4. Flush the transfer case with solvent and drain Figure 5-16. Radiator Recovery Reservoir
completely. 1 - Radiator Recovery Reservoir
5. Install drain plug and fill with oil until oil flows from the 2 - Cold Level
oil level/fill plug opening (Figure 5-15,1).
3 - Hot Level
6. Install oil level plug.
5. Add coolant to the reservoir, as needed, to the cold
7. Start engine and check operation. level (Figure 5-16,2) when the engine is cold and to
the hot level (Figure 5-16,3) when the engine is hot.

Maintenance
Draining, Flushing, and Filling Engine

Coolant System
See the engine manufacturer’s operation and
maintenance manual for information on draining
and replacing engine coolant, coolant levels, and
coolant specifications. Use engine manufacturer’s
recommendations for coolant service.
The motor grader is filled with a 50/50 mixture of
antifreeze and water at the factory with protection to
-34°F (-37°C). Some geographical areas may require
special antifreeze or coolant practices. Contact the local
authorized dealer for additional information.
page 5-8 and park the machine.
(Figure 3-2,1) counterclockwise (CCW) to the OFF
position.
3. Inspect radiator for leaks, dents, cracks and Figure 5-17. Radiator Petcock
damaged cooling fins. Repair or replace as 1 - Radiator Petcock
necessary.
5. Open engine block drain plugs1(see engine
Hot engine coolant causes severe manufacturer’s Operation and Maintenance
burns. Shut engine off and allow radiator to cool manual). Drain coolant into a drain pan or suitable
to touch before removing the radiator cap. After container.
cooling, slowly turn the cap to the first stop to relieve
6. Using a good quality coolant system flush product,
pressure before removing cap completely.
flush the cooling system using the product
Dispose of used coolant properly. directions.
Check with local environmental officials for 7. Close radiator petcock (Figure 5-17,1) and engine
information of disposal procedures. Coolant block drains plugs.
is extremely poisonous and will cause death if
ingested. 8. Fill radiator to full level with 50/50 mixture of
antifreeze and water.
4. Center a drain pan or suitable container underneath
the radiator petcock (Figure 5-17,1), open radiator NOTE: Contact the local authorized dealer for
petcock and drain coolant into container. Dispose of information on local coolant protection levels.
coolant properly. 9. Inspect radiator cap (Figure 5-18,1) for wear and
damage. Perform pressure/temperature test if
necessary.

Maintenance
1 Cleaning Engine Ventilation

Tube (Blow-By Tube)
engine service. Use manufacturer’s recommendations
for engine ventilation tube cleaning.
Checking Engine Speed

engine service. Use manufacturer’s recommendations
for engine speed and adjustments.
Fuel System
Draining Fuel Tank Sump
Diesel fuel is highly flammable. Keep
all sparks and flames away when draining fuel. Do
not smoke when filling fuel tank or working on fuel
5
system.
Figure 5-18. Radiator Cap 1. Remove fuel tank filler cap (Figure 5-19,1).
1 - Radiator Cap
10. Leave the radiator cap (Figure 5-18,1) off, start
engine and run for 15 to 30 minutes to purge air from
the engine block. Once the coolant heats up, the
air will exit the radiator and after all air is removed,
there should be more room for coolant.
11. Check radiator recovery reservoir (Figure 5-16,1)
and fill as necessary radiator recovery reservoir.
12. Check for leaks after adding new coolant. This can
be done by removing drain pan or suitable container
from underneath the vehicle and checking for any
coolant dripping from the radiator.
13. Check radiator recovery reservoir (Figure 5-16,1) 1
frequently for proper coolant level.
Figure 5-19. Diesel Fuel Tank Filler Cap
1 - Diesel Fuel Tank Filler Cap

Maintenance
2. Remove fuel tank drain plug (Figure 5-20,1).
Figure 5-20. Fuel Tank Drain Plug Location

1 - Fuel Tank 2
2 - Fuel Tank Drain Plug

3. Allow water and sediment to drain from fuel tank into
a suitable container. Dispose of fuel properly. 1
4. Install drain plug (Figure 5-20,1).
Figure 5-21. Fuel Filter Location
Changing Engine Fuel Filters
1 - Fuel Filter
2 - Priming Plunger
engine service. Use manufacturer’s recommendations 5. Turn the fuel filter (Figure 5-21,1) counterclockwise
for engine fuel filter replacement and bleeding the fuel (CCW) to remove. Clean the mounting surface
system. and remove any loose filter seals in the filter head-
mounting surface.
page 5-8 and park the machine. 6. Fill the replacement fuel filter with clean diesel fuel.
2. Allow the engine to cool completely. 7. Lightly lubricate the fuel filter seal with clean engine
oil. Turn the filter clockwise (CW) until seal contacts
Diesel fuel is highly explosive. Do not filter head. Tighten filter 1/2 to 3/4 additional turn.
expose fuel to sparks or flames. Do not smoke while
performing maintenance on the engine fuel system. 8. Using the priming plunger (Figure 5-21,2) and
instructions in the engine manufacturer’s operation
3. Thoroughly clean and dry the area surrounding the and maintenance manual, fill the filter with fuel and
fuel filter. bleed the fuel system.
4. Open the engine access panel door (Figure 3-1,2) 9. Start engine and check for leaks.
located on the right hand side of machine.
10. Tighten or replace filter as necessary.

Maintenance
Checking and Cleaning Fuel Checking Engine Air Cleaner

Filler Cap Assembly
Wear eye protection and chemical NOTE: Do not open the air cleaner assembly unless
resistant gloves when using solvent for cleaning the air filter restriction indicator (Figure 5-23,1)
purposes. Some solvent can cause skin irritation and indicates an air filter restriction or engine opera-
eye damage. tion indicates possible air filter restriction.
Wear eye protection when using compressed air 1
for drying or cleaning components. Never point
the nozzle at another individual. Use a safety
reduction valve to reduce air pressure to a safe level.
Compressed air can cause serious personal injury if
misused.
Figure 5-23. Air Cleaner Indicator Location

1 - Air Cleaner Restriction Indicator
5
1. Check the air cleaner restriction indicator (Figure
1 5-23,1). The air filter element requires changing
when the clear air cleaner restriction indicator
window turns red (Figure 5-24,1).
Figure 5-22. Diesel Fuel Tank Filler Cap
1 - Diesel Fuel Tank Filler Cap
1
1. Open engine access panel door (Figure 3-1,1)
located on RH side of machine.
2. Remove diesel fuel tank filler cap (Figure 5-22,1)
and inspect for damage. Check cap for dirt and
clogging.
3. Using solvent, clean diesel fuel tank filler
cap (Figure 5-22,1) thoroughly and dry with Figure 5-24. Air Cleaner Restriction Indicator
compressed air. 1 - Air Cleaner Restriction Indicator Window
4. Check diesel fuel filler cap (Figure 5-22,1) for free 2. Replace the air filter element, if necessary.
air flow. Replace as necessary.
3. Reset the air cleaner restriction indicator (Figure
5. Install diesel fuel tank filler cap (Figure 5-22,1). 5-23,1) by pushing button on top.
6. Close the engine access panel door (Figure 3-1,1).

Maintenance
Replacing Engine Air Filter

Elements
NOTE: Do not open the air cleaner assembly unless
the air filter restriction indicator (Figure 5-23,1)
indicates an air filter restriction or engine opera-
tion indicates possible air filter restriction.
2. Allow engine to cool. 1
3. Thoroughly clean air cleaner assembly.
4. Loosen air filter access clamp (Figure 5-25,2) on
the air cleaner cover (Figure 5-25,1) and remove
the filter element.
Figure 5-26. Air Filter Element

1 - Air Filter Element
6. Slide air filter element (Figure 5-26,1) out of
canister.
7. Clean the inside of the air filter element canister. Dry
using lint-free cloth.
8. Inspect hose clamps and tighten as necessary.
1
9. Install new air filter element.
10. Install air cleaner cover (Figure 5-25,1) and secure
with air filter access clamp (Figure 5-25,2).
11. Reset air cleaner restriction indicator (Figure
5-23,1) by pushing the button on top.
2
Figure 5-25. Air Cleaner Assembly

1 - Air Cleaner Cover
2 - Air Filter Access Clamp
5. Set the engine air cleaner canister cover (Figure
5-25,1) aside, exposing the air filter element (Figure
5-26,1).

Maintenance
Hydraulic System
Checking Hydraulic Oil Level
NOTE: With all attachments at ground level, roll the
moldboard back. Front wheels must be straight
up and machine-aligned front to rear.
2. Make sure all cylinders are retracted.
3. Wait ten minutes for oil to drain after engine has
been shut down.
4. Check hydraulic oil level. Oil level is determined by
sight gauge located on LH side of machine. The
hydraulic oil level should be in the upper half of the 1
sight gauge but never above the upper black fill line
(Figure 5-27,1).
80
70
60
180
160
140
5
50 120
40
100
30
80
20
60
10
0 40
-10 20
Figure 5-28. Hydraulic Oil Filler Cap
°C °F
1 - Hydraulic Oil Filler Cap
6. Fill the tank to the black fill line (Figure 5-27,1).
7. DO NOT OVERFILL THE TANK. Leave
approximately 1 in. (25 mm) of space for expansion
of hot oil.
8. Screw the hydraulic oil filler cap (Figure 5-28,1)
back on the hydraulic tank opening.
Figure 5-27. Hydraulic Oil Level Sight Gauge 9. Clean any spilled oil with a clean cloth.
1 - Fill Line
5. If necessary, remove hydraulic oil filler cap (Figure
5-28,1) to add hydraulic oil to the tank. (See Table
2-11. Fuel and Lubricant Specifications on page
2-14 for hydraulic oil requirements.) The cap is
located on top of the machine directly above the
hydraulic oil level sight gauge.

Maintenance
Changing Hydraulic Charge

Filter
Burn Injury Hazard! Hot hydraulic
oil can burn upon contact with the skin. Change
hydraulic charge filter while system is warm, not hot.
Avoid contact with hot hydraulic oil. Failure to obey
this warning could result in serious injury.
2. Allow the engine to cool completely.
3. Open the hydraulic supply line gate valves access
panel (Figure 3-1,21).
4. Close the hydraulic oil reservoir supply line gate
valves by turning valve handles (Figure 5-29,1)
1
Figure 5-29. Supply Line Gate Valves

1 - Supply Line Gate Valve Handles Figure 5-30. Hydraulic Filter
5. Open the engine access panel door (Figure 3-1,2) 7. Turn the filter (Figure 5-30) counterclockwise
located on RH side of machine. (CCW) to remove. Clean the mounting surface
and remove any loose filter seals in the filter head
6. Thoroughly clean the hydraulic filter and filter head
mounting surface.
(Figure 5-30).
8. To install the new filter, turn it clockwise (CW) until
the seal contacts the mounting surface. Tighten the
filter 1/2 to 3/4 additional turn.
9. Open hydraulic reservoir supply line gate valves
(Figure 5-29,1) by turning valve handles clockwise
(CW).
Equipment Damage Hazard! Open
hydraulic reservoir supply line gate valves before
starting engine to prevent pump and drive motor
damage or failure.
10. Start engine and check for leaks. Tighten or replace
filter as necessary.

Maintenance
Checking and Cleaning Hydraulic 2. Using solvent, clean hydraulic oil reservoir filler
cap (Figure 5-31,1) thoroughly and dry with
Oil Reservoir Filler Cap compressed air.
Wear eye protection and chemical 3. Check hydraulic oil reservoir filler cap (Figure
resistant gloves when using solvent for cleaning 5-31,1) for free air flow. Replace as necessary.
purposes. Some solvent can cause skin irritation and
4. Install hydraulic oil reservoir filler cap (Figure
eye damage.
5-31,1) by turning clockwise (CW).
Wear eye protection when using compressed air
for drying or cleaning components. Never point Draining, Flushing, and Filling
the nozzle at another individual. Use a safety Hydraulic Oil Reservoir
reduction valve to reduce air pressure to a safe level.
Compressed air can cause serious personal injury if 1. Refer to Preparing Machine for Maintenance on
misused. page 5-8 and park machine.
1. Remove hydraulic oil reservoir filler cap (Figure 2. Close the hydraulic tank supply line gate
5-31,1) by turning counterclockwise (CCW) and valves by turning valve handles (Figure 5-29,1)
inspect for damage. Check cap for dirt and clogging. counterclockwise (CCW).
3. Remove hydraulic oil reservoir filler cap (Figure
5-31,1).
4. Remove drain plug and drain the hydraulic oil into a
5
suitable container. Dispose of oil properly.
5. Flush hydraulic reservoir completely.
6. Install drain plug.
7. Replace the charge filter.
8. Fill hydraulic oil reservoir to proper level.
9. Install filler cap.
10. Open reservoir gate valves (Figure 5-29,1).
hydraulic tank gate valves before starting engine to
1 prevent pump and drive motor failure.
11. Start engine and operate hydraulic control levers
several times. Check hydraulic oil sight gauge and
fill as necessary.
Figure 5-31. Hydraulic Oil Reservoir Filler Cap

1 - Hydraulic Oil Reservoir Filler Cap

Maintenance
Rear Drive Housing Electrical System

Checking Rear Axle Oil Level When servicing the electrical system,
always remove the ground cable from the battery
1. Refer to Preparing Machine for Maintenance on first, followed by the positive cable. Generally, if the
page 5-8 and park machine. negative cable is grounded during removal, sparks
2. Remove differential fill plug (Figure 5-32,1). Oil will not occur. If the positive is grounded during
level is correct if oil runs from oil level plug (Figure removal, sparks will occur and could ignite explosive
5-32,2). Add oil as needed. gases.
When batteries are connected, follow these rules:
1. Disconnect negative (-) battery cable when working
on or near the alternator.
2. Do not attempt to polarize alternator.
3. Make sure alternator wires are correctly connected
before connecting battery terminals.
4. Do not ground alternator output terminal.
5. Do not disconnect or connect alternator wires
while batteries are connected or while alternator is
operating.
6. Connect batteries or booster battery in the correct
polarity [positive (+) to positive (+), negative (-) to
negative (-)].
7. Do not disconnect batteries when engine is running
and alternator is charging.
2 1 8. Disconnect battery cables before connecting
battery charger to batteries. Charge batteries
Figure 5-32. Rear Drive Housing separately.
1 - Differential Fill Plug
2 - Oil Level Plug

Maintenance
Fuses And Circuit Breakers

The fuse block is mounted inside the instrument control
panel to the left of the operator’s seat. The blade-type
fuse color codes are listed in (Table 5-2). See (Figure
5-33) for the fuse block schematic. Circuit breakers are
mounted on the back of the ignition control panel.
Replace fuses and circuit breakers
with correct amperage to prevent damage from
system overload.
When a circuit breaker opens due to short circuit or
overloading, turn off lights and place ignition switch
in the OFF position. Wait one minute before starting
machine or turning on lights. The circuit breaker will
automatically reset. If the circuit breaker continues to
trip (open), check the electrical system for short circuits
and defective components. Replace the circuit breaker
as necessary.
Table 5-2. Blade Type Fuse Color Codes
AMPERAGE RATING COLOR
1
3
4
Black
Violet
Pink
Figure 5-33. Fuse Block Schematic
5
5 Tan
7 1/2 Brown
10 Red
15 Light blue
20 Yellow
25 Natural (White)
30 Light Green

Maintenance
Component Replacement When servicing batteries, always

remove the ground (black)cable first followed by the
Procedures positive (red) cable. Generally, if the negative cable
General Information is grounded during removal, sparks will not occur.
If the positive cable is grounded during removal,
This section provides instructions for replacing motor sparks will occur and could ignite explosive gases.
grader components during maintenance.
2. Remove the ground (-) (black) cable (Figure
The following instructions can be used in conjunction 5-34,6) from the negative (-) battery terminal
with the illustrations in the (IPL) illustrated Part List to (Figure 5-34,7) followed by the positive (+) (red)
remove and replace motor grader components. cable (Figure 5-34,4) from the positive (+) battery
NOTE: Make sure the motor grader is parked correctly terminal (Figure 5-34,5).
before performing the replacement procedures. 3. Remove the hold down bar (Figure 5-34,3).
Refer to instructions in Preparing Machine for
Maintenance on page 5-8. 4. Inspect the batteries for cracks, wear and damage
that could result in leaks.
Replacing Batteries 5. Carefully remove the batteries from the battery plate.
Removal Take note of the battery position during removal.
Batteries create explosive gases when Do not dry batteries using compressed
charging. Do not expose these gases to sparks or pressed air. Allow the batteries and surrounding
open flame during maintenance. Always perform area to air dry. Battery acid can cause severe injury if
battery service in a well-ventilated area or outside. blown into the face or other areas of the body. If injury
Serious injury can occur from exploding batteries. occurs, seek medical attention immediately. Flush
eyes and skin for 30 minutes with clean fresh water.
1. Unhook battery box locks (Figure 5-34,1) on the
battery compartment and remove cover (Figure 6. Make sure the battery cells are sealed and clean
5-34,2). the batteries, battery tray, cables, and brackets with
baking soda and warm water. Allow to air dry.
Installation
1. Place the batteries in proper position in the battery tray.
1 2. Install hold down bar (Figure 5-34,3). Tighten bar to
retain battery but not so tight as to damage battery.
2 When installing batteries, always

install the positive cable first followed by the
negative cable. Reversed polarity can damage the
electrical system.
5 4
3. Install positive (+) (red) battery cable (Figure
5-34,4) to positive (+) battery terminal (Figure
5-34,5).
6 4. Install negative (-) (black) battery cable (Figure
3
7 5-34,6) to negative (-) battery terminal (Figure
5-34,7).
Figure 5-34. 12-Volt System 5. Attach battery box cover (Figure 5-34,2) and hook
battery box locks (Figure 5-34,1).
1 - Battery Box Lock
2 - Battery Box Cover
3 - Hold Down Bar
4 - Positive (+) Cables
5 - Positive (+) Terminals
6 - Negative (-) Cables
7 - Negative (-) Terminals
Maintenance
Replacing Scarifier Tooth Shank Replacing Scarifier Tooth

Removal Removal
Wear eye protection when using a 1. Raise and support the scarifier frame (Figure
hammer on metal structures to prevent damage from 5-35,1).
flying metallic objects. Flying metallic objects can
Wear eye protection when using a
cause serious eye injuries.
hammer on metal structures to prevent damage from
1. Raise and support the scarifier frame (Figure flying metallic objects. Flying metallic objects can
5-35,1). cause serious eye injuries.
2. Using a pry bar or lock pin tool, remove the scarifier 2. Refer to Replacing Scarifier Tooth Shank and
shank lock pin (Figure 5-35,2) from between the remove the scarifier tooth shank (Figure 5-35,3)
scarifier support (Figure 5-35,5) and the scarifier from the scarifier support (Figure 5-35,5).
tooth shank (Figure 5-35,3).
3. While supporting the scarifier tooth shank (Figure
5-35,3), drive the scarifier tooth (Figure 5-35,4)
from the scarifier tooth shank (Figure 5-35,3).
Installation
1. While supporting the scarifier tooth shank (Figure
5-35,3), drive the new scarifier tooth on the scarifier
5
tooth shank (Figure 5-35,3).
5 2. Refer to Replacing Scarifier Tooth Shank and
install the scarifier tooth shank in the scarifier
3 support (Figure 5-35,1) .
4
1 2
Figure 5-35. Scarifier

1 - Scarifier Frame
2 -Scarifier Shank Lock Pin (5 Total)
3 - Scarifier Tooth Shank (5 Total)
4 - Scarifier Tooth (5 Total)
5 - Scarifier Support
3. Remove the scarifier tooth shank (Figure 5-35,3)
from the scarifier support (Figure 5-35,5).
Installation
1. Position the new tooth shank in the scarifier support
(Figure 5-35,5) in the desired position.
2. Secure with the scarifier shank lock pin (Figure
5-35,5).

Maintenance
Replacing Articulate Cylinders 2. Tag and disconnect hydraulic hoses from the
articulate cylinder. Immediately plug the hoses and
Removal cylinder to prevent contamination of the hydraulic
system.
1. Thoroughly clean the articulate cylinder (Figure
5-36,1), especially in the area surrounding the 3. While supporting the articulate cylinder, remove the
hydraulic hoses and fittings. pins from the end yokes.
4. Remove the articulate cylinder (Figure 5-36,1).
5. Inspect the hydraulic fittings. Replace if necessary.
Remove fittings for reuse on replacement articulate
cylinder.
Installation
1. Install hydraulic fittings on replacement articulate
cylinder (Figure 5-36,1).
2. Position the articulate cylinder (Figure 5-36,1) on
the frame mounts and install pins through the end
yokes. Secure the pins with new cotter pins.
3. Using tags created during removal, remove plugs
and connect the hydraulic hoses to the articulate
cylinder fittings.
4. Using a grease gun, lubricate articulate cylinder
1 (Figure 5-36,1) swivel joints.
2 5. Start the motor grader and check operation. Repair
3 leaks as necessary.
Figure 5-36. Articulate Cylinder

1 - Articulate Cylinder
2 - Clevis Pin
3 - Cotter Pin

Maintenance
Replacing Wheel Steering Installation

Cylinder 1. Install end connectors on the new steering cylinder
using the same number of turns noted during
Removal removal.
1. Thoroughly clean the wheel steering cylinder 2. Install hydraulic fittings on replacement fittings.
(Figure 5-37,1), especially in the area surrounding
3. Position the steering cylinder for installation on
the hydraulic hoses and fittings.
the frame mounts. Adjust the end connectors to
mate with the frame and position the cylinder for
hose installation. Secure the end connectors by
tightening the end connector jam nuts.
4. Install the end connector mounting nuts, pulling the
ball joints through the mount and securing cylinder
installation.
5. Using tags created during removal, remove plugs
and connect steering cylinder hydraulic hoses.
6. Using a grease gun, lubricate cylinder swivel joints.
7. Start motor grader and check operation. Repair
1 leaks as necessary.
Figure 5-37. Wheel Steering Cylinder

1 - Wheel Steering Cylinder (2 Total; LH Shown)
5
2. Tag and disconnect the hydraulic hoses.
Immediately plug the hoses and cylinder ports to
prevent contamination of the hydraulic system.
3. While supporting the wheel steering cylinder,
remove the end connector mounting nuts and
washers (refer to Figure 7-7).
4. While supporting the wheel steering cylinder
(Figure 5-37,1), use a ball joint removal tool to
remove the end connectors from the frame mounts
(Figure 7-7,7,8).
5. Inspect the end connectors for excessive wear,
loose ball joints, and damage.
NOTE: When removing the end connectors, count the
number of turns needed for removal. The end
connector or replacement can be threaded into
the new steering cylinder the same number of
turns, providing a close match for mounting the
cylinder (Figure 7-3,7,8).
6. Loosen the jam nuts and remove the end
connectors from the rod and cylinder ends. Count
the number of turns needed to remove the end
connector.
Remove fittings for reuse on replacement cylinder.

Maintenance
Replacing Wheel Lean Cylinder Installation

NOTE: Refer to Figure 7-7 on page 7-18 and Figure 1. Install hydraulic fittings on replacement wheel lean
cylinder.
7-8 on page 7-22 for illustrated parts list.
Removal 2. Place the new or rebuilt wheel lean cylinder in
position between the front axle spindle and the
NOTE: Before shutting down the engine, make sure the front axle support. Secure with mounting pins and
wheel lean cylinder is retracted. washers. Install new cotter pins in the mounting pins.
1. Thoroughly clean the wheel lean cylinder (Figure 3. Using tags created during removal, install hydraulic
5-38,1), especially in the area surrounding the hoses on the wheel lean cylinder fittings.
hydraulic hoses and fittings.
4. Using a grease gun, lubricate wheel lean cylinder
swivel joints.
5. Remove supports and lower machine.
6. Start motor grader and check operation. Repair
leaks as necessary.
Figure 5-38. Wheel Lean

1 - Wheel Lean Cylinder
3. Raise front of machine enough to tilt axle to remove
inside pin.
4. Support front of machine with approved jack stands.
5. While supporting the wheel lean cylinder (Figure
5-38,1), remove cotter pins, washers, and mounting
pins from the wheel lean cylinder.
6. Remove the wheel lean cylinder (Figure 5-38,1).
Remove the fittings for reuse on the replacement
cylinder.

Maintenance
Replacing Front Blade Lift Replacing Scarifier Lift Cylinder

Cylinder NOTE: Refer to Figure 7-16 on page 7-40 for
NOTE: Refer to Figure 7-15 on page 7-38 for illustrated parts list. .
illustrated parts list. Removal
Removal 1. Thoroughly clean the scarifier lift cylinder (Figure
1. Thoroughly clean the front blade lift cylinder (Figure 5-40,1), especially in the area surrounding the
5-39,1), especially in the area surrounding the hydraulic hoses and fittings.
hydraulic hoses and fittings.
5
1
Figure 5-39. Front Blade 1
1 - Front Blade Lift Cylinder Figure 5-40. Scarifier
2. Support the bottom portion of the blade to prevent 1 - Scarifier Lift Cylinder
the blade from falling.
3. Tag and disconnect the hydraulic hoses. Immediately plug the hoses and cylinder ports to
Immediately plug the hoses and cylinder ports to prevent contamination of the hydraulic system.
3. Either support or lower the scarifier.
4. While supporting the front blade lift cylinder, remove
4. While supporting the scarifier lift cylinder, remove
the bolts and nuts.
the bolts and nuts (refer to Figure 7-16).
5. Remove the front blade lift cylinder (Figure 5-39,1).
5. Remove the scarifier lift cylinders (Figure 5-40,1).
6. Inspect the hydraulic fittings. Replace as necessary.
Remove the fittings for reuse in the replacement
cylinder.
cylinder.
Installation Installation
1. Install the fittings on the replacement cylinder.
1. Install the fittings on the replacement cylinder.
2. Position the new front blade lift cylinder between the
upper frame mounting and lower front blade mount. 2. Position the scarifier lift cylinder between the upper
Secure the cylinder with mounting pins. frame mounting and scarifier support frame mount.
Secure the cylinder with bolts and nuts.
3. Install new cotter pins.
3. Using tags created during removal, connect the
4. Using tags created during removal, connect the hydraulic hoses to the fittings.
hydraulic hoses to the fittings.
4. Using a grease gun, lubricate scarifier lift cylinder
5. Using a grease gun, lubricate cylinder swivel joints. swivel joints.
6. Start the motor grader and check operation. Repair 5. Start the motor grader and check operation. Repair
leaks as necessary. leaks as necessary.

Maintenance
Replacing Moldboard Slide Installation

Cylinder 1. Install the fittings on the replacement cylinder.
NOTE: Refer to Figure 7-16 on page 7-40 for 2. Position the moldboard slide cylinder between the
illustrated parts list. moldboard support frame mount and moldboard
mount. Secure the cylinder with inside mounting pin.
Removal
3. Install flat washers and new cotter pins.
1. Extend moldboard slide cylinder (Figure 5-41,1).
5. Start motor grader and extend moldboard slide
cylinder. Install outer mounting pin.
7. Start the motor grader and check operation. Repair
leaks as necessary.
1
1- Moldboard Slide Cylinder
2. Remove outer moldboard slide cylinder pin.
3. Retract moldboard slide cylinder before shutting
down engine.
4. Thoroughly clean the moldboard slide cylinder,
especially in the area surrounding the hydraulic
hoses and fittings.
6. While supporting the moldboard slide cylinder,
remove the bolts and nuts .
7. Remove the moldboard slide cylinder (Figure 5-41,1).
cylinder.

Maintenance
Replacing Moldboard Tilt Replacing Moldboard Angle

Cylinders Cylinders
NOTE: Refer to Figure 7-12 on page 7-32 for NOTE: Refer to Figure 7-10 on page 7-28 for
illustrated parts list. illustrated parts list.
NOTE: With moldboard on the ground, extend the tilt NOTE: With moldboard on the ground, center angle
cylinder before shutting down the engine. cylinders before shutting down the engine.
Removal Removal
1. Thoroughly clean the moldboard tilt cylinder (Figure 1. Thoroughly clean the moldboard angle cylinder
5-42,1), especially in the area surrounding the (Figure 5-43,1), especially in the area surrounding
hydraulic hoses and fittings. the hydraulic hoses and fittings.
5
1
Figure 5-43. Moldboard Angle Cylinder
1 - Moldboard Angle Cylinder
1- Moldboard Tilt Cylinder
3. While supporting the moldboard angle cylinder,
3. While supporting the moldboard tilt cylinder, remove
remove the cotter pins, flat washers, and mounting
the cotter pins, flat washers, and mounting pins.
pins.
4. Remove the moldboard tilt cylinder (Figure 5-42,1).
4. Remove the moldboard angle cylinder (Figure
5. Inspect the hydraulic fittings. Replace as necessary. 5-43,1).
cylinder.
Installation cylinder.
1. Install the fittings on the replacement cylinder. Installation

2. Position the moldboard tilt cylinder between the 1. Install fittings on the replacement moldboard angle
moldboard support frame mount and turntable cylinder.
support frame mount. Secure the cylinder with
2. Position the angle cylinder between the drawbar
mounting pins.
mount and turntable mount. Secure the moldboard
3. Install flat washers and new cotter pins. angle cylinder with mounting pins.
4. Using tags created during removal, connect the 3. Install flat washers and new cotter pins.
5. Using a grease gun, lubricate cylinder swivel joints. hydraulic hoses to the fittings.
6. Start the motor grader and check operation. Repair 5. Using a grease gun, lubricate moldboard angle
leaks as necessary. cylinder swivel joints.
leaks as necessary.

Maintenance
Replacing Moldboard Lift 9. Inspect the rod end for excessive wear, play, and
damage. Replace if necessary or remove for
Cylinder installation on new moldboard lift cylinder (Figure
NOTE: Refer to Figure 7-11 on page 7-30 for 5-44,1).
illustrated parts list. 10. Inspect upper mounting bushings. Replace if worn,
broken, or damaged.
Removal
1. Thoroughly clean the moldboard lift cylinder (Figure Installation
5-44,1), especially in the area surrounding the NOTE: Rod end fittings have small orifice holes to slow
hydraulic hoses and fittings. down drop speed.
1 1. Install the fittings on the replacement cylinder.
2. Install rod end on new cylinder.
3. If removed, install upper mounting bushings.
4. Position the lift cylinder in the upper mount and
secure with side plate, flat washers, and bolts.
5. Install rod end in tow bar mount and secure with flat
washer, nut, and new cotter pin.
leaks as necessary.
Replacing Moldboard Blade

2 NOTE: Refer to Figure 7-11 on page 7-30 for
illustrated parts list.
Figure 5-44. Moldboard Lift Cylinders
NOTE: Raise moldboard (Figure 5-44,2) and support
1 - Moldboard Lift Cylinders
with jack stands before shutting down the
2 - Moldboard engine.
2. Tag and disconnect the hydraulic hoses. Removal
prevent contamination of the hydraulic system. 1. While supporting blade, remove blade mounting
screws, lock washers, and nuts.
3. While supporting the moldboard lift cylinder (Figure
5-44,1), remove the bolts and flat washers from the 2. Remove worn blade.
moldboard lift cylinder rod end. 3. Clean the blade mounting surface thoroughly.
4. Using a ball joint removal tool, remove the ball joint.
Installation
5. Support the moldboard lift cylinder (Figure 5-44,1)
and remove the bolts and flat washers from the 1. Position replacement blade on moldboard.
moldboard lift cylinder mount. 2. Secure with mounting screws, lock washers, and
6. Remove the side plate. nuts.
7. Remove the moldboard lift cylinder (Figure 5-44,1).

8. Inspect the hydraulic fittings, replace as necessary.
cylinder.

Maintenance
Replacing Hydraulic Charge

Filter
Removal
Burn Injury Hazard! Hot hydraulic
oil can burn upon contact with the skin. Change
hydraulic charge filter while system is warm, not hot.
Avoid contact with hot hydraulic oil. Failure to obey
this warning could result in serious injury.
1. Open the hydraulic supply line gate valves access
panel (Figure 3-1,21).
2. Allow the engine to cool completely.
3. Close the hydraulic supply line gate valves
by turning valve handles (Figure 5-45,1)
1
5
Figure 5-46. Hydraulic Filter Location
6. Turn the filter element counterclockwise (CCW) to
remove.
Figure 5-45. Supply Line Gate Valves
7. Clean the filter head mounting surface and inspect
1 - Supply Line Gate Valve Handles for dislodged seals from the old filter element.
4. Open the engine access panel door (Figure 3-1,2)
Installation
located on the RH side of machine.
5. Thoroughly clean and dry the hydraulic charge 1. Lightly lubricate element with clean hydraulic oil.
filter assembly (see Figure 5-46 for hydraulic filter 2. Install element on the filter head hand tight plus one-
location.) half turn.
3. Open hydraulic supply line gate valve (Figure
5-45,1) by turning valve handles clockwise (CW).
hydraulic reservoir supply line gate valves before
starting engine to prevent pump and drive motor
damage or failure.
4. Check hydraulic tank sight gauge and fill as
necessary.(see Checking Hydraulic Oil Level on
page 5-25).
5. Start engine and check operation. Repair leaks as
necessary.

Maintenance
Replacing Radiator/Oil Cooler 5. Remove the upper and lower radiator hoses (Figure
7-27,7,8).
Assembly
6. Disconnect the radiator overflow hose (Figure
NOTE: Allow engine to cool completely. 7-27,2).
NOTE: Refer to Figure 7-27 on page 7-66 for 7. While supporting the radiator, remove the radiator
illustrated parts list. mounting bolts and washers (Figure 7-27,3).
Removal 8. Remove the radiator/oil cooler.
1. Remove engine and starter access panels (Figure Installation
2-1,2,17), hood, and grill (Figure 5-47,1,2).
1. Position the replacement radiator/oil cooler and
secure with mounting bolts and washers.
2. Install overflow hose and secure with clamp.
2 3. Install upper and lower radiator hoses and secure

with hose clamps.
4. Using tags created during removal, connect charge
air hoses and hydraulic hoses to radiator.
5. Fill radiator with coolant mixture consisting of at
1
least 50/50 mix of anti-freeze and water.
6. Inspect and test radiator cap (Figure 5-48,1).
Replace if necessary.
1
Figure 5-47. Radiator Grill and Hood

1 - Radiator Grill
2 - Hood
2. Drain the engine coolant system. Dispose of coolant
properly.
NOTE: Dispose of engine coolant in an environmentally
safe manner. Contact local recycling centers
or environmental officials for coolant disposal
instructions.
3. Tag and disconnect charge air hoses and hydraulic Figure 5-48. Radiator Cap
hoses from radiator. Immediately plug hoses to 1 - Radiator Cap
7. Install grill, hood, and engine access panels.
4. Thoroughly clean the radiator and oil cooler
assembly especially the area surrounding hydraulic 8. Start engine and check operation. Repair leaks as
hoses and fittings. necessary.

Maintenance
Replacing Control Valve Installation

Assembly 1. Install fittings in replacement valve.
NOTE: Refer to Figure 7-31 on page 7-74 for 2. Insert control valve and secure with mounting bolts
illustrated parts list. and washers.
Removal 3. While supporting valve and using tags created

during removal, connect hydraulic hoses to fittings.
1. Remove valve bank access cover (Figure 5-49,1).
4. Install control levers and linkage.
5. Start engine and check operation. Repair leaks as
necessary.
6. Install valve bank access cover and secure with flat
washers and wing nuts.
988271
Figure 5-49. Valve Bank Access Cover

1 5
1 - Valve Bank Access Cover
2. Thoroughly clean the control valve and surrounding
area, especially around the hydraulic hoses and
fittings.
3. Tag and disconnect hydraulic hoses. Immediately
plug the hoses and control valve ports to prevent
contamination of the hydraulic system.
4. Support the control valve (Figure 7-31,5B) and
remove the control valve mounting bolts and
washers.
5. Remove the control valve assembly.
6. Inspect the control valve levers and linkages for
wear and damage. Replace levers and linkages if
necessary.
7. Remove control levers and linkage.
8. Inspect hydraulic fittings for wear and damage.
Replace if necessary. Remove fittings for installation
in replacement valve.

Maintenance
Storage
This section contains instructions to prepare the
machine for long-term storage. It also contains the
procedures necessary to inspect the machines monthly
during storage.
Preparing Machine For Long-

Term Storage
1. Inspect the machine thoroughly and repair worn or
damaged parts.
2. Retract all hydraulic cylinders, if possible.
3. Shut down engine and remove ignition key.
4. Remove alternator belt.
5. Check air filter restriction gauge. Clean the air
cleaner assembly and precleaner. Replace air filter
elements if restricted.
6. Clean the machine. Paint chipped or rusty areas to
prevent rusting. Replace worn or damaged decals.
7. Cover seat with plastic.
8. Place a “DO NOT OPERATE” tag on the steering
wheel.
NOTE: Some rust inhibitors can destroy painted
surfaces. Do not spray rust inhibitor on painted
surfaces.
9. Coat exposed cylinder rods with rust inhibitor.
10. Lubricate all grease points. Refer to Figure 5-1 and
Table 5-1.
11. Check engine oil level and fill as necessary.
12. Check hydraulic oil sight gauge and fill as
necessary.
13. Perform specific gravity test on engine coolant.
Drain and replace or fill coolant reservoir as needed
to prevent freeze damage.
14. If possible, raise and support machine with tires off
the ground or park machine on a hard surface to
prevent tires from freezing to ground.
15. Store machine in a dry, protected area. If stored
outside, cover with waterproof material.

Maintenance
Troubleshooting NOTE: The following troubleshooting solutions include

common problems encountered with diesel
The troubleshooting chart below identifies the most engines. For additional information and trouble-
common symptoms of failure. Use this chart to help shooting procedures, see the Engine Manufac-
identify the failed component. turer’s Operation and Maintenance Manual.
Table 5-3. Troubleshooting Chart

SYMPTOM CAUSE REMEDY
Engine cranks but does not start, Fuel tank empty. Check fuel level and fill as required
or starts hard.
Water in fuel or water frozen in fuel Thaw and/or drain water from fuel tank
lines. Water frozen in fuel filter. sump. Thaw ice in fuel lines and drain.
Install new fuel filter
Fuel tank cap vent clogged. Remove cap. Listen for air entering tank
suddenly. Clean and replace cap.
Debris or dirt in fuel. Drain small amount of fuel from tank
sump into clean container. Inspect for
debris. Drain and flush fuel system and
change fuel filter.
Wrong grade fuel for low ambient Fuel “jelled” in tank or lines. Warm
5
temperature. machine. Drain fuel system and change
fuel filter. Refill tank with correct fuel.
Air entering charge side of fuel Check for bubbles in fuel filter. Tighten
system. connections. Inspect fuel lines for
damage.
Fuel transfer pump malfunctions. Repair or replace fuel transfer pump.
Air filter elements restricted with dirt, Clean or replace filter elements.
snow, or water.
Injection pump malfunctions. See your authorized dealer.
Injection nozzle(s) malfunctions. See your authorized dealer.
Worn piston rings or low See your authorized dealer.
compression.
Blown head gasket. See your authorized dealer.
Engine cranks slowly. Wrong weight oil for low ambient Drain and refill with correct weight oil.
temperature. Change oil filter.
Loose or dirty connections at Clean battery posts and cable ends.
batteries. Reinstall cables.
Loose or dirty connections at starter. Clean connections at start relay and
starter.
Batteries discharged or failing to Disconnect batteries from machine
take a charge. and each other. Recharge batteries
separately. Replace both batteries if
either fails to charge. Check alternator
output (28 volts), wiring for shorting to
ground, and alternator tension. Repair
or replace components as required.

Maintenance
Table 5-3. Troubleshooting Chart (Cont.)

Engine cranks slowly Starter motor malfunctions. Seized bushings, bent armature shaft, worn
(continued). bushings, and armature "dragging". Check
starter current draw. See your authorized
dealer for starter repair.
Engine surges or stalls Air entering charge side of fuel system. Check fuel filter for air bubbles. Tighten
frequently. fittings and connections. Inspect lines for
damage.
Fuel tank cap vent clogged. Remove cap. Listen for air entering tank
Water or debris in fuel. Drain water from sump in fuel tank. Check
drained fuel for debris. Drain and flush fuel
system. Replace fuel filter.
Fuel "jelled" due to low ambient Drain fuel system. Refill engine with correct
temperature. grade fuel. Replace fuel filter.
Fuel filter clogged. Check for debris in fuel system. Replace
filter.
Return line from injection pump to tank Check line for kinks or damage. Check line
restricted. for debris. Clean with compressed air.
Air filter elements clogged. Clean or replace air filter elements.
Fuel transfer pump clogged. Repair or replace pump. See your
authorized dealer.
Injection pump or nozzle(s) See your authorized dealer.
malfunctions.
Basic engine malfunction. Leaking Refer to Cummins engine manual.
head gasket, sticking or burnt valves,
valve clearance or valve timing
incorrect, or worn or broken piston
rings.
Engine misses, operates Air entering charge side of fuel system. Check fuel filter for air bubbles. Tighten
erratically, or operates fittings. Inspect lines for damage.
Water or debris in fuel.
poorly at low speed.
Drain water from sump in fuel tank. Check
drained fuel for debris. Drain and flush fuel
system. Replace fuel filter.
Fuel tank cap vent clogged.
Remove cap. Listen for air entering tank
Return line from injection pump to tank
restricted. Check line for kinks or damage. Check line
for debris. Clean with compressed air.
Slow idle speed set too low. Check for bent, worn, or loose speed
control linkage. Repair as needed. Adjust
linkage and reset slow idle speed.
malfunctions.

Maintenance

Engine misses, operates Incorrect valve clearance. Adjust clearance.
erratically, or operates
poorly at low speed
(continued).
rings.
Engine not developing full Fuel filter clogged. Check for debris in fuel system. Replace
power. filter.
Air filter elements clogged. Clean or replace air filter elements.
Water in fuel or wrong grade of fuel Drain water from fuel tank sump or drain
used. and flush fuel tank and refill with correct
fuel. Replace fuel filter.
Exhaust system restriction. Check condition of muffler interior.
Fast idle speed set too low. Check for bent, worn, or loose speed
control linkage. Repair as needed. Adjust
linkage and reset fast idle speed.
Incorrect valve clearance.
Fuel line or injection pump line
restricted.
Adjust clearance.
Clear restriction with compressed air.
Replace line.
5
Park brake dragging. Adjust linkage. Check park brake disc for
warping or scoring. Check park brake
cable for binding. Overheating of park
brake disc indicates dragging. Repair or
replace park brake disc and/or park brake
cable as required.
Service brakes dragging. Check brake linkage for damage. Check
brake valve for leakage. Check brake discs
for warping or scoring. Dragging brakes
could cause overheating of transmission/
hydraulics or engine.
malfunctions.
Internal hydraulic system leakage. Repair linkage. See your authorized dealer.
Turbocharger gasket leakage. Repair or replace. See your authorized
dealer.
rings.

Maintenance

Engine emits excessive Restricted air filter element. Check, clean or replace air filter elements.
black or gray exhaust
Incorrect grade of fuel. Drain and flush fuel tank and fill with correct
smoke.
grade of fuel. Replace fuel filter.
Engine overloaded. Remove load. Run at fast idle to clear the
engine.
Turbocharger gasket leakage. Repair or replace. See your authorized
dealer.
Incorrect injection pump timing. Repair or replace pump. See your
authorized dealer.
Excessive fuel delivery. Injection pump See your authorized dealer.
or nozzle(s) malfunctions.
Excessive blue or white Engine will not start. Incorrect grade of Cranking speed too slow.
exhaust smoke. fuel used.
Drain and flush fuel tank and refill with
correct grade of fuel. Replace fuel filter.
Injection pump or nozzle(s)
See your authorized dealer.
malfunctions.
Basic engine malfunction Excessive oil
Refer to Cummins engine manual.
consumption.
Detonation (excessive Stuck starting aid solenoid or switch. Repair or replace solenoid or switch.
engine knock).
Injection pump timing or pump advance See your authorized dealer.
faulty.
Incorrect fuel (gasoline mixed with Drain and flush fuel tank and refill with
diesel fuel). correct fuel. Replace fuel filter.
Abnormal engine noise Low engine oil level. Fill reservoir to correct level.
(rattle, knock, or squeal). and
Oil viscosity too low for high ambient Drain and refill reservoir with correct
repair leaks.
temperatures. weight oil.
Fuel in engine oil. Drain and refill reservoir with correct oil.
Check fuel system to find le
Loose or worn hydraulic pump drive Repair or replace damaged coupling.
coupling.
Injection pump timing incorrect. See your authorized dealer.
Turbocharger bearing or turbine Remove turbo air inlet hose and check
damaged. vertical movement of shaft. Repair or
replace shaft. See your authorized dealer.
Excessive valve clearance. Adjust clearance.
Internal engine component wear. Refer to Cummins engine manual.

Maintenance

Low engine oil pressure (oil Low oil level. Check oil level. Fill reservoir to correct
pressure indicator light ON, level. Check for leaks. Repair leaks.
Red STOP light flashing, and
Low viscosity (using winter oil in Drain, flush, and fill reservoir with correct
alarm ON).
summer). weight oil.
Oil diluted with fuel. Drain and refill reservoir with correct oil.
Check fuel system to find leakage and
repair leaks.
Oil pressure sensor faulty. Replace oil pressure sensor.
Oil pressure control valve faulty. Repair or replace valve. See your
authorized dealer.
Oil pump intake screen clogged. See your authorized dealer.
Loose oil pump drive gear or worn See your authorized dealer.
pump housing.
Internal engine component wear. Refer to Cummins engine manual.
5
Engine overheats. Low coolant level. Fill radiator with coolant to correct level
and check for leaks.
Loose, worn, or broken fan belt. Tighten or replace fan belt. Refer to
Cummins engine manual.
Worn pulley grooves, allowing belt Replace pulleys and belt. Refer to
slippage. Cummins engine manual.
Radiator dirty or clogged. Check airflow. Clean radiator and recheck
airflow.
Radiator shroud missing or damaged. Replace radiator shroud. Refer to
Engine overloaded. Reduce load. Operate in lower gear.
Radiator cap not sealing. Replace radiator cap.
Fan on backwards or damaged. Inspect and reinstall or replace fan. Refer
to Cummins engine manual.
Injection pump timing incorrect. See your authorized dealer.
Excessive brake drag. Refer to Cummins engine manual.
Hydraulic system overheating due to Check for clogged hydraulic oil cooler. See
internal leakage. your authorized dealer.
Thermostats stuck or missing. Replace thermostats. Refer to Cummins
engine manual.
Cooling system interior coated with Flush the cooling system with cleaner. Refill
lime deposits. with water/antifreeze solution.
Water pump leaking. Repair or replace water pump. Refer to
Excessive fuel delivery or injection See your authorized dealer.
pump malfunctions.

Maintenance

Oil in coolant or coolant in Leaking cylinder head gasket or liner Refer to Cummins engine manual.
oil. packings. Cracked cylinder or block.
Excessive fuel consumption. Air system restricted. Clean or replace air filter elements.
Fuel system leakage. Refer to Cummins engine manual. Drain
and flush fuel tank and refill with correct
Incorrect grade of fuel.
grade of fuel. Replace fuel filter. Check
for clogged hydraulic oil cooler. See your
authorized dealer.
No hydraulic power. Low hydraulic/transmission oil level. Add oil to the hydraulic oil reservoir to the
correct level. Replace filter element. See
Hydraulic filter clogged.
your authorized dealer.
Hydraulic pumps or pump drive
coupling damaged or excessive
leakage in hydraulic system.
All hydraulic systems Low oil level. Add oil to the hydraulic oil reservoir to the
function slowly. correct level.
Air in hydraulic oil (foamy appearance). Inspect charge side hoses and fittings
to pump for leakage. Tighten fittings or
replace hoses and fittings as required.
Engine RPM low. Inspect speed control linkage for damage.
Repair or replace parts as required and
adjust linkage.
Hydraulic filter clogged. Replace filter element.
Low pump flow or excessive leakage in See your authorized dealer.
system.
Hydraulic functions Low oil level. Add oil to the hydraulic oil reservoir to the
correct level.
make "chattering" noise.
Hydraulic filter restricted. Replace filter element.
Hydraulic filter relief valve stuck open See your authorized dealer.
or setting is too low.
Hydraulic functions drift or Cylinder or control valve leakage. See your authorized dealer.
settle.
Control valve linkage binding or out of Repair and/or adjust linkage.
adjustment.
Control valve sticks or is Control valve linkage binding Repair linkage.
hard to operate.
Broken return spring in control valve. See your authorized dealer.
Contamination in valve bore, scored
valve bore, or bent valve spool.

Maintenance

Hydraulics overheat. Excessive load. Reduce load.
Oil cooler clogged. Clean oil cooler and measure air flow.
Low oil level. Fill the hydraulic oil reservoir to the correct
level.
Using low viscosity oil in summer. Drain, flush, and fill the hydraulic oil
reservoir with the correct oil. Replace the
oil filter.
Transmission or hydraulic internal See your authorized dealer.
leakage.
Foaming oil. Oil level is too high or too low. Adjust oil level to full mark on dipstick.
Incorrect type of oil. Drain, flush, and fill the hydraulic oil
reservoir with the correct oil. Replace the
oil filter.
Pump suction screen restricted. Clean the screen.
Air leakage on suction side of pump. Tighten fittings and inspect hoses for
5
damage. Replace damaged hoses.
Hydraulic pump leaking. Cap screws holding pump housing Tighten screws to torque specification.
together are loose.
Worn shaft seal. See your authorized dealer.
Excessive pump noise. Low oil level. Fill the hydraulic oil reservoir to the correct
level.
Transmission or hydraulic filter Replace filter.
restricted.
Aeration of oil - charge side leaking. Tighten fittings and inspect hoses for
damage. Replace damaged hoses.
Oil lines contacting operator's station Inspect lines, clamps, and isolators. Repair
or frame (clamps or isolators). or replace as required.
Worn transmission pump, loose pump See your authorized dealer.
drive coupling, loose pump attaching
hardware, leakage in hydraulic
system (pump remains in stroke),
or misalignment between pump and
engine.

Maintenance

Starter motor will not turn. Batteries not charged or bad. Charge or replace batteries.
Battery connections. Clean and tighten battery connections at
battery and starter solenoid.
Starter motor. Listen for starter solenoid to click when
key is placed in the start position. If
solenoid clicks, repair or replace starter
motor.
Starter solenoid.
Check for 12 volts at small solenoid
connections when key is placed in the
start position. If 12 volts is present, replace
solenoid.
Start relay.
Listen for relay to click when key is placed
in the start position. If relay does not
click, check wiring. Repair or replace as
necessary.
Start system circuit breaker.
Check for 12 volts at both sides of the
circuit breaker. If 12 volts is not present
on either side, check wiring. If 12 volts
is available on one side, replace circuit
breaker.
Key switch.
Check for 12 volts at ignition switch
terminal "st" when key is placed in start
position. If 12 volts is available, check
Neutral start switch on pump.
wiring harness.
Check for 12 volts on both sides of switch
with machine in neutral. If 12 volts is
available, check wiring harness. If 12 volts
Major engine malfunction.
is available on one side.
See authorized dealer.
Starter solenoid chatters. Bad connections at batteries or Clean and tighten connections.
solenoid.
Batteries discharged or bad. Charge or replace batteries.
Bad solenoid. Replace solenoid.
Starter motor turns but will Starter pinion gear not engaging Pinion shift mechanism jammed. Repair or
not crank engine. flywheel ring gear. replace starter motor.
Pinion gear teeth broken. Repair or replace starter motor.
Flywheel ring gear teeth broken. Replace ring gear.

Maintenance

Starter motor continues to Starter solenoid stuck. Gently tap solenoid. Replace solenoid.
turn after engine starts.
Starter pinion gear not disengaging Gently tap starter motor. Repair or replace
from flywheel. starter motor.
Ignition switch malfunction. Check for 12 volts at "st" terminal with
ignition switch in the ON position. If 12 volts
available, replace ignition switch.
Excessive noise when Broken teeth on flywheel ring gear or Replace starter motor or ring gear.
cranking engine. starter pinion gear.
Major engine malfunction. See authorized dealer.
Battery uses too much water. Battery overcharged. With batteries fully charged, check
alternator charging rate. Repair or replace
Cracked or broken battery case.
alternator.
Replace battery.
Cracked battery case. Battery hold down clamps too tight, Replace battery and install hold down
loose or missing. clamps properly.
Frozen batteries. Keep battery fully charged during cold
Low battery output. Low water level.

Corroded or loose battery cable
weather. Replace batteries.
Fill with distilled water and charge.
Clean and tighten all connections.
5
connections.
Broken or loose battery posts. Replace battery.
Loose, slipping alternator belt. Replace alternator belt.
Low alternator output. Test and replace alternator.
Alternator warning light stays Alternator. Load test alternator and replace as
on or voltmeter shows low necessary.
charge.
Alternator charging rate to Alternator. Load test alternator and replace as
high (batteries hot or boiling). necessary.
Noisy alternator. Alternator bearings. Remove alternator belt and turn alternator
by hand. If pulley turns rough, repair or
replace alternator.
Worn drive belt. Check and replace belt.
Internal alternator malfunction. Repair or replace alternator.
Horn will not sound. Horn fuse. Check and replace fuse.
Horn ground connection. Check and repair ground connection.
Horn connection. Check and repair horn connection.
Horn is inoperable. Replace horn.

Maintenance

Machine will not move Low hydraulic oil level. Check and fill reservoir. Release park
forward or reverse. brake. Repair or replace linkage. See
Park brake engaged.
authorized dealer.
Forward/neutral/reverse (FNR) pedal
linkage broken.
Traction pump malfunctions.
Pump destroke valve on or stuck.
Machine jumps when Park brake sticking. Repair park brake.
forward/neutral/reverse
Traction pump malfunction. See authorized dealer.
(FNR) pedal engaged.
Transfer case malfunction. See authorized dealer.
Differential (final drive) malfunction. See authorized dealer.
Machine creeps. Forward/neutral/reverse (FNR) pedal Adjust forward/neutral/reverse (FNR)
misaligned. pedal linkage.
Traction pump responds Low hydraulic oil level. Check and fill reservoir.
slowly.
Traction pump boost pump malfunction. See authorized dealer.
Traction pump malfunction. See authorized dealer.
Cold oil. Allow machine to warm completely.
Drive selector levers or pedal Bent, damaged, corroded linkage. Clean, straighten and adjust linkage.
do not move freely.
Excessive noise in drive Worn transfer case. See authorized dealer.
system.
Worn traction pump. See authorized dealer.
Worn differential (final drive). See authorized dealer.
Park brake dragging. Check park brake operation.
Hydraulic drive system has Defeat coil on drive motor not receiving Check all switches and wiring.
no power. signal correctly.
Max coil (Figure 5-50,2) should have
power when:
• Reverse in high gear, auto/work
switch either position.
• Forward in low gear with work/auto
switch in WORK position.
1 • Forward in high gear with work/auto
switch in WORK position.
2
Figure 5-50. Drive Motor Defeat coil (Figure 5-50,1) should have
power when:
1 - Defeat Coil
• Reverse in low gear.
2 - Max Coil
• Reverse in high gear.
Two-speed won’t shift. Two-speed valve not receiving signal. Check all switches and wiring.
Park brake not set. Set part brake.

Section 6
SCHEMATICS
Page
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Electrical 1 of 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Cab: Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Electrical 2 of 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Electrical 3 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Electrical 4 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6
Canopy: Instrument Panel . . . . . . . . . . . . . . . . . . . . . . 6-9
Electrical 5 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Electrical 6 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Electrical 7 of 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Secondary Instrument Panel. . . . . . . . . . . . . . . . . . . . . 6-15
Electrical 8 of 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
One-Line Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Hydraulic 1 of 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Overall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Hydraulic 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Hydraulic 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Front Wheel Assist. . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Hydraulic 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Schematics
NOTES

Schematics
ELECTRICAL 1 OF 8
Cab: Instrument Panel
BUTT
SPLICE
RIGHT TURN
LEFT TURN
TAIL LIGHT
BEACON REAR WIPER HEAD FRONT WIPER DOME THROTTLE

LIGHT LIGHT LIGHT LIGHT
TERMINAL
GND
BLU
6
BRN
RED
GRN DECREASE THROTTLE

LT BLU INCREASE THROTTLE
START
ORN WARNING LAMP
WAIT TO START LAMP
WHT STOP LAMP
BRN
BLU
SWITCH
TERMINAL
FUEL GAUGE
Figure 6-1.

Schematics
Notes

Schematics
ELECTRICAL 2 OF 8
Cab: Instrument Panel (Cont.)
BUTT
SPLICE
SWITCH
TERMINAL
C
HEADLIGHTS TAILLIGHTS
TO STEERING
WHEEL BUTTON
TERMINAL BU AL SW
HORN
FUEL SENDER CAN BUS BU AL SW
ECM
ECM PWR
Figure 6-2. 1010896: Instrument Panel

Schematics
Notes

Schematics
ELECTRICAL 3 OF 8
Cab: Instrument Panel (Cont.)
OIL
PRESS TEMP
GND
TERM
TACH
6
RESISTOR LT BLU
B
WHT A
Figure 6-3.

Schematics
Notes

Schematics
ELECTRICAL 4 OF 8
Canopy: Instrument Panel
RIGHT TURN
LEFT TURN
TAIL LIGHT
BEACON HEAD THROTTLE

LIGHT LIGHT LIGHT
TERMINAL
GND
6
BLU
BRN
RED
GRN DECREASE THROTTLE

LT BLU INCREASE THROTTLE
START
ORN WARNING LAMP
WAIT TO START LAMP
WHT STOP LAMP
BRN
BLU
SWITCH
TERMINAL
FUEL GAUGE
Figure 6-4.

Schematics
Notes

Schematics
ELECTRICAL 5 OF 8
Canopy: Instrument Panel (Cont.)
SWITCH
TERMINAL
B
HEADLIGHTS TAILLIGHTS
TO STEERING
WHEEL BUTTON
TERMINAL BU AL SW
HORN
FUEL SENDER CAN BUS BU AL SW
ECM
ECM PWR
Figure 6-5. 1011159: Instrument Panel

Schematics
Notes

Schematics
ELECTRICAL 6 OF 8
Canopy: Instrument Panel (Cont.)
OIL
PRESS TEMP
GND
TERM
6
TACH
RESISTOR LT BLU
B
WHT A
Figure 6-6.

Schematics
Notes

Schematics
ELECTRICAL 7 OF 8
Secondary Instrument Panel
NOTES:
FAN
PRESSURE ALL INTERNAL CONNECTIONS TO BE SOLDERED
LO LO
RED
HI HI AUTO
SPADE TERM
RED
RED
RED
ACCUMULATOR
PRESS SW
GND
TERMINAL
TERMINAL
TERMINAL LO
6
RED BR SW PWR
TERMINAL
TERMINAL
GND
HI
TERMINAL
RED RED
CB
RELIEF
CB RED
RED
CB
SWITCH
Figure 6-7. 1011191: Secondary Instrument Panel

Schematics
Notes

Schematics
ELECTRICAL 8 OF 8
ESTOP 2 SPEED WORK/AUTO
RED RED LO
One-Line Diagram
YEL/RED
BLU/WHT
YEL YEL YEL HI
DESTROKE
BRAKE BLU/WHT HI/LO SW DEFEAT
PRESS SW BRAKE N/O IN HI
RED BLU/WHT BLU/WHT 85
87
86
BRAKE
PRESS SW FAIL LIGHT
RED/WHT RED/BLK
WORK LOAD
RELAY
OIL TACH FUEL

PRESS 1
2
1
2
3 3
6 1 6 1 AC 17
6 6 1 6 1 G
1 S
I
RED GREEN A A
B B
C C
FRONT TRACTION WHT

FUEL ASSIST OPTION A A
LT BLU
SENDER B
C
B
C SHIELD
BLU/RED
BLU/RED BLU/RED
1 1
GRN 4 ISC1
1 1 2 2
LT BLU 25 DEC THROTTLE
GRN GRN 3 3 24 INC THROTTLE
2 2
4 4 5A RED/BLK
LT BLU LT BLU WHT
RED/BLK
3 3
RED/BLK
GREEN 5
6
5
6 YEL/BLK
4 4
7 7 ORG
YEL 5 5 YEL 8 8 PNK
YEL/BL YEL/BL WHT
6 6 BLU/RED
WAIT TO START ORN 7 7 ORN ORN
WHT WHT ORN/YEL
8 8
TURN SIGNAL
6
THROTTLE
INCREASE
DECREASE
25A 1 BLK/GRY
2 YEL 1
25A 3 BLU 2
WORK LIGHT
4 BLK 3
5 GRY ALTERNATOR 4
25A 6 RED
W 7 GRN
BEACON
25A 8
25A
25A GRN 14GA FRONT LEFT TURN

RED 14GA FRONT RIGHT TURN
GRY 14GA REAR LEFT TURN
BLK 14GA REAR RIGHT TURN
FLASHER
BLK/WHT 14GA BRAKE LIGHT SIGNAL BATTERY
HORN RELAY
ORN/YEL 14GA DISCONNECT
X
85
87
86 P
L
START STARTER
SOLENOID
FRONT WIPER SWITCH YEL/RED

HEADLIGHT
FRONT RUNNING
SWITCH
H
WIPER LIGHT
L W
BATTERY BATTERY
BRN
P B
HEAD LIGHT
BLU
REAR WIPER SWITCH
H REAR HIGH
L W WIPER
B
RED
P
B
Figure 6-8.

Schematics
Notes

Schematics
HYDRAULIC 1 OF 4
Overall
90
1010517
1000567 89
MAIN PUMP
23 67
RIGHT SIDE
88 24 160380
61
3 40
60 63 25 26 82
27
3 40
1010390 22
26
T P 26 33
57 56 53 35
853850
66 3
62 853190 29
983361
14 34
65 54 66
58
64
31 65 36
4 A B 27
T
COOLER, HYD OIL

3
64
6 7
P 852740 36123
81
25 59 CHARGE 99607
3
55 VALVE 36
STRAINER, 6339
5 65 HYD PIPE, VALVE,
SUCTION NIPPLE, GATE, 36
988242
35
54
8 30 FRONT 1.00 X 4.00 1.00 32
852720 69
68 68
54
T OUT 35 31
750602
52
T
RELIEF
VALVE 480052
31 33 34
7 13
53
T IN
53
RED BUSHING 980560
STRAINER,
D
P
12 32
34 84 HYD
7
BLADE LIFT RIGHT
9
SUCTION 140640 290010/290030
36 VALVE GATE, FILTER HEAD,
B
685010 1.250 CHARGE

DIFFUSER, HYD 85 86 87
BLADE LIFT LEFT RETURN/FILTER
TANK RETURN, 2.00
B
ELEMENT, HYD
ARTICULATION CHARGE
27 DONALDSON
A
B
6
P16-9317/P17-6566
VALVE ASSY,10
21 21
SCARIFIER
SECTION,685
20
14
B
12
B 1000567
MOLDBOARD TILT MAIN PUMP
72689 IN
989177
9 64 C
29 28
E
WHEEL LEAN
B
160260
FRONT BLADE PUMP
B
21
D
CIRCLE SIDE SHIFT S OUT
A
20
LEFT SIDE
B
MOLDBOARD SLIDE 20 21 47
B
BLADE ANGLE
8 Y 46
B
22 1 1
PBR
DETAIL A
T
8 11 2
B
1000569
FRONT
20
10 HYD MOTOR 1
2 FRONT
14 20
140500 13
PR
TL
MOTOR, HYD, 2
POWER STEERING 83
9
66
72
A T
T8
T5
T6
T7
21 20
33 2 3
T9 42 1
10 T1 T2 T3 T4 1
DETAIL B 5
30 4
15 1 1
70
32
550214 RETURN
MANIFOLD BLOCK
Figure 6-9.

Schematics
Notes

Schematics
HYDRAULIC 2 OF 4
Control Valves
851436 REAR SCARIFIER CYL
42 43
18
100060
43
ARTICULATION CYL 18
19
76 12
78
11 42
76 58 16 16
110220 STEERING CYL
15 15 19
80 140500
130050 MOLDBOARD LIFT (RIGHT)
PR
TL
MOTOR, HYD,
110230 WHEEL LEAN CYL
POWER STEERING
59 17
76 71
49 17
48
49
48
16 17
79 130020 MOLDBOARD ANGLE (RH) 47
46
51 16 17
80
ARTICULATION
77
77
15 16 15 16
VALVE,
CHECK
D
75
100190
75
53 77 50
MOLDBOARD SLIDE, 685

77 BLADE LIFT 19
RIGHT 48/49
75
B
75
A
62 63
38 39 45 70 BLADE LIFT
V1 75
LEFT 46/47
B
75
A
C1
19
550213
ARTICULATION 18
C2 75
54/55
B
75
A
TOP
V2 18
44
130100 SCARIFIER
MOLDBOARD TILT 16/16
130110
55 54
75
B
75
A
CYLINDER 77
MOLDBOARD TILT
50/53
75 851436 REAR SCARIFIER CYL
B
75
A
6
77 77 WHEEL LEAN
131090 52 38/39
75
B
75
A
FRONT BLADE LIFT
FRONT BLADE
60 61
75
40/41
75
A
CIRCLE SIDE SHIFT
41 80 40 80 130020 MOLDBOARD ANGLE (LH) 92/91 100190
75 75
A
VALVE,
47 MOLDBOARD SLIDE CHECK
46 76 56
75
52/51 ARTICULATION
A
76 71
BLADE ANGLE
44/45
A
76
57 75
130050 MOLDBOARD LIFT (LEFT)
PBR
T
100060 53
989177
ARTICULATION CYL 50 VALVE SHOWN HERE FOR
VALVE ASSY,10
REFERENCE, FITTINGS
39 SECTION,685
INCLUDED WITH VALVE
38
40
41
91
92
51
52
44
45
91
92
77
76
852620
MOLDBOARD CIRCLE SHIFT
CIRCLE SIDE SHIFT OPTIONAL

KIT 987384 Figure 6-10.

Schematics
Notes

Schematics
HYDRAULIC 3 OF 4
Front Wheel Assist
103444 WHEEL MOTOR
12
2 12 11
3
Y
1010731
1
HYDRAULIC
TANK
4
14 4
6
11
B
FRONT
2
13
20
6 7 6 7
1
6 7
8 7
5
1000569
HYD MOTOR
10 9
6 7
5
X
9
A
10
11
6
8
6 7 6 7 2 3 20
36
13
5 3
2 11 4
FITTINGS 10 AND 11 ARE

15
2 12
11
SPECIFIC TO THE AWD KIT
AND REPLACE THOSE THAT
COME IN THE STANDARD KIT
12
(OPT) FRONT WHEEL ASSIST
99MG6854WD HOSE KIT, 685 4WD OPT
103444 WHEEL MOTOR
Figure 6-11.

Schematics
Notes

Schematics
HYDRAULIC 4 OF 4
Brakes
1009952
B2 - BLEEDING SCREW FOR BRAKES
P1 - CONNECTOR FOR FAILSAFE BRAKE,
WORKING PRESSURE - MIN 15, MAX 35 BAR
P2 - CONNECTOR FOR HYDRAULIC OPERATED
DISC BRAKES, OIL IMMERSED, 80 BAR MAX
B
P1 B2 P2
6
A
DETAIL A
SCALE 1 : 5
DETAIL B
SCALE 1 : 5
Figure 6-12.

Schematics
Notes

Section 7
ILLUSTRATED PARTS LIST (IPL)
Page
Illustrated Parts List (IPL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Replacement Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Main Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Tire Assembly And Axles (W/Out AWD). . . . . . . . . . . . . . . . . . . 7-10
Front Blade Assembly (With Boom And Front Axle). . . . . . . . . . . . . 7-12
Wheels And Front Axle, AWD (Option) . . . . . . . . . . . . . . . . . . . . 7-14
Rear Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Front Axle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Front Wheel Assist / Awd (Option) Assembly . . . . . . . . . . . . . . . . 7-22
Boom, 10’ Turntable Moldboard Assembly (W/Out AWD) . . . . . . . . . . . 7-26
Moldboard Drawbar Assembly (W/Out AWD) . . . . . . . . . . . . . . . . 7-28 7
Moldboard Lift Assembly (In All Models) . . . . . . . . . . . . . . . . . . 7-30
Turntable Assembly (In All Models) . . . . . . . . . . . . . . . . . . . . . 7-32
Moldboard Assembly (10’) . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Turntable Moldboard Assembly (12’) . . . . . . . . . . . . . . . . . . . . 7-36
Front Dozer Blade Assembly (Option) . . . . . . . . . . . . . . . . . . . 7-38
Scarifier Assembly (Option). . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Cab And Canopy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Cab (Option) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Canopy Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Motor, Windshield Wiper And Misc.. . . . . . . . . . . . . . . . . . . . . 7-50
Vandalism Assembly (Option). . . . . . . . . . . . . . . . . . . . . . . . 7-52
Heater And A/C Evaporator Unit . . . . . . . . . . . . . . . . . . . . . . . 7-54

Illustrated Parts List (IPL)
A/C Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Engine Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Battery Box And Battery Assembly. . . . . . . . . . . . . . . . . . . . . 7-62
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64
Radiator And Hydraulic Oil Cooler Assembly. . . . . . . . . . . . . . . . 7-66
Hydraulic Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 7-68
Engine, Cummins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
Steering Wheel, Seat And Pedals. . . . . . . . . . . . . . . . . . . . . . 7-72
Steering Wheel and Control Console Assembly. . . . . . . . . . . . . . . 7-74
Dead Engine Steering (Option) Assembly. . . . . . . . . . . . . . . . . . 7-76
Instrument Panels (Canopy And Cab). . . . . . . . . . . . . . . . . . . . 7-78
Instrument Panel (Canopy Only) . . . . . . . . . . . . . . . . . . . . . . 7-80
Hydraulic Valve Bank (Block 10 Stack) . . . . . . . . . . . . . . . . . . . 7-82
Hydraulic Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84
Alphabetical Parts Index (API) . . . . . . . . . . . . . . . . . . . . . . . . 7-86

REPLACEMENT PARTS LIST

Description Part #
(For specific instructions about replacing parts for the 685C Motor Grader, see Section 5 -
Maintenance of this manual.)
ENGINE/FRAME
FILTER ELEMENT, HYDRAULIC CHARGE 290030
RECIRC. FILTER 12755490
ELEMENT, FUEL FILTER, 4.5QSB 988666-04
ELEMENT, OIL FILTER, 4.5QSB 988666-03
AIR FILTER 1011053-03
FUEL CAP 140030FL
TAIL LIGHT 1007529
BACK UP ALARM 852520
RUBBER MAT 985877
CAB
DOME LIGHT 38840
WIPER ARM 151180
WIPER BLADE 151190
WORK LIGHT 1003862
HYDRAULIC SYSTEM
KNOB 1-7/8 920225
CAB (DETAIL)
TURN SIGNAL W/ HAZARD, 7 WIRE 33687
7
FLASHER 981512
HEAD LIGHT 852560
BEACON LIGHT 210893
DOME LIGHT 38840
WIPER BLADE 151190
WORK LIGHT 1003862
DECALS
DECAL, NOTICE, OPERATOR’S MANUAL 988634
DECAL, KIT, SAFETY/OPS, 685C 1011106
DECAL, KIT, DECO, 685C 1010958
DECAL, NO UNATTENDED 1005474
DECAL, 685AWD, FRONT, ON/OFF 856579-15
SEAL KITS
SEAL KIT, VALVE SECTION, V20 910062
SEAL KIT, VALVE SPOOL, V20 910059
SEAL KIT (FRAME) 100060-1

REPLACEMENT PARTS LIST (CONT.)
Description Part #
SEAL KIT (FRONT AXLE) 110230-1
SEAL KIT (FRONT AXLE) 110220-01
SEAL KIT (MOLDBOARD DRAWBAR) 130020-01
SEAL KIT (MOLDBOARD LIFT) 130050-01
SEAL KIT (MOLDBOARD TURNTABLE) 130100-1
SEAL KIT (DOZER BLADE) 131090-01

NOTES

MAIN FRAME ASSEMBLY
1A
3
1B
3A
3B
2 2A
1A
Figure 7-1

Main Frame Assembly Parts List

Item
No. Part Number Qty. Description Remarks
1A 1010700 1 Main Frame
1B 220360 2 Bushing, 1.00 ID x 1.25 OD x 1.00
2 988283 1 Boom (Group) (no All-Wheel Drive (AWD))
2A 220360 2 Bushing, 1.00 ID X 1.25 OD X 1.00
3 100071 2 Clamp Half, 685 Articulation
3A 118-6 8 Washer, Lock, 5/8
3B 100-6-16-16-5F 8 CSHH, 3/8-16 X 1, GR5, FT
4 100060 2 Cylinder, Hydraulic, 3.00 X 6.00 X 1.25 Rodulation
- 930041 2 Bushing, Tension, 1.25 OD X 1.00 ID (not shown; f/Item 4)
- 100060-1 1 Seal Kit (not shown; f/Item 4)
5 210060 4 Pin, Clevis, 1.00 X 2.625 W/1.5HD
6 100180 1 Hitch, Pintle

BOOM ASSEMBLY
1A
2
1B
1A
1D
1C
1E
12A
13
14B
12A
14A
12
12C
9
12B
1A
1A
11
10
3
4
5
6
8
6
5
Figure 7-2

Boom Assembly Parts List

Item
1A 988283 1 Boom (Group) (Boom for no-AWD)
- 100024 1 Boom (only)
1B 982002 1 Partial Boom (for AWD only)
1C 857406 2 Plate, 685 AWD Boom Side
1D 302-4 4 Washer, Lock, 1/4
1E 100-4-20-16-5 4 CSHH,1/4-20 X 1, GR5
2 852560 2 Light Kit (Only one (1) Light Kit showing)
3 100141 1 Nut, Articulating Shaft
4 100090 2 Seal, Articulation Shaft
5 100110 2 Bearing Cone, Articulate Shaft
6 100120 2 Bearing Cup, Articulate Shaft
7 100102 1 Shaft, Articulation Joint
8 859317 2 Moldboard Trunion
9 100170 12 Bushing, 2.5 x 2.00 x 1.50 Lg.
10 859439 6 Washer, 3.00 x 2.0312 x 22 GA
11 858961 4 Washer, Trunion Pin
12 100152 2 Assembly, Trunion Mount (One set per side)
12A 100080A 2 Bushing, 1.75 ID X 2.25OD X 1.50 Lg.
12B 858965 2 Pin, Moldboard Lift Cylinder
12C 100163 2 Plate, 685 Moldboard Lift Trunion Back
13 100161 2 Assembly, Moldboard Lift Trunion (One set per side)
14A
14B
-
100-10-11-48-8
118-6
140610
8
8
14
CSHH, 5/8-11 X 3, UNC
Washer, Flat, SAE, 5/8
Fitting, Lube, Str., 1/4”-28 (not shown; universal for 685C)
7

TIRE ASSEMBLY AND AXLES (W/OUT AWD)
11
10
12
7
8
9
1
3
2
4
6
5
3A
3C
3D
3C
3B
Figure 7-3

Tire Assembly and Axles (w/out AWD) Parts List

Item
1 1010197L 2 Left Wheel, Tire Assembly, W/ Dana
2 1010197R 2 Right Wheel, Tire Assembly, W/ Dana
3 1009952 1 Axle, Drive Assembly, Dana 150 Bogie
3A 95383832 8 7/8-14 Locknut
3B 100-14-14-192-8 8 CSHH, 7/8-14 X 12, GR8
3C 300-14 16 Washer, Flat, SAE, 7/8
3D 1010700 1 Main Frame
4 A120330AR 1 Tire & Wheel Assembly, 685 RH (also listed as 100518R)
5 A120330AL 2 Tire & Wheel Assembly, 685 LH (also listed as 100518L)
6 988284 1 Group, Front Axle Details in Figure 7-7
7 100514 1 Tire, 15 X 19.5 Gauge Tread, 8 Ply.
8 1010198 1 Wheel, W/ Dana
9 100513 1 Two Piece Air Valve, Tire/ Wheel (consists of housing and core)
10 120330B 1 Rim, 12" X 19.5"
11 110340 1 Tire, 15" X 19.5" 8 Ply.
12 20192233 1 Valve Stem
Note: For AWD Axle Exploded

View -- also called Front
Wheel Assist --- see: Figure
7-8

FRONT BLADE ASSEMBLY (WITH BOOM AND FRONT AXLE)
8
3
5
4
7A
7B
Figure 7-4

Front Blade Assembly (with Boom and Front Axle) Parts List
Item
1 100024 1 Boom
2 988284 1 Front Axle Details in Figure 7-7
3 A120330AR 1 Tire & Wheel Assembly, 685 RH
4 A120330AL 1 Tire & Wheel Assembly, 685 LH
5 982027SRV 1 Front Dozer Blade (Optional) Welded; See Figure 7-15
6 988328 2 Clamp, Front Axle
7A 300-10 4 Washer, Flat, SAE, 5/8
7B 100-10-11-48-8 4 CSHH, 5/8-11 X 3, GR8
8 852560 2 Light Kit
9 120350A 16 Lug Nut (non-AWD Axle)

WHEELS AND FRONT AXLE, AWD (OPTION)
5
6
7
3B
3C
3A
Figure 7-5

Front Axle, AWD (option) Parts List

Item
1 982002 1 Boom (for AWD)
2 981935 1 AWD Axle Details in Figure 7-8
3 100518L 1 Tire & Wheel Assembly, 15 X 19.5, LH
3A 100513 2 Two Piece Air Valve, Tire/Wheel (same P/N for both Wheels)
3B 100514 2 Tire, 15 x 19.5 Guard Tread, 8 Ply. (same P/N for both Wheels)
3C 100519 2 Front Wheel Weldment, 12.25 X 19.5 (same P/N for both Wheels)
4 100518R 1 Tire & Wheel Assembly, 15 X 19.5, RH
5 988328 2 Clamp, Front Axle
6 300-10 4 Washer, Flat, SAE, 5/8
7 100-10-11-48-8 4 CSHH, 5/8-11 X 3, GR8
- 120350A 16 Lug Nut (AWD Axle)

REAR STEPS
2B
1A
1B 2A
Figure 7-6

Rear Steps (Mount to Rear Axle) Parts List

Item
1 982560 1 Rear Step, Right
1A 302-9 2 Washer, Lock, 9/16
1B 100-M14-2-30-8.8F 2 CSHH, M14 x2 X 30, C8.8, FT
2 1010739 1 Rear Step, Left
2A 302-10 2 Washer, Lock, 5/8
2B 100-M16-2-40-8.8F 2 CSHH, M16x2 X 40, C8.8, FT

7-18
26 23
22
20
16
24 18 21 15
27 12A 3
19 21 13
9
12B
17
7
27 2A 12
8
2C
25 2B 3
12B
FRONT AXLE ASSEMBLY
8 27
24 27 4 14 12A
8 6
18 13
16
19
5
21
21
Figure 7-7
17
4
20 2B
22 2C
10 1E
23 13 2B 1F
12A 6
15
12B 1G
1D 1I
2 1H 1F
1A 1E
2D
2E 12B
11 1C
14
1B
2 12A
13
LeeBoy Model 685C Motor Grader

Front Axle Assembly Parts List

Item
1A 110014SRV 1 Axle Assembly, Front
1B 100-10-11-40-5 8 CSHH,5/8-11 X 2.5,GR5
1C 302-10 8 Washer, Lock, 5/8
1D 110161 1 Pin, 685 Front Wheel Lean Cyl.
1E 984625 2 Bushing, Front Yoke, Groove, 400
1F 984625-1 2 Bushing
1G 400-6-28 1 Roll Pin, 3/8 X 1.75
1H 857297 1 Tube, 685 Wheel Lean Cyl Mount
1I 857311 1 Tube, 685 Wheel Lean Cyl Mount
- 400-3-12 1 Roll Pin, 3/16 X 0.75
2 110033SRV 1 Spindle Mount, Front, RH (Assembly)
2A 110130 2 Bushing, McGill Mi-24
2B 855002 6 Washer, Flat, 1.250X2.063X.130 (3 are welded)
2C 80338 3 Pin, Cotter, .188X2.00
2D 302-7 8 Washer, Lock, 7/16
2E 100-16-8-120-8 8 CSHH, 1-8 X 7.5, GR8
3 110043SRV 1 Spindle Mount, Front, LH (Assembly)
4 110170 2 Clevis, 685 Front Wheel Lean
5 110182 1 Tie Rod, Wheel Lean
6 857359 3 Pin, Wheel Lean Mount (welded to washer)
7 110200 1 Ball Joint, LH
7
8 110210 3 Ball Joint, RH
- 110210-1 3 Mount, Tie Rod End (welded to 857315)
9 110192 1 Tie Rod, Steering
10 110230 1 Cylinder, Hydraulic, 3.50 X 5.00 X 1.50 Rod
- 110230-1 1 Seal Kit (not shown)
11 110112SRV 1 Steering Arm W/Axle, RH
12 110122SRV 1 LH Steering Arm W/ Axle
12A 210180 4 Bearing Cone
12B 210190 2 Bearing Cup
13 210240 4 Seal
14 110061 2 King Pin, 685/2800/300 Front
15 110101 2 Machined Nut, Artic / FE
16 110240A 2 Hub Assembly, Wheel, Idler
17 110260 2 Bearing Cone, Wheel Hub, Inner
18 36830 2 Seal, 3.628 OD X 2.250 ID X .468
19 610210 2 Bearing Cone

7-20
26 23
22
20
16
24 18 21 15
27 12A 3
19 21 13
9
12B
17
7
27 2A 12
8
2C
25 2B 3
12B
8 27
27 4
24 14 12A
8 6
18 13
16
19
5
FRONT AXLE ASSEMBLY (CONT.)
21
21
17
Figure 7-7
4
20 2B
22 2C
10 1E
23 13 2B 1F
12A 6
15
12B 1G
1D 1I
2 1H 1F
1A 1E
2D
2E 12B
11 1C
14
1B
2 12A
13

Front Axle Assembly Parts List (Cont.)
Item
20 110300 2 Thick Washer, 685/3000 Front
21 110310 4 Nut, Front Spindle, 685/3000
22 110320 2 Lock Washer, 685/3000 Front Spindle
23 110330 2 Dust Cap, 685/3000 Front Wheel
24 110350A 16 Stud, Wheel, AWD
- 120350A 16 Lug Nut (not shown)
26 988284 1 Group, Front Axle
27 200-6-16-5 4 Nut, Hex, Jam, Heavy, 3/8-16, GR5

7-22
18D
18C
18A
18D
18B
2C 18E
2D
16 12
17
14A
10
3 15A
11 18
21 20
2B 13A
1 5
14A 11
Figure 7-8
17 9 7
6 15B
15A
15B 19A 13
15A 14 13
8
14A
6
4 15
19
FRONT WHEEL ASSIST / AWD (OPTION) ASSEMBLY
15B
18 2B
2B
23
22
22
23
2A 1A

Front Wheel Assist / AWD (Option) Parts List
Item
1 981935 1 Subassembly, Front Wheel Assist
1A 986369 1 Axle Assembly, Front, 685B W/AWD
2A 110220 1 Cylinder, Hydraulic, 2.50 X 12.00 x 1.50 Rod
2B 110210 3 Ball Joint, RH
2C 110200 1 Ball Joint, LH
2D 202-6-16-5 3 Nut, Hex, Jam, Heavy, 3/8-16, GR5
3 140615 1 Fitting, Grease, 45 1/4-28
4 986366 1 Spindle Mount, RH, 685 AWD
5 110130 2 Bushing, 1.5" OD x 1.25" ID x 1.0"
6 210040 2 McGill Mi-32-N
- 302-7 16 Washer, Lock, 7/16
7 859375 1 Shaft, Front Wheel Lean
- 140610 5 Fitting, Lube, Straight, 1/4"-28 (not shown)
8 110170 2 Clevis, 685 Front Wheel Lean
9 986364 1 Steering Arm Assembly, RH AWD
10 986365 1 Spindle Mount, LH, 685 AWD (includes bushings)
11 210040 2 McGill Mi-32-N
12 110130 1 Bushing, 1.5"ODx1.25"IDx1.0"
- 859377 1 Roll Pin, 3/8x1.75
13 857377 4 Spindle Mount Clamp, 685 AWD
13A
14
14A
102-611-1A
857368
80338
8
2
3
CSHH, .625-11X2.50, GR5
Shaft, 685 AWD Ft. Wheel Lean
Cotter Pin, .188X2.00
7
15 110230 1 Cylinder, Hydraulic, 3.50X5.00x1.50 Rod (includes 4 bushings)
15A 855002 6 Washer, 1.250X2.063, Clevis Pin
15B 857359 3 Pin, 685 Wheel Lean Mount (welded with washer)
16 986363 1 Steering Arm Assembly, LH AWD
17 110210-1 3 Mount, Tie Rod End
18 112870 2 Wheel Drive Assembly
18A BL30000-16 1 Manifold, Equa-Trac, AWD
18B BL30000-17 1 Solenoid Valve, Equa-Trac
18C 104378 1 Coil, Solenoid Valve
18D X280 4 FITT, STR 10MJ-12MB
18E 71775 2 FITT, 90 12MJ-12MB
19 110161 1 Pin, Cylinder, Wheel Lean

FRONT WHEEL ASSIST / AWD (OPTION) ASSEMBLY (CONT.)
23
22
22
23
18C
13A
18
18B
1A
13
19
18E
15B
14
13
15A
14A
15
18D
10
19A
15B
2B
18A
2C
16 12
15B
11
15A
17
18D
14A
15A
11
14A
2D
20
2A
5
6
21
4
6
2B
3
917
18
2B
1
Figure 7-8

Front Wheel Assist / AWD (Option) Parts List (Cont.)
Item
19A 400-6-28 1 Roll Pin, 3/8 x 1.75
20 101-10-11-24-5 1 Nut, Hex, Jam, Heavy, 3/8-16, GR5
21 110192 1 Tie Rod, Steering Tie Rod, Steering
22 984625-1 2 Bushing
23 984625 2 Bushing, Front Yoke, Groove, 400

BOOM, 10’ TURNTABLE MOLDBOARD ASSEMBLY (W/OUT AWD)
7
Figure 7-9

Boom, 10’ Turntable Moldboard Assembly (w/out AWD) Parts List
Item
1 988283 1 Boom, Group See Figure 7-2
Ref. 986750 1 Group, Boom, AWD, 685 See Figure 7-2 for AWD Boom
2 130050 2 Cylinder, Hydraulic, 2.50X22.00X1.50 Rod See Figure 7-11
3 986755 1 10 Ft. Turntable Moldboard (entire assembly)
4 130004 1 Weldment, Turntable See Figure 7-12
5 130243 1 Subassembly, 685 Moldboard Slide See Figure 7-13
7 130204 1 Subassembly, Moldboard, 10’ See Figure 7-13
9 130031 1 Rod W/Ends, 685 Moldboard See Figure 7-10
* NOTE: There is a 12’ Turntable Moldboard

option as well; see Figure 7-14 for an exploded
view of the 12’ Moldboard.

MOLDBOARD DRAWBAR ASSEMBLY (W/OUT AWD)
1
9
10
9
9A
5
11
6
8 (Welded
7 on Boom)
1 4 (WELDMENT)
12C
12A 12B
12
12C
2A
5
7
86
Figure 7-10

Moldboard Drawbar Assembly Parts List

Item
1 988283 1 Boom
2 130014-1SRV 1 Moldboard Drawbar Assembly
2A 220360 2 Bushing,1.00 IDX1.25 ODX1.00
3 857578 1 Plate, 685 Turntable Top Dust
4 130101 1 Socket Half, Drawbar Pull Ball (welded to Drawbar)
5 130106 1 Ball, Drawbar Pull
6 130104 1 Shim, .030, Drawbar Pull Ball
7 130105 1 Shim (.055), 685B Drawbar Pull
8 130103 1 Shim (.025), 685B Drawbar Pull
9 130020 2 Cylinder, Hydraulic, 2.50 X 32.00 X 1.50 Rod (connects To 130224SRV)
9A 80338 2 Pin, Cotter, .188X2.00
- 930041 2 Bushing, Tension, 1.25 ODX1.00 ID, .50 LG (not shown; f/ 130020)
- 130020-01 1 Seal Kit (not shown; f/ 130020)
10 130231SRV 4 Pin, 685 Moldboard Slide to Turntable
11 103421 1 Socket-Pull Ball-Welded on Boom
12 130031 1 Rod W/Ends, 685 Moldboard
12A 101-20-7-72-8F 1 CSHH, Heavy, 1-1/4-7 X 4.5, GR8,FT (connects to 100024 - Boom)
12B 100-20-7-72-5F 1 CSHH, 1-1/4-7 X 4.5, GR5, FT
12C 204-20-7-5 2 Nut, Lock, Stover, 1-1/4-7, GR5
NOTE: Item No. 9 is an option referred
7
to in the manual sometimes as “Circle
Sideshift”; see Pages 3-8 and 3-9 for more
information.

MOLDBOARD LIFT ASSEMBLY (IN ALL MODELS)
3B
1 3C
3A
1A
1C
1D
1F
1G 1B
1E
Figure 7-11

Moldboard Lift Assembly Parts List

Item
1 130050 2 Cylinder, Hydraulic, 2.50 X 22.00 X 1.50 Rod w/130050-01 (Seal Kit)
- 930041 2 Bushing, Tension, 1.25 ODX1.00 ID, .50 LG (not shown)
1A Ref. 2 Cylinder, Hydraulic, 2.50 X 22.00 X 1.50 Rod (body only)
1B 130060 2 Ball Joint, Moldboard Lift
1C 100080B 4 Bushing (2 pair)
1D 300-6 4 Washer, Flat, 3/8”
1E 302-6 4 Lock Washer, 3/8”
1F 100-6-16-16-5F 4 CSHH, 3/8-16 X 1, GR5, FT
1G 858953 4 Washer, Flat, .438 X 2.50 X .188
2 988283 1 Boom
3 130004 1 Turntable and Moldboard Assembly
3A 80338 2 Pin, Cotter, .188X2.00
3B 206 -14-14-5 2 Nut, Hex, Castle, .875-14
3C 300-14 2 Washer, Flat, SAE, .875

TURNTABLE ASSEMBLY (IN ALL MODELS)
4&5
9
8
6
1A
7 8 1B
7 10
3
2B
13
2A 12
11
1B
1A
1
1
1B
Figure 7-12

Turntable Assembly Parts List

Item
1 130224SRV 1 Turntable, 685 Moldboard Assembly Sub-assembly
1A 220360 2 Bushing, 1.00 ID X 1.25 OD X 1.00
1B 1009981 2 Bushing, 685 Moldboard Tilt
2A 130231 2 Pin, 685 Moldboard Slide
2B 100250 2 Washer, Flat, 1.500 X 2.50
3 130232 2 Pin, Cotter, .250 X 2.25
4 857614 1 Disc, .625 X 28.750, W/6.00 Hole (Welded to 5)
5 857608 1 Ring, 685 Turntable (Welds to Drawbar)
6 857591 1 Pin, 685 Moldboard Tilt Cylinder
7 855002 2 Washer, Flat, 1.250 X 2.063 X .130
8 80338 2 Cotter Pin
10 857585SRV 1 Pin, 685 Moldboard Tilt Cylinder
11 100-7-14-60-8 6 CSHH, 7/16-14 X 3, GR8, FT
12 300-20 6 Washer, Flat, SAE, 1-1/4
13 204-20-7-5 6 Nut, Lock, Stover, 1-1/4-7, GR5

MOLDBOARD ASSEMBLY (10’)
19
19A
2A
19B
2
13
13A
9
18 11 10
17
1 16 8 3D
14
12 3C
15
11 10
5
6 (KIT) 7A
3B 3A
4 7B
5
7
Figure 7-13

Moldboard (10’) Assembly Parts List

Item
1 130204SRV 1 Moldboard Assembly, 10' (Sub-assembly)
2 130243SRV 1 Moldboard Slide Assembly
2A 930041 2 Bushing, Tension, 1.25OD X 1.00 ID
3A 857281 1 Plate, 685 Moldboard Upper
3B 857335 1 Plate, 685 Moldboard LH End
3C 857336 1 Plate, 685 Moldboard RH End
3D 220360 1 Bushing, 1.00 ID X 1.25 OD X 1.00
4 130210 1 Cutting Edge, 10', Moldboard
5 130180 2 Curved End Bit, 685 Moldboard
6 130210-1SRV 12 Bolt Kit, Cutting Edge, 10' Entire kit
7 130220 20 Plow Bolt, .625-11 X 2.00
7A 200-20-12-5LH 20 Nut, Hex, 1-1/4-12, GR5, LH
7B 302-7 20 Washer, Lock, 7/16
8 130172SRV 1 Dirt Guard, 685 Moldboard
9 857665 2 Moldboard Slide End Assembly (includes 130130)
10 130141 2 Clamp, Moldboard Slide, Upper
11 130161 2 Clamp, Moldboard Slide, Lower (includes 130150)
12 130261 1 Moldboard Center Clamp
13 119-10-11-48 4 Set S, SQHD, Flat, 1/2-13 X 2.5
13A 202-10-11-5 4 Hex, Jam, Nut
14 100-10-11-56-5 8 CSHH, 5/8-11 X 3.5, GR5
15
16
17
100-10-11-48-5
100-10-11-24-5F
200-10-11-5
8
3
8
CSHH, 5/8-11 X 3, GR5
CSHH, 5/8-11 X 1.5, GR5, FT
Nut, Hex, 5/8-11, GR5
7
18 302-10 19 Washer, Lock, 5/8
- 130150 2 Shim, Moldboard Lower Clamp (not shown)
- 130121 2 Shim, 685 Moldboard Top (not shown)
- 130251 1 Shim, 685 Moldboard Center (not shown)
- 130130 2 Shim (3 Hole), 685 Moldboard (not shown)
19 130110 1 Cylinder, Hydraulic, 3.00 X 36.00 X 1.75 ROD
19A 210060 2 Pin, Clevis, 1.00 X 2.625 W/1.5 HD
19B 80338 2 Pin, Cotter, .188 X 2.00

TURNTABLE MOLDBOARD ASSEMBLY (12’)
5 4
3B 3A
3C
1
2
6A 6B
2
6C
Figure 7-14

Turntable Moldboard (12’) Assembly Parts List

Item
1 985171 1 12’ Moldboard from 1005406 and 1005407 (Entire Assembly)
Assembly
2 853860 2 Cutting Edge, 6’
3 130172 1 Guard, Dirt, Moldboard
3B 204-7-14-5 6 Nut, Lock, Stover, 7/16-14, GR5
3C 100-7-14-24-5 6 CSHH, .437-14 X 1.50, GR5
4 130180 2 Curved End Bit, 685 Moldboard
5 220360 1 Bushing, 1.00 IDX1.25 OD X 1.00
6A 116-7 24 Nut, Hex, .625-11
6B 130220 24 Plot Bolt, .625-11 X 2.00
6C 118-7 24 Washer, Lock, .625

FRONT DOZER BLADE ASSEMBLY (OPTION)
3 7
5
5
4 2A
6
2B
Figure 7-15

Front Dozer Blade Assembly (option) Parts List

Item
1 982027SRV 1 Front Dozer Blade (Optional)
2A 1006198 1 Front Dozer (Sub-assembly)
2B 131020 1 Cutting Edge, 7’, Front Blade
3 131090 1 Cylinder, Hydraulic, 2.50 X 15.00 x 1.50 Rod
- 930041 2 Bushing, Tension, 1.25OD X 1.00ID (not shown; f/ 131090)
- 131090-01 1 Seal Kit (not shown; f/ 131090)
4 1006197 1 Shaft, Lower Front Pivot
5 859363SRV 2 Arm, Upper Pivot (1 is welded to 2-#7s)
6 100 6243 1 Shaft, Lower Rear Pivot, 685 Front Blade (both ends are welded)
7 131061SRV 2 Shaft, Front Blade, Upper Pivot
- 100250 4 Washer, Flat, 1.500 X 2.50 (not shown)
- 984892 2 Pin, Cotter, .250 X 3.00 (not shown)
8 858963 1 Bar, Round With Hole
9 131033SRV 1 Frame, Front Blade Lower (welded w/#6)

SCARIFIER ASSEMBLY (OPTION)
3B
3A
3A
4
4A 4A
Figure 7-16

Scarifier Assembly (option) Parts List

Item
1 1010770 1 Weldment, Rear Scarifier Mount
2 1010700 1 Weldment, Frame, 685C
3A 132040 5 Shank W/Tooth, Scarifier
3B 132031 5 Pin, Lock, Scarifier Tooth
4A 100-16-8-88-8 2 CSHH, 1-8X5.50, GR 8
- 930041 2 Bushing, Tension, 1.25ODX1.00ID (not shown)

CAB AND CANOPY
Figure 7-17

Cab and Canopy Parts List

Item
1 1010801 1 Cab (option) Details of Cab are shown in
Figure 7-18
2 1010899 1 Canopy Shown with vandalism cover;
details of Canopy are shown in
Figure 7-19

7-44
28C 44G
44B
44E
19
28B
28A 44F
18
44C
28B 34
28E 28H
28G 27 4B 44A
28D (Welded)
28F
28 - ASSEMBLY, STEP, 685C 6 5
16 44D
22 10
CAB (OPTION) ASSEMBLY
11
43
22 42
32 44
35 31 36
16 44 - A/C/HEAT ASSEMBLY
38 3
30
26 43 42 39 2015 7
4C
Figure 7-18
14 2
12 29 40
37
13
24
25 20 27
8 28 (ASSY.)
1
4A 17
(Welded) 17 29 12
21 9 41
27
6 3
33
23
46 5
28 (ASSY.) 23
45
7
42 AND 43

Cab (Option) Assembly Parts List

Item
1 1010801 1 Cab (option)
2 1010861 1 Cab Door, LH
3 851156 2 Knob, Round Ball, 1.375 X .375-16
4A 983026 2 Right Door Latch Assembly (Welded)
4B 983027 2 Left Door Latch Assembly (Welded)
4C 982415 2 Handle
5 982415 2 Handle, Door, Push Button
- 35560 1 Key (not shown)
6 980678 2 Plate, 685 Cab Door Inner
7 982416 2 Striker Bolt 2.025" Long
8 1010871 1 Weldment, Cab Door, RH
9 1010872 1 Plate, Access Panel, Seat Box
10 1010873 1 Plate, Access Panel, Front
11 859133 9 Plate, 685 Cab Wiring Cover (hole dia. is 9/32)
12 140591 1 Plate, 685 Floor Board Access
13 1010886 1 Assembly, Access Door
- 1010887 1 Plate, Access Door
- 160450 1 Latch, Engine Access Panel Door
14 1011120 1 Plate, Hand Control Opening Cover
15 1010894 2 Plate, Diffuser Mount
16 1011198 4 Louver, 2.7 Sonora Front Panel
7
17 1011201 2 Louver, Pacifica Narrow Frame W/O Holes
18 1010874 1 Plate, Ceiling, Front
19 1010875 1 Plate, Ceiling, Rear
20 1010882 2 Door Open Latch Bolted as one piece
21 1010884 2 Door Open Latch Ext.
22 38392 2 Bumper, 1.50OD X .75
23 12754576 4 Cab Isolation Mount - Two Piece
24 1011114 1 Plate, Washer Bottle Mount
25 151200 1 Tank, Windshield Wiper Washer
26 1010794 1 Drop In Cup Holder
27 1003862 6 Light, 4.5", Tractor
28 1010891 2 Step Assembly
28A 1010892 1 Plate, Step Bracket
28B 983383 2 Rubber, 5 Ply., Frame Step
28C 985512SRV 1 Step Assembly, 11.5" Long
28D 985513 1 Step Assembly, 8.5" Long
28E 1007855 2 Bar, Step Mount End

7-46
28C 44G
44B
44E
19
28B
28A 44F
18
44C
28B 34
28E 28H
28G 27 4B 44A
28D (Welded)
28F
28 - ASSEMBLY, STEP, 685C 6 5
CAB ASSEMBLY (CONT.)
16 44D
22 10
11
43
22 42
32 44
35 31 36
16 44 - A/C/HEAT ASSEMBLY
38 3
30
26 43 42 39 2015 7
14 4C
Figure 7-18
12 29 40 2
37
13
24
25 20 27
8 28 (ASSY.)
1
4A 17
(Welded) 17 29 12
21 9 41
27
6 3
33
23
46 5
28 (ASSY.) 23
45
7
42 AND 43

Cab Assembly Parts List (Cont.)
Item
28F 100-7-14-48-8FT 8 CSHH, 7/16-14 X 3, GR8, FT
28G 300-18 8 Washer, Flat, SAE, 1-1/4
28H 204-20-7-5 8 Nut, Lock, Stover, 1-1/4-7, GR5
29 1010893 2 Plate, Threshold
30 1010896 1 Instrument Panel, Cab
31 38840 1 Light, Dome
32 35425 1 Defrost Fan Assembly, 12 Volt
33 1010790-01 1 Sound Insulation, Floor Mat Pre-Cut Foam
34 1010790-02 1 Sound Insulation, Headliner Pre-Cut Foam
35 1010790-03 1 Sound Insulation, Rear Pre-Cut Foam
36 1010790-04 1 Sound Insulation, LH Pre-Cut Foam
37 1010790-05 1 Sound Insulation, RH Pre-Cut Foam
38 1010790-06 1 Sound Insulation, Front LH Pre-Cut Foam
39 1010790-07 1 Sound Insulation, Front RH Pre-Cut Foam
40 1010790-08 1 Sound, Insulation, Front, Bottom, LH Pre-Cut Foam
41 1010790-09 1 Sound, Insulation, Front, Bottom, RH Pre-Cut Foam
42 10623 2 Mirror Arm
43 151370 2 Mirror, Outside Rearview
44 - 1 A/C/Heat Assembly (pictoral only)
44A 853700 1 Kit, A/C/Heat, 3000 (not included f/Canopy)
44B 1010876 1 Plate, A/C Condenser Mounting Bracket, LH
44C
44D
44E
1010877
1010878
1010889
1
1
1
Plate, A/C Condenser Mounting Bracket, RH
A/C Hose Channel
Plate, Beacon Light Mount Brace
7
44F 1010890 1 Plate, Beacon Light Mount Panel
44G 210893 1 Beacon Light, Amber Strobe
45 1010791 1 Sound Insulation, Floor Mat, Canopy
46 988293 - Door Seal, Window Frame To Cab (order by the foot)
47 1010888 1 Beacon Light Mount Assembly

CANOPY ASSEMBLY
11
13
12
10
5
7
4 1
2
6
Figure 7-19

Canopy Assembly Parts List

Item
1 1010899 1 Weldment, Canopy
2 1011120 1 Plate, Hand Control Opening Cover
3 1010872 1 Plate, Access Panel, Seat Box
4 1010886 1 Assembly, Access Door Panel
- 35560 1 Key (not shown)
5 859133 10 Plate, 685 Cab Wiring Cover
6 1011323 1 Weldment, Floor Board Access
7 720260 1 Rear View Mirror
8 151370 2 Mirror, Outside Rearview
9 10 623 2 Mirror Arm
10 100 3862 2 Light, 4.5”, Tractor
11 1010888 1 Assembly, Beacon Light Mount
12 1010877 1 Plate, A/C Condenser Mounting Bracket, RH
13 1010876 1 Plate, A/C Condenser Mounting Bracket, LH
NOTE: See Cab Exploded View (Figure 7-18)

for internal details of the Canopy Assembly.

MOTOR, WINDSHIELD WIPER AND MISC.
2
12
3
13
10 8
6
11
Figure 7-20

Motor, Windshield Wiper and Misc. Parts List

Item
1 1010895 1 Heater & A/C Evaporator Unit
2 151170 2 Motor, Windshield Wiper
3 151180 2 Windshield Wiper Arm
4 151190 2 Windshield Wiper, 20" Blade
5 1011124 1 Plate, Wiper Motor Cover (Rear)
6 1011114 1 Plate, Washer Bottle Mount
7 151200 1 Windshield Wiper Washer Tank
8 720260 1 Inside Rearview Mirror
9 1011314 1 Radio, AM/FM/CD, W/Aux. Input (option)
10 1002021 1 Antenna, AM/FM, Flexible
11 852520 1 Backup Alarm
12 1011200 2 Louver, 4.0 Sonora Front Panel & Retainer
13 852810 1 Nozzle Kit, Windshield Washer

VANDALISM ASSEMBLY (OPTION)
1 4
Figure 7-21

Vandalism Assembly (option) Parts List

Item
1 1011325 1 Angle, Vandalism Cover Retainer, Rear
2 1011326 1 Plate, Vandalism Cover Retainer, Bottom
3 1011327 1 Vandalism Cover, Canopy Only
4 35812 1 Access Cover Latch/Lock

HEATER AND A/C EVAPORATOR UNIT

2
1
8
9
4
5
6
7
Figure 7-22

Heater and A/C Evaporator Unit Parts List

Item
- 1010895 1 Heater & A/C Evaporator Unit
1 1010895-01 1 Blower Fan
2 1010895-02 1 Blower Motor
3 12755045 1 Evaporator Assembly
4 12755496 1 Cold Control
5 36745-18 1 Fan Switch
6 12755494 1 Cable Control Assembly
7 12755492 3 Knob
8 12755490 1 Recirc. Filter
9 367 45-20 2 Knob

A/C COMPRESSOR
3
4
1 4
2
Figure 7-23

A/C Compressor Parts List

Item
1 P204324 1 Compressor, A/C
- 300-6 4 Washer, Flat, SAE, 3/8 (not shown; to Item 2)
- 302-6 2 Washer, Lock, 3/8 (not shown; to Item 2)
- 200-6-16-5 2 Nut,Hex,3/8-16,GR5 (not shown; to Item 2)
- 100-6-16-32-5 2 CSHH,3/8-16 X 2,GR5 (not shown; to Item 2)
2 1009339 1 Compressor Mount
- 300-6 4 Washer, Flat, SAE, 3/8 (not shown; to engine)
- 302-6 4 Washer, Lock, 3/8 (not shown; to engine)
- 100-6-16-16-5F 4 CSHH,3/8-16 X 1,GR5, FT (not shown; to engine)
3 1009338 2 Tension Arm
4 10 09337 2 Spacer
5 1008969 1 V-Belt

ENGINE COVER ASSEMBLY
19
31
13
20
29
32
2
30
23
22
21
16
1
19
28
15
13
10
34
33
7
26
25
24
3
8
3A
34 17
34
14
3C
2
12
33
27
18
3B
3D
5/6
9
4
11
10
19
18
36
35
37
Figure 7-24

Engine Cover Assembly Parts List

Item
- 1010730 1 Engine Cover Assembly
1 1010731 1 Tank, Hydraulic, 27.5 Gallon
2 1010749 2 Plate, Door Span
3 1011053 1 Assembly, Air Cleaner (Entire Assembly)
3A 1011053-01 1 Clamp, Filter
3B 1011053-02 1 Cover, Filter
3C 1011053-03 1 Filter, Replacement
3D 1011053-04 1 Vacuator Valve
4 983544 2 9” Band
5/6 1011278 2 Air Cleaner Mount
7 1011081 1 Precleaner, 4.5", Enginaire
8 1010745 1 Cover, Hood
9 1010750 2 Plate, Door, Engine Cover
10 160450 2 Latch, Engine Access Panel Door
- 35560 1 Key (for the door) (not shown)
11 1010960 2 Door Stop And Catch
12 1010753 2 Mount, Radiator, Spacer
13 1010754 2 Plate, Cover, Tank, Hydraulic, Door
14 1010961 1 Radiator Access Door And Hinge
15 1010756 1 Plate, Tank, Cover, Hydraulic Cleanout
16 1010765 1 Plate, Mount, Coolant Overflow
7
17 983273 1 Tank, Radiator Overflow
18 1010752 2 Mount, Radiator
19 1010736 4 Plate, Cover, Support, Engine
20 500070 1 Gauge, Sight Level/Temp, Hydraulic Oil
21 140030GK 1 Strainer & Gasket Kit
22 140030FN 1 Filler Neck, Hydraulic Oil/Fuel Cap
23 140030FL 1 Cap, Fuel Tank, Lockable
24 1008650 1 Engine, Cummins (shown as partial)
25 115284 1 Muffler Assembly, All, Nelson
26 161250 1 3” Muffler Clamp
27 161250 1 Clamp, Muffler 3"
28 982522 1 Toobox Assembly, Frame Mount
29 982254 1 Plate, Battery Box Top
30 Ref. 1 Bracket, Anchor
31 Ref. 1 Bracket, Hood
32 Ref. 1 Hook, Rubber

ENGINE COVER ASSEMBLY (CONT.)
19
31
13
20
29
32
2
30
23
22
21
16
1
19
28
15
13
10
34
33
7
26
25
24
3
8
3A
34 17
34
14
3C
2
12
33
27
18
3B
3D
5/6
9
4
11
10
19
18
36
35
37
Figure 7-24

Engine Cover Assembly Parts List (Cont.)
Item
33 1010769 - Kit, Engine Insulation
34 1011166 4 Door Hinge
35 1010740 1 Cover, Radiator
36 1007529 2 Light, Brake
37 1010748 1 Plate, Grill

BATTERY BOX AND BATTERY ASSEMBLY
2
9 8 6
12
7
5
4
9
10
3
1A 14
16 13
1B
1
15
18
12
10
9
11
17
19
Figure 7-25

Battery Box and Battery Assembly Parts List

Item
1 982253 1 Plate, Battery Box (mounted to Frame/Channel)
1A 302-8 4 Washer, Lock, 1/2
1B 100-8-13-10-5F 4 CSHH, 1/2-13 X .625, GR5, FT
2 982254 1 Plate, Battery Box Top
3 982962 1 Battery Holdown Assembly
4 1011182 2 Battery, 12V, 835 CCA, Group 24
5 109740 1 Switch, Master Disconnect, Battery
6 122795 1 Cable, Battery, Positive To Positive, 17”
7 122796 1 Cable, Battery, Positive To Iso SW, 22”
8 122797 1 Cable, Battery, Negative To Negative, 17”
9 122798 1 Cable, Battery, Negative To Starter Gnd., 42” (Bundle to Starter and Switch)
10 120632 1 Cable, Starter Positive To Iso Sw.
11 120642 1 Cable, Starter Ground To Frame
12 1011365 1 Cable, Positive, Battery Disconnect To Starter
13 007020097 1 Bracket, Anchor
14 007020098 1 Bracket, Hood
15 007020096 1 Hook, Rubber
16 1011224 1 Plate, Battery Disconnect Switch Bracket
- 985877 1 Rubber Pad, 25.5X8x.125TH, Rib (not shown*)
17 1008650-01 1 Cummins Starter
18 204-6-16-5 2 Nut, Lock, Stover, 3/8-16, GR5
19 100-6-16-152-5 2 CSHH, 3/8-16X9.5, GR5
7
* NOTE: Rubber Mat (Parts A
& B) not shown - located in the
floor of Item No. 1.

FUEL SYSTEM
7 8
6
3
1B 1A
1C
Figure 7-26

Fuel System Parts List

Item
1 1010757 1 Tank, Fuel, 31 Gallon (mounts to Frame/Channel)
1B 302-8 4 Washer, Lock, 1/2
1C 100-8-13-20-5F 4 CSHH, 1/2-13 X 1.25, GR5
2 12757874 1 Fuel Tank Fill Neck
3 1010900 2 Fuel Tank Rubber Reducer 2.25 To 2"
4 1010901 1 Fuel Tank Rubber Reducer 45°
5 1011265 1 Round Tube, Fuel Filler, Short
6 1011266 1 Round Tube, Fuel Filler, Long
7 140040 1 Fuel Sender (Internal to the Fuel Tank)
8 140030FL 1 Cap Fuel Tank, Lockable

RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY
11B
11A 6
4
10
9
5
4
8
12
1
3
12
Figure 7-27

Radiator and Hydraulic Oil Cooler Assembly Parts List

Item
1 988646 1 Radiator/Cooler & Chg. Air, Tier 3
- 300-8 4 Washer, Flat, SAE, 1/2 (not shown; f/mount)
- 302-8 4 Washer, Lock, 1/2 (not shown; f/mount)
- 100-8-13-24-5 4 CSHH, 1/2-13 X 1.5, GR5 (not shown; f/mount)
2 983273 1 Tank, Radiator Overflow
- 302-6 6 Washer, Lock, 3/8 (not shown; f/overflow)
- 100-6-16-16-5F 6 CSHH, 3/8-16 X 1, GR5, FT (not shown; f/overflow)
- 200-6-16-5 6 Nut, Hex, 3/8-16, GR5 (not shown; f/overflow)
- 984130 1 Hose Clamp (not shown)
- 5LOLA 1 Hose, .312 (Sold Per Foot) (not shown)
3 1010718 2 Radiator Mount
4 440040 2 Shock Mount, Seat/Engine
5 1010997 2 Bar, Radiator To Shroud Mount
6 35812 1 Radiator Access Cover Latch/Lock
7 988147 1 Radiator Hose, Upper
8 984263 1 Radiator Hose 30° Elbow
9 1009137 1 Radiator Tube, Bent
10 1008963 1 Radiator Hose 90° Elbow
11A 981164 2 Radiator Rubber Flashing (Top and Bottom)
11B 986163 2 Radiator Rubber Flashing (Sides)
- 100-5-18-16-5F 20 CSHH, 5/16-18 X 1, GR5, FT (not shown; f/flashing)
-
-
12
300-5
981511
1010753
20
20
2
Washer, Flat, SAE, 5/16
Washer, Fender, .375
Mount, Radiator, Spacers
(not shown; f/flashing)
(not shown; f/flashing) 7

HYDRAULIC PUMP ASSEMBLY
3A
7
6A
4A 3B 6B
4B 6C
3C
4
3
2B 6
1
2A
Figure 7-28

Hydraulic Pump Assembly Parts List

Item
1 1009952 1 Rear Axle
2 1000569 1 Motor, Hydraulic, 4.92 Cir., 2-Speed (mounts to Axle)
2A 302-M14 4 Washer, Lock, Split, 16MM
2B 102-M14-2.0-50-8.8F 4 Socket Head Cap Screw, 16MM-2.0 X 3.125, GR8.8, FT
3 1000567 1 Pump, Hydraulic, 4.57 Cir., Man., B-Pad, RH (to Adapter Plate)
3B 302-8 4 Washer, Lock, 1/2
3C 100-M10-1.5-40-8.8F 4 Bolt, Hex, 12MM-1.5 X 2.5, GR8.8, FT
4 987743 1 Adapter, Pump To Engine (mounts to Engine)
4A 302-6 12 Washer, Lock, 3/8
4B 100-6-16-16-5F 12 CSHH,3/8-16 X 1,GR5, FT
5 1008684 1 Engine ASM Cummins
6 160260 1 Auxiliary Pump (Piggyback) (to Hydraulic Pump)
6B 302-6 2 Washer, Lock, 3/8
6C 100-6-16-16-5F 2 CSHH,3/8-16 X 1,GR5,FT
7 36808 1 O-Ring, 3.237 ID X .103, SAE 152
NOTE: For more
information on the
Rear Axle, see
the ‘APL-2943’,
7
which has been
appended to this
IPL.

ENGINE, CUMMINS
16 17
1
19
26
24 22 24
23 25
20
27
21 13
28
18
31
4
29
30
3
10
2
8
14 12
6 11
9
15
Figure 7-29

Engine, Cummins Parts List

Item
1 100 8969 1 V-Belt
2 160300-1 1 Shaft, Flywheel, Pump Drive
3 160300 1 Plate, Drive
4 987743 1 Adapter,Pump To Engine
5 1010655 1 Engine Oil Drain Bracket
6 1010196 2 Bracket, Engine Mount, Front
7 120533 1 Bracket, Engine Mount, RH
8 120534 1 Bracket, Engine Mount, LH
9 113360 4 Engine Rubber Mount
10 100 8684 1 Engine, Cummins
11 988666-04 1 Element, Fuel Filter, 4.5QSB
12 988666-03 1 Element, Oil Filter, 4.5QSB
13 1008650-02 1 Fan Spacer
14 987743 1 Adapter, Pump To Engine
15 113683 4 Washer
16 987282 3 Tube, High Temp, 3" 90°
17 982779 1 Tube, High Temp, 3" 45°
18 855195 1 Tube, 3" Aluminum, 11" Lg. (behind the engine)
19 1009196 1 Tube, Bent, 3"
20 853521170 1 4 To 3 Hump Rubber Reducer
21 34031 1 3" 90° Rubber
22
23
24
953521245
1011133
1011134
1
1
1
3 To 3 Hump Rubber
Pipe, 3.00 X 12.00, Aluminum, Air Intake
Pipe, 3.00 X 5.50, Aluminum, Air Intake
7
25 171090 5 Clamp, 3.00 T-Bolt
26 953521243 1 Clamp, 4.00 T-Bolt
27 36600 8 Clamp, T-Bolt, 4.00 ID
28 983454 1 Fan, 22”, Blower
29 984263 1 Hose, Radiator, 2.25 ID, 30 Deg.
30 1009137 1 Pipe, Radiator, Lower
31 100 8963 1 Hose Radiator, 90 Deg., 2” ID

STEERING WHEEL, SEAT AND PEDALS
1
6
Figure 7-30

Steering Wheel, Seat and Pedals Parts List

Item
1 12754910 1 Seat Plate
2 1011196 4 Square Tube, Seat Plate Spacer
3 100 9335 1 Seat, Vinyl
4 988240 1 Assembly, Foot Pedal
5 1010517 1 Foot Brake Valve & Pedal
6 1010789 1 Console
7 N/A - Steering Column And Wheel (pictoral reference only)

STEERING WHEEL AND CONTROL CONSOLE ASSEMBLY
12
1B
11
18
7 1C
23
9 5B
1A
20 15 22
AWD ON / OFF Switch (Option)
17
13
14C
14A
14B 16
21
19
24
7 5D 9
4
9
5B
5E
8
5A
3
8
5D
2A 5C
2B
Valve Lever Bracket Assembly Valve Lever Assembly 6
Figure 7-31

Steering Wheel and Control Console Assembly Parts List

Item
1A 985051 1 Housing, 685 AWD, Switch
1B 500040 1 Switch, Toggle, SPST, 2-Position
1C 113-5-18-6 2 Set S, HSKT, Cup, 5/16-18X0.375
- 910058 6 Kit, Valve Lever Bracket
2A 910058-01 1 Bracket
2B 100-4-20-14F 2 CSSH, 1/4-20X0.875, FT
- 901010 6 Kit, Valve Lever Link Arm
3 901010 1 Link Arm
4 140630-1 4 Lever, For 141000 Box
- 140630-2 2 Lever, For 141000 Box (2 In Center) (shown as 140630-1)
- 1006586 4 Assembly, Valve Lever, 685
5B 140531 4 Lever, Control
5C 140571 1 Arm Actuator Valve Lever
5D 2 02-8-13-5 2 Nut, Hex, Jam, 1/2-13, GR5
5E 140551 1 Block, Lever Mount
- 140610 1 Fitting, Lube, Str., 1/4”-28
6 140560 1 Link, Master, #100 Chain
7 920225 4 Knob, Round Ball, 1-7/8"X1/2-13
8 989177 1 Valve Assembly, 10 Section
9 1010789 1 Weldment, Console
7
11 33687 1 Turn Signal W/Hazard, 7-Wire
12 112662 1 Horn Button
13 200-20-12-5 5 Nut, Hex, 1-1/4-12, GR5
14A 31877 2 Wingnut, .375-16
14B 302-6 2 Washer, Lock, 3/8
14C 300-6 2 Washer, Flat, SAE, 3/8
15 140661 1 Plate, Steer, Console, Low, Cover
16 1010768 1 Kit, Gas Spring
17 140641A 1 Plate, 685 10 Section Valve
18 984130 1 Hose Clamp
19 36128 1 Steering Column, 6.00, W/Wire
20 115772 1 Steering Wheel, 14"
21 1011258 2 Spring, Extension, .105 X .875 X 8.500
22 35136-4 1 Plug, Hole, .500,Flush Mt., Plstc.
23 300020 1 Nut, Hex, .813-20
24 140500 1 Motor, Hyd., Power Steering

DEAD ENGINE STEERING (OPTION) ASSEMBLY
Figure 7-32

Dead Engine Steering (option) Parts List

Item
- 982057 1 Dead Engine Steering (Option)
1 685020 1 Motor & Pump, Dead Engine Steering
2 36871 1 Valve, Check, Dead Engine Steering
3 160520 1 Switch, Press, 685 Dead Engine Steering
4 160260 1 Pump, Hydraulic, Gear, Tandem, .84 & .58 Cir.
5 P7 8556A 1 Check Valve, Tandem Hydraulic, Pump
6 1011351 1 Kit, Hose, Dead Engine Steering
7 720290 1 Solenoid, 12V, Constant Duty
- 1011338 1 Plate, Motor Mount, Dead Engine Steering (not shown)

INSTRUMENT PANELS (CANOPY AND CAB)
18
23
1
24
21
22
2
7
20
13
14 15
16
19
3 9
4A
4B
11
6A 13 13
17
15
12
6
8
10
Figure 7-33

Instrument Panel Parts List

Item
1 1010896 1 Instrument Panel Assembly, Cab (in the Cab only)
2 1001571 1 Instrument Panel, 685 Tier 3
3 31983 1 Light, Red, Dash, .50 Hole
4A 1001625 1 Light, Amber, Dash, .50 Hole
4B 31985 1 Light, Green,Dash, .50 Hole
5 31985 1 Light, Green, Dash, .50 Hole
6 39146-14 1 Switch, Ignition, W/Heat St.
6A 982008-04 1 Ignition Key
7 985855 1 Gauge, Temp
8 35366 1 Gauge, Fuel Level
9 985853 1 Gauge, Press, Oil, J1939
10 985854 1 Gauge, Volt Meter, J1939
11 985852 1 Gauge, Tachometer W/Hour
12 35701 6 Circuit Breaker, 25A, Pan Mt.
13 851391 3 Switch, Toggle, SPST, 2-Pos
14 851392 1 Switch, Toggle, 3-Pos, SPDT, Mom
15 853090 2 Switch, Wiper/Washer (3000)
16 982250 1 Switch, Light, W/Harness
17 35136-3 2 Plug, Hole, .375, Flush Mt., Plastic
- 1011191 1 Instrument Panel Assembly, Secondary (Entire Assembly)
18 1011178 1 Plate, Instrument Panel, Secondary
7
19 100 5965 1 Switch, Emergency Stop, Base W/Button
20 100 5967 3 Switch, Emergency Stop, N/O Contact
21 851090624 2 Switch,Toggle, SPDT, 2-Pos
24 851090613 1 Switch, Toggle, SPDT, 3-Pos

INSTRUMENT PANEL (CANOPY ONLY)
2
14
7
15
15 16
13
9
3
17 15 13
4
5
6A 12
8
10
11
Figure 7-34

Instrument Panel Parts List

Item
1 1011159 1 Instrument Panel Assembly, Canopy
2 1001571 1 Instrument Panel, 685 Tier 3
4 1001625 1 Light, Amber, Dash, .50 Hole
5 31985 1 Light, Green, Dash, .50 Hole
6 39146-14 1 Switch, Ignition, W/Heat St.
6A 982008-04 1 Ignition Key
7 985855 1 Gauge, Temp.
8 35366 1 Gauge, Fuel Level
9 985853 1 Gauge, Press, Oil, J1939
10 985854 1 Gauge, Volt Meter, J1939
11 985852 1 Gauge, Tachometer W/Hour Meter
12 35701 6 Circuit Breaker, 25A, Pan Mt.
14 851392 1 Switch, Toggle, 3-Pos, SPDT, Mom
15 851441 3 Weather Boot, Toggle Switch
16 982250 1 Switch, Light, W/Harness
17 35136-3 5 Plug, Hole, .375, Flush Mt., Plstc.

HYDRAULIC VALVE BANK (BLOCK 10 STACK)
Figure 7-35

Hydraulic Value Bank (BLOCK 10 STACK) Parts List
Item No. Part Number Qty. Description Remarks

- 989177 Valve Assembly, 10-Section
1 910056 1 Cover, Valve Outlet, V-20
2 901002 1 Power Beyond Sleeve, V-20 Valve
3 141010 1 Dust Boot, V-20 Valve Spool
4 910058 1 Bracket, Valve Lever Mount
5 141020 1 Valve & Plug, Anti Cavitation
6 901009 1 Valve, Main Relief, V-20
7 910055 1 Cover, Valve Inlet, V-20
8 853590 3 Bolt Kit, 10 Section Valve, 20”
9 910054 10 Valve Section, Spring Return
10 910062 1 Seal Kit, Valve Section, V20
11 901014 1 Spring Center Kit, V-20 Valve
12 141040 1 Cap, Valve Spool End Spring
13 141050 1 Float Positioner Kit, V-20
14 901007 1 Detent Kit, V-20 Valve Spool
15 910059 1 Seal Kit, Valve Spool, V20
16 141060 1 Clevis, Valve Spool End (V20 | Valve)
- 140641A 1 Plate, 685 10 Section Valve (not shown)

HYDRAULIC VALVES
18
19
20
11 13
14
12
15
17
5
16 4
3
10
9
10A
6
8
7
Figure 7-36

Hydraulic Valves Parts List

Item
1 160380 1 Valve, Solenoid, Pump Destroke
2 100190 1 Valve, Check, Articulation Lock
3 853850 1 Valve, Solenoid, Fwd./Rev. Shift (Parking Brake)
4 984876 1 Mount, 2 Speed Valve
5 983361 1 Valve, Trans Shift (2-Speed Valve)
6 750602 1 Manifold W/Relief, 3000 Brake
7 852720 1 Switch, Brake, Low Press, Set at 1300PSI
8 852740 1 Valve, Brake Charge
9 1010390 1 Accumulator, 60 CI, Brake Sys.
10 550214 1 Manifold, Hydraulic Return
10A 1011007 1 Kit, Hose, 685C With Dana Bogie (Entire Kit)
11 290010 1 Filter Head, Hydraulic Charge/Return
12 290030 1 Filter Element, Hydraulic Charge
13 980560 1 Strainer, Hydraulic Suction, 8816
14 36123 1 Strainer, Hydraulic Suction, 200 Mesh
15 140640 1 Valve, Gate, 1.250
16 6339 1 Valve, Gate, 1.00
- 1011007-01 1 Schematic Hose Layout (Begins on Page 6-19)
- 1011252 1 Kit, Hydraulic Hose, AWD (not shown)
17 685010 1 Diffuser, Hydraulic Tank Return, 2.00
18 140030HL 1 Cap, Hydraulic, Lockable
19
20
140030FN
140030GK
1
1
Filler Neck, Hyd Oil/Fuel Cap
Strainer & Gasket Kit 7

Alphabetical Parts Index (API)
ALPHABETICAL PARTS INDEX (API)

ITEM
DESCRIPTION PART NUMBER FIG. NO. NO.
10 Ft. Turntable Moldboard 986755 Figure 7-9 3
12’ Moldboard from 1005406 AND 1005407 Assembly 985171 Figure 7-14 1
3 To 3 Hump Rubber 953521245 Figure 7-29 22
3" 90° Rubber 34031 Figure 7-29 21
3” Muffler Clamp 161250 Figure 7-24 26
4 To 3 Hump Rubber Reducer 853521170 Figure 7-29 20
7/8-14 Locknut 95383832 Figure 7-3 3A
9” Band 983544 Figure 7-24 4
A/C Hose Channel 1010878 Figure 7-18 44D
A/C/Heat Assembly - Figure 7-18 44
Access Cover Latch/Lock 35812 Figure 7-21 4
Accumulator, 60 CI, Brake System 1010390 Figure 7-36 9
Adapter, Pump To Engine 987743 Figure 7-28 4
Air Cleaner Mount 1011278 Figure 7-24 5
Angle, Vandalism Cover Retainer, Rear 1011325 Figure 7-21 1
Antenna, AM/FM, Flexible 1002021 Figure 7-20 10
Arm Actuator Valve Lever 140571 Figure 7-31 5C
Arm, Upper Pivot 859363SRV Figure 7-15 5
Assembly, Access Door Panel 1010886 Figure 7-19 4
Assembly, Access Door 1010886 Figure 7-18 13
Assembly, Air Cleaner 1011053 Figure 7-24 3
Assembly, Beacon Light Mount 1010888 Figure 7-19 11
Assembly, Foot Pedal 988240 Figure 7-30 5
Assembly, Moldboard Lift Trunion 100161 Figure 7-2 13
Assembly, Trunion Mount 100152 Figure 7-2 12
Assembly, Valve Lever 1006586 Figure 7-31 -
Auxiliary Pump (Piggyback) 160260 Figure 7-28 6
AWD Axle 981935 Figure 7-5 2
Axle Assembly, Front 110014SRV Figure 7-7 1A
Axle Assembly, Front 986369 Figure 7-8 1A
Axle, Drive Assembly, Dana 150 Bogie 1009952 Figure 7-3 3
Backup Alarm 852520 Figure 7-20 11
Ball Joint, LH 110200 Figure 7-8 2C
Ball Joint, RH 110210 Figure 7-8 2B
Ball Joint, LH 110200 Figure 7-7 7
Ball Joint, Moldboard Lift 130060 Figure 7-11 1B

ITEM
Ball Joint, RH 110210 Figure 7-7 8
Ball, Drawbar Pull 130106 Figure 7-10 5
Bar, Radiator To Shroud Mount 1010997 Figure 7-27 5
Bar, Round With Hole 858963 Figure 7-15 8
Bar, Step Mount End 1007855 Figure 7-18 28E
Battery Holdown Assembly 982962 Figure 7-25 3
Battery, 12V, 835 CCA, Group 24 1011182 Figure 7-25 4
Beacon Light Mount Assembly 1010888 Figure 7-18 47
Beacon Light, Amber Strobe 210893 Figure 7-18 44G
Bearing Cone 210180 Figure 7-7 12A
Bearing Cone 610210 Figure 7-7 19
Bearing Cone, Articulate Shaft 100110 Figure 7-2 5
Bearing Cone, Wheel Hub, Inner 110260 Figure 7-7 17
Bearing Cup 210190 Figure 7-7 12B
Bearing Cup, Articulate Shaft 100120 Figure 7-2 6
Block, Lever Mount 140551 Figure 7-31 5E
Blower Fan 1010895-01 Figure 7-22 1
Blower Motor 1010895-02 Figure 7-22 2
Bolt Kit, 10 Section Valve, 20” 853590 Figure 7-35 8
Bolt Kit, Cutting Edge, 10' 130210-1SRV Figure 7-13 6
Bolt, Hex, 12MM-1.5 X 2.5, GR8.8, FT 100-M10-1.5-40-8.8F Figure 7-28 3C
Boom 100024 Figure 7-4 1
Boom 988283 Figure 7-10 1
Boom
Boom (for AWD)
Boom (Group)
988283
982002
988283
Figure 7-11
Figure 7-5
Figure 7-1
2
1
2
7
Boom (Group) 988283 Figure 7-2 1A
Boom (only) 100024 Figure 7-2 -
Boom, Group 988283 Figure 7-9 1
Bracket 910058-01 Figure 7-31 2A
Bracket, Anchor Ref. Figure 7-24 30
Bracket, Anchor 7020097 Figure 7-25 13
Bracket, Engine Mount, Front 1010196 Figure 7-29 6
Bracket, Engine Mount, LH 120534 Figure 7-29 8
Bracket, Engine Mount, RH 120533 Figure 7-29 7
Bracket, Hood Ref. Figure 7-24 31
Bracket, Hood 7020098 Figure 7-25 14
Bracket, Valve Lever Mount 910058 Figure 7-35 4
Bumper, 1.50OD X .75 38392 Figure 7-18 22

API (Cont.)
ITEM
Bushing 984625-1 Figure 7-7 1F
Bushing 984625-1 Figure 7-8 22
Bushing 100080B Figure 7-11 1C
Bushing, McGill Mi-24 110130 Figure 7-7 2A
Bushing, 1.00 ID x 1.25 OD x 1.00 220360 Figure 7-1 1B
Bushing, 1.00 ID X 1.25 OD X 1.00 220360 Figure 7-1 2A
Bushing, 1.00 IDX1.25 ODX1.00 220360 Figure 7-12 1A
Bushing, 1.00 ID X 1.25 OD X 1.00 220360 Figure 7-13 3D
Bushing, 1.00 ID X 1.25 OD X 1.00 220360 Figure 7-14 5
Bushing, 1.5" OD x 1.25" ID x 1.0" 110130 Figure 7-8 5
Bushing, 1.5"OD x 1.25"ID x 1.0" 110130 Figure 7-8 12
Bushing, 1.75 ID X 2.25OD X 1.50 Lg. 100080A Figure 7-2 12A
Bushing, 2.5 x 2.00 x 1.50 Lg. 100170 Figure 7-2 9
Bushing, 685 Moldboard Tilt 1009981 Figure 7-12 1B
Bushing, Front Yoke, Groove, 400 984625 Figure 7-7 1E
Bushing, Front Yoke, Groove, 400 984625 Figure 7-8 23
Bushing, Tension, 1.25 OD X 1.00 ID 930041 Figure 7-1 -
Bushing, Tension, 1.25 OD X 1.00 ID, .50 LG 930041 Figure 7-10 -
Bushing, Tension, 1.25 OD X 1.00 ID, .50 LG 930041 Figure 7-11 -
Bushing, Tension, 1.25OD X 1.00 ID 930041 Figure 7-13 2A
Bushing, Tension, 1.25OD X 1.00ID 930041 Figure 7-16 -
Bushing, Tension, 1.25OD X 1.00ID 930041 Figure 7-15 -
Bushing,1.00 ID X 1.25 OD X 1.00 220360 Figure 7-10 2A
Cab 1010801 Figure 7-18 1
Cab (option) 1010801 Figure 7-17 1
Cab Door, LH 1010861 Figure 7-18 2
Cab Isolation Mount - Two Piece 12754576 Figure 7-18 23
Cable Control Assembly 12755494 Figure 7-22 6
Cable, Battery, Negative To Negative, 17” 122797 Figure 7-25 8
Cable, Battery, Negative To Starter Gnd., 42” 122798 Figure 7-25 9
Cable, Battery, Positive To Iso SW, 22” 122796 Figure 7-25 7
Cable, Battery, Positive To Positive, 17” 122795 Figure 7-25 6
Cable, Positive, Battery Disconnect To Starter 1011365 Figure 7-25 12
Cable, Starter Ground To Frame 120642 Figure 7-25 11
Cable, Starter Positive To Iso Sw. 120632 Figure 7-25 10
Canopy 1010899 Figure 7-17 2
Cap Fuel Tank, Lockable 140030FL Figure 7-26 8

ITEM
Cap, Fuel Tank, Lockable 140030FL Figure 7-24 23
Cap, Hydraulic, Lockable 140030HL Figure 7-36 18
Cap, Valve Spool End Spring 141040 Figure 7-35 12
Check Valve, Tandem Hydraulic, Pump P78556A Figure 7-32 5
Circuit Breaker, 25A, Pan Mt. 35701 Figure 7-34 12
Circuit Breaker, 25A, Pan Mt. 35701 Figure 7-33 12
Clamp Half, 685 Articulation 100071 Figure 7-1 3
Clamp, 3.00 T-Bolt 171090 Figure 7-29 25
Clamp, 4.00 T-Bolt 953521243 Figure 7-29 26
Clamp, Filter 1011053-01 Figure 7-24 3A
Clamp, Front Axle 988328 Figure 7-4 6
Clamp, Front Axle 988328 Figure 7-5 5
Clamp, Moldboard Slide, Lower 130161 Figure 7-13 11
Clamp, Moldboard Slide, Upper 130141 Figure 7-13 10
Clamp, Muffler 3" 161250 Figure 7-24 27
Clamp, T-Bolt, 4.00 ID 36600 Figure 7-29 27
Clevis, 685 Front Wheel Lean 110170 Figure 7-8 8
Clevis, 685 Front Wheel Lean 110170 Figure 7-7 4
Clevis, Valve Spool End (V20 | Valve) 141060 Figure 7-35 16
Coil, Solenoid Valve 104378 Figure 7-8 18C
Cold Control 12755496 Figure 7-22 4
Compressor Mount 1009339 Figure 7-23 2
Compressor, A/C P204324 Figure 7-23 1
Console
Cotter Pin
Cotter Pin, .188X2.00
1010789
80338
80338
Figure 7-30
Figure 7-12
Figure 7-8
7
8
14A
7
Cover, Filter 1011053-02 Figure 7-24 3B
Cover, Hood 1010745 Figure 7-24 8
Cover, Radiator 1010740 Figure 7-24 35
Cover, Valve Inlet, V-20 910055 Figure 7-35 7
Cover, Valve Outlet, V-20 910056 Figure 7-35 1
CSHH, .437-14X1.50, GR5 100-7-14-24-5 Figure 7-14 3C
CSHH, .625-11X2.50, GR5 102-611-1A Figure 7-8 13A
CSHH, 1/2-13 X .625, GR5, FT 100-8-13-10-5F Figure 7-25 1B
CSHH, 1/2-13 X 1.25, GR5 100-8-13-20-5F Figure 7-26 1C
CSHH, 1/2-13 X 1.5, GR5 100-8-13-24-5 Figure 7-27 -
CSHH, 1-1/4-7 X 4.5, GR5, FT 100-20-7-72-5F Figure 7-10 12B
CSHH, 1-8 X 7.5, GR8 100-16-8-120-8 Figure 7-7 2E
CSHH, 1-8 X 7.5, GR8 100-16-8-120-8 Figure 7-31 -

API (Cont.)
ITEM
CSHH, 1-8X5.50, GR 8 100-16-8-88-8 Figure 7-16 4A
CSHH, 3/8-16 X 1, GR5, FT 100-6-16-16-5F Figure 7-11 1F
CSHH, 3/8-16 X 1, GR5, FT 100-6-16-16-5F Figure 7-27 -
CSHH, 3/8-16 X 1, GR5, FT 100-6-16-16-5F Figure 7-1 3B
CSHH, 3/8-16X9.5, GR5 100-6-16-152-5 Figure 7-25 19
CSHH, 5/16-18 X 1, GR5, FT 100-5-18-16-5F Figure 7-27 -
CSHH, 5/8-11 X 1.5, GR5, FT 100-10-11-24-5F Figure 7-13 16
CSHH, 5/8-11 X 3, GR5 100-10-11-48-5 Figure 7-13 15
CSHH, 5/8-11 X 3, GR8 100-10-11-48-8 Figure 7-4 7B
CSHH, 5/8-11 X 3, GR8 100-10-11-48-8 Figure 7-5 7
CSHH, 5/8-11 X 3, UNC 100-10-11-48-8 Figure 7-2 14A
CSHH, 5/8-11 X 3.5, GR5 100-10-11-56-5 Figure 7-13 14
CSHH, 5/8-11 X 2.5,GR5 100-10-11-40-5 Figure 7-7 1B
CSHH, 7/16-14 X 3, GR8, FT 100-7-14-60-8 Figure 7-12 11
CSHH, 7/16-14 X 3, GR8, FT 100-7-14-48-8F Figure 7-18 28F
CSHH, 7/8-14 X 12, GR8 100-14-14-192-8 Figure 7-3 3B
CSHH, Heavy, 1-1/4-7 X 4.5, GR8,FT 101-20-7-72-8F Figure 7-10 12A
CSHH, M14 x2 X 30, C8.8, FT 100-M14-2-30-8.8F Figure 7-6 1B
CSHH, M16x2 X 40, C8.8, FT 100-M16-2-40-8.8F Figure 7-6 2B
CSHH,1/4-20 X 1,GR5 100-4-20-16-5 Figure 7-2 1E
CSHH,3/8-16 X 1,GR5,FT 100-6-16-16-5F Figure 7-23 -
CSHH,3/8-16 X 1,GR5,FT 100-6-16-16-5F Figure 7-28 4B
CSHH,3/8-16 X 1,GR5,FT 100-6-16-16-5F Figure 7-28 6C
CSHH,3/8-16 X 2,GR5 100-6-16-32-5 Figure 7-23 -
CSSH, 1/4-20 X 0.875, FT 100-4-20-14F Figure 7-31 2B
CSSQH, 3/4-10 X 2.5, FT 124-12-10-40F Figure 7-31 10
Cummins Starter 1008650-01 Figure 7-25 17
Curved End Bit, 685 Moldboard 130180 Figure 7-14 4
Curved End Bit, 685 Moldboard 130180 Figure 7-13 5
Cutting Edge, 10', Moldboard 130210 Figure 7-13 4
Cutting Edge, 6’ 853860 Figure 7-14 2
Cutting Edge, 7’, Front Blade 131020 Figure 7-15 2B
Cylinder, Hydraulic, 2.00 X 12.00 X 1.00 Rod 851436 Figure 7-16 4
Cylinder, Hydraulic, 2.50 X 12.00 x 1.50 Rod 110220 Figure 7-8 2A
Cylinder, Hydraulic, 2.50 X 15.00 x 1.50 Rod 131090 Figure 7-15 3

ITEM
Cylinder, Hydraulic, 2.50 X 22.00 X 1.50 Rod Ref. Figure 7-11 1A
Cylinder, Hydraulic, 2.50X22.00X1.50 ROD 130050 Figure 7-9 2
Cylinder, Hydraulic, 2.50X32.00X1.50 ROD 130020 Figure 7-9 8
Cylinder, Hydraulic, 3.00 X 6.00 X 1.25 Rodulation 100060 Figure 7-1 4
Cylinder, Hydraulic, 3.00X36.00X1.75 Rod 130110 Figure 7-9 6
Cylinder, Hydraulic, 3.00X36.00X1.75 Rod 130110 Figure 7-13 19
Cylinder, Hydraulic, 3.50X5.00x1.50 Rod 110230 Figure 7-8 15
Dead Engine Steering (Option) 982057 Figure 7-32 -
Defrost Fan Assembly, 12 Volt 35425 Figure 7-18 32
Detent Kit, V-20 Valve Spool 901007 Figure 7-35 14
Diffuser, Hydraulic Tank Return, 2.00 685010 Figure 7-36 17
Dirt Guard, 685 Moldboard 130172SRV Figure 7-13 8
Disc, .625 X 28.750, W/6.00 Hole 857614 Figure 7-12 4
Door Hinge 1011166 Figure 7-24 34
Door Open Latch 1010882 Figure 7-18 20
Door Open Latch Ext. 1010884 Figure 7-18 21
Door Seal, Window Frame To Cab 988293 Figure 7-18 46
Door Stop And Catch 1010960 Figure 7-24 11
Drop In Cup Holder 1010794 Figure 7-18 26
Dust Boot, V-20 Valve Spool 141010 Figure 7-35 3
Dust Cap, 685/3000 Front Wheel
Element, Fuel Filter, 4.5QSB
Element, Oil Filter, 4.5QSB
110330
988666-04
988666-03
Figure 7-7
Figure 7-29
Figure 7-29
23
11
12
7
Engine ASM Cummins 1008684 Figure 7-28 5
Engine Cover Assembly 1010730 Figure 7-24 -
Engine Oil Drain Bracket 1010655 Figure 7-29 5
Engine Rubber Mount 113360 Figure 7-29 9
Engine, Cummins 1008650 Figure 7-24 24
Engine, Cummins 1008684 Figure 7-29 10
Evaporator Assembly 12755045 Figure 7-22 3
Fan Spacer 1008650-02 Figure 7-29 13
Fan Switch 36745-18 Figure 7-22 5
Fan, 22”, Blower 983454 Figure 7-29 28
Filler Neck, Hyd Oil/Fuel Cap 140030FN Figure 7-36 19
Filler Neck, Hydraulic Oil/Fuel Cap 140030FN Figure 7-24 22
Filter Element, Hydraulic Charge 290030 Figure 7-36 12

API (Cont.)
ITEM
Filter Head, Hydraulic Charge/Return 290010 Figure 7-36 11
Filter, Replacement 1011053-03 Figure 7-24 3C
FITT, 90 12MJ-12MB 71775 Figure 7-8 18E
FITT, STR 10MJ-12MB X280 Figure 7-8 18D
Fitting, Grease, 45 1/4-28 140615 Figure 7-8 3
Fitting, Lube, Str., 1/4”-28 140610 Figure 7-2 -
Fitting, Lube, Str., 1/4”-28 140610 Figure 7-31 -
Fitting, Lube, Straight, 1/4"-28 140610 Figure 7-8 -
Float Positioner Kit, V-20 141050 Figure 7-35 13
Foot Brake Valve & Pedal 1010517 Figure 7-30 6
Frame, Front Blade Lower 131033SRV Figure 7-15 9
Front Axle 988284 Figure 7-4 2
Front Dozer (Sub-assembly) 1006198 Figure 7-15 2A
Front Dozer Blade (Optional) 982027SRV Figure 7-4 5
Front Dozer Blade (Optional) 982027SRV Figure 7-15 1
Front Wheel Weldment, 12.25 X 19.5 100519 Figure 7-5 3C
Fuel Sender 140040 Figure 7-26 7
Fuel Tank Fill Neck 12757874 Figure 7-26 2
Fuel Tank Rubber Reducer 2.25 To 2" 1010900 Figure 7-26 3
Fuel Tank Rubber Reducer 45° 1010901 Figure 7-26 4
Gauge, Fuel Level 35366 Figure 7-33 8
Gauge, Fuel Level 35366 Figure 7-34 8
Gauge, Press, Oil, J1939 985853 Figure 7-33 9
Gauge, Press, Oil, J1939 985853 Figure 7-34 9
Gauge, Sight Level/Temp, Hydraulic Oil 500070 Figure 7-24 20
Gauge, Tachometer W/Hour 985852 Figure 7-33 11
Gauge, Tachometer W/Hour Meter 985852 Figure 7-34 11
Gauge, Temp 985855 Figure 7-33 7
Gauge, Temp. 985855 Figure 7-34 7
Gauge, Volt Meter, J1939 985854 Figure 7-33 10
Gauge, Volt Meter, J1939 985854 Figure 7-34 10
Group, Boom, AWD, 685 986750 Figure 7-9 Ref.
Group, Front Axle 988284 Figure 7-3 6
Group, Front Axle 988284 Figure 7-7 26
Guard, Dirt, Moldboard 130172 Figure 7-14 3
Handle 982415 Figure 7-18 4C
Handle, Door, Push Button 982415 Figure 7-18 5

ITEM
Heater & A/C Evaporator Unit 1010895 Figure 7-20 1
Heater & A/C Evaporator Unit 1010895 Figure 7-22 -
Hex, Jam, Nut 202-10-11-5 Figure 7-13 13A
Hitch, Pintle 100180 Figure 7-1 6
Hook, Rubber Ref. Figure 7-24 32
Hook, Rubber 7020096 Figure 7-25 15
Horn Button 112662 Figure 7-31 12
Hose Clamp 984130 Figure 7-27 -
Hose Clamp 984130 Figure 7-31 18
Hose Radiator, 90 Deg., 2” ID 1008963 Figure 7-29 31
Hose, .312 (Sold Per Foot) 5LOLA Figure 7-27 -
Hose, Radiator, 2.25 ID, 30 Deg. 984263 Figure 7-29 29
Housing, 685 AWD, Switch 985051 Figure 7-31 1A
Hub Assembly, Wheel, Idler 110240A Figure 7-7 16
Ignition Key 982008-04 Figure 7-33 6A
Ignition Key 982008-04 Figure 7-34 6A
Inside Rearview Mirror 720260 Figure 7-20 8
Instrument Panel Assembly, Cab 1010896 Figure 7-33 1
Instrument Panel Assembly, Canopy 1011159 Figure 7-34 1
Instrument Panel Assembly, Secondary 1011191 Figure 7-33 -
Instrument Panel, 685 Tier 3 1001571 Figure 7-33 2
Instrument Panel, 685 Tier 3 1001571 Figure 7-34 2
Instrument Panel, Cab 1010896 Figure 7-18 30
Key
Key
Key (for the door)
35560
35560
35560
Figure 7-19
Figure 7-18
Figure 7-24
-
-
-
7
King Pin, 685/2800/300 Front 110061 Figure 7-7 14
Kit, Gas Spring 1010768 Figure 7-31 16
Kit, Valve Lever Bracket 910058 Figure 7-31 -
Kit, Valve Lever Link Arm 901010 Figure 7-31 -
Kit, A/C/Heat, 3000 853700 Figure 7-18 44A
Kit, Engine Insulation 1010769 Figure 7-24 33
Kit, Hose, 685C With Dana Bogie 1011007 Figure 7-36 10A
Kit, Hose, Dead Engine Steering 1011351 Figure 7-32 6
Kit, Hydraulic Hose, AWD 1011252 Figure 7-36 -
Knob 12755492 Figure 7-22 7
Knob 36745-20 Figure 7-22 9
Knob, Round Ball, 1.375 X .375-16 851156 Figure 7-18 3
Knob, Round Ball, 1-7/8" X 1/2-13 920225 Figure 7-31 7

API (Cont.)
ITEM
Latch, Engine Access Panel Door 160450 Figure 7-18 -
Latch, Engine Access Panel Door 160450 Figure 7-24 10
Left Door Latch Assembly (Welded) 983027 Figure 7-18 4B
Left Wheel, Tire Assembly, W/ Dana 1010197L Figure 7-3 1
Lever, Control 140531 Figure 7-31 5B
Lever, For 141000 Box 140630-1 Figure 7-31 4
Lever, For 141000 Box (2 In Center) 140630-2 Figure 7-31 -
LH Steering Arm W/ Axle 110122SRV Figure 7-7 12
Light Kit 852560 Figure 7-2 2
Light Kit 852560 Figure 7-4 8
Light, 4.5", Tractor 1003862 Figure 7-18 27
Light, 4.5”, Tractor 1003862 Figure 7-19 10
Light, Amber, Dash, .50 Hole 1001625 Figure 7-33 4A
Light, Amber, Dash, .50 Hole 1001625 Figure 7-34 4
Light, Brake 1007529 Figure 7-24 36
Light, Dome 38840 Figure 7-18 31
Light, Green, Dash, .50 Hole 31985 Figure 7-33 5
Light, Green, Dash, .50 Hole 31985 Figure 7-34 5
Light, Green,Dash, .50 Hole 31985 Figure 7-33 4B
Light, Red, Dash, .50 Hole 31983 Figure 7-33 3
Link Arm 901010 Figure 7-31 3A
Link, Master, #100 Chain 140560 Figure 7-31 6
Lock Washer, 3/8” 302-6 Figure 7-11 1E
Lock Washer, 685/3000 Front Spindle 110320 Figure 7-7 22
Louver, 2.7 Sonora Front Panel 1011198 Figure 7-18 16
Louver, 4.0 Sonora Front Panel & Retainer 1011200 Figure 7-20 12
Louver, Pacifica Narrow Frame W/O Holes 1011201 Figure 7-18 17
Lug Nut 120350A Figure 7-7 -
Lug Nut (AWD Axle) 120350A Figure 7-5 -
Lug Nut (non-AWD Axle) 120350A Figure 7-4 9
Machined Nut, Artic / FE 110101 Figure 7-7 15
Main Frame 1010700 Figure 7-1 1A
Main Frame 1010700 Figure 7-3 3D
Manifold W/Relief, 3000 Brake 750602 Figure 7-36 6
Manifold, Hydraulic Return 550214 Figure 7-36 10

ITEM
Manifold, Equa-Trac, AWD BL30000-16 Figure 7-8 18A
McGill Mi-32-N 210040 Figure 7-8 6
McGill Mi-32-N 210040 Figure 7-8 11
Mirror Arm 10623 Figure 7-18 42
Mirror Arm 10623 Figure 7-19 9
Mirror, Outside Rearview 151370 Figure 7-18 43
Mirror, Outside Rearview 151370 Figure 7-19 8
Moldboard Assembly, 10' 130204SRV Figure 7-13 1
Moldboard Center Clamp 130261 Figure 7-13 12
Moldboard Drawbar Assembly 130014-1SRV Figure 7-10 2
Moldboard Slide Assembly 130243SRV Figure 7-13 2
Moldboard Slide End Assembly 857665 Figure 7-13 9
Moldboard Trunion 859317 Figure 7-2 8
Motor & Pump, Dead Engine Steering 685020 Figure 7-32 1
Motor, Hyd., Power Steering 140500 Figure 7-31 24
Motor, Hydraulic, 4.92 Cir., 2-Speed 1000569 Figure 7-28 2
Motor, Windshield Wiper 151170 Figure 7-20 2
Mount, Tie Rod End 110210-1 Figure 7-7 -
Mount, Tie Rod End 110210-1 Figure 7-8 17
Mount, 2 Speed Valve 984876 Figure 7-36 4
Mount, Radiator 1010752 Figure 7-24 18
Mount, Radiator, Spacer 1010753 Figure 7-24 12
Mount, Radiator, Spacers 1010753 Figure 7-27 12
Muffler Assembly, All, Nelson
Nozzle Kit, Windshield Washer
Nut, Articulating Shaft
115284
852810
100141
Figure 7-24
Figure 7-20
Figure 7-2
25
13
3
7
Nut, Front Spindle, 685/3000 110310 Figure 7-7 21
Nut, Hex, .625-11 116-7 Figure 7-14 6A
Nut, Hex, .813-20 300020 Figure 7-31 23
Nut, Hex, 1-1/4-12, GR5, LH 200-20-12-5LH Figure 7-13 7A
Nut, Hex, 1-1/4-12, GR5, LH 200-20-12-5LH Figure 7-31 13
Nut, Hex, 3/8-16, GR5 200-6-16-5 Figure 7-27 -
Nut, Hex, 5/8-11, GR5 200-10-11-5 Figure 7-13 17
Nut, Hex, Castle, .875-14 206-14-14-5 Figure 7-11 3B
Nut, Hex, Jam, 1/2-13, GR5 202-8-13-5 Figure 7-31 5D
Nut, Hex, Jam, Heavy, 3/8-16, GR5 200-6-16-5 Figure 7-7 27
Nut, Hex, Jam, Heavy, 3/8-16, GR5 202-6-16-5 Figure 7-8 2D
Nut, Hex, Jam, Heavy, 3/8-16, GR5 101-10-11-24-5 Figure 7-8 20
Nut, Lock, Stover, 1-1/4-7, GR5 204-20-7-5 Figure 7-12 13

API (Cont.)
ITEM
Nut, Lock, Stover, 1-1/4-7, GR5 204-20-7-5 Figure 7-18 28H
Nut, Lock, Stover, 1-1/4-7, GR5 204-20-7-5 Figure 7-10 12C
Nut, Lock, Stover, 3/8-16, GR5 204-6-16-5 Figure 7-25 18
Nut, Lock, Stover, 7/16-14, GR5 204-7-14-5 Figure 7-14 3B
Nut, Hex, 3/8-16, GR5 200-6-16-5 Figure 7-23 -
O-Ring, 3.237 ID X .103, SAE 152 36808 Figure 7-28 7
Partial Boom (for AWD only) 982002 Figure 7-2 1B
Pin, Cylinder, Wheel Lean 110161 Figure 7-8 19
Pin, Moldboard Lift Cylinder 858965 Figure 7-2 12B
Pin, 685 Front Wheel Lean Cylinder 110161 Figure 7-7 1D
Pin, 685 Moldboard Slide 130231 Figure 7-12 2A
Pin, 685 Moldboard Slide to Turntable 130231SRV Figure 7-10 10
Pin, 685 Moldboard Tilt Cylinder 857591 Figure 7-12 6
Pin, 685 Moldboard Tilt Cylinder 857585SRV Figure 7-12 10
Pin, 685 Wheel Lean Mount 857359 Figure 7-8 15B
Pin, Clevis, 1.00 X 2.625 W/1.5HD 210060 Figure 7-1 5
Pin, Clevis, 1.00X2.625 W/1.5 HD 210060 Figure 7-13 19A
Pin, Cotter, .188X2.00 80338 Figure 7-7 2C
Pin, Cotter, .188X2.00 80338 Figure 7-10 9A
Pin, Cotter, .188X2.00 80338 Figure 7-11 3A
Pin, Cotter, .188X2.00 80338 Figure 7-13 19B
Pin, Cotter, .250X2.25 130232 Figure 7-12 3
Pin, Cotter, .250X3.00 984892 Figure 7-15 -
Pin, Lock, Scarifier Tooth 132031 Figure 7-16 3B
Roll Pin, 3/8 X 1.75 400-6-28 Figure 7-7 1G
Pin, Wheel Lean Mount 857359 Figure 7-7 6
Pipe, 3.00 X 12.00, Aluminum, Air Intake 1011133 Figure 7-29 23
Pipe, 3.00 X 5.50, Aluminum, Air Intake 1011134 Figure 7-29 24
Pipe, Radiator, Lower 1009137 Figure 7-29 30
Plate, 685 Cab Wiring Cover 859133 Figure 7-19 5
Plate, Access Door 1010887 Figure 7-18 -
Plate, Access Panel, Seat Box 1010872 Figure 7-19 3
Plate, Battery Box 982253 Figure 7-25 1
Plate, Hand Control Opening Cover 1011120 Figure 7-19 2
Plate, 685 10 Section Valve 140641A Figure 7-31 17
Plate, 685 10 Section Valve 140641A Figure 7-35 -
Plate, 685 AWD Boom Side 857406 Figure 7-2 1C

ITEM
Plate, 685 Cab Door Inner 980678 Figure 7-18 6
Plate, 685 Cab Wiring Cover 859133 Figure 7-18 11
Plate, 685 Floor Board Access 140591 Figure 7-18 12
Plate, 685 Moldboard LH End 857335 Figure 7-13 3B
Plate, 685 Moldboard Lift Trunion Back 100163 Figure 7-2 12C
Plate, 685 Moldboard RH End 857336 Figure 7-13 3C
Plate, 685 Moldboard Upper 857281 Figure 7-13 3A
Plate, 685 Turntable Top Dust 857578 Figure 7-10 3
Plate, A/C Condenser Mounting Bracket, LH 1010876 Figure 7-18 44B
Plate, A/C Condenser Mounting Bracket, LH 1010876 Figure 7-19 13
Plate, A/C Condenser Mounting Bracket, RH 1010877 Figure 7-18 44C
Plate, A/C Condenser Mounting Bracket, RH 1010877 Figure 7-19 12
Plate, Access Panel, Front 1010873 Figure 7-18 10
Plate, Access Panel, Seat Box 1010872 Figure 7-18 9
Plate, Battery Box Top 982254 Figure 7-24 29
Plate, Battery Box Top 982254 Figure 7-25 2
Plate, Battery Disconnect Switch Bracket 1011224 Figure 7-25 16
Plate, Beacon Light Mount Brace 1010889 Figure 7-18 44E
Plate, Beacon Light Mount Panel 1010890 Figure 7-18 44F
Plate, Ceiling, Front 1010874 Figure 7-18 18
Plate, Ceiling, Rear 1010875 Figure 7-18 19
Plate, Cover, Support, Engine 1010736 Figure 7-24 19
Plate, Cover, Tank, Hydraulic, Door 1010754 Figure 7-24 13
Plate, Diffuser Mount
Plate, Door Span
Plate, Door, Engine Cover
1010894
1010749
1010750
Figure 7-18
Figure 7-24
Figure 7-24
15
2
9
7
Plate, Drive 160300 Figure 7-29 3
Plate, Grill 1010748 Figure 7-24 37
Plate, Hand Control Opening Cover 1011120 Figure 7-18 14
Plate, Instrument Panel, Secondary 1011178 Figure 7-33 18
Plate, Motor Mount, Dead Engine Steering 1011338 Figure 7-32 -
Plate, Mount, Coolant Overflow 1010765 Figure 7-24 16
Plate, Steer, Console, Low, Cover 140661 Figure 7-31 15
Plate, Step Bracket 1010892 Figure 7-18 28A
Plate, Tank, Cover, Hydraulic Cleanout 1010756 Figure 7-24 15
Plate, Threshold 1010893 Figure 7-18 29
Plate, Vandalism Cover Retainer, Bottom 1011326 Figure 7-21 2
Plate, Washer Bottle Mount 1011114 Figure 7-18 24
Plate, Washer Bottle Mount 1011114 Figure 7-20 6

API (Cont.)
ITEM
Plate, Wiper Motor Cover (Rear) 1011124 Figure 7-20 5
Plot Bolt, .625-11X2.00 130220 Figure 7-14 6B
Plow Bolt, .625-11 X 2.00 130220 Figure 7-13 7
Plug, Hole, .375, Flush Mt., Plastic 35136-3 Figure 7-33 17
Plug, Hole, .375, Flush Mt., Plastic 35136-3 Figure 7-34 17
Plug, Hole, .500,Flush Mt., Plastic 35136-4 Figure 7-31 22
Power Beyond Sleeve, V-20 Valve 901002 Figure 7-35 2
Precleaner, 4.5", Enginaire 1011081 Figure 7-24 7
Pump, Hydraulic, 4.57 Cir., Man., B-Pad, RH 1000567 Figure 7-28 3
Pump, Hydraulic, Gear, Tandem, .84 & .58 Cir. 160260 Figure 7-32 4
Radiator Access Cover Latch/Lock 35812 Figure 7-27 6
Radiator Access Door And Hinge 1010961 Figure 7-24 14
Radiator Hose 30° Elbow 984263 Figure 7-27 8
Radiator Hose 90° Elbow 1008963 Figure 7-27 10
Radiator Hose, Upper 988147 Figure 7-27 7
Radiator Mount 1010718 Figure 7-27 3
Radiator Rubber Flashing (Sides) 986163 Figure 7-27 11B
Radiator Rubber Flashing (Top and Bottom) 981164 Figure 7-27 11A
Radiator Tube, Bent 1009137 Figure 7-27 9
Radiator/Cooler & Chg. Air, Tier 3 988646 Figure 7-27 1
Radio, AM/FM/CD, W/Aux. Input 1011314 Figure 7-20 9
Rear Axle 1009952 Figure 7-28 1
Rear Step, Left 1010739 Figure 7-6 2
Rear Step, Right 982560 Figure 7-6 1
Rear View Mirror 720260 Figure 7-19 7
Recirc. Filter 12755490 Figure 7-22 8
Right Door Latch Assembly (Welded) 983026 Figure 7-18 4A
Right Wheel, Tire Assembly, W/ Dana 1010197R Figure 7-3 2
Rim, 12" X 19.5" 120330B Figure 7-3 10
Ring, 685 Turntable 857608 Figure 7-12 5
Rod W/Ends, 685 Moldboard 130031 Figure 7-9 9
Rod W/Ends, 685 Moldboard 130031 Figure 7-10 12
Roll Pin, 3/16 X 0.75 400-3-12 Figure 7-7 -
Roll Pin, 3/8 x 1.75 400-6-28 Figure 7-8 19A
Roll Pin, 3/8x1.75 859377 Figure 7-8 -
Round Tube, Fuel Filler, Long 1011266 Figure 7-26 6
Round Tube, Fuel Filler, Short 1011265 Figure 7-26 5

ITEM
Rubber Pad, 25.5X8x.125TH, Rib 985877 Figure 7-25 -
Rubber, 5 Ply., Frame Step 983383 Figure 7-18 28B
Schematic Hose Layout 1011007-01 Figure 7-36 -
Seal 210240 Figure 7-7 13
Seal Kit 100060-1 Figure 7-1 -
Seal Kit, Valve Section, V20 910062 Figure 7-35 10
Seal Kit, Valve Spool, V20 910059 Figure 7-35 15
Seal, 3.628 OD X 2.250 ID X .468 36830 Figure 7-7 18
Seal, Articulation Shaft 100090 Figure 7-2 4
Seat Plate 12754910 Figure 7-30 1
Seat, Vinyl 1009335 Figure 7-30 3
Set S, HSKT, Cup, 5/16-18X0.375 113-5-18-6 Figure 7-31 1C
Set S, SQHD, Flat, 1/2-13X2.5 119-10-11-48 Figure 7-13 13
Shaft, 685 AWD Ft. Wheel Lean 857368 Figure 7-8 14
Shaft, Articulation Joint 100102 Figure 7-2 7
Shaft, Flywheel, Pump Drive 160300-1 Figure 7-29 2
Shaft, Front Blade, Upper Pivot 131061SRV Figure 7-15 7
Shaft, Front Wheel Lean
Shaft, Lower Front Pivot
Shaft, Lower Rear Pivot, 685 Front Blade
859375
1006197
1006243
Figure 7-8
Figure 7-15
Figure 7-15
7
4
6
7
Shank W/Tooth, Scarifier 132040 Figure 7-16 3A
Shim (.025), 685B Drawbar Pull 130103 Figure 7-10 8
Shim (.055), 685B Drawbar Pull 130105 Figure 7-10 7
Shim (3 Hole), 685 Moldboard 130130 Figure 7-13 -
Shim, 685 Moldboard Center 130251 Figure 7-13 -
Shim, 685 Moldboard Top 130121 Figure 7-13 -
Shim, Moldboard Lower Clamp 130150 Figure 7-13 -
Shim, .030, Drawbar Pull Ball 130104 Figure 7-10 6
Shock Mount, Seat/Engine 440040 Figure 7-27 4
Socket Half, Drawbar Pull Ball 130101 Figure 7-10 4
Socket Head Cap Screw, 16MM-2.0 X 3.125, GR8.8, FT 102-M14-2.0-50-8.8F Figure 7-28 2B
Socket-Pull Ball-Welded on Boom 103421 Figure 7-10 11
Solenoid Valve, Equa-Trac BL30000-17 Figure 7-8 18B

API (Cont.)
ITEM
Solenoid, 12V, Constant Duty 720290 Figure 7-32 7
Sound Insulation, Floor Mat 1010790-01 Figure 7-18 33
Sound Insulation, Floor Mat, Canopy 1010791 Figure 7-18 45
Sound Insulation, Front LH 1010790-06 Figure 7-18 38
Sound Insulation, Front RH 1010790-07 Figure 7-18 39
Sound Insulation, Headliner 1010790-02 Figure 7-18 34
Sound Insulation, LH 1010790-04 Figure 7-18 36
Sound Insulation, Rear 1010790-03 Figure 7-18 35
Sound Insulation, RH 1010790-05 Figure 7-18 37
Sound, Insulation, Front, Bottom, LH 1010790-08 Figure 7-18 40
Sound, Insulation, Front, Bottom, RH 1010790-09 Figure 7-18 41
Spacer 1009337 Figure 7-23 4
Spindle Mount Clamp, 685 AWD 857377 Figure 7-8 13
Spindle Mount, Front, LH (Assembly) 110043SRV Figure 7-7 3
Spindle Mount, Front, RH (Assembly) 110033SRV Figure 7-7 2
Spindle Mount, LH, 685 AWD 986365 Figure 7-8 10
Spindle Mount, RH, 685 AWD 986366 Figure 7-8 4
Spring Center Kit, V-20 Valve 901014 Figure 7-35 11
Spring, Extension, .105 X .875 X 8.500 1011258 Figure 7-31 21
Square Tube, Seat Plate Spacer 1011196 Figure 7-30 2
Steering Arm Assembly, LH AWD 986363 Figure 7-8 16
Steering Arm Assembly, RH AWD 986364 Figure 7-8 9
Steering Arm W/Axle, RH 110112SRV Figure 7-7 11
Steering Column And Wheel N/A Figure 7-30 8
Steering Column, 6.00, W/Wire 36128 Figure 7-31 19
Steering Wheel, 14" 115772 Figure 7-31 20
Step Assembly 1010891 Figure 7-18 28
Step Assembly, 11.5" Long 985512SRV Figure 7-18 28C
Step Assembly, 8.5" Long 985513 Figure 7-18 28D
Strainer & Gasket Kit 140030GK Figure 7-24 21
Strainer & Gasket Kit 140030GK Figure 7-36 20
Strainer, Hydraulic Suction, 200 Mesh 36123 Figure 7-36 14
Strainer, Hydraulic Suction, 8816 980560 Figure 7-36 13
Striker Bolt 2.025" Long 982416 Figure 7-18 7
Stud, Wheel, AWD 110350A Figure 7-7 24
Subassembly, 685 Moldboard Slide 130243 Figure 7-9 5
Subassembly, Front Wheel Assist 981935 Figure 7-8 1

ITEM
Subassembly, Moldboard, 10’ 130204 Figure 7-9 7
Switch, Toggle, SPST, 2-Position 500040 Figure 7-31 1B
Switch, Brake, Low Press, Set at 1300PSI 852720 Figure 7-36 7
Switch, Emergency Stop, Base W/Button 1005965 Figure 7-33 19
Switch, Emergency Stop, N/O Contact 1005967 Figure 7-33 20
Switch, Ignition, W/Heat St. 39146-14 Figure 7-33 6
Switch, Ignition, W/Heat St. 39146-14 Figure 7-34 6
Switch, Light, W/Harness 982250 Figure 7-33 16
Switch, Light, W/Harness 982250 Figure 7-34 16
Switch, Master Disconnect, Battery 109740 Figure 7-25 5
Switch, Press, 685 Dead Engine Steering 160520 Figure 7-32 3
Switch, Toggle, 3-Pos, SPDT, Mom 851392 Figure 7-33 14
Switch, Toggle, 3-Pos, SPDT, Mom 851392 Figure 7-34 14
Switch, Toggle, SPDT, 3-Pos 851090613 Figure 7-33 24
Switch, Toggle, SPST, 2-Pos 851391 Figure 7-33 13
Switch, Wiper/Washer (3000) 853090 Figure 7-33 15
Switch,Toggle, SPDT, 2-Pos. 851090624 Figure 7-33 21
Tank, Fuel, 31 Gallon 1010757 Figure 7-26 1
Tank, Hydraulic, 27.5 Gallon 1010731 Figure 7-24 1
Tank, Radiator Overflow 983273 Figure 7-24 17
Tank, Radiator Overflow 983273 Figure 7-27 2
Tank, Windshield Wiper Washer
Tension Arm
Thick Washer, 685/3000 Front
151200
1009338
110300
Figure 7-18
Figure 7-23
Figure 7-7
25
3
20
7
Tie Rod, Steering Tie Rod, Steering 110192 Figure 7-8 21
Tie Rod, Steering 110192 Figure 7-7 9
Tie Rod, Wheel Lean 110182 Figure 7-7 5
Tire & Wheel Assembly, 15 X 19.5, LH 100518L Figure 7-5 3
Tire & Wheel Assembly, 15 X 19.5, RH 100518R Figure 7-5 4
Tire & Wheel Assembly, 685 LH A120330AL Figure 7-3 5
Tire & Wheel Assembly, 685 LH A120330AL Figure 7-4 4
Tire & Wheel Assembly, 685 RH A120330AR Figure 7-3 4
Tire & Wheel Assembly, 685 RH A120330AR Figure 7-4 3
Tire, 15 x 19.5 Guard Tread, 8 Ply. 100514 Figure 7-5 3B
Tire, 15 X 19.5 Gauge Tread, 8 Ply. 100514 Figure 7-3 7
Tire, 15" X 19.5" 8 Ply. 110340 Figure 7-3 11
Toobox Assembly, Frame Mount 982522 Figure 7-24 28

API (Cont.)
ITEM
Tube, 3" Aluminum, 11" Lg. 855195 Figure 7-29 18
Tube, 685 Wheel Lean Cyl Mount 857297 Figure 7-7 1H
Tube, 685 Wheel Lean Cyl Mount 857311 Figure 7-7 1I
Tube, Bent, 3" 1009196 Figure 7-29 19
Tube, High Temp, 3" 45° 982779 Figure 7-29 17
Tube, High Temp, 3" 90° 987282 Figure 7-29 16
Turn Signal W/Hazard, 7-Wire 33687 Figure 7-31 11
Turntable and Moldboard Assembly 130004 Figure 7-11 3
Turntable, 685 Moldboard Assembly 130224SRV Figure 7-12 1
Two Piece Air Valve, Tire/ Wheel 100513 Figure 7-3 9
Two Piece Air Valve, Tire/Wheel 100513 Figure 7-5 3A
Vacuator Valve 1011053-04 Figure 7-24 3D
Valve & Plug, Anti Cavitation 141020 Figure 7-35 5
Valve Assembly, 10-Section 989177 Figure 7-35 -
Valve Assembly, 10-Section 989177 Figure 7-31 8
Valve Section, Spring Return 910054 Figure 7-35 9
Valve Stem 20192233 Figure 7-3 12
Valve, Brake Charge 852740 Figure 7-36 8
Valve, Check, Articulation Lock 100190 Figure 7-36 2
Valve, Check, Dead Engine Steering 36871 Figure 7-32 2
Valve, Gate, 1.00 6339 Figure 7-36 16
Valve, Gate, 1.250 140640 Figure 7-36 15
Valve, Main Relief, V-20 901009 Figure 7-35 6
Valve, Solenoid, Fwd./Rev. Shift (Parking Brake) 853850 Figure 7-36 3
Valve, Solenoid, Pump Destroke 160380 Figure 7-36 1
Valve, Trans Shift (2-Speed Valve) 983361 Figure 7-36 5
Vandalism Cover, Canopy Only 1011327 Figure 7-21 3
V-Belt 1008969 Figure 7-23 5
V-Belt 1008969 Figure 7-29 1
Washer 113683 Figure 7-29 15
Washer, Flat, SAE, 1-1/4 300-18 Figure 7-18 28G
Washer, Lock, 7/16 302-7 Figure 7-7 2D
Washer, Lock, 7/16 302-7 Figure 7-8 -
Washer, 1.250X2.063, Clevis Pin 855002 Figure 7-8 15A
Washer, 3.00 x 2.0312 x 22 GA 859439 Figure 7-2 10
Washer, Fender, .375 981511 Figure 7-27 -

ITEM
Washer, Flat, .438 X 2.50 X .188 858953 Figure 7-11 1G
Washer, Flat, 1.250 X 2.063 X .130 855002 Figure 7-12 7
Washer, Flat, 1.250 X 2.063 X .130 (3 are welded) 855002 Figure 7-7 2B
Washer, Flat, 1.500 X 2.50 100250 Figure 7-12 2B
Washer, Flat, 1.500 X 2.50 100250 Figure 7-15 -
Washer, Flat, 3/8” 300-6 Figure 7-11 1D
Washer, Flat, SAE, .875 300-14 Figure 7-11 3C
Washer, Flat, SAE, 1/2 300-8 Figure 7-26 1A
Washer, Flat, SAE, 1/2 300-8 Figure 7-27 -
Washer, Flat, SAE, 1-1/4 300-20 Figure 7-12 12
Washer, Flat, SAE, 3/8 300-6 Figure 7-31 14C
Washer, Flat, SAE, 5/8 118-6 Figure 7-2 14B
Washer, Flat, SAE, 5/8 300-10 Figure 7-5 6
Washer, Flat, SAE, 7/8 300-14 Figure 7-3 3C
Washer, Lock, 5/8 302-10 Figure 7-7 1C
Washer, Lock, .625
Washer, Lock, 1/2
Washer, Lock, 1/2
118-7
302-8
302-8
Figure 7-14
Figure 7-25
Figure 7-26
6C
1A
1B
7
Washer, Lock, 1/2 302-8 Figure 7-28 3B
Washer, Lock, 1/4 302-4 Figure 7-2 1D
Washer, Lock, 3/8 302-6 Figure 7-28 4A
Washer, Lock, 5/8 302-10 Figure 7-13 18

API (Cont.)
ITEM
Washer, Lock, Split, 16MM 302-M14 Figure 7-28 2A
Washer, Trunion Pin 858961 Figure 7-2 11
Weather Boot, Toggle Switch 851441 Figure 7-34 15
Weldment, Console 1010789 Figure 7-31 9
Weldment, Floor Board Access 1011323 Figure 7-19 6
Weldment, Cab Door, RH 1010871 Figure 7-18 8
Weldment, Canopy 1010899 Figure 7-19 1
Weldment, Frame 1010700 Figure 7-16 2
Weldment, Rear Scarifier Mount 1010770 Figure 7-16 1
Weldment, Turntable 130004 Figure 7-9 4
Wheel Drive Assembly 112870 Figure 7-8 18
Wheel, W/ Dana 1010198 Figure 7-3 8
Windshield Wiper Arm 151180 Figure 7-20 3
Windshield Wiper Washer Tank 151200 Figure 7-20 7
Windshield Wiper, 20" Blade 151190 Figure 7-20 4
Wingnut, .375-16 31877 Figure 7-31 14A

NOTES

500 Lincoln County Parkway Ext.
Lincolnton, North Carolina 28092
Phone: (704) 966-3300 - Fax Sales: (704) 483-5802
www.leeboy.com
1011484-01
Printed in the U.S.A.
Service Parts List
Axle
360/150/152
APL-2943
June 2013
2012-11-27
32
21
20
19
12
26
18 Right
23 Left
14 6
31
15
10 7
22 1
17
29
25
11 24
15
16
8
5 13
8
4
9 3
27
30 2
28
DANA ITALIA S.P.A. CENTRAL HOUSING

TECHNICAL DOCUMENTATION Type 150 Tav. 150-01-0002
150-01-0002
360/150/152 1
CENTRAL HOUSING 20/06/13
150 150-01/15
1 176.06.036.03 2 CUSCINETTO A SFERE
ROULEMENT A BILLES
BALL BEARING
COJINETE DE BOLAS
RILLENKUGELLAGER
2 001.01.0868 2 ANELLO DI TENUTA
JOINT D'ETANCHEITE
SEAL
ANILLO DE ESTANQUEIDAD
DICHTRING
3 005.01.0121 2 CUSCINETTO A SFERE
ROULEMENT A BILLES
BALL BEARING
COJINETE DE BOLAS
RILLENKUGELLAGER
4 006.04.2864 4 DADO
ECROU
NUT
TUERCA
MUTTER
5 011.04.1309 4 RONDELLA ELASTICA
RONDELLE ELASTIQUE
SPRING WASHER
ARANDELA ELÁSTICA
FEDERSCHEIBE
6 150.06.019.04 2 BRACCIO
CORPS D'ESSIEU
AXLE CASE
BRAZO
ACHSKOERPER
7 176.06.037.01 14 PRIGIONIERO
GOUJON
STUD
PRISIONERO
STIFTSCHRAUBE
8 006.21.4176 46 DADO
ECROU
NUT
TUERCA
MUTTER
150-01-0002
360/150/152 2
150 150-01/15
9 016.04.3650 48 VITE A TESTA CILINDRICA
VIS A TETE CYLINDRIQUE
CYLINDER BOLT
TORNILLO DE CABEZA CILÍNDRICA
ZYLINDERSCHRAUBE
10 176.06.038.01 6 PRIGIONIERO
GOUJON
STUD
PRISIONERO
STIFTSCHRAUBE
11 176.06.056.01 2 PRIGIONIERO
GOUJON
STUD
PRISIONERO
STIFTSCHRAUBE
12 151.06.028.01 2 SEMIASSE
DEMI-ARBRE
HALF SHAFT
SEMIEJE
ACHSWELLE
RONDELLE ELASTIQUE
SPRING WASHER
ARANDELA ELÁSTICA
FEDERSCHEIBE
14 112.01.610.01 1 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
15 808.01.017.01 4 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
16 015.01.0363 6 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
150-01-0002
360/150/152 3
150 150-01/15
17 176.07.029.01 2 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
18 176.01.003.19 1 COPERCHIO INTERMEDIO
COUVERCLE INTERMEDIAIRE
INTERMEDIATE COVER
TAPA DE INTERMEDIO
ZWISCHENDECKEL
19 176.01.001.15 1 SCATOLA
CARTER
HOUSING
CAJA
GEHAEUSE
20 176.01.035.04 1 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
21 002.02.1429 1 ANELLO D'ARRESTO
BAGUE D'ARRET
SNAP RING
ARO DE RETENCIÓN
SPRENGRING
22 819.01.610.01 2 TAPPO MAGNETICO
BOUCHON MAGNETIQUE
MAGNETIC PLUG
TAPÓN MAGNÉTICO
MAGNETSTOPFEN
INTERMEDIATE COVER
TAPA DE INTERMEDIO
ZWISCHENDECKEL
24 176.06.035.01 22 PRIGIONIERO
GOUJON
STUD
PRISIONERO
STIFTSCHRAUBE
150-01-0002
360/150/152 4
150 150-01/15
25 176.06.034.01 4 PRIGIONIERO
GOUJON
STUD
PRISIONERO
STIFTSCHRAUBE
26 702.01.003.01 2 TAPPO SFIATO
RENIFLARD
VENT
TAPÓN DE RESPIRADERO
ENTLUEFTER
27 002.02.0088 2 ANELLO DI SICUREZZA
ARRETOIR
CIRCLIP
ANILLO DE SEGURIDAD
SICHERUNGSRING
28 001.05.1248 2 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
29 016.14.2739 2 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
RONDELLE ELASTIQUE
SPRING WASHER
ARANDELA ELÁSTICA
FEDERSCHEIBE
31 176.07.029.03 4 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
32 176.01.701.01 1 ASTA LIVELLO OLIO
JAUGE DE NIVEAU D'HUILE
DIP STICK
VARILLA DEL NIVEL DE ACEITE
OELMESS - STAB
2012-11-27
6 7
30
5 8
4 9
12
OPTIONAL 17
10
8 11
27 13
26 32
25
20 18
24 2 3 5 30
15 2 6
12
17 4
14
19
2
1 14
16 15
2 22 21 16
23 24 19 For Type 360
1 29
21
14
23
1
26 25
28 27
31 Kit = 9+13 16 17
2
See mounting position of bevel crown wheel on sketch page 1
18
DANA ITALIA S.P.A. DIFFERENTIAL 2
TECHNICAL DOCUMENTATION
15
Type 176 Tav. 176-04-0003
176-04-0003
360/150/152 1
DIFFERENTIAL 20/06/13
176 176-04/92
1 007.01.0881 1 GHIERA
ECROU
RING NUT
ABRAZADERA
WELLENMUTTER
2 005.09.0878 2 CUSCINETTO A RULLI CONICI
ROULEMENT A R. CONIQUES
TAPER ROLLER BEARING
COJINETE DE BOLAS
KEGELROLLENLAGER
3
4 176.04.009.02 2 GHIERA
ECROU
RING NUT
ABRAZADERA
WELLENMUTTER
5 176.04.010.01 2 LAMIERA DI SICUREZZA
TOLE DE SECURITE
LOCKING PLATE
BLOQUEO DE LA CUBIERTA
SICHERUNGSBLECH
6 016.01.1495 2 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
7 016.31.4353 8 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
8 176.04.701.01 1 SCATOLA DIFFERENZIALE
CARTER DIFFERENTIEL
DIFFERENTIAL CARRIER
CAJA DE DIFERENCIAL
DIFFERENTIALGEHAEUSE
9 176.04.610.01 1 DIFFERENZIALE NO-SPIN
DIFFERENTIEL NO-SPIN
NO-SPIN DIFFERENTIAL
DIFENCIAL NO-SPIN
176-04-0003
360/150/152 2
176 176-04/92
RONDELLE ELASTIQUE
SPRING WASHER
ARANDELA ELÁSTICA
FEDERSCHEIBE
11 016.34.4287 16 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
12 005.09.0762 1 CUSCINETTO A RULLI CONICI
1 ROULEMENT A R. CONIQUES
TAPER ROLLER BEARING
COJINETE DE BOLAS
KEGELROLLENLAGER
13 176.04.008.01 1 DISTANZIALE
ENTRETOISE
SPACER
DISTANCIADOR
DISTANZRING
14 176.04.400.28 1 KIT SPESSORI
KIT CALES
SHIM KIT
KIT DE ESPESOR
PASS-SCHEIBEN KIT
15 734.04.070.03 1 DISTANZIALE
ENTRETOISE
SPACER
DISTANCIADOR
DISTANZRING
JOINT D'ETANCHEITE
SEAL
DICHTRING
17 734.04.508.17 1 COPPIA CONICA
COUPLE CONIQUE
BEVEL GEAR SET
PAR CONICO
KEGEL- UND TELLERRADPAAR
176-04-0003
360/150/152 3
176 176-04/92
18 001.05.2918 1 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
19 176.01.400.12 1 KIT SPESSORI
KIT CALES
SHIM KIT
KIT DE ESPESOR
PASS-SCHEIBEN KIT
20
21 176.01.038.01 1 COPERCHIO
COUVERCLE
COVER
TAPA
DECKEL
22
23 734.04.032.01 1 DISTANZIALE
ENTRETOISE
SPACER
DISTANCIADOR
DISTANZRING
CYLINDER BOLT
ZYLINDERSCHRAUBE
25 017.02.0791 10 PRIGIONIERO
GOUJON
STUD
PRISIONERO
STIFTSCHRAUBE
RONDELLE ELASTIQUE
SPRING WASHER
ARANDELA ELÁSTICA
FEDERSCHEIBE
176-04-0003
360/150/152 4
176 176-04/92
27 006.03.0198 10 DADO
ECROU
NUT
TUERCA
MUTTER
28 001.05.2606 1 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
29 011.14.1455 10 ROSETTA ELASTICA
RONDELLE ELASTIQUE
SPRING WASHER
ARANDELA ELÁSTICA
FEDERRING
RONDELLE ELASTIQUE
SPRING WASHER
ARANDELA ELÁSTICA
FEDERSCHEIBE
31 176.04.610.02 1 DIFFERENZIALE NO-SPIN
DIFFERENTIEL NO-SPIN
DIFENCIAL NO-SPIN
TOLE DE SECURITE
LOCKING PLATE
SICHERUNGSBLECH
2013-06-20 47
1 8
57 x
60 58
3
4 5 48 50
45 50
6 10 62
37 38
7 9
2 49 39
46
55
35 40
53 36
44
59 D
10 B C 34
28 10 A 51
A 27
B 14
52 13 42
C 14 41 43
D 26
25
11 21
12 24
15 16 23
20 22
18 52
19 54
61
31
62 Kit =36+44+49 32
41 Kit =35+37+38+39 33
17
9 28 59 OPTIONAL
56
30
DANA ITALIA S.P.A. CENTRAL HOUSING 29
TECHNICAL DOCUMENTATION Type 150 Tav. 150-06-0002 x
150-06-0002
360/150/152 1
HUB REDUCTION 20/06/13
150 150-06/13
CYLINDER BOLT
ZYLINDERSCHRAUBE
2 150.06.003.04 2 COPERCHIO
COUVERCLE
COVER
TAPA
DECKEL
3 001.05.1119 4 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
4 000.051804 2 ANELLO DI TENUTA
JOINT D'ETANCHEITE
SEAL
DICHTRING
5 005.02.2843 2 CUSCINETTO
ROULEMENT
BEARING
COJINETE
LAGER
6 150.06.021.01 2 INGRANAGGIO
ENGRENAGE
GEAR
ENGRANAJE
ZAHNRAD
ROULEMENT A BILLES
BALL BEARING
COJINETE DE BOLAS
RILLENKUGELLAGER
8 702.01.003.03 2 TAPPO SFIATO
RENIFLARD
VENT
ENTLUEFTER
150-06-0002
360/150/152 2
150 150-06/13
9

BOUCHON MAGNETIQUE
MAGNETIC PLUG
TAPÓN MAGNÉTICO
MAGNETSTOPFEN
11 150.06.001.04 2 SCATOLA
CARTER
HOUSING
CAJA
GEHAEUSE
ROULEMENT A BILLES
BALL BEARING
COJINETE DE BOLAS
RILLENKUGELLAGER
13 151.06.012.01 4 INGRANAGGIO
ENGRENAGE
GEAR
ENGRANAJE
ZAHNRAD
14 150.06.017.01 8 INGRANAGGIO
ENGRENAGE
GEAR
ENGRANAJE
ZAHNRAD
15 150.06.018.01 4 INGRANAGGIO
ENGRENAGE
GEAR
ENGRANAJE
ZAHNRAD
ARRETOIR
CIRCLIP
ANILLO DE SEGURIDAD
SICHERUNGSRING
17 001.05.1352 4 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
150-06-0002
360/150/152 3
150 150-06/13
O - RING
18 005.01.2725 4 CUSCINETTO
ROULEMENT
BEARING
COJINETE
LAGER
JOINT D'ETANCHEITE
SEAL
DICHTRING
20 730.08.017.01 4 DISTANZIALE
ENTRETOISE
SPACER
DISTANCIADOR
DISTANZRING
21 001.05.2844 12 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
22 016.01.2993 72 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
RONDELLE ELASTIQUE
SPRING WASHER
ARANDELA ELÁSTICA
FEDERSCHEIBE
24 151.06.011.01 12 COPERCHIO
COUVERCLE
COVER
TAPA
DECKEL
ROULEMENT A BILLES
BALL BEARING
COJINETE DE BOLAS
RILLENKUGELLAGER
150-06-0002
360/150/152 4
150 150-06/13
26 150.06.009.01 12 PERNO
AXE
PIN
PERNO
BOLZEN
27 005.06.0709 12 CUSCINETTO A RULLI
ROULEMENT A ROULEAUX
ROLLER BEARING
RODAMIENTO DE RODILLOS
RILLENROLLENLAGER
28 808.01.017.01 4 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
29 150.06.004.10 4 FLANGIA PORTANTE
BRIDE DE MOYEU
STUB AXLE
MANGUETA
NABENFLANSCH
30 150.06.024.01 4 LAMIERA
TOLE
SHEET
CHAPA
BLECH
31 006.21.4176 44 DADO
ECROU
NUT
TUERCA
MUTTER
32 017.06.4171 44 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
33 150.06.014.03 4 SEMIASSE
DEMI-ARBRE
HALF SHAFT
SEMIEJE
ACHSWELLE
150-06-0002
360/150/152 5
150 150-06/13
34 112.06.025.02 40 PRIGIONIERO
GOUJON
STUD
PRISIONERO
STIFTSCHRAUBE
35 112.06.054.02 2 SUPPORTO SATELLITI
SUPPORT SATELLITES
PLANET GEAR CARRIER
TAPA PORTASATÉLITES
PLANETENGEHAEUSE
36 290.06.014.02 4 ANELLO DI SICUREZZA
ARRETOIR
CIRCLIP
ANILLO DE SEGURIDAD
SICHERUNGSRING
37 002.14.3202 6 ANELLO D'ARRESTO
BAGUE D'ARRET
SNAP RING
ARO DE RETENCIÓN
SPRENGRING
38 290.06.011.02 12 SATELLITE (PLAN.)
SATELLITE
PLANET GEAR
ENGRANAJE PLANETARIO
PLANETENRAD
39 290.06.013.03 12 CUSCINETTO
ROULEMENT
BEARING
COJINETE
LAGER
40
41 212.06.710.23 4 SUPPORTO SATELLITI

SUPPORT SATELLITES
PLANET GEAR CARRIER
TAPA PORTASATÉLITES
PLANETENGEHAEUSE
42 016.06.0442 8 VITE A TESTA CONICA
VIS A TETE CONIQUE
COUNTERSUNK BOLT
TORNILLO DE CABEZA CONICA
150-06-0002
360/150/152 6
150 150-06/13
SENKSCHRAUBE
43 112.01.610.01 4 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
44 290.06.010.07 4 CORONA DENTATA
COURONNE DENTEE
RING GEAR
CORONA DENTADA
ZAHNKRANZ
45 011.07.2763 4 RONDELLA
RONDELLE
WASHER
ARANDELA
SCHEIBE
46 150.06.023.02 4 MOZZO RUOTA
MOYEU DE ROUE
WHEEL HUB
CUBO DE MAZA
RADNABE
47 932.06.074.01 40 COLONNETTA
GOUJON DE ROUE
WHEEL STUD
PRISIONERO
RADBOLZEN
48 183.06.034.01 4 ANELLO DI TENUTA
JOINT D'ETANCHEITE
SEAL
DICHTRING
49 150.06.027.01 4 SUPPORTO PORTACORONA
SUPPORT PORTE COURONNE
RING GEAR SUPPORT
SOPORTE DE CORONA
HOHLRADTRAEGER
50 005.10.2742 8 CUSCINETTO
ROULEMENT
BEARING
COJINETE
LAGER
150-06-0002
360/150/152 7
150 150-06/13
51 006.22.4380 40 DADO
ECROU
NUT
TUERCA
MUTTER
ROULEMENT A BILLES
BALL BEARING
COJINETE DE BOLAS
RILLENKUGELLAGER
53 150.06.013.01 2 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
54

TOLE DE SECURITE
LOCKING PLATE
SICHERUNGSBLECH
JOINT D'ETANCHEITE
SEAL
DICHTRING
57 307.14.006.01 2 RACCORDO
RACCORD
ADAPTOR
EMPALME
VERBINDUNGSSTUECK
58 307.14.005.01 2 RACCORDO
RACCORD
ADAPTOR
EMPALME
VERBINDUNGSSTUECK
59 150.06.022.01 2 BUSSOLA
MANCHON DE REDUCTION
BUSHING
CASQUILLO
150-06-0002
360/150/152 8
150 150-06/13
BUCHSE
60 001.05.1424 2 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
RONDELLE ELASTIQUE
SPRING WASHER
ARANDELA ELÁSTICA
FEDERSCHEIBE
62 150.06.727.02 4 SUPPORTO PORTACORONA
SUPPORT PORTE COURONNE
RING GEAR SUPPORT
SOPORTE DE CORONA
HOHLRADTRAEGER
2012-09-20
39 17
45
46 18
44
45
44
46 Kit = 44+45
Kit = 4+6
176-07-0002
360/150/152 1
BRAKES 20/06/13
176 176-07/175
1 176.07.007.08 4 PISTONE
PISTON
PISTON
PISTÓN
KOLBEN
2 001.05.1420 12 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
CYLINDER BOLT
ZYLINDERSCHRAUBE
4 176.07.016.02 1 BUSSOLA
REDUCTION BUSHING
CASQUILLO
ZWISCHENBUCHSE
5 001.05.1494 4 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
6 005.32.1525 4 BOCCOLA
DOUILLE
BUSHING
CASQUILLO GUÍA
BUCHSE
7 005.35.1524 4 RONDELLA DI RASAMENTO
RONDELLE
FRICTION WASHER
ARANDELA DE FRICCIÓN
ANLAUFSCHEIBE
8 011.13.1227 2 ROSETTA
RONDELLE
LOCK WASHER
RONDANA
SCHEIBE
176-07-0002
360/150/152 2
BRAKES 20/06/13
176 176-07/175
9 006.05.0684 2 DADO
ECROU
NUT
TUERCA
MUTTER
10 171.07.021.02 4 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
11 001.05.1238 4 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
12 171.07.020.02 4 PUNTALINO
POINTEAU
PUSHER
PUNTA
DRUCKBOLZEN
13 176.07.003.07 1 DISCO
DISQUE
DISC
DISCO
SCHEIBE
14 176.07.002.07 1 DISCO
DISQUE
DISC
DISCO
SCHEIBE
15 176.07.006.01 6 MOLLA
RESSORT
SPRING
MUELLE
FEDER
16 176.07.019.01 6 VITE REGISTRO
VIS DE REGLAGE
ADJUSTING BOLT
TORNILLO EN REGISTRO
NACHSTELLSCHRAUBE
176-07-0002
360/150/152 3
BRAKES 20/06/13
176 176-07/175
17 734.07.015.01 2 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
18 734.07.014.01 2 VITE SPURGO
VIS DE PURGE
BLEEDING BOLT
PURGADOR
ABBLASESCHRAUBE
19 112.07.610.04 10 DISCO
DISQUE
DISC
DISCO
SCHEIBE
20 176.07.048.01 2 ANELLO
BAGUE
RING
ANILLO
RING
21 001.05.1526 2 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
22 016.36.4305 2 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
TOLE DE SECURITE
LOCKING PLATE
SICHERUNGSBLECH
24 176.07.021.01 2 PIGNONE
PIGNON
PINION
PIÑÓN
RITZEL
176-07-0002
360/150/152 4
BRAKES 20/06/13
176 176-07/175
25 734.07.004.02 10 DISCO FRENO
DISQUE DE FREIN
BRAKE DISC
DISCO DE FRENO
BREMSSCHEIBE
26 176.07.022.01 2 VITE REGISTRO
VIS DE REGLAGE
ADJUSTING BOLT
TORNILLO EN REGISTRO
NACHSTELLSCHRAUBE
27 176.07.010.01 6 ANELLO ANTIESTRUSIONE
BAGUE ANTIEXTRUSION
BACK - UP RING
ANILLO ANTIEXTRUSIÓN
ANTIEXTRUSIONSRING
28 176.07.015.01 6 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
29 176.07.004.02 6 PISTONE
PISTON
PISTON
PISTÓN
KOLBEN
30 176.07.014.05 1 LEVA
LEVIER
LEVER
PALANCA
HEBEL
31 176.07.014.06 1 LEVA
LEVIER
LEVER
PALANCA
HEBEL
32 176.07.053.01 4 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
176-07-0002
360/150/152 5
BRAKES 20/06/13
176 176-07/175
33 176.07.012.01 4 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
34 176.07.052.01 4 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
35 176.07.046.01 76 MOLLA
RESSORT
SPRING
MUELLE
FEDER
36 176.07.008.09 4 CILINDRO FRENO
CYLINDRE FREIN
WHEEL CYLINDER
CILINDRO DEL FRENO
RADZYLINDER
TOLE DE SECURITE
LOCKING PLATE
SICHERUNGSBLECH
38 016.01.1495 6 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
RONDELLE ELASTIQUE
SPRING WASHER
ARANDELA ELÁSTICA
FEDERSCHEIBE
40
41
176-07-0002
360/150/152 6
BRAKES 20/06/13
176 176-07/175
42
43 176.07.716.02 4 BOCCOLA
DOUILLE
BUSHING
CASQUILLO GUÍA
BUCHSE
44 011.07.4225 4 ROSETTA DI TENUTA
BAGUE D'ETANCHEITE
SEAL WASHER
ARANDELA DE ESTANQUIDAD
DICHTRING
45 016.10.4218 4 VITE DI CHIUSURA
VIS DE FERMETURE
PLUG
TAPÓN
VERSCHLUSS-SCHRAUBE
46 112.07.615.01 4 TAPPO
BOUCHON
PLUG
TAPÓN
STOPFEN
2013-02-18
15
72 69 14 A or B
2
73 17 6
A 13 11
74 5
67
75 B 12 G
68
71 10
70 59 4 5 66 77
56
58 9
78 3
57 16
55 9
13 A or B 1 14
8
54 60
39 7 61
40
53
47 43 42 G
52 44
32 46 63
41 27
49 50 51 45 28
37 65 26
36 29
35
48 14 34
13 33 38
64
14 62
13
30 18 30
19 17 Oil charge plug
20
31 25 76
21 20
78
24 36
29 23
28 25
30 26 22 66 67 76 77 Optional 65 FOR 2 FLANGE VERSION
27
DANA ITALIA S.P.A. GEAR BOX
TECHNICAL DOCUMENTATION Type 360 Tav. 360-14-0001 G See gears on table 360-14-0002
360-14-0001
360/150/152 1
GEAR BOX 20/06/13
360 360-14/20
1 360.14.001.02 1 SCATOLA
CARTER
HOUSING
CAJA
GEHAEUSE
JOINT D'ETANCHEITE
SEAL
DICHTRING
3 355.14.056.01 2 PATTINO
PATIN
SLIDING PIN
ZAPATA
GLEITSTUECK
4 360.14.701.03 1 ASTA
TIGE
BAR
VARILLA
STANGE
ROULEMENT A BILLES
BALL BEARING
COJINETE DE BOLAS
RILLENKUGELLAGER
6 723.14.020.27 1 BUSSOLA
REDUCTION BUSHING
CASQUILLO
ZWISCHENBUCHSE
7 355.14.055.01 1 RONDELLA DI RASAMENTO
RONDELLE
FRICTION WASHER
ANLAUFSCHEIBE
8 355.14.100.01 1 MANICOTTO GUIDA
TUYAU DE GUIDAGE
GUIDE - TUBE
MANGUITO DE CONDUCCIÓN
FUEHRUNGSROHR
360-14-0001
360/150/152 2
GEAR BOX 20/06/13
360 360-14/20
9 005.13.2708 2 GABBIA A RULLINI
ROULEMENT A AIGUILLE
NEEDLE BEARING
JAULA DE RODILLOS
NADELKAEFIG
10 005.06.2454 1 CUSCINETTO
ROULEMENT
BEARING
COJINETE
LAGER
11 722.14.039.01 2 BUSSOLA
REDUCTION BUSHING
CASQUILLO
ZWISCHENBUCHSE
12 360.14.005.01 1 COPERCHIO
COUVERCLE
COVER
TAPA
DECKEL
13 016.01.0375 4 VITE A TESTA ESAGONALE
4 VIS A TETE EXAGONALE
2 HEXAGON BOLT
TORNILLO DE CABEZA HEXAGONAL
SECHSKANTSCHRAUBE
4 RONDELLE ELASTIQUE
2 SPRING WASHER
ARANDELA ELÁSTICA
FEDERRING
15 360.14.002.07 1 COPERCHIO
COUVERCLE
COVER
TAPA
DECKEL
VIS A TETE EXAGONALE
HEXAGON BOLT
SECHSKANTSCHRAUBE
360-14-0001
360/150/152 3
GEAR BOX 20/06/13
360 360-14/20
17 808.01.017.01 1 TAPPO
1 BOUCHON
PLUG
TAPÓN
STOPFEN
BOUCHON MAGNETIQUE
MAGNETIC PLUG
TAPÓN MAGNÉTICO
MAGNETSTOPFEN
ROULEMENT A BILLES
BALL BEARING
COJINETE DE BOLAS
RILLENKUGELLAGER
JOINT D'ETANCHEITE
SEAL
DICHTRING
21
22
23
24
25 722.14.006.01 1 COPERCHIO
COUVERCLE
COVER
TAPA
DECKEL
360-14-0001
360/150/152 4
GEAR BOX 20/06/13
360 360-14/20
RONDELLE ELASTIQUE
SPRING WASHER
ARANDELA ELÁSTICA
FEDERRING
27 016.36.4241 4 VITE
VIS
BOLT
TORNILLO
SCHRAUBE
28 746.04.008.01 1 DADO
ECROU
NUT
TUERCA
MUTTER
29 001.05.0044 1 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
30 714.02.013.01 1 FLANGIA
BRIDE
FLANGE
BRIDA
FLANSCH
31 702.01.003.01 1 TAPPO SFIATO
RENIFLARD
VENT
ENTLUEFTER
32 360.14.019.02 1 CILINDRO
CILINDRE
CYLINDER
CILINDRO
ZYLINDER
33 111.07.400.10 1 KIT SPESSORI
KIT CALES
SHIM KIT
KIT DE ESPESOR
PASS-SCHEIBEN KIT
360-14-0001
360/150/152 5
GEAR BOX 20/06/13
360 360-14/20
ARRETOIR
CIRCLIP
ANILLO DE SEGURIDAD
SICHERUNGSRING
35 013.01.0650 1 SPESSORE
CALE
SHIM
ESPESOR
PASS - SCHEIBE
36 005.06.3677 1 CUSCINETTO A RULLI
ROULEMENT A ROULEAUX
ROLLER BEARING
RODAMIENTO DE RODILLOS
RILLENROLLENLAGER
37 360.14.016.01 1 RONDELLA DI RASAMENTO
RONDELLE
FRICTION WASHER
ANLAUFSCHEIBE
38 005.13.1165 1 GABBIA A RULLINI
ROULEMENT A AIGUILLE
NEEDLE BEARING
JAULA DE RODILLOS
NADELKAEFIG
39 001.05.1592 1 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
40 355.14.140.02 1 BUSSOLA
REDUCTION BUSHING
CASQUILLO
ZWISCHENBUCHSE
41 001.05.0039 2 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
360-14-0001
360/150/152 6
GEAR BOX 20/06/13
360 360-14/20
42 001.05.0591 1 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
43 001.05.1587 1 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
44 355.14.139.01 1 PISTONE
PISTON
PISTON
PISTÓN
KOLBEN
ARRETOIR
CIRCLIP
ANILLO DE SEGURIDAD
SICHERUNGSRING
46 001.05.0934 1 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
47 001.05.1479 1 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
JOINT D'ETANCHEITE
SEAL
DICHTRING
49 016.08.1240 1 GRANO FILETTATO
POINTEAU FILETE
GRUB BOLT
PASADOR
GEWINDEKORN
360-14-0001
360/150/152 7
GEAR BOX 20/06/13
360 360-14/20
50 542.03.020.01 1 MOLLA
RESSORT
SPRING
MUELLE
FEDER
51 012.01.0249 1 SFERA
BILLE
DETEND BALL
BOLA
KUGEL
52 011.07.1478 1 ROSETTA DI TENUTA
BAGUE D'ETANCHEITE
SEAL WASHER
ARANDELA DE ESTANQUIDAD
DICHTRING
53 932.03.600.04 1 INTERRUTTORE DI SICUREZZA
DISJONCTEUR DE SURETE
SECURITY SWITCH
INTERRUPTOR DE SEGURIDAD
ANLASSERSPERRE
54 932.03.020.01 1 PROTEZIONE IN GOMMA
CAPUCHON
BOOT
PROTECCIÓN DE GOMA
SCHUTZKAPPE
HEXAGON BOLT
SECHSKANTSCHRAUBE
56 723.14.053.02 1 LAMIERA
TOLE
SHEET
CHAPA
BLECH
57 001.05.1356 1 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
360-14-0001
360/150/152 8
GEAR BOX 20/06/13
360 360-14/20
58 360.14.007.01 1 COPERCHIO
COUVERCLE
COVER
TAPA
DECKEL
59 001.05.1422 1 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
HEXAGON BOLT
SECHSKANTSCHRAUBE
61 355.14.101.03 1 MANICOTTO SCORREVOLE
MANCHON DE COMMANDE
CHANGE SELECTOR
MANGUITO DESLIZANTE
SCHALTMUFFE
62 360.14.015.01 1 LAMIERA DI PROTEZIONE
PROTECTION EN TOLE
COVER PLATE
CHAPA DE PROTECCIÓN
SCHUTZBLECH
ARRETOIR
CIRCLIP
ANILLO DE SEGURIDAD
SICHERUNGSRING
64 360.14.003.02 1 COPERCHIO
COUVERCLE
COVER
TAPA
DECKEL
65 360.14.014.04 1 ALBERO USCITA
ARBRE DE SORTIE
OUTPUT SHAFT
EJE DE SALIDA
ABTRIEBSWELLE
360-14-0001
360/150/152 9
GEAR BOX 20/06/13
360 360-14/20
66
67

ARRETOIR
CIRCLIP
ANILLO DE SEGURIDAD
SICHERUNGSRING
INTERMEDIATE COVER
TAPA DE INTERMEDIO
ZWISCHENDECKEL
70
71 001.05.3661 1 ANELLO OR
JOINT OR
O - RING
ANILLO TOROIDAL
O - RING
360-14-0002
360/150/152 1
GEARS 20/06/13
360 360-3,09-1,34-A
1 360.14.012.02 1 INGRANAGGIO
ENGRENAGE
GEAR
ENGRANAJE
ZAHNRAD
2 360.14.013.05 1 ALBERO ENTRATA
ARBRE D'ENTREE
INPUT SHAFT
ÁRBOL DE TRANSMISIÓN
ANTRIEBSWELLE
3 360.14.010.03 1 INGRANAGGIO
ENGRENAGE
GEAR
ENGRANAJE
ZAHNRAD
4 360.14.008.14 1 ALBERO
ARBRE
SHAFT
ÁRBOL
WELLE
5 360.14.009.07 1 INGRANAGGIO
ENGRENAGE
GEAR
ENGRANAJE
ZAHNRAD
6 360.14.011.02 1 INGRANAGGIO
ENGRENAGE
GEAR
ENGRANAJE
ZAHNRAD
Copyright 2013 Dana Holding Corporation For product inquiries or support,
All content is subject to copyright by Dana and may not visit www.dana.com or call 419-887-6445
be reproduced in whole or in part by any means, For other service publications,
electronic or otherwise, without prior written approval. visit www.SpicerParts.com/literature.asp
THIS INFORMATION IS NOT INTENDED FOR SALE OR For online service parts ordering,
RESALE, AND THIS NOTICE MUST REMAIN ON ALL visit www.SpicerParts.com/order.asp
COPIES.

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LEEBOY MODEL 685C MOTOR GRADER

Manual No. 1011484-01

LeeBoy Model 685C Motor Grader i

Disclaimer And Copyright

ii LeeBoy Model 685C Motor Grader

LeeBoy Model 685C Motor Grader iii

Operator’s Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

iv LeeBoy Model 685C Motor Grader

Spreading Piles . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

LeeBoy Model 685C Motor Grader v

Checking Neutral Start System . . . . . . . . . . . . . . . . . . . . 5-13

vi LeeBoy Model 685C Motor Grader

Replacing Scarifier Tooth Shank. . . . . . . . . . . . . . . . . . . 5-31

LeeBoy Model 685C Motor Grader vii

viii LeeBoy Model 685C Motor Grader

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64

LeeBoy Model 685C Motor Grader ix

x LeeBoy Model 685C Motor Grader

LeeBoy Model 685C Motor Grader xi

xii LeeBoy Model 685C Motor Grader

LeeBoy Model 685C Motor Grader 1-1

1-2 LeeBoy Model 685C Motor Grader

This manual provides important information to familiarize

LeeBoy Model 685C Motor Grader 1-3

1-4 LeeBoy Model 685C Motor Grader

Fire and Explosion Hazard If the engine must be serviced while it is

LeeBoy Model 685C Motor Grader 1-5

Flying Object Hazard

Coolant Hazard Always tighten components to the specified torque.

• Handle hot components with heat-resistant gloves.

If any alert indicator illuminates during grader operation,

1-6 LeeBoy Model 685C Motor Grader

SAFETY LABEL LOCATIONS A description of location is provided below for each

ADVERTENCIA ¡ CONTENIDO BAJO PRESION! d’opérations.

AVERTISSEMENT CONTENU SOUS PRESSION !

CAUTION BURN HAZARD!

856579-03 DANGER PINCH POINT

DANGER EXPLOSION HAZARD! DANGER

WARNING ADVERTENCIA AVERTISSEMENT

Failure to comply Si no se cumple con Le non-respect de cette

DANGER PINCH POINT

Figure 1-1. Safety Labels and Safety Label Locations

LeeBoy Model 685C Motor Grader 1-7

1-8 LeeBoy Model 685C Motor Grader

LeeBoy Model 685C Motor Grader 2-1

LIMITED WARRANTY POLICY Limitations

2-2 LeeBoy Model 685C Motor Grader

Items Not Covered Other Limitations

LeeBoy Model 685C Motor Grader 2-3

CONTACT INFORMATION If you have a persistent problem your dealer is unable to

ON SIDE OF STEERING CONSOLE

Figure 2-1. Nameplate Location

2-4 LeeBoy Model 685C Motor Grader

LeeBoy Model 685C Motor Grader 2-5

A fuel filter removes contami­nants from the diesel fuel

Figure 2-4. Engine Oil Filter Location

Figure 2-3. Fuel Filter Location 1

2-6 LeeBoy Model 685C Motor Grader

LeeBoy Model 685C Motor Grader 2-7

Hydraulic System Drive System

A fuel filter removes contaminants from the diesel fuel