AVANT STAGEV 860i Operator'S Manual Download Page 126

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Service and maintenance

Avant 860i

126

5. Change hydraulic oil filters

Hydraulic oil return filter:



Located on top of the hydraulic tank, under the

cover front cover. Take off the cover and replace

the oil filter cartridge.

Hydraulic pressure filter:



Hydraulic oil pressure filter is located on top the

hydraulic pump assembly. Use general filter

replacement tool to unscrew the filter. Collect all

waste oil.
When installing a new filter, rub its seal with oil.

6. Clean or replace hydraulic oil tank

breather

There is a breather filter inside the dipstick cap which

must be cleaned or changed once a year.

7. Change fuel filters

In demanding operating environment, or when

frequently adding fuel from fuel canisters, the fuel

filters must be changed more frequently than the

recommended service interval.

The fuel lines are connected to the main filter

through a pre filter. The fuel pre filter is located on

the left hand side of the engine, near the fuel tank.
Replace fuel filters carefully to avoid fuel spill. Make

sure to keep all parts clean during service. Wipe all

spilled fuel thoroughly. Service only when engine is

cold. Check the condition of the fuel hoses and

replace any damaged or loose hose clamps.

Avant 860i fuel filters

The main fuel filter and water separator assembly is

located on the left side of the loader, and its top is

accessible when all covers are installed on the

loader.
After replacing the fuel filter, prime the fuel system by

pressing the manual pump on the filter repeatedly,

until it becomes stiff. Shown in the following picture:

Main fuel filter and water separator housing

assembly

Manual fuel pump button

Fuel pre filter

Summary of Contents for STAGEV 860i

Page 1: ...English Operator s Manual 2020 A432324EN 2021 1 2020 www avanttecno com ...

Page 2: ... 62 Counterweights 63 Extra auxiliary hydraulics outlets front and rear 65 Seat Seat belt and seat adjustments 67 Lights 69 Cabs optional extra 71 OPERATING INSTRUCTIONS 74 Starting the loader 75 Ignition key 76 Stopping the engine Safe stopping procedure 77 Drive control 79 Steering of the loader 84 In case the loader tips over 85 Material handling 86 WORKING WITH ATTACHMENTS 87 Requirements for ...

Page 3: ...rtant safety information in this manual It warns of an immediate hazard that could cause serious personal injury to yourself or others near the equipment The safety alert symbol by itself and with related safety statement indicates important safety messages throughout this Manual It is used to draw attention to instructions involving your personal safety or the safety of others When you see this s...

Page 4: ...y from your Avant dealer Remember also to give this Manual to the new owner when the loader changes ownership Manuals of attachments DANGER Attachments can create significant risks that are not covered by this Operator s manual of the loader Make sure you have all attachments manual available Wrong use of an attachment can cause serious injuries or death Each attachment is accompanied by its own r...

Page 5: ...ot be used in underground or tunneling work Loads must not be suspended onto the loader boom This loader has been designed to require as little maintenance as possible The operator can perform the routine maintenance operations There are however more demanding service operations that can be done by professional service personnel only Any service operation is permitted only when wearing appropriate...

Page 6: ...f optional equipment is subject to change Some options may preclude the installation and use of some other option or options Check with your Avant dealer for more information Versions of this manual Avant has a policy on continuous product development Updated versions of the manual replace the previous versions of this manual as long as the year on the cover page matches with the original manual Y...

Page 7: ... in this manual is excluded 3 Avant Tecno Oy accepts no responsibility for interruption to working or any other consequential losses resulting from any failure of the product 4 Only Avant Tecno Oy approved replacement or original quality parts shall be used during routine maintenance 5 Any damage caused by the use of incorrect fuel lubricants cooling liquid or cleaning solvents is excluded 6 The A...

Page 8: ...l and deliberate movements Avoid abrupt movements when handling the load in order to prevent the load from falling and to keep the machine stable 7 Keep away from the danger zone of the lifted boom and don t let anyone go there 8 Always read the operator s manuals of relevant attachments and always keep the manuals available for all users Read the attachment manuals and follow given instructions 9...

Page 9: ...r judgment or cause drowsiness or if not otherwise medically fit to operate the equipment DANGER Risk of crushing under boom or attachment Stay away from lifted boom and attachment Always remember that load can fall and the boom can lower unexpectedly due to loss of stability mechanical fault or if another person operates the controls of the loader leading to crushing hazard Lower the boom or any ...

Page 10: ...ll If it is necessary to park on a hill use chocks or other additional means to prevent the loader from moving DANGER Safety devices are installed for your safety Never modify or bypass any safety function Safety functions are installed for your safety Never modify or block any of the safety systems of the loader If you notice that a system is not in good condition stop the use of the loader and m...

Page 11: ... and can also emit carbon monoxide CO under some conditions that can concentrate quickly to a dangerous level Never leave the engine running in garages or sheds Operate the loader only outdoors and far from windows doors and vents Elevated level of carbon dioxide or carbon monoxide in breathing air cannot be noticed without dedicated measuring equipment Signs of carbon monoxide poisoning include n...

Page 12: ...ARNING Handle heavy loads and attachments with care Risk of tipping over Follow all instructions and warning labels to avoid tipping over of the loader Always lower the load or attachment down on the ground before you leave the driver s seat Keep loads as low and as close to the loader as possible Never take a heavy load on the loader from high level e g from truck shelf etc When loading always ke...

Page 13: ... high speed Never turn frame towards the slope while operating on inclined ground Always drive slowly when carrying load or when turning with the loader WARNING Risk of overturning Sudden movements can tip the machine over Movements such as stopping turning or lowering the boom abruptly can cause loss of stability Always drive slowly and operate the controls of the loader very carefully especially...

Page 14: ...el on firm ground When the loader is operated in conditions that deviate from these criteria e g on soft or uneven ground on a slope or when subject to slide loads you must take these conditions into account WARNING Risk of tipping over on uneven ground Drive slow on inclined surfaces Always keep loads close to the ground Keep the seat belt fastened to stay within the Roll over protective structur...

Page 15: ...ng with a load or heavy attachment keep the load downhill and close to the ground and reverse the hill up Never drive along an excavation Note that the excavation or trench may suddenly cave in Exercise extreme caution when driving near ditches or embankments and avoid driving along a ditch or trench as the machine could suddenly tip over if an edge caves in Avoid driving along trenches and keep a...

Page 16: ...ty glasses may be needed while using the loader Always fasten seat belt while operating the machine When working at construction sites a safety helmet is recommended and may be mandatory in addition to the falling objects protective structure FOPS on the loader Depending on work and working area also a respirator mask or other breathing air filtering apparatus may be required Find out about other ...

Page 17: ...ject Protective structure FOPS The loader is equipped with a Level 1 FOPS which gives protection against moderate impacts Your work environment may have specific risks related to falling objects and the level of protection that is needed to reduce the risk Use of the loader with FOPS level 1 may be prohibited in the work area Modifications Never modify the loader or the attachments Never drill hol...

Page 18: ...e it possible to reach overhead powerlines with the loader creating hazard of electric shock and electrocution Plan work ahead and take necessary safety precautions Deeper excavations may cave in Depending on various factors such as the type of the soil moisture content rainwater steepness of the excavation the excavation can collapse and bury in people Contact local authorities or surveying compa...

Page 19: ...ery A frozen battery can explode during charging WARNING Lead warning Wear protective gloves Battery and its terminals contain lead a harmful substance which should not be handled more than what is necessary Wear protective gloves when handling battery Wash hands with soap and water after handling the battery Dispose of and recycle a used battery correctly Whenever you handle the battery keep the ...

Page 20: ...her available near the place where you store the loader Fuses There are several fuses located in different fuse boxes on the loader Always replace a blown fuse only with a fuse with the same rating For more information about fuses see page 133 Battery disconnect switch The loader is equipped with a battery disconnect switch The switch is located at the rear of the loader on the right side Always s...

Page 21: ...ne serial no Serial number of the loader is printed on the type plate which also indicates the loader model Location of engine serial number is described on the following page Dealer Contact information Write down the serial number and the manufacturing week of your loader and have them ready when you communicate with your dealer or Avant dealer or service partner The serial number together with t...

Page 22: ...g mass The labels shown in this manual are examples of the labels on loaders See the identification plates on your loader for detailed information about your specific loader unit Some loaders that are intended to be used outside of the European Union may not bear the CE mark Engine identification plate Avant 860i The Kohler Stage V engines have an EU type approval label Label shows information abo...

Page 23: ...om The boom is telescopic extending 700 mm hydraulically 5 Attachment coupling plate Attachments are mounted on the attachment coupling plate The locking pins on the plate can be operated manually standard or hydraulically option For more information see page 89 6 Auxiliary hydraulics outlet The hydraulic hoses of hydraulically operated attachments are coupled on this outlet using its multi connec...

Page 24: ... a new decal clean the surface from dirt dust grease or other material Peel small portion of the decal backing paper and apply exposed adhesive to cleaned surface aligning the decal properly Peel rest of backing paper and press firmly with hands or decal application tool to smooth out the decal and to activate the glue of the label WARNING The warning labels contain important safety information an...

Page 25: ... or serious injury Keep out from the danger zone of the machine c Risks of falling from height and getting run over Never lift people or carry passengers with the loader or its attachments d High pressure fluid injection hazard Never use hands to search for leaks Use a piece of cardboard and a magnifying glass when searching for leaks e Risk of dropping of attachment Make sure both locking pins ar...

Page 26: ...grip and feet protection Label Message 2 Product code A441496 Location ROPS Canopy Near steering wheel On cab GT Above screen panel on cab frame CAUTION Stop before using the parking brake and before changing the drive speed range Changing the drive speed range or engaging the parking brake while the machine is moving may cause locking of wheels and sudden stop Repeated use while driving will dama...

Page 27: ... information about how to avoid tipping over 5 Location Panel below steering wheel Product code A441498 WARNING Always follow this safe stopping procedure 1 Release the auxiliary hydraulics control lever to its neutral position 2 Lower the attachment on the ground 3 Engage parking brake 4 Stop the engine a Set engine RPM to idle b Allow the engine to run at idle to allow the turbocharger to cool c...

Page 28: ...414244 WARNING Hot exhaust outlet Risk of burns Stay away from the exhaust outlet at the rear of the loader 8 Location At loader entry point Product code A411455 WARNING Risk of crushing Small gap between tyres of articulated loader Do not grip the steering wheel from outside the machine or when getting into the driver s seat to prevent moving of the wheels 9 Location Only on loaders ROPS canopy o...

Page 29: ...ot necessary to open the cap to check the coolant level the level can be seen through the transparent reservoir Check the water level in reservoir when engine is cool See page 119 for more information 11 Location Engine bay left side of engine Product code A417271 WARNING Risk of contact with moving parts Always shut down the engine before accessing the engine compartment Engine cooling fan altern...

Page 30: ...mer to break glass Make sure the safety hammer is available for emergency use 14 Location Only on CAB L Near right window Product code A411021 EMERGENCY HAMMER Use the hammer to break a glass window pane On loaders equipped with CAB L the front window windshield can be used as an emergency exit when broken with the hammer Keep in mind that if the side and rear panels are made from polycarbonate th...

Page 31: ...T Location Cab GT inside Product code A441541 17 Sound power level 101 dB A 2000 14 EC Sound pressure level 88 dB A at driver s seat Location Right panel near driver s seat Product code A441557 18 Correct type of hydraulic oil and engine oil See pages 125 and 35 Location Front panel below driver s seat Product code A415780 19 Information about Rated operating capacity For more information see page...

Page 32: ...ce 373 mm Operating mass ISO 6016 This mass represents the weight of a loader with standard counterweight typical options standard tyres with no attachment fitted and 75 kg driver on the driver s seat Additional options or counterweights can increase the mass of the loader The mass of your specific loader may also be lower Height and width Tyre Width Height 380 55 17 TR 1490 mm 2200 mm 380 55 17 G...

Page 33: ...ndard Faster multiconnector system on front Optional Extra auxiliary hydraulics coupling on front or rear Attachment coupling Avant quick coupling attachment plate Hydraulic oil tank capacity 48 l Hydraulic oil type ISO VG 46 mineral oil only See page 125 Battery type 65197 12 V lead acid battery See page 127 Sound pressure level 2000 14 EC LpA ISO 6396 86 dB A Sound power level 2000 14 EC LwA ISO...

Page 34: ... 1 LE 5W 30 See page 35 Engine oil viscosity 5W 30 0W 30 below 25 C Engine oil capacity Min 5 l max 8 7 l including oil filter Exhaust system Diesel oxidation catalyst DOC Diesel Particulate filter DPF exhaust gas recirculation EGR Max inclination Max intermittent 30 Continuous operation max 25 any direction Emission control information The engine of the loader is certified by the manufacturer of ...

Page 35: ...l must be less than 15 ppm 0 0015 Never add petroleum or any additive that does not comply with the fuel standards listed below In cold ambient temperatures below 0 C ensure that the fuel is intended for cold temperatures If fuel is not intended for cold temperatures it will form paraffin which will block the fuel filter and interrupts the flow of fuel Avant 860i Kohler KDI Fuel must meet the foll...

Page 36: ...there are visible differences between the tyres Always use the same size of tyres on all wheels Tyre options for Avant 860i Tyre Tread Pattern Code Fill pressure Recommended Maximum Snow chains Fits with fenders Remarks 380 55 17 TR 66505 2 8 bar 2 8 bar x Standard on 860i 380 55 17 GR A442475 4 0 bar 4 0 bar x Use the widest possible tyres For the best stability and controllability always use the...

Page 37: ... with ballasted tyres the following symbol must be applied to a visible location on the loader frame near tyres If you replace the tyres and install normal tyres make sure to also remove this label Auxiliary hydraulics oil flow The following graphs show auxiliary hydraulics output flow at different engine rpm levels The 1 pump setting is illustrated with dashed line and 2 pump setting with uniform...

Page 38: ...low levels If the attachment requires only low power to operate in some cases it can be useful to use the two pump setting while using low engine rpm This reduces the noise of the loader If the attachment or loader stalls switch to 1 pump setting and increase engine rpm In normal use keep the pump selection switch at the 1 pump setting to avoid overspeed of the attachment and stalling of the loade...

Page 39: ...ctors influencing the tipping load into account are shown on page 45 There are many influencing factors that affect the stability of the loader Use the load chart and ROC table to estimate the load handling capacity of the loader Observe the instructions and information given in this manual The lifting capacity and the stability of the loader are at the best when the ground is level the loader fra...

Page 40: ...he indicated load values WARNING All counterweights affect stability Also the driver Always lower the load on the ground before leaving the driver s seat If the load is close to the tipping load in the position and in the current situation of the loader the loader could tip over as a result of leaving the driver s seat Load charts of other attachments In this manual there is only a load chart for ...

Page 41: ... 86 The load sensor must be calibrated if counterweights are added or removed The sensor must also be calibrated at least annually Calibration instructions for the load sensor system can be found on page 124 WARNING Risk of tipping over Observe the load indicator warning When the load indicator warning is triggered there is high risk that the loader will start tipping forward Lower the load in a c...

Page 42: ...tipping over on firm stable ground They describe the loads that can be handled at different positions of the loader boom The ROC label below shows the lifting capacity with pallet forks in different positions of the loader boom The lifting capacity of the loader depends on the horizontal distance between the center of gravity of the load and the front axle of the loader When the load is lifted off...

Page 43: ...en lifting load just off the ground with pallet forks NOTE The tipping load exceeds the maximum lift capacity of the loader Values in brackets show theoretical tipping load 2 Boom lifted to horizontal position a Tipping load in this position b Rated operating capacity 60 of tipping load with pallet forks 3 Boom lifted to horizontal position telescopic boom fully extended least stable position a Ti...

Page 44: ... frame in straight position b Tipping load with the loader frame in maximum articulation ROC Rated operating capacity defined as 60 of tipping load for pallet forks The tipping load chart describes only the stability of the loader to forward direction it does not refer to maximum available lift force The tipping load lines in the chart extend beyond the hydraulic lift capacity of the loader Exampl...

Page 45: ...the front tyres The further away the load is from the loader the less stable the loader is Keep the load as close to the ground and the loader as possible Never drive while load is lifted more than just off the ground Straight or articulated position of the loader frame If you turn the articulated frame the loader will tip over more easily Keep the loader in straight position when lifting heavy lo...

Page 46: ... attachments 55 Telescopic boom control lever 56 Joystick 8 function 56 Hand throttle lever 57 Parking brake switch 57 Opticontrol option 57 PTO switch 59 Control lever of extra hydraulics outlet option 59 Attachment control switch pack for rear mounted attachments option 59 Electric 12 V outlet 59 Engine compartment and storage spaces on the loader 60 Boom self levelling 61 Boom floating 61 Smoot...

Page 47: ...play 50 6 Auxiliary hydraulics control lever 55 7 Control lever of boom and bucket 55 8 Boom telescope control lever 9 Extra auxiliary hydraulics control lever 10 Control switches on the panel 48 11 Hand throttle lever 57 12 12 V outlet max 15 A 13 CAN Diagnostics port 14 Seat belt buckle 67 15 Storage compartment 60 16 Fuse box 133 Controls in footwell A Drive pedal right drive forward 79 B Drive...

Page 48: ...are located above the instrument panel Controls related to the heating of the cab are located on the left of the seat base For more information see page 72 Extra work lights 2 at front 1 rear Optional equipment Drive speed range selection switch See page 79 Emergency blinker Included in road traffic light kit Optional equipment Warning beacon Optional equipment See page 70 Smooth drive Optional eq...

Page 49: ... on the dashboard Symbol Switch 1 Ignition switch See page 76 2 Signal horn 3 Cross lock valve switch See page 81 4 1 PUMP 2 PUMP Auxiliary hydraulics pump output selection switch See page 38 5 PTO override switch See page 50 6 Seat heater switch See page 67 7 Work light switch Standard front work lights of the loader 8 Multi function display See page 50 9 CAB GT Switches above dashboard On cab GT...

Page 50: ...sic information whenever the loader is running The display also has other information available which can be selected with the buttons of the display Shown in the basic display view This view is automatically shown when the loader is started 1 Ambient temperature can be displayed in Celsius of Fahrenheit 2 Current fuel consumption in litres per hour 3 Total operating hours 4 Current time 5 Message...

Page 51: ...splay B DPF Control buttons 4 Inhibit DPF regeneration This button postpones DPF regeneration process Pushing this button changes the symbol above the button to green or back to gray Use this to prevent hot exhaust when operating in enclosed spaces near flammable material and when you wish to inhibit the DPF regeneration until next use For more information about DPF regeneration see page 110 5 For...

Page 52: ...formation symbols loader Symbol Colour Remarks Red Safety alert symbol When this symbol appears there is a safety related situation that needs action from operator This symbol may appear by itself or with other warning symbols Red Hydraulic attachment locking switch in open position When this symbol is shown the switch controlling the hydraulic attachment coupling is in position that unlocks the l...

Page 53: ...at DPF regeneration can be done only with service tool NO MESSAGES No messages active CAN CONNECTION ERROR ENGINE ECU CAN control area network connection is not working between display and Engine ECU Electronic control unit CAN CONNECTION ERROR VEHICLE ECU CAN control area network connection is not working between display and Vehicle ECU Electronic control unit ENGAGE P BRAKE TO START FORCED REGEN...

Page 54: ... and try again OPERATOR NOT SEATED Seat switch is not active this message may activate when engine is started or drive pedal is pressed while operator is not seated DRIVE DISABLED CHECK PTO SWITCH Interlock switch that disables drive functions but allows to use auxiliary hydraulics is active while operator try to start the engine or use drive pedals Operator is notified to disengage switch before ...

Page 55: ...right to lower the tip of the bucket emptying 2 Control lever of auxiliary hydraulics hydraulically operated attachments Hydraulically operated attachments are connected to the loader using the multi connector system for more information see page 92 Operation directions depend on the attachment used When using an attachment for the first time carefully move the lever to test and check the operatin...

Page 56: ...ctric pushbuttons to control the auxiliary hydraulics and the telescopic boom 1 Electric control of auxiliary hydraulics If the loader is equipped with the optional 8 function joystick the auxiliary hydraulics can be controlled with electric buttons on the joystick Push and hold either button to control the direction of auxiliary hydraulics flow The operation of the buttons depends on the attachme...

Page 57: ... throttle lever should be kept at its minimum setting when starting the engine The lever must be set to idle during or after starting the engine otherwise the engine rpm will not increase when moving the lever 6 Parking brake switch The parking brake is activated when loader is switched off or when hydraulic pressure is otherwise lost due to a failure Parking brake can be released only when the lo...

Page 58: ...ep the switch in OFF position unless using an attachment that is intended to be used with the combined control mode Switch ON combined control mode The combined mode of hydraulic and electric control enables more simple and flexible operation of certain attachments In this mode Opticontrol combines the auxiliary hydraulic control of the loader and electric control of the attachment Auxiliary hydra...

Page 59: ...sing rear mounted attachments together with the hydraulic rear lift device For example when using rear mounted sand spreaders with the rear lift device the attachment control switch pack is necessary The socket for the rear mounted attachment is located near the rear hydraulic quick couplers The switch pack is equipped with a strong magnet This makes it possible to fasten the switch pack to a suit...

Page 60: ...haust system Some objects such as soft coated gloves may get damaged due to heat in the engine bay Always check objects that are placed in storage to avoid burns when removing them Storage near driver s seat ROPS and CAB L A storage space is located at the left side of the steering wheel Note that this storage space is not designed to be watertight This storage space can also be used to store a fi...

Page 61: ...loating is integrated to the joystick control lever of boom and bucket Boom floating is a system that allows an attachment to follow the surface of the ground The floating system releases the lift cylinder and allows it to float up and down as the attachment is on the ground To activate the boom floating 1 Lower the attachment on the ground to the operating position described in the operator s man...

Page 62: ...ch is a shock absorber system for the boom Smooth drive is switched on with a separate switch on the dashboard When driving at high speed or with a heavy load or heavy attachment the front of the loader may start to swing making driving unpleasant The smooth drive system includes a pressure accumulator which absorbs and dampens boom movements It makes driving considerably smoother and more stable ...

Page 63: ... Avant 800 series loaders is a 275 kg cast block mounted on the rear of the loader In all technical information concerning the mass and lift capacity of the loader this counterweight is installed on the loader If necessary to remove it i e for installation of a rear lift device see the picture below for mounting points Special lifting equipment is necessary when adding or removing this counterweig...

Page 64: ... of loss of control of loader Too much counterweight can make the front of the loader too light If you install too much counterweights to the loader the front wheels of the loader will be easily lifted from the ground This will make steering of the loader difficult If counterweights are fitted to handle a certain attachment remove counterweights if driving without an attachment CAUTION Risk of sud...

Page 65: ...ely after installation work Trailer coupling option The loader can be equipped with a trailer coupling for towing of trailers There are two types available 1 50 mm ball hitch A417323 2 50 mm ball hitch with towing pin A417337 Trailer coupling can be mounted either directly on the rear bumper or on the extra back weight Max allowed vertical load 500 kg Maximum towing load is 1000 kg Make sure that ...

Page 66: ...nted to the loader boom WARNING Risk of loss of control Heavy attachment at the rear lift device may cause the loader to tip rearwards Keep an attachment mounted on the boom to balance the weight at the rear lift device Remove attachment from the rear lift device before uncoupling the attachment from the loader boom Follow the manual of the rear lift device and the operator s manuals of attachment...

Page 67: ...tch is located by the steering column and indicator light is on the dashboard If the loader is equipped with the air suspension seat the seat heater switch on the dashboard is removed and its corresponding indicator light on the dashboard is disabled The seat heater of the air suspension seat is controlled with an additional switch on the backrest of the seat Suspension seat The suspension seat ha...

Page 68: ...stance of the seat from the steering wheel can be adjusted with the lever which is located under the front edge of the seat Always make sure that the adjustment is locked after adjusting the seat 2 Suspension adjustment or Air suspension seat 1 Sit on the seat and switch the ignition switch to ON 2 Check the indicator on front of the seat 3 Pull the handle up or push it down so that the indicator ...

Page 69: ...right and powerful work lights may dazzle yourself or other persons nearby Direct the lights so that they do not disrupt the visibility from the cab Headlight beacon blinker reflector kit option This optional kit makes it possible to register the loader for road traffic use in certain countries Requirements vary in different countries please consult your local AVANT dealer Always use lights and re...

Page 70: ...y by loosening its retaining screw and then by pulling the beacon out Place the protective seal on the beacon stand to prevent water entering and damaging the connectors Handle the beacon with care The beacon is sealed and its inner components cannot be replaced or repaired by user Beacon includes high voltage components Do not use or repair damaged beacon replace with new one Warning lights on CA...

Page 71: ...ptional equipment on different cab models ROPS canopy Cab GT ROPS FOPS Certified Mounts on standard ROPS frame Windscreen wiper and washer right side window and rear window Door and heater Air Conditioning A C Front rear mudguards Front lights Road traffic light kit Work light kit Warning beacon Integrated flashing warning lights Panel interior fabric seat Radio and speakers Air suspension seat Se...

Page 72: ...per and washer Functional heater and its blower for de misting the windscreen Side mirrors Cab air filter must be in place CAUTION Risk of breaking glass Do not drive with an open cabin door The door may break upon contact with wheels Also turn the articulated frame to straight position before opening the door Windscreen washer and wiper The windscreen washer is operated with multi function contro...

Page 73: ...pes of dust Using the ventilation system without the filter in place increases the level of dust inside the cab Defrosting De misting Turn heater fan to position 4 high speed Set temperature to warmest possible Switch on A C if fitted The air conditioning will dry air Direct front vents towards the windows Close other vents Keep air recirculation hatch closed Using the air recirculation will incre...

Page 74: ...ention of the operator Do not perform distractive actions while operating such as using mobile devices WARNING Risk of collision Pay attention to other machines and persons that are moving in the area Make sure that there are no persons in the danger zone of the loader and the attachment The danger zone of the loader covers the reach area of the loader boom the turning area on the side and in the ...

Page 75: ...switch on lights of the loader Everyone should wear high visibility clothing Exhaust emissions can kill within minutes Do not operate the loader in enclosed spaces or insufficiently ventilated spaces i e open garage door first before starting the loader WARNING Collision hazard Prevent unintended movements of the loader Keep hands and feet away from other controls of the loader while starting WARN...

Page 76: ...ten seat belt The loader will not start unless driver is seated 4 Leave hand throttle lever to minimum position See page 57 5 Make sure that auxiliary hydraulics is switched off lever is released to its neutral position see page 55 Do not press on the drive pedals 6 Turn the ignition key to the right to ON position The multi function display will switch on Signal lamps on the dashboard will light ...

Page 77: ...e otherwise the engine rpm will not increase when moving the lever Stopping the engine Safe stopping procedure 1 Lower the boom completely down Place attachment firmly on the ground engage parking brake stop the attachment move auxiliary hydraulics control lever to neutral position see page 55 set engine rpm to idle NOTE Allow the loader to idle for a moment before stopping the engine especially a...

Page 78: ...e whenever leaving the driver s seat Stop if you notice any of the following Stop the engine as soon as possible if any of the following symptoms is observed Find out the cause before restarting The oil pressure warning light or malfunction indication light turns on during operation Engine rpm increases and or decreases suddenly by itself without touching the throttle lever A sudden and unusual no...

Page 79: ...to drive with slow speed operating mode increase speed gradually and learn how to drive and steer the loader with higher drive speeds Drive pedals Using the drive pedals Driving forward press gently on the right drive pedal until the machine starts to move slowly To drive backward press gently on the left drive pedal When you wish to stop gently release the pedal by lifting your foot and the loade...

Page 80: ...rupt control movements can cause the loader to roll over Do not turn the steering wheel quickly when you drive at high travel speed Drive slowly whenever carrying loads driving on inclined or rough terrain or on slippery surfaces Always reduce speed before sharp turns OptiDrive The 860i loaders are equipped with the efficient Avant OptiDrive hydraulic drive system as standard The system is designe...

Page 81: ...stricted The effect is similar to a limited differential lock in operation This improves the pushing capability of the loader With the X lock is switched on the hydraulic motors on one side of the loader may receive larger portion of the total hydraulic flow leading to spinning of the wheels on one side of the loader In general the X lock should be switched off during general use where high pushin...

Page 82: ...ns Contact Avant service In case the braking power of the hydrostatic drive system has decreased engage the parking brake The rear wheels may lock immediately Parking brake acts as an emergency brake and will also engage in case of loss of oil pressure Parking brake is intended to keep the loader stationary and not for repeated braking Engage while loader moves only when necessary Engine block hea...

Page 83: ...nstalled on the loader a green electric mains cable is provided with the loader Do not use other types of cables The cable must be approved for outdoor use The engine block heater A410648 is intended to operate with electric supply of 220 240 V 50 60 Hz AC power Do not modify the cable or use transformers Contact your Avant dealer or service point for information about other types of block heaters...

Page 84: ...iving always keep the loader boom as low and close to the loader as possible Risk of tipping over increases considerably when there is a heavy load on the loader a heavy attachment or a big load in the bucket and the boom is up when driving WARNING Risk of tipping over Avoid high speed turns The loader can tip over if you turn the steering wheel sharply while driving Slow down before making sharp ...

Page 85: ...ways use the seat belt and stay within the space protected by the ROPS safety frame Always keep seatbelt on to stay on driver s seat and to avoid getting crushed between ground and a loader that tips over In case the loader tips over Switch off the engine of the loader immediately Running the engine and pumps of an overturned loader will damage them quickly and will spill hydraulic oil and fuel As...

Page 86: ...loads WARNING Risk of tipping over always carry heavy loads as close to the ground as possible and only on level ground Carrying heavy loads can shift the centre of gravity of the loader and lead to tipping over of the loader Always transport the load as low and close to the machine as possible to keep the centre of gravity low and for the best stability DANGER Risk of rolling over Keep loads clos...

Page 87: ... Avant 860i must be specifically listed in the operator s manual of the attachment Contact your Avant dealer if necessary Incompatible attachments can cause risks of injuries resulting from eg the stability of the loader contact with moving parts reduced visibility or ejected debris Use all attachments only for their intended purpose that is described in the Operator s Manual of the attachment Mak...

Page 88: ...eliability of the combination of the loader and the attachment Consult your Avant dealer if you are unsure about the compatibility of the equipment with your Avant loader Compatibility of attachments Use only Avant attachments that have been designed for your loader model Any attachment that is fitted to the loader must be designed to be used specifically with Avant 860i and this must be stated in...

Page 89: ...between the attachment and the loader Mount the attachment only on level surface Never move or lift an attachment that has not been locked Always read also the additional instructions for coupling and using of the attachment in the Operator s Manual of the attachment The coupling procedure of an attachment may require additional steps in addition to the basic steps described below Always follow in...

Page 90: ... fall under the loader during driving causing injuries or loss of control of the loader Never move or lift an attachment that has not been fully locked with both locking pins Hydraulic attachment coupling The optional hydraulic attachment coupling plate enables locking and unlocking of an attachment from driver s seat A control switch is located at the control panel on the right see page 48 The sw...

Page 91: ... connector is upside down 2 Connect and lock the multiconnector by turning the lever towards the loader The lever should move easily all the way to its locking position If the lever does not slide smoothly check the alignment and position of the connector and clean the connectors Also shut down the loader and release the residual hydraulic pressure To disconnect the multiconnector system Before di...

Page 92: ...er of the auxiliary hydraulics and electric buttons of the joystick see page 55 directs hydraulic oil as follows 1 Moving the control lever towards the locking position will direct hydraulic flow to port 1 This is normally the normal or positive movement of the attachment 2 Moving the lever away from the locking position will direct flow in reverse direction pressure in port 2 3 The third port is ...

Page 93: ...ticonnector Before you connect or disconnect standard couplings relieve hydraulic pressure as described on page 93 To connect and disconnect the standard couplings move the collar at the end of the female fitting Note that the protective caps on the loader and the attachment can be fastened to each other during operation to reduce the accumulation of dirt When disconnecting the standard quick coup...

Page 94: ...g guides which can also be lubricated If a hydraulic attachment is mounted on the hydraulic side shift adapter the loader must be equipped with the optional second auxiliary hydraulics outlet in the front The attachment hoses are mounted on the multi connector and the side shift adapter hoses on the optional outlet Contact your Avant dealer for more information about the availability of the side s...

Page 95: ...t be used only on level ground CAUTION Adapter plates reduce lifting capacity Do not use adapters with heavy loads or attachments The adapter plates move the centre of gravity of the attachment further away from the loader This increases the risk of tipping over and can limit the use of heavy attachments All coupling adapters are intended only for specific attachments that can be safely and effici...

Page 96: ...ember to remove the frame lock and test the steering of the loader after transport Tie down points The loader must be tied down securely if transporting it on a trailer for example All four tie down points must be used If an attachment is fitted also it must be tied down As standard there are 4 tie down points Two on the front frame close to the boom Two on the rear frame near rear counterweight T...

Page 97: ...The center of gravity of a loader without an attachment is located slightly forward from the rear axle Take into account the size and weight of the attachment and any additional counterweights on the loader Always secure the loader and its attachment onto the trailer DANGER Risk of loss of control of towing vehicle Never load trailer so that there is lifting force on the tow bar Trailer must never...

Page 98: ...A418623 installed at the side of rear frame For side installation two brackets are needed Tie down bracket on wheel hub A423091 Installed to a wheel hub with 5 bolts DANGER Risk of moving or falling of the loader Never lift or tie down loader from side counterweights Eyelets on extra side counterweights are for installing or removing the side counterweight only Never attempt to lift the loader fro...

Page 99: ...e the tyres to the recommended tyre pressure Fill the fuel tank and the hydraulic oil tank to the maximum marks Cover the engine exhaust pipe outlet Lifting of the loader Lifting a loader with ROPS When lifting a loader equipped with the ROPS frame use four lifting slings that are approved for lifting purpose and which are minimum 2000 mm 79 inches long Loop the slings around the four ROPS posts L...

Page 100: ...NING Risk of dropping of loader Never attempt to lift the loader from the counterweights or use them as tie down points Eyelets on extra side counterweights are for installing or removing the sideweight only Remove eyelets from counterweights to prevent their use Towing retrieval of the machine The loader cannot be towed It is equipped with a hydrostatic transmission and a hydraulic parking brake ...

Page 101: ...fety instructions WARNING Always follow the basic safety procedures and keep the following instructions in mind when doing any maintenance or service 1 Switch off the loader and let it cool down before starting any service operation 2 Switch on the parking brake 3 Turn the battery disconnect switch to position OFF 4 Keep boom lowered Install and secure the service support on the boom cylinder when...

Page 102: ...jury might be barely visible but serious injury can develop within just hours WARNING Risk of injuries and burns caused by leaking hydraulic oil Never operate loader or attachments if there are hydraulic leaks Check hydraulic hoses and components only when the loader is safely stopped and hydraulic pressure is released Repair all leaks as soon as you have noticed them because a small leak can quic...

Page 103: ... completely before opening WARNING Risk of contact with moving parts Always shut down the engine before accessing the engine compartment Engine cooling fan alternator belt and belt pulleys will move at high speed when engine is running Never open the engine cover when engine is running Consider the environment The fluids in the machine are harmful to the environment Never allow fluids to leak in t...

Page 104: ... manual nut 5 While seated on the driver s seat keep the engine off and lower the boom until it rests on the service support Service support is stored at the front storage compartment Service support in place Frame lock A red frame lock bar is stored under the operator s cab This lock bar is intended to lock the articulated frame to make the loader frame stay straight during e g lifting or transpo...

Page 105: ...e operations are intended to be made when the loader engine is off except those checks that are specifically intended to be made with the engine running Follow the recommended service schedule Keep records of services made Contact Avant service if you are unsure about any of the service procedures or if you need spare parts Keep the loader in good condition Always do the daily inspections and foll...

Page 106: ... clean Check that all controls of the loader function correctly Daily and weekly inspections Check before each work shift Check weekly 1 Add fuel 2 Check the general condition of the loader its equipment and safety labels 3 Clean the loader 4 Add grease to the lubricating points 5 Check the boom and other metal structures visually 6 Check tightness of bolts nuts and fittings 7 Check wheels 8 Check...

Page 107: ...components 12 Check hydraulic hoses fittings and other hydraulic components 13 Measure hydraulic pressures of auxiliary and boom hydraulics adjust if necessary 14 Measure the charge pressure of the variable displacement pump 15 Measure the power control valve adjust if necessary 16 Check and adjust slide pads of telescopic boom replace if necessary 17 Check mounting and operation of drive motors 1...

Page 108: ... marked with an asterisk are intended for professional service technicians There is additional information about maintenance and service of the engine in the Operator s manual of the engine Use only spare parts and oils that comply with recommended specifications If conflicting information is found the information shown in the Operator s Manual of the loader must be followed Reset the service remi...

Page 109: ...ntion to the hot exhaust gas symbol on the display When it is lit the exhaust gas is especially hot Wait until DPF regeneration is completed Do not drive or park near combustible materials The automatic and manually activated DPF regeneration process produce hot exhaust gas DPF Regeneration Regeneration method of the DPF depends on accumulated soot load In normal use the regeneration process start...

Page 110: ...stop the loader or to leave it idling during regeneration 90 100 A request for parked regeneration is shown on the display When request appears Operate the loader until the engine reaches its normal operating temperature at least 60 C To speed up the engine warming you can run the engine with auxiliary hydraulics ON without any attachment and the hydraulic pump in selection 1 Avoid idling 1 Park t...

Page 111: ...n fuel helps to prevent the fuel injectors from clogging Immediately clean up any spilled fuel Prevent spilling of fuel by using appropriate equipment Never store fuel in galvanized containers i e coated with zinc Diesel fuel and the galvanized coating react chemically to each other producing flaking that quickly clogs filters or causes fuel pump and or injector failure Risk of fire or explosion H...

Page 112: ...igns of leakage Never operate the loader or its attachments if you have noticed a leak Repair all leaks before use Check the condition of the safety frame seat belt lamps and other safety equipment Safety frame ROPS and protective roof FOPS must be fitted Safety structures must not have visible damage or deformations They must be replaced with new ones after any incident Make sure all lighting dev...

Page 113: ...er with a rag Clean also the space between the front hydraulic motors periodically by removing the cover panel at the front of the loader After cleaning the exterior of the loader grease all greasing points B Clean the interior of the loader Clean cab and interior with appropriate mild detergent and cleaning supplies Keep the cab and the driver s seat clean to reduce exposure to dust C Clean the e...

Page 114: ...ne intake cooling fan The engine intercooler fan and its surrounding area on top of the engine must be kept clean to avoid engine damage and for the best performance of the engine Check the fan and the surrounding area on top the engine visually If there is visible dust or other dirt on them clean with a wet cloth Make sure that dirt does not enter the engine air filter intake that is connected to...

Page 115: ...ng cylinder near articulation joint 2 B 3 Boom pivot pin Both ends of boom pivot 2 4 Lift cylinder 2 5 Levelling cylinder 2 C 6 Telescopic boom Grease when boom is completely retracted 2 D 7 Tilt cylinders 4 8 Attachment coupling plate Pivot pins and tilting mechanism 8 A Articulation joint and steering cylinder B Front frame C Telescopic boom D Coupling plate and tilt cylinders ...

Page 116: ...e in case the steel structure of the loader gets damaged A faulty reparation or wrong methods and materials used for reparation can cause hazardous failures or further damage the loader WARNING Damaged or modified safety structures do not protect in same way as original ones In case the ROPS safety frame or the FOPS canopy of the machine gets damaged the machine must be taken to Avant service for ...

Page 117: ...ced Hydraulic fittings of drive motors and hoses of drive system Hydraulic fittings of the drive system are equipped with a visible marker where a yellow marker is fully visible when the fitting is tightened correctly If a hose or fitting needs to be replaced use only hoses which are equipped with compatible fittings Reuse of hydraulic hoses or fittings Never reuse pressed fittings that are part o...

Page 118: ...draulic attachment locking check that both locking pins move up and lower down completely by using the switch on the dashboard Do not operate the loader if the attachment locking system pins do not lower down completely Use the hydraulic locking periodically even if you don t change attachments 9 Check hydraulic oil level Check the level of hydraulic oil with the dipstick of the filler cap Remove ...

Page 119: ...gine is hot Always check the coolant level when the engine is cool WARNING Risk of burns due to hot coolant Never open hot radiator or reservoir Never open the pressurized coolant reservoir while engine is warm Hot coolant may burst out causing serious burns Allow engine to cool completely before opening The cooling system of the engine uses a pressurized reservoir tank Coolant level should be abo...

Page 120: ...ter cartridge by pulling it out 4 To clean the filter tap the closed end of the filter gently against a flat clean surface Never use compressed air to clean the filter 5 Do not remove the inner element 6 Clean the inner components of the filter housing with a damp cloth 7 Clean the sealing edges of the air filter 8 Reinstall the filter cartridge and sealing Ensure the proper tightness between the ...

Page 121: ...f cables of a moving battery may get damaged causing risk of fire short circuit and sparks A moving battery can also short circuit due to contact between battery pole and the frame of the loader Battery can get damaged due to movements Always ensure that the battery is securely fastened from its base flange Keep the battery and its surrounding area clean so that dirt or other material does not dam...

Page 122: ...tering the ducts after the filter the air ducts must be cleaned and a new filter must be installed making sure that its seal makes good contact with its casing 1 Loosen and remove the screws 2 pcs from the air recirculation system frame 2 Pull the frame and filter housing away from its slot Notice that it might be tight 3 Now you can see the filter element inside the slot 4 Move the filter element...

Page 123: ... attachment only for its intended use 17 Test drive control and steering Check operation of pedals and steering Pedals must move freely and not get stuck or feel stiff Check that loader stops when not pressing the drive pedals Do not use the loader if the braking performance is decreased or if the loader creeps Allow the loader to warm up and check steering When the engine is running turning the s...

Page 124: ...ensor 1 Add or remove the counterweights from the loader 2 Remove the engine cover plate and the lower left side rear cover plate 3 Lift something so heavy with the loader that the rear wheels lift off the ground Use the loader boom to lift the rear wheels slightly off the ground Lift only solid objects when doing the calibration If you lift soft materials e g sand with bucket the loader can move ...

Page 125: ...from the filter housing 3 Remove the housing cover 4 Change hydraulic oil When changing hydraulic oil you can remove the oil with a suction pump or by opening the drain plug on the right side of the front frame next to the articulation joint In both cases it is important to clean the magnetic drain plug Hydraulic oil tank capacity is 50 litres Hydraulic oil type Always use correct type of clean hi...

Page 126: ... must be changed more frequently than the recommended service interval The fuel lines are connected to the main filter through a pre filter The fuel pre filter is located on the left hand side of the engine near the fuel tank Replace fuel filters carefully to avoid fuel spill Make sure to keep all parts clean during service Wipe all spilled fuel thoroughly Service only when engine is cold Check th...

Page 127: ...dedicated service tool A voltage reading of a battery does not give good indication of its condition Checking the performance of the battery requires a suitable testing tool contact your Avant service If necessary replace the battery with a battery that is identical type and size as the original one Make sure the battery is fastened correctly and that battery cables are in good condition Also chec...

Page 128: ...t recommended to use the pressure gauge adapter A422475 Boom control valve pressure There are two pressure relief valves at the main control valve of the boom and auxiliary hydraulics The auxiliary hydraulics pressure can be measured from the multiconnector but the boom pressure must be measured from the valve assembly with a pressure gauge that has a measurement fitting Contact Avant service for ...

Page 129: ...ment tools and training is required for testing the charge pump Contact your nearest Avant service 15 Measure and adjust power control valve The power control valve of the hydraulic drive pump optimizes driving performance of the loader by reducing stalling of the loader when load increases quickly and by making starting and stopping of the loader smoother The valve is installed to the variable di...

Page 130: ...ur nearest Avant service partner Slide pad part numbers Slide pad 1 A430928 Adjustment sheet long A430931 Slide pad 2 A430929 Adjustment sheet short A430932 Slide pad 3 A48343 Slide pad 4 A47922 Spacer under slide pad 4 A47941 17 Check mounting and operation of drive motors Check the tightness of the drive motor fastening bolts The bolts should be tightened to 200 Nm Test the functionality of the ...

Page 131: ...all adjustments Clean the surface of the seat with appropriate cleaning supplies Check and test the seat belt Make sure the buckle locks firmly and can be released easily Test the reeling of the seat belt the belt must reel in completely and it must lock instantly when pulling the belt quickly Clean the seat belt with damp cloth and mild soap Test all lamps and lighting devices If the loader is eq...

Page 132: ...e with a series of M12 Allen bolts Check the tightness of the bolts after the first 50 hours of use and then after every 400 hours or annually The bolts of the articulation joint must be tightened to 136 Nm If loader is equipped with enclosed cab 24 Change cab air filter Change the cab air filter at least once a year If you operate the loader frequently in dusty conditions change the filter more o...

Page 133: ... right side panel near drivers seat 12 V Fuse box 1 1 ECU Parking brake release 2 Dashboard Drive speed range selection switch 3 12 V outlet 4 ECU diagnostics ECU start control 5 Hydraulic oil cooler fan fuse 6 Smooth drive 12 V Fuse box 2 1 Lights Road traffic lights 2 Joystick 3 Seat heater Warning beacon 4 Opticontrol 5 Extra work lights 6 Windscreen washer and wiper Fuses in Cab GT There is an...

Page 134: ...e of hydraulic oil cooler Vehicle Power Distribution Unit Instead of separate relays a vehicle ECU with electric power distribution unit PDU at the rear right of the loader controls the electric functions of the loader There are additional fuses within the unit In case of trouble related to a electric function and the fuses in the regular fuse boxes are not blown check the PDU Always disconnect th...

Page 135: ...d only when other means are not available Replace a worn battery do not jump start repeatedly Charge the battery with an external charger whenever it is possible WARNING Risk of uncontrolled movement and contact with moving or hot parts sparks and fire and engine damage Never bypass battery or connect cables directly to starter motor There is a risk of serious injuries caused by moving parts of th...

Page 136: ...rrectly Cables that are damaged not clamped correctly or cables which have small cross section of the conducting cable may become extremely hot or even burn See the instructions that are provided by the manufacturer of the jump start cables The current through the cables is high during start of the diesel engine of the loader End of life disposal When the loader is at the end of its useful life re...

Page 137: ...Avant 860i 137 ...

Page 138: ... with correct type of fuel Drain water from the fuel filter Prime the fuel system see page 112 Engine does not get fuel clogged fuel filter or fuel line Drain water from the fuel filter Prime the fuel system see page 112 Make sure that the fuel hoses and fuel filter are clean and not frozen Replace fuel filter clean fuel lines If using fuel that has not been designed for low temperatures has been ...

Page 139: ...ne Release the pressure by moving the extra auxiliary hydraulics control lever in both directions Hydraulic system overheats Hydraulic oil level low Check and refill see page 118 Clogged oil cooler Clean cooler and fan Fan faulty Check and clean repair if necessary Hydraulic oil flow restricted Make sure auxiliary hydraulics valve is completely opened when using high flow attachments Adjust lever ...

Page 140: ...ng hours Remarks Serviced by Stamp signature ___ ___ _____ _____ 50 h ___ ___ _____ _____ 450 h ___ ___ _____ _____ 850 h ___ ___ _____ _____ 1250 h ___ ___ _____ _____ 1650 h ___ ___ _____ _____ 2050 h ___ ___ _____ _____ 2450 h ___ ___ _____ _____ 2850 h ___ ___ _____ _____ 3250 h ___ ___ _____ _____ 3650 h ___ ___ _____ _____ 4050 h ...

Page 141: ...Avant 860i Services made 141 Notes ...

Page 142: ...Services made Avant 860i 142 Notes ...

Page 143: ......

Page 144: ...ures visually 112 116 Check the general condition of the loader 112 Check the safety frame seat seat belt lamps and other safety related equipment 131 Check tightness of bolts nuts and fittings 116 Check water separator 52 120 Check wheels 117 Clean fuel tank 127 Clean or replace hydraulic oil tank breather 126 Clean the loader 113 Control lever of auxiliary hydraulics hydraulically operated attac...

Page 145: ...2 O Operating instructions 74 Operation on uneven surfaces gradients and near excavations 14 Operator qualification 6 Opticontrol option 48 58 OptiDrive 80 Overview of controls 47 P Parking brake switch 57 Periodic service 125 Personal safety and protective equipment 16 PTO switch 59 R Rated operating capacity 31 33 42 Rear lift device 66 Refueling 111 Relays 134 Releasing the residual pressure of...

Page 146: ...ubleshoot 76 77 138 Tyres 36 U Use only clean fuel 111 Using the auxiliary hydraulics 92 V Vehicle Power Distribution Unit 134 Ventilation and heating 48 72 W Warning beacon option 48 70 Warnings and symbols on the display 52 Windscreen washer and wiper 72 Work lights 69 Working near powerlines 18 Working with attachments 87 X X lock Cross lock and anti slip 49 52 81 ...

Page 147: ...S Catégorie ENGINS DE TERRASSEMENT CHARGEURS CHARGEURS COMPACTS Kategorie ERDBEWEGUNGSGERÄT LADER KOMPAKTLADER Original language Langue d origine Originalsprache Original language version Model Modèle Modell Cabin Cabine Kabine Serial Number Numero de serie Seriennummer Year of Manufacture Annee de fabrication Baujahr Week of Manufacture Semaine de fabrication Woche der Herstellung Country Etat St...

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AVANT STAGEV 860i, Operator'S Manual

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