Fiat Allis FR220.2 Wheel Loader Service Manual Set, 1970s–1980s (P/N 604.02.209)

The operating volume covers machine use and scheduled care; the service volume provides workshop diagnosis, repair and overhaul procedures.

Engine identification differs between the volumes: the operating manual lists the Iveco-Unic 8465.21.014, while the service specifications list the Fiat 8465.21.004. Match the engine data plate and installed equipment to the applicable instructions before selecting repair specifications. Torque, weight and fluid data also differ between the publications.

Bookmarks, Wiring Detail and File Limitations

Search and navigation: PDF text search is unavailable. Embedded bookmarks cover both publications and their service sections, although the two “MAIN MENU” links reference a separate menu file. Small wiring codes in the large circuit sheets require zooming. PDF p. 206, within transmission troubleshooting, is entirely black and has no readable content.

The download is one printable, English-language 533-page PDF, including both publications and one additional cover page.

Engine Overhaul, Powershift Diagnosis and Loader Hydraulics

The following selected coverage highlights outline the main workshop areas. Further topics include wheel and tire service and rear-axle oscillating-support adjustment.

• Engine repair: Teardown and reassembly, cylinder-liner protrusion checks, cylinder-head work, injection-pump timing and injector bench testing.

• Powershift transmission: WG-2000S removal, clutch-pack rebuilding and clearance adjustment, control-valve pressure tests and magnetic speed-sensor checks.

• Axles and final drives: Super Max-Trac differential overhaul, planetary final-drive repair, pinion-depth adjustment, bearing preload and separate front/rear brake-disc arrangements.

• Brake controls: Hydraulic pressure tests, accumulator precharge and recharge checks, brake-pedal valve repair, parking-brake service and system bleeding.

• Steering and implement hydraulics: Steering-unit overhaul, flow-amplifier service, dual-vane pump rebuilding, control-valve repair and hydraulic-cylinder overhaul.

• Boom, bucket and frame: Articulated-frame separation, pivot-bushing replacement, double-Z boom removal, bucket inspection and cutting-edge repair.

• Electrical and optional LTS: Numbered wiring diagrams, connector maps, sensor specifications, and hydraulic and electrical function tests for the anti-pitch system.

The service procedures are intended for the manufacturer's service organization and call for the specified workshop equipment.

Operation and Scheduled Maintenance

The operating volume explains cab controls, instrument panels and the Electronic Data Monitor (E.D.M.). It details transmission gear-shifting modes alongside automatic bucket-leveler adjustments. Boom kick-out settings, cold starting, towing and lowering the attachment without engine power are covered as well.

Maintenance schedules distinguish break-in work, routine service and condition-based maintenance. Lubrication points, filter replacement sequences and cooling-system requirements sit alongside fuel-system bleeding with the EHAB solenoid valve and brake-system bleeding. Optional equipment includes supplementary hydraulic controls.

Always verify proper lockout protocols and relieve hydraulic pressure before loosening fittings or starting diagnostic work.

Internal Engine Work

Step-by-step engine procedures are supported by inspection limits, machining dimensions and special-tool references. The HOLSET H2C turbocharger receives internal inspection and rebuilding coverage, while a longitudinal water-pump section illustrates the cooling assembly. The engine chapter also describes the optional Start Pilote cold-starting system.

Transmission, Axle and Brake Diagnosis

WG-2000S fault charts connect pressure measurements and electrical checks with specific shifting symptoms, helping distinguish control faults from internal clutch problems. Electrical functional testing calls for the PR-78 test kit, part number 75299002.

The transmission hydraulic-system diagram explains clutch-control oil paths. Brake hydraulic-system diagrams show different operating states, while differential contact-pattern illustrations support bevel-gear adjustment.

The clutch rebuild instructions identify quick-discharge valves as vulnerable to damage during piston assembly; sticking valves can cause clutch-release problems.

Hydraulic Circuits and Structural Repairs

An exploded flow-amplifier view supports steering-component identification. The boom quick-dropping hydraulic diagram explains the relationship between the control valve and cylinder circuits. Optional LTS coverage separates electrical activation checks, valve-opening tests and the hydraulic connection between the boom cylinders and accumulator.

Boom-bushing replacement includes cautions about press setup and alignment: incorrect handling can deform the boom or damage the replacement bushing and its seat.

Electrical Fault Tracing and Cab Service

The ZF transmission diagram maps the selector, sensors, control unit, display and harnesses. Component sheets add terminal assignments, wire codes and installation locations. Cab air-conditioning wiring is included.

E.D.M. coverage explains the indicator self-test and connector assignments; the module itself is nonrepairable. The cab chapter covers removal, wiper and washer service, and glazing replacement. It also identifies major hydraulic and drivetrain components that can be serviced without removing the cab.

Selected Sensor and Cold Valve-Clearance Data

The transmission speed-sensor section specifies a sensor-to-gear relationship: a 0.5–0.8 mm gap between each input/output sensor and its gear teeth, with 1,400–1,450 Ω measured across the sensor terminals.

For the engine's cold valve-clearance check, the listed settings are 0.25 mm intake and 0.50 mm exhaust. The operating manual assigns this check to authorized service-center personnel.