1991–2001 Fiat-Hitachi FR 130.2 Wheel Loader Service, Operation and Maintenance Manuals (P/N 604.00.557)

This 1991–2001 Fiat-Hitachi FR 130.2 wheel loader set combines the Service Manual, Print No. 604.02.205, with the Operation and Maintenance Instruction Manual, Form 604.00.557.

• Engine service: Engine removal and installation, turbocharger inspection, injection-pump timing, radiator replacement, and fuel-system service.

• Transmission repair: Powershift control-valve overhaul, torque-converter and clutch-pack work, hydraulic pressure tests, and gear-selector electrical checks.

• Axles and brakes: Super Max-Trac differential adjustment, planetary final-drive repair, wet-brake service, accumulator testing, and brake-system bleeding.

• Steering and hydraulics: Power-steering overhaul, pump and control-valve repair, cylinder service, and optional Load Travel Stabilizer functional tests.

• Bucket, boom, and frame: Removal and installation, cutting-edge repairs, pivot inspection, bushing dimensions, and shimming data.

• Electrical system and cab: Wiring diagrams, Electronic Data Monitor circuits, sensor connections, cab removal, and optional air-conditioning components.

• Operation and maintenance: Cab controls, break-in procedures, walk-around inspections, lubrication schedules, filter changes, and automatic bucket-leveler and boom kick-out adjustments.

The operation manual addresses qualified operators; the service manual reserves its maintenance and repair procedures for the manufacturer's service organization using the specified tools.

Engine Installation, Fuel System, and Cooling

The engine chapter covers removal and refitting of the 8065.25.093, turbocharger inspection, injection-pump calibration data and timing, and starter and alternator replacement. Turbocharger functional diagrams and an LDA air intake device section view explain how boost pressure affects fuel delivery.

Engine repair scope: Detailed engine troubleshooting and internal repair are referred to separate engine manual 604.06.299, which is not included. The supplied service manual concentrates on the engine installation and associated equipment.

Routine service includes fuel-system bleeding and alternator/fan belt adjustment. The turbocharger notes explain how accelerating immediately before shutdown can leave the rotating shaft without lubrication and damage its bushings.

Powershift, Axles, and Brake Diagnosis

Transmission coverage extends to control-valve disassembly, clutch-pack inspection and assembly, and component-specific torque tables. Selector continuity charts and checks with tester 75299002 (PR68) help distinguish electrical control faults from problems that require hydraulic testing or transmission disassembly.

The axle section explains pinion-depth adjustment, bearing preload, and tooth-contact checks for the Super Max-Trac differential. Planetary final-drive section views show the relationship between the reduction gears and oil-bath brakes. Brake coverage includes pedal-valve repair, parking-brake adjustment, and accumulator recharge tests.

Axle chapter limitation: The rear-axle removal and installation page listed as 3-11 is missing, and printed page 3-15 appears twice.

Steering, Loader Hydraulics, and Structural Repairs

The hydraulic sections distinguish the shared steering/implement pump from the brake and pilot-control supply. They include priority-valve and cushion-valve testing, steering-unit assembly, and loader pump, control-valve, and cylinder repair.

The optional LTS anti-pitching section combines a hydraulic circuit diagram with functional tests and accumulator checks. Bucket and frame work includes cutting-edge replacement, boom removal, articulation service, dimensional drawings, and pin-and-bushing inspection data.

The safety sections address raised equipment, articulation locks, and stored accumulator pressure, which can remain after the engine stops.

Controls, Electrical Circuits, and Scheduled Service

The operating instructions explain manual and automatic transmission modes, HOLD, SHIFT-DOWN, and kick-down functions. Instrument-panel layouts and the lubrication guide connect the machine's controls and warning indicators with its scheduled service requirements.

The electrical chapter covers the 24-volt system through full-machine wiring diagrams, fuse-box layouts, and individual component connection drawings. Electronic Data Monitor sensor descriptions support checks of fluid-level, pressure, temperature, and filter-restriction warnings. Cab sections add heater troubleshooting, glazing replacement, and optional air-conditioning wiring.

Selected Engine Settings and Cooling-Capacity Data

These examples represent a small selection of the engine and cooling specifications in the two manuals.

Cold valve-clearance figures differ: the operation and maintenance manual lists 0.25 mm intake and 0.35 mm exhaust, while the service manual specifies 0.30 mm for both. Injector calibration for the 8065.25.093 is listed at 230–238 bar.

The operation manual's cooling-system table lists 28 liters; the service manual specifies 34 liters for first filling with the piping empty. The two documents' figures should not be treated as interchangeable specifications.

PDF Bookmarks, Diagram Detail, and Included Manuals

Search and diagram access: PDF text search is not available. Embedded bookmarks cover both manuals, although two original MAIN MENU links point outside this file. Full-machine wiring diagrams require enlargement, and some tiny wire labels remain difficult to read; individual component connection drawings are clearer.

The download is one printable 481-page PDF: 77 pages of operation and maintenance instructions, 403 pages of service information, and one additional introductory page. That additional page is already included in the total.