This 533-page FiatAllis FR220.2 Wheel Loader Operation and Service Manual puts the entire drive train, hydraulic circuit, and cab electrical system in front of you, not just a parts flyer. Inside you get full wiring diagrams with connector pinouts, hydraulic system schematics covering the loader and steering circuits, exploded views for teardown reference, and a dedicated troubleshooting section built around real error codes instead of guesswork. You also get the complete 10 through 2000-hour service schedule, so you know exactly what's due and when. Set front tire pressure at 4.0 bar for work conditions and 2.0 bar for travel, and keep the air filter cleaning pressure capped at 2 bar (30 psi) so you don't blow a fresh element. Your loader won't wait for you to guess at a torque value or a wire color. This PDF is bookmarked by section, so you can jump straight from the cab to the hydraulic pump on whatever device you're carrying to the machine.
What's Inside This FiatAllis FR220 & FR220.2 Manual
| System | Pages | Key Topics |
|---|---|---|
| Identification & Specifications | 2-6 | Machine Identification, Engine, Transmission, Axle, Hydraulic Specifications |
| Safety & Stability | 7-13 | Center of Gravity, Noise Levels, Safety Plates, Residual Dangers |
| Controls & Operation | 14-46 | Break-In, Operating Warnings, Controls and Instruments, Machine Operation |
| Operator Maintenance | 47-99 | Maintenance Schedule, Lubrication, Filters, Fluid Checks |
| Service Specifications & Lubricants | 102-115 | Technical Specifications, Safety Rules, Units of Measure, Lubricants |
| Engine Components | 116-188 | Engine, Cooling System, Fuel System, Lubrication, Removal and Installation |
| Transmission | 189-265 | Torque Converter, Clutch Packs, Controls, Overhaul |
| Axles | 266-313 | Front Axle, Rear Axle, Differential, Planetary Reduction, Wheel Hubs |
| Brakes System | 314-340 | Service Brakes, Parking Brake, Brake Valve, Discs, Accumulator |
| Steering System | 341-363 | Hydrostatic Steering, Steering Cylinders, Priority Valve, Steering Pump |
| Equipment Hydraulic System | 364-414 | Hydraulic Pump, Control Valve, Lift/Tilt Cylinders, Relief Valves, Reservoir |
| Bucket, Boom and Frame | 415-435 | Bucket, Boom, Loader Linkage, Frame, Pins and Bushings |
| Electrical System | 436-524 | Wiring, Connectors, Starting and Charging, Instruments, Lights, Sensors |
| Cab | 525-533 | Cab Tilting, Seat Assembly, Doors, Heating and A/C, Glass |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| fasteners of wheels and rims | retighten to the prescribed torque | p. 4 |
| Battery acid | SULPHURIC ACID | p. 21 |
| Air filter cleaning pressure | 2 bar (30 psi) | p. 69 |
| Tire inflation pressure (cold, MICHELIN 26.5 R25 XHA) - Front WORK | 4.0 bar | p. 71 |
| Starting opening pressure for REGULATION VALVE | 5 bar | p. 123 |
| Starting opening pressure for PRESSURE SAFETY VALVE | 8 bar | p. 123 |
| Inside diameter of drive gear | 26.923 + 26.944 | p. 123 |
| Fitting between drive shaft and relevant gear (interference) | 0.015 + 0.049 | p. 123 |
| Fuel filters clogged | Remove filtering elements, if necessary, replace them. | p. 124 |
| Fuel filter and feeding pump valves clogged | Replace fuel filter and overhaul valves of feeding pump. | p. 125 |
| Batteries partially exhausted | Check and recharge batteries. If necessary, replace batteries. | p. 124 |
| Air cleaner clogged | Clean the air cleaner and all related system. | p. 125 |
FiatAllis FR220 & FR220.2 Common Problems This Manual Covers
FiatAllis FR220.2 wheel loader ungodly slow travel speed while most other functions operate normally.
Check the transmission diagnostic test values. Drain the rear axle oil and inspect the differential components for wear. If replacing the final drive securing ring nut, tighten it to 70 + 90 daNm as specified on page 268. Refill the rear axle with 54 Ltrs of oil.
Manual Section: Transmission Diagnostic and TestsWeak or non-responsive hydraulic system with complete loader lift and tilt failure under load.
Test the equipment hydraulic system maximum operating pressure on page 104 to verify it reaches 200 bar. Inspect the double vane pump rear cover. If repairing the pump, torque the rear cover securing screws to 8,8 + 10 daNm as shown on page 385.
Manual Section: Equipment Hydraulic System Diagnostic and Tests p. 104Engine runs excessively hot and overheats rapidly during heavy pushing or loading operations.
Inspect the radiator for scaling or inefficient cooling on page 125. Eliminate any scaling with an accurate cleaning procedure. Check the coolant level and refill the system to its full 69 Ltrs capacity as outlined on page 104. Verify there are no leakages from the radiator pipes.
Manual Section: Engine Troubleshooting p. 125Engine turns over at normal speed but fails to start in cold or warm weather.
Remove the filtering elements to see if the fuel filters are clogged on page 124. Replace the fuel filter and overhaul the feeding pump valves if they are blocked. Clean, check, and tighten the battery terminal nuts. Verify the fuel reservoir contains adequate fuel up to its 350 Ltrs capacity.
Manual Section: Engine Troubleshooting p. 124Frequently Asked Questions
What are the torque specifications for wheel lug nuts on the Fiat Hitachi FR220.2?
The wheel mounting torque for lug nuts on the Fiat Hitachi FR220.2 is 60 daNm, which is equivalent to 443 ft lbs. It is important to check the wheel nut tightening torque before each work shift and tighten them according to current procedures and specifications, as indicated on page 71 and page 312. p. 71
What are the replacement specifications for Front and rear axle differential parts on the Fiat Hitachi FR220.2?
For the front and rear axle differentials, if the final drive sun gear teeth are worn or broken, the sun gear and planetary gears should be replaced, and potentially the crown gear. If differential side gears or idle gears are worn or broken, replace the gears. The manual recommends replacing the whole set of components rather than single parts if wear or damage is found, as stated on page 296. p. 296
What are the replacement specifications for the Drive gear set on the Fiat Hitachi FR220.2?
For the engine's timing drive, if gears show signs of damage or excessive wear, they must be replaced. Similarly, for the final drives of the axles, if sun gear teeth are worn or broken, the sun gear and planetary gears should be replaced, and potentially the crown gear as well, as noted on page 272. p. 155
What is the engine oil capacity for the Fiat Hitachi FR220.2?
The engine oil capacity for the Fiat Hitachi FR220.2 is 27 liters. This quantity refers to a complete filling with pipes entirely empty, as specified in the lubricants section on page 115 and technical specifications on page 104. p. 115
What format is this FiatAllis FR220.2, Wheel Loader manual in?
Immediate download of the complete 533-page searchable Operation and Service Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Am I able to print pages from this FiatAllis FR220.2, Wheel Loader manual?
No restrictions at all. Print individual pages, full chapters, or the entire manual. The PDF is completely unlocked.
Are hydraulic system diagrams in this FiatAllis FR220.2, Wheel Loader manual?
Yes, this FiatAllis FR220.2, Wheel Loader Operation and Service Manual includes hydraulic system diagrams, circuit schematics, and component specifications.
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