Every one of the 495 pages in this Fiat-hitachi FR 160.2 Service Manual PDF (OEM #604.00.552) is aimed at one machine: your FR 160.2 wheel loader. Inside: factory wiring diagrams for the full electrical system, hydraulic schematics covering the loader circuit and L.T.S. anti-pitching system, and step-by-step repair procedures for the engine, transmission, axles, brakes, and steering. You also get a full troubleshooting section plus tightening torque tables for every major assembly. Change the engine oil every 250 hours, set the oil pressure switch at 0.4 plus or minus 0.2 bar, and never crank the starter past 20 to 30 seconds straight. No more chasing electrical gremlins with a multimeter and a prayer. Bookmarked for quick jumps between sections; download it, pull it up on your phone next to the loader, and get back to work.
What's Inside This FiatAllis FR160, FR160.2 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety Rules and Identification | 4-16 | Safety During Start, Operation, Stop and Maintenance, Machine Identification Data Plate, Frame and Engine Serial Numbers, Machine Specifications Summary |
| Operation and Controls | 17-46 | Preliminary Instructions and Run-In, Fuel Handling and Fluid Level Checks, Engine Starting and Idling, Steering Wheel, Accelerator and Brake Pedals, Instrument Panel, Cab and Operator's Seat, Heating and Ventilation, Operating Tips (Bucket Loading, Excavating, Transport) |
| Maintenance Schedule | 47-77 | Walk-Around Inspection, 100-Hour Services (Boom and Bucket Articulation Greasing), 250-Hour (Engine Oil and First Fuel Filter), 500-Hour (Oil Filters, Second Fuel Filter), 1000-Hour (Valve Clearance, Transmission Oil), As-Required Services, Master Switch and Wiring Diagram |
| Lubricants and Capacities | 78-104 | Cooling System, Fuel Tank, Engine Lube System, Transmission and Axle Oils, Hydraulic System Capacities, Grease Specifications, Refill Quantities |
| Technical Specifications and Main Data | 105-118 | Main Dimensions, Engine, Torque Converter, Transmission, Axles, Brakes, Hydraulic System Data, Units of Measure Conversion, Standard Torque Values |
| Engine | 119-151 | General Description, Diagnostics and Tests, Removal and Installation, Cooling System, Fuel System, Turbocharger, Specifications and Torque Values |
| Transmission | 152-217 | Description and Operation, Gear-Shifting, Torque Converter, Diagnostics and Pressure Tests, Removal, Disassembly and Assembly, Clutch Packs, Control Valve |
| Axles | 218-271 | Description, Troubleshooting and Tests, Differential and Final Drive Repair, Planetary Gears, Wheel Hubs, Bearing Preload, Torque Values |
| Brake System | 272-297 | General Description and Operation, Diagnostics, Service Brake Circuit, Parking Brake, Accumulator and Brake Valve, Bleeding, Repair |
| Steering System | 298-318 | Steering Pressure Relief Valve, Safety Valve, Steering Pump and Orbitrol Unit, Steering Cylinders, Diagnostics and Pressure Settings |
| Equipment Hydraulic System | 319-371 | Control Valve, Pressure Relief Valve, Pilot Valve, Hydraulic Pump, Lift and Tilt Cylinders, Hydraulic Circuit Diagrams, Pressure Tests and Adjustments |
| Bucket, Boom and Frame | 372-394 | Bucket and Bucket Teeth, Boom, Frame, Bucket Pivot Pins and Bushings, Wear Checks, Removal and Installation |
| Electrical System | 395-485 | Complete Wiring Diagrams, Master Switch, Starting and Charging Circuits, Instrument and Lighting Circuits, Fuses and Relays, Component Location, Circuit Troubleshooting |
| Cab | 486-495 | Operator's Seat Adjustments, Steering Wheel Removal, Cab Glass and Door, Cab Removal and Installation |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine Starting | 18 | p. 2 |
| Engine idling | 19 | p. 2 |
| Engine oil change interval | 250 hours | p. 2 |
| Setting of engine oil resistor for pressure gauge | 0 + 8 bar | p. 106 |
| Setting of engine oil low pressure switch and hourmeter drive | 0.4±0.2 bar | p. 106 |
| Transmission oil filters (q.ty 2) one paper and one metal. | one paper and one metal | p. 106 |
| Operation voltage | 24 V | p. 107 |
| Batteries, in series | 2 | p. 107 |
| Control valve | 3 spools | p. 107 |
| solenoid continuity (resistance) | 90 + 95 ohm | p. 166 |
| 3rd speed (K3) Outer teeth disc G quantity | 9 | p. 187 |
| 3rd speed (K3) Outer teeth disc G S (mm) | 2.0 | p. 187 |
FiatAllis FR160, FR160.2 Common Problems This Manual Covers
Fiat-Hitachi FR 160.2 boom raises slowly and bucket lacks breakout force at full throttle
Time a full boom raise; anything slower than the rated 6.3 seconds points to low system pressure. Check hydraulic oil level and change the return oil filter first. Then work through the hydraulic troubleshooting steps starting on page 319, testing relief valve pressure and inspecting control valve spools for seizing before condemning the pump.
Manual Section: Equipment Hydraulic System p. 319Engine cranks but won't start cold, or starts then blows black smoke under load
Check for air in the fuel lines first; air in the system makes starting hard. Bleed the fuel system and change both fuel filters. Never run the starter more than 20/30 seconds continuously (page 30). If smoke persists, verify injector release pressure at 230 to 238 bar and follow the engine troubleshooting chart on page 96.
Manual Section: Engine Troubleshooting p. 96Transmission won't shift into gear or drops out of gear under load
Test transmission main pressure at the test port; you want 16 to 18 bar (page 106). Measure coil resistance at each shift solenoid; 90 to 95 ohms is good, anything open or shorted gets replaced (page 166). If pressure and solenoids check out, plan a clutch pack inspection per the transmission section starting on page 152.
Manual Section: Transmission Troubleshooting p. 166Brake pedal feels mushy or spongy and stopping power fades after several hard stops
Bleed the brake system with two people: engine idling, one loosens the bleeding plugs (two per axle) while the other holds the pedal, tightening each plug before release; repeat until fluid runs bubble-free (page 286). Then verify operating pressure reaches 65 bar and confirm brake valve output pressure reads nil with the pedal fully released.
Manual Section: Service Brakes Troubleshooting p. 286Starter clicks but won't turn over, dashboard stays dead, and batteries drain flat overnight
Check the electrical system master switch first, then load-test both 12 V batteries; the machine runs two in series for 24 V. Clean and tighten ground connections and verify charging output with the engine running; the 55 A alternator should hold system voltage steady. Trace any parasitic drain using the wiring diagram.
Manual Section: Electrical System TroubleshootingFrequently Asked Questions
What are the torque specifications for the wheel bolts on the Fiat Hitachi FR 160.2?
The wheel mounting torque for the Fiat Hitachi FR 160.2 is 60 daNm (440 ft lbs or 443 ft lbs). This applies to wheel locking nuts with a thread of 20 x 1.5. It is important to check the wheel nut tightening torque before each work shift and tighten them according to current procedures and specifications. p. 15
What do the warning indicators on the Electronic Data Monitor (E.D.M.) panel mean for the Fiat Hitachi FR 160.2 wheel loader?
The Fiat Hitachi FR 160.2 uses warning indicators on the Electronic Data Monitor (E.D.M.) panel to signal malfunctions. For example, the general malfunction indicator (k) flashes and sounds a buzzer for faulty conditions signaled by other indicators (p, s, a, b, c). The "wrench" symbol (4) on the automatic transmission display signals a deficiency in that circuit. The manual provides troubleshooting steps for these symptoms, but not a general "reset error codes" procedure; the remedy is to address the underlying problem. p. 25
What type of engine is in the Fiat Hitachi FR 160.2, and are parts available?
The Fiat Hitachi FR 160.2 is equipped with a FIAT-IVECO turbo-charger engine type 8365.25.584. While the manual does not comment on the engine's reliability, it states that repair procedures and troubleshooting information are available in a separate Service Manual (print no. 604.06.184) from your local FIAT-HITACHI Dealer. Genuine spare parts are recommended and can be ordered by quoting the frame type, serial number, engine type, and part number. p. 120
How do I replace the hydraulic pump on the Fiat Hitachi FR 160.2?
To replace the hydraulic pump on the Fiat Hitachi FR 160.2, first drain the hydraulic oil from the equipment reservoir. Then, disconnect the delivery and return piping, remove the securing screws, and detach the pump from the transmission. To disassemble the pump, remove the nuts (C1, fig. 4.14) and pull the bolts securing the pump elements, then pull the cartridge from the rear. p. 340
What is the engine oil capacity and recommended change interval for the Fiat Hitachi FR 160.2?
The engine lube system capacity for the Fiat Hitachi FR 160.2 is 15 Liters. The engine oil should be changed every 250 hours. However, if the fuel used contains more than 1% sulphur, the oil change interval is reduced to every 150 hours. p. 78
What format is this Fiat-hitachi FR 160.2 manual in?
Instant PDF download. You get the full 495-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 Fiat-hitachi FR 160.2 manual?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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