This 266-page FiatAllis FR180 / FR180.2 Wheel Loader manual (OEM #75314958 / #75314937) is a 2-in-1 book: the operator's manual up front (p1-82) and the complete service manual behind it (p83-266). It covers the 194 CV (142 kW) engine, the power-shift transmission and torque converter, the Graziano axles with their 1:21.097 planetary final drives, the brake and steering circuits with their pressure tests and relief-valve settings, and the Vickers-pumped implement hydraulics running at 200 kgf/cm². You also get the wiring diagram with its legend, the hydraulic schematic, the maintenance schedule (10 to 1000-hour services) and the fluid capacities.
What's Inside This FiatAllis FR180, FR180.2 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction & Safety | 1-18 | Machine Symbols, Warning Signals, General Safety Rules, Operating, Shutdown, Maintenance, Hydraulic Safety |
| Identification, Dimensions & Specifications | 19-22 | Wheel Loader Serial Number, Engine Serial Number, Machine Dimensions, Engine, Torque Converter, Transmission, Axles, Brakes, Hydraulics, Wheels and Tires |
| Instruments & Operator Controls | 23-36 | Instrument Panel, Check Control, Fuse Box, Instrument Console, Gearshift Selector Lever, Turn Signal and Horn, Brake and Accelerator Pedals, Parking Brake, Steering Wheel Tilt, Operator's Seat, ROPS Cab, Walk-Around Inspection |
| Machine Operation | 37-46 | Engine Starting, Travel and Steering, Bucket Loading, Excavating, Operating Warnings, Operating Tips, Transport |
| Maintenance Schedule & Services | 47-69 | Service Intervals, Service and Lubrication Guide, Lubricant Types and Grades, 10-Hour Services, 100-Hour Services, 250-Hour Services, 500-Hour Services, 1000-Hour Services, As-Required Services, Brake System Bleeding |
| Electrical System Overview (Operation Manual) | 70-77 | Sensors and Switches, Lighting Components, Power Supply, Fuses and Relays, Circuit Legend |
| Service Manual: Safety Rules & General Information | 83-89 | Personal Protective Equipment, Machine Operation Safety, Service Precautions, Standard Torques, Units of Measure |
| Engine | 90-93 | Description, Removal and Installation, Engine Mounts, Cooling and Fuel Connections, Net Flywheel Power 194 Cv (142 kW), Maximum Torque 769 Nm |
| Transmission & Torque Converter | 94-97 | Description, Power-Shift Transmission, Torque Converter, Removal and Installation, Speeds and Ratios |
| Axles, Final Drives & Wheels | 98-151 | Description, Trouble-Shooting and Tests, Repairs, Differential, Planetary Final Drives (Graziano), Total Reduction Ratio 1:21.097, Propeller Shafts, Wheel Mounting Torque |
| Brake System | 152-177 | Brake System Diagram, Brake Pedal Valve Hydraulics, Accumulators, Service and Parking Brakes, Diagnostics and Tests, Bleeding, Overhaul |
| Steering System | 178-197 | Test and Setting of Steering Pressure Relief Valve, Power Steering Unit, Steering Cylinders, Priority Valve, Trouble-Shooting, Overhaul |
| Implement Hydraulic System | 198-236 | Implement Hydraulic System Diagram, Setting of Relief Valves, Vickers Pump (160 l/min), Control Valve, Lift and Tilt Cylinders, Diagnostics and Tests, Overhaul |
| Bucket, Boom & Frame | 237-259 | Removal and Installation of Bucket, Inspection of Teeth and Bucket, Boom and Linkage, Articulated Frame, Cutting Edges |
| Electrical System Diagram (Service) | 260-263 | Wiring Diagram, Diagram Legend, Wire Colour Codes, Component Description |
| Hydraulic System Diagram (Appendix) | 264-266 | Hydraulic Schematic, Glossary of Terms, Circuit Legend |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine Net Flywheel Power (DIN 6270) | 194 CV (142 kW) | p. 21 |
| Engine Maximum Torque | 769 Nm (567 lb.ft) | p. 21 |
| Transmission Speed (1st Forward) | 6.0 km/h (3.7 mph) | p. 21 |
| Hydraulic System Maximum Pressure | 200 kgf/cm² (2,843 psi) | p. 21 |
| Cooling System Capacity | 45.0 litres (11.9 US gallons) | p. 22 |
| Fuel Tank Capacity | 270.0 litres (71.3 US gallons) | p. 22 |
| Engine Coolant Normal Operating Temperature | 75 to 108 °C (167 to 226 °F) | p. 52 |
| Antifreeze Mixture (down to -8 °C / 18 °F) | 20% antifreeze, 80% water | p. 52 |
| Antifreeze Mixture (down to -15 °C / 5 °F) | 30% antifreeze, 70% water | p. 52 |
| Axles Make | FiatAllis (Graziano) | p. 21 |
| Axle Total Reduction Ratio (front and rear) | 1:21.097 | p. 21 |
| Hydraulic Pump Make / Main Flow | Vickers, 160 l/min (42 gpm) | p. 21 |
FiatAllis FR180, FR180.2 Common Problems This Manual Covers
FiatAllis FR180.2 hydraulic system loses lifting power after 30 minutes of operation, bucket rises slowly
Check the hydraulic oil level first and top off if low. Inspect suction piping for clogs and air leaks that emulsify the oil. If clean, the pressure relief valve may be jammed on debris: with engine idling, loosen its setting screw two turns to flush it, then reset to the original setting of 200 ± 5 bar (2900 ± 72 psi) per page 208.
Manual Section: Implement Hydraulic System: Troubleshooting p. 211Boom drops under load or lowers on its own when the engine is shut off
Inspect the boom cylinder piston seals for wear and replace any that leak, checking the oil for metal particles that signal wear elsewhere in the circuit. Test the pilot valve pressure regulation and confirm the implement pressure relief valve still holds at 200 ± 5 bar (2900 ± 72 psi) as set on page 208. Bleed trapped air before returning the loader to service.
Manual Section: Implement Hydraulic System: Troubleshooting p. 211Transmission fails to engage forward gear, producing a loud grinding noise on shift
Check transmission oil level and condition first; low or contaminated fluid causes clutch pack slippage that grinds on engagement. Verify the temperature gauge on the instrument console (page 27) reads within the normal 65° to 125°C (149° to 257°F) range, since sustained overheating burns the clutch discs. If level and temperature check out, pull the clutch pack for inspection.
Manual Section: Transmission p. 94Engine overheats in hot weather or under heavy load with coolant temperature climbing fast
Drain and flush the radiator; system capacity is 45.0 liters (11.9 US gallons) per page 82. Refill with the correct antifreeze ratio for your climate, for example 30% antifreeze to 70% water for -15°C (5°F) operation per page 43. Check that the radiator cap releases at 0.49 bar (15 psi); a weak cap drops the boiling point and lets the system run hot.
Manual Section: Engine p. 82Brake pedal requires excessive pumping before the machine comes to a full stop
Run the accumulator precharge test in the brake troubleshooting procedure on page 167; precharge should hold at 60 bar (870 psi) per the page 80 specification. Low precharge causes pedal fade and forces repeated pumping to build pressure. Inspect the feeding pump for wear, bleed the system per the page 167 procedure to purge trapped air, and confirm the parking brake switch trips at 60 bar.
Manual Section: Brake System: Troubleshooting p. 167Axle housing produces grinding noise and lubricant leaks around the wheel hub seals
Check differential and planetary oil level at each axle; correct fill sits at the bottom edge of the plug hole per page 64. Low or contaminated lube causes gear whine and leaks past worn seals. Inspect wheel hub sealing surfaces and torque securing screws to the specs on page 144 if reassembled. Persistent leaks after refill point to a cracked housing or a failed seal needing replacement.
Manual Section: Axles: Troubleshooting and TestsFrequently Asked Questions
What are the torque specifications for the wheel bolts on the FiatAllis FR180.2?
The wheel locking nuts should be tightened to a torque of 60 daNm (435 lb.ft). This specification applies to a 20 x 1.5 thread and should be lubricated with engine oil. p. 150
Where is the serial number located on the FiatAllis FR180.2 wheel loader?
The wheel loader serial number is found on an identification plate. Additionally, the engine serial number is located on a separate plate, both detailed in the Identification Data section. p. 19
What are the replacement specifications for the Hydraulic pump (main drive)?
The implement hydraulic system is supplied by a double section vane pump, tandem assembled. Its main flow specification is 160 l/min (42 gpm). p. 81
What is the engine oil capacity for the FiatAllis FR180.2?
The engine oil capacity for the FiatAllis FR180.2 is 20.3 liters (5.4 U.S gallons). This is the specified volume for the crankcase. p. 82
What is the cooling system capacity for the FiatAllis FR180.2?
The cooling system capacity for the FiatAllis FR180.2 is 45.0 liters (11.9 U.S gallons). This is the total volume for the cooling system. p. 82
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