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This 252-page FiatAllis FR120 / FR120.2 Wheel Loader manual (OEM #75314935) is a 2-in-1 book: the operator's manual up front (p1-76) and the complete service manual behind it (p77-252). It walks you through every system on the machine: the 45 A / 24 V electrical system with full wiring schematic and circuit colour codes, the power-shift transmission and torque converter, the axles with their final drives and differentials, the brake and steering circuits with their diagnostic pressure tests, and the equipment hydraulics with the control-valve and relief-valve settings. You also get the maintenance schedule (10 to 1000-hour services), the fluid capacities, and the removal, overhaul and installation procedures for the bucket, boom and articulated frame.
What's Inside This FiatAllis FR120, FR120.2 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction & Safety | 1-18 | Machine Symbols, Warning Symbols, General Safety Rules, Start-Up, Operating, Shutdown, Maintenance, Hydraulic Safety |
| Identification, Dimensions & Specifications | 19-22 | Wheel Loader Serial Number, Engine Serial Number, Machine Dimensions, Engine Specs, Valve Clearance, Fluid Capacities, Electrical System, Wheels and Tires |
| Instruments & Operator Controls | 23-36 | Instrument Panel, Check Control, Fuse Box, Instrument Console, Gearshift Selector, Turn Signal and Horn, Brake and Accelerator Pedals, Master Switch, Boom and Bucket Control Lever, Additional Hydraulic Function Lever, Parking Brake, Operator's Seat, 4th Function Switch, ROPS Cab, Walk-Around Inspection |
| Machine Operation | 37-50 | Engine Starting, Cold Start Aid, Automatic Bucket Leveller, Quick Direction Shift, V-Cycle Loading, Travel and Steering, Operating Warnings, Machine Towing, Transport |
| Maintenance Schedule & Services | 51-72 | 10-Hour Services, 100-Hour Services, 250-Hour Services, 500-Hour Services, 1000-Hour Services, As-Required Services, Engine Sump and Filter, Fuel Filter, Hydraulic Return Filter, Transmission Oil Filter, Brake System Bleeding, Lubrication Points |
| Electrical System Overview (Operation Manual) | 73-76 | Circuit Color Codes, Electrical Component Legend, Electrical Schematic, Fuses and Relays |
| Service Manual: General Information & Specifications | 77-93 | Service Manual Introduction, Safety Rules, General Machine Specifications, Fluid Capacities, Standard Torque Values, Special Tools |
| Engine | 94-97 | Engine Make and Model, Cylinders, Fuel Injection Pump, Nozzle Relief Pressure, Valve Clearance, Removal and Installation, Cooling System |
| Transmission & Torque Converter | 98-101 | Power-Shift Transmission, Speeds and Ratios, Torque Converter, Gear Shifting, Removal and Installation, Oil Capacity |
| Axles, Final Drives & Wheels | 102-153 | Axle Drive Diagram, Trouble-Shooting and Tests, Final Drives, Differential, Propeller Shafts, Planetary Reduction, Wheel Removal, Wheel Locking Nut Torque, Tire Disassembly and Inflation |
| Brake System | 154-179 | General Description, Brake System Diagram, Operation, Diagnostics and Tests, Pedal Valve, Accumulator Precharge, Parking Brake, Bleeding, Removal and Overhaul |
| Steering System | 180-199 | General Description, Operation, Diagnostics and Tests, Trouble-Shooting, Power Steering Unit, Steering Cylinders, Priority Valve, Relief Valve Pressure, Overhaul |
| Equipment Hydraulic System | 200-224 | Control Valve Functioning, Diagnostics and Tests, Trouble-Shooting, Hydraulic Pump, Relief Valve Setting, Lift and Tilt Cylinders, Pilot Circuit, Hydraulic Tank and Filters |
| Bucket, Boom & Frame | 225-245 | Bucket Removal and Installation, Inspection and Repair, Boom and Linkage, Articulation Joints, Bucket Leveller, Cutting Edges and Teeth |
| Hydraulic & Electrical Schematics | 246-252 | Equipment Hydraulic Schematic, Brake Hydraulic Schematic, Steering Hydraulic Schematic, Electrical Wiring Diagram, Component Legend |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine Oil Capacity (Crankcase) | 20.0 litres | p. 22 |
| Fuel Tank Capacity | 180.0 litres | p. 22 |
| Hydraulic System Capacity | 120.0 litres | p. 22 |
| Cooling System Capacity | 38.0 litres | p. 22 |
| Torque Converter and Transmission Capacity | 27.0 litres | p. 22 |
| Axles (Front/Rear, Differential & Wheels) Capacity | 72.0 litres | p. 22 |
| Engine Valve Clearance (Intake, cold) | 0.25 mm | p. 21 |
| Engine Valve Clearance (Exhaust, cold) | 0.51 mm | p. 21 |
| Wheel Locking Nut Tightening Torque | 60 daNm (880 ft lbs) | p. 152 |
| Brake Accumulator Precharge Pressure | 60 bar (870 psi) | p. 167 |
| Steering Pressure Relief Valve Pressure | 185 ± 10 bar (2680 ± 140 psi) | p. 184 |
| Equipment Hydraulic System Pressure Relief Valve Setting | 230 ± 5 bar (3336 ± 72 psi) | p. 206 |
| Alternator Output | 45 A | p. 92 |
| Fuel Injection Nozzle Relief Pressure | 205 bar | p. 70 |
FiatAllis FR120, FR120.2 Common Problems This Manual Covers
FiatAllis FR120.2 wheel loader hydraulic system losing pressure or slow loader arm movement
Test the equipment hydraulic system pressure relief valve setting as detailed on page 206. Verify the pressure reaches 230 ± 5 bar (3336 ± 72 psi). If readings fall below this specification, inspect the control valve spool for wear and replace the hydraulic pump seals if scored.
Manual Section: Hydraulic System Troubleshooting p. 206Brake fade or complete loss of braking power and low brake pressure indicator light illuminates
Measure the brake accumulator precharge pressure using a calibrated gauge. Confirm the precharge pressure holds steady at 60 bar (870 psi) according to page 167. Drain the system and inspect the pedal valve if the pressure drops, then recharge the accumulator to the specified limits.
Manual Section: Brake System Troubleshooting p. 167Transmission slipping or failure to engage gears smoothly when shifting directions under heavy load
Inspect the differential clutch pack play using a feeler gauge as outlined on page 141. Verify the clearance remains between 0.05 + 0.10 mm (0.002 + 0.004 in). Adjust the shims or replace the worn clutch disks if the measurement exceeds this tolerance to restore proper engagement.
Manual Section: Axles & Wheels Troubleshooting p. 141Engine stalling under load or inability to reach rated RPM during normal operating conditions
Remove and test the fuel injection nozzles to verify proper operation. Check the nozzle relief pressure on page 70 to ensure it meets the required 205 BAR specification. Clean the series cartridges and replace the fuel filter assemblies if the pressure is out of spec.
Manual Section: Engine & Fuel System Troubleshooting p. 70Frequently Asked Questions
What is the engine oil capacity and recommended type for the FiatAllis FR120.2?
The crankcase capacity for the FiatAllis FR120.2 is 20.0 liters (5.28 US gallons). For engine oil, use TUTELA URANIA, API CE/CCMC D-3, MIL-L-2104-E, MIL-L-46152 D, with viscosity grades 15W40 or 10W30 depending on ambient temperature. The change capacity for engine sump and filter is 14.2L (3.7488 GAL). p. 22
What are the recommended tire inflation pressures for the FiatAllis FR120.2?
For 20.5x25, 12 PR (tubeless) tires, the normal cold inflation pressure for both front and rear is 3.4 bar (50 psi) for both work and travel. For 17.5 x 25 12 PR Tubeless L2 (standard) tires, the recommended pressure is also 3.4 bar (50 psi) for both front and rear, during operation and travel. p. 59
What are the engine valve clearance specifications for the FiatAllis FR120.2?
The engine valve clearance specifications for a cold engine are: Intake 0.25 mm (0.01 in) and Exhaust 0.51 mm (0.02 in) according to the specifications. However, the valve lash adjustment procedure states the intake valve clearance should be 0.30 mm and the exhaust valve clearance 0.61 mm. p. 21
What is the precharge pressure for the brake system accumulators on the FiatAllis FR120.2?
The precharge pressure for the brake system accumulators (both service and parking brake) is 60 bar (870 psi). The service brake accumulators each hold 2 litres, the parking brake accumulator 0.7 litres. p. 161
What is the tightening torque for the wheel locking nuts on the FiatAllis FR120.2?
The manual specifies 60 daNm (600 Nm) for the wheel locking nuts (20 x 1.5 thread), printed in the book as "60 daNm (880 ft lbs)" on page 152 — note that 60 daNm actually converts to about 443 lb-ft, so torque to the daNm/Nm figure. Check the nuts before each work shift. p. 59
How quickly can I access this FiatAllis FR120, FR120.2 manual?
Instant PDF download. You get the full 252-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Are there any print restrictions on this FiatAllis FR120/FR120.2?
Yes. The PDF has no DRM restrictions, so print any page or section you need for your shop. Works with any standard printer.
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