FiatAllis FR 160.2 Wheel Loader Operation, Maintenance and Service Manual Set, 1998 (P/N 604.00.552)

The operating manual covers machine setup, controls, and scheduled service. The supplement adds gearshift instructions, safety-plate locations, and symptom-based troubleshooting. The Service Manual provides component tests and repair procedures.

The engine specifications differ between publications. The operating manual lists the 8065.25.093, and the Service Manual covers the Iveco-Fiat 8365.25.584. For internal engine repair and additional engine tests, the Service Manual refers to a separate publication, Print No. 604.06.184, which is outside this set.

PDF Bookmarks and Wiring Diagram Readability

Search and diagram detail: PDF text search is unavailable. Embedded bookmarks lead to operating and service sections. Two MAIN MENU entries point to an external file. Small labels on the overview wiring diagrams need zooming, and some component pages have cropped text and wire numbers along the left edge. The printed page numbering has gaps.

The download is one printable English PDF with 496 pages. The total includes all three publications, one additional opening page, and four repeated pages within the Service Manual.

Loader Operation, System Tests, and Component Repair

This selection of topics gives a preview of the set. The supplement also covers lowering the attachment with the engine stopped.

• Operation and maintenance: Operating controls, instrument-panel layouts, walk-around inspections, lubrication charts, tire inflation tables, and dimensional drawings.
• Engine service: Engine removal and installation, injection-pump bench calibration and phasing, turbocharger inspection and reassembly, cold-starting equipment, and starter and alternator removal.
• Driveline overhaul: Hydraulic torque converter, powershift clutch packs, planetary final drives, Super Max Trac differentials, propeller shafts, and wheel bearings.
• Brakes and steering: Pressure testing, accumulator checks, step-by-step brake bleeding, brake-pedal valve overhaul, and steering-cylinder service.
• Implement hydraulics: Pump, control-valve and pilot-valve repair, boom and bucket cylinder overhaul, and tests for the optional L.T.S. anti-pitch system.
• Frame and cab: Bucket and boom removal, linkage and frame-pivot inspection, ROPS cab removal, heater troubleshooting, wipers, and glazing.
• Electrical reference: Wiring diagrams, component locations, connector assignments, and fuse ratings and circuit assignments for boxes A, B, and C.

The operating instructions are for authorized operators familiar with the loader. The Service Manual assigns maintenance and repair work described there to the manufacturer’s service organization.

Break-In, Loader Controls, and Scheduled Service

Machine preparation and break-in instructions lead into daily walk-around checks and operation of the powershift transmission. The operating manual gives separate adjustment procedures for the automatic bucket leveler and boom kick-out.

Scheduled and occasional service covers fuel-system bleeding, alternator and fan drive-belt adjustment, and valve-clearance checks. Before servicing the loader, follow the manual’s precautions for locking the articulated frame and relieving stored hydraulic pressure.

Injection Pump, Shift Controls, and Final Drives

The Service Manual identifies fixture 75295704 for injection-pump phasing. Its turbocharger section includes inspection and troubleshooting, with checks for shaft play and wheel contact.

The transmission hydraulic diagram, selector continuity checks, solenoid tests, and pressure checks help distinguish electrical shift-control faults from hydraulic engagement problems before disassembly. The clutch overhaul instructions address sticking quick-discharge valves, and the axle procedures cover bearing preload, shims, and differential adjustment.

Hydraulic Circuits and Electrical Fault Tracing

The brake hydraulic diagram traces the shared brake and pilot supply. The steering section covers priority-valve and cushion-valve tests, and the optional L.T.S. section pairs its wiring diagram with valve-opening and accumulator checks.

Boom and bucket linkage drawings show pivot arrangements and bushing fits. The boom-bushing procedure explains how misalignment can damage the bushing and its seat.

The wiring references cover starting, charging, lighting, wipers, and optional air conditioning. The operating manual explains Electronic Data Monitor (E.D.M.) warnings for pressure, fluid level, and temperature. The supplement addresses the transmission display’s flashing wrench symbol and EE code.

Selected Injector, Refill, and Wheel Torque Specs

Injector opening pressure is 230–238 bar for the 8065.25.093 in the operating manual and 200–208 bar for the 8365.25.584 in the Service Manual.

The operating manual lists 37.5 liters for the cooling system and 18 liters for a periodic transmission oil change. The Service Manual lists 44 liters and 20 liters, respectively. Both publications specify 60 daNm for wheel mounting torque.