Iveco STRALIS AS EURO 4 & 5 Truck Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Iveco Model: STRALIS AS Codes Euro Standard: Euro 4 & 5 👋 Introduction Market Position Target Audience: Professional mechanics, fleet maintenance personnel, and experienced DIY enthusiasts. Key Features Content Quality: Detailed illustrations, step-by-step instructions, diagrams, and pictures for clarity. Value Proposition Cost Saving: Inexpensive method to maintain vehicle health, perform routine maintenance, and execute larger repairs, saving on service costs. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Page Count Page Count: > 2100 Language Language: English Format File Format: PDF Delivery Format: ZIP Archive 📖 Manual Coverage Systems Covered All Systems: Comprehensive coverage of all major vehicle systems including engine, transmission, chassis, electrical, pneumatic, and bodywork. Procedures Included Repair And Maintenance: Step-by-step repair instructions, routine maintenance procedures, diagnostics, troubleshooting, and overhaul procedures. Technical Depth Diagnostics And Overhaul: Detailed diagnostic procedures, engine diagnosis, electronic control unit (ECU) troubleshooting, and complete engine/component overhaul instructions. 📊 Manual Specifications File Format Readability: Requires Adobe Acrobat Reader File Type: Electronic/Digital Print Quality Printability: All pages are printable ⚙️ Engine Specifications Primary Engine 1 Engine Family: F3A Displacement: 10.30 Liters Configuration: 6-Cylinder, In-line Cycle: 4-Stroke Diesel Aspiration: Turbocharged with Aftercooler Engine Codes: F3AE3681D, F3AE3681A Primary Engine 2 Engine Family: F3B Displacement: 12.88 Liters Configuration: 6-Cylinder, In-line Cycle: 4-Stroke Diesel Aspiration: Turbocharged with Intercooler Engine Codes: F3BE3681B, F3BE3681A Performance Horsepower And Torque Data: Specific horsepower and torque figures for each engine variant are detailed within the manual, crucial for diagnosis and performance tuning. Fuel System System Type: Common Rail Direct Injection (CRDI) is typical for Euro 4/5 applications, with detailed fuel system diagnostics and component testing covered. Cooling System Coverage: Covers radiator, fan, thermostat, water pump, coolant flow, and pressure testing. Lubrication System Coverage: Details oil pump, oil filter, oil cooler, lubrication passages, and oil pressure testing. Turbocharging Coverage: Includes turbocharger operation, wastegate control, intercooler function, and troubleshooting turbo-related issues. Emission Control Denox 2 System: Comprehensive coverage of the Selective Catalytic Reduction (SCR) system, including AdBlue dosing, NOx sensors, and system diagnostics. Engine Diagnosis: Detailed diagnostic procedures for engine performance issues, error codes, and electronic control unit (ECU) interactions. 🔧 Transmission Standard Manual Transmissions Zf 16 Speed Td: ZF 16 S 1920 T.D., ZF 16 S 2220 T.D., ZF 16 S 2320 T.D., ZF 16 S 2520 T.D. Zf 16 Speed To: ZF 16 S 2220 T.O., ZF 16 S 2520 T.O. Zf 16 Speed With Intarder: ZF 16 S 1921 T.D., ZF 16 S 2221 T.D., ZF 16 S 2321 T.D., ZF 16 S 2521 T.O. (Note: '1' often denotes intarder integration) Automated Manual Transmissions Eurotronic 12 Speed Td: EuroTronic 12 AS 1930 T.D., 12 AS 2330 T.D. Eurotronic 12 Speed To: EuroTronic 12 AS 2330 T.O., 12 AS 2530 T.O. Automated Manual Transmissions With Intarder Eurotronic 12 Speed Td Intarder: EuroTronic 12 AS 1931 T.D., 12 AS 2331 T.D. Eurotronic 12 Speed To Intarder: EuroTronic 12 AS 2331 T.O., 12 AS 2531 T.O. Features Clutch System: Details on clutch operation, release bearings, slave cylinders, and adjustments. Power Take Off Pto: Information regarding PTO installation, operation, and maintenance for various configurations. Transfer Box: Coverage for 4x4 or specific traction configurations if applicable. Overhauling: Detailed step-by-step overhaul procedures for all listed transmissions. Fluid Specifications: Specific ATF or gear oil types and capacities for each transmission model (e.g., ZF TE-ML specifications). 📐 Dimensions Exterior Vehicle Type: Heavy-duty Truck Weights Gross Vehicle Weight: GVW ratings vary significantly by configuration (e.g., 18-44+ tons), detailed in specific model data within the manual. Curb Weight: Not specified, but typically high for heavy-duty trucks. 🛡️ Safety Features Active Features Brake System: Comprehensive coverage of air brake systems, ABS (Anti-lock Braking System), EBS (Electronic Braking System), and drum/disc brake components, including service and adjustment. Anti Skid System: Detailed diagnostics and troubleshooting for traction control and stability systems. Passive Features Bodywork And Chassis: Information on frame construction, body panels, and associated structural integrity aspects. 💡 Technology Features Infotainment Control Panel: Covers the operation and diagnostics of the driver's control panel, including display functions and warning indicators. Driver Assistance Electronic Control: Detailed coverage of EDC (Engine Control Data) / ECM (Engine Control Module) systems, including parameter monitoring and fault diagnosis. Electrical System Components: Extensive electrical schematics, wiring diagrams, junction connectors, remote switches, and body controller modules. Charging System: Alternator system diagnostics and repair. Starting System: Starter motor diagnostics and repair. Security Immobilizer System: Details on the immobilizer system operation and troubleshooting. Climate Control Air Conditioning And Heating: Covers HVAC system components, operation, service, and refrigerant handling. Suspension Air Suspension System: Detailed information on air suspension components, operation, diagnostics, and repair procedures. Steering Hydraulic Steering: Coverage of the power steering system, including pump, steering gear, and hydraulic circuits. 🔧 Maintenance Service Intervals General Recommendations: The manual provides detailed service intervals for all major components, including oil changes, filter...
Includes turbocharger operation, wastegate control, intercooler function, and troubleshooting turbo-related issues.
Emission Control
Denox 2 System:
Comprehensive coverage of the Selective Catalytic Reduction (SCR) system, including AdBlue dosing, NOx sensors, and system diagnostics.
Engine Diagnosis:
Detailed diagnostic procedures for engine performance issues, error codes, and electronic control unit (ECU) interactions.
🔧 Transmission
Standard Manual Transmissions
Zf 16 Speed Td:
ZF 16 S 1920 T.D., ZF 16 S 2220 T.D., ZF 16 S 2320 T.D., ZF 16 S 2520 T.D.
Zf 16 Speed To:
ZF 16 S 2220 T.O., ZF 16 S 2520 T.O.
Zf 16 Speed With Intarder:
ZF 16 S 1921 T.D., ZF 16 S 2221 T.D., ZF 16 S 2321 T.D., ZF 16 S 2521 T.O. (Note: '1' often denotes intarder integration)
Automated Manual Transmissions
Eurotronic 12 Speed Td:
EuroTronic 12 AS 1930 T.D., 12 AS 2330 T.D.
Eurotronic 12 Speed To:
EuroTronic 12 AS 2330 T.O., 12 AS 2530 T.O.
Automated Manual Transmissions With Intarder
Eurotronic 12 Speed Td Intarder:
EuroTronic 12 AS 1931 T.D., 12 AS 2331 T.D.
Eurotronic 12 Speed To Intarder:
EuroTronic 12 AS 2331 T.O., 12 AS 2531 T.O.
Features
Clutch System:
Details on clutch operation, release bearings, slave cylinders, and adjustments.
Power Take Off Pto:
Information regarding PTO installation, operation, and maintenance for various configurations.
Transfer Box:
Coverage for 4x4 or specific traction configurations if applicable.
Overhauling:
Detailed step-by-step overhaul procedures for all listed transmissions.
Fluid Specifications:
Specific ATF or gear oil types and capacities for each transmission model (e.g., ZF TE-ML specifications).
📐 Dimensions
Exterior
Vehicle Type:
Heavy-duty Truck
Weights
Gross Vehicle Weight:
GVW ratings vary significantly by configuration (e.g., 18-44+ tons), detailed in specific model data within the manual.
Curb Weight:
Not specified, but typically high for heavy-duty trucks.
🛡️ Safety Features
Active Features
Brake System:
Comprehensive coverage of air brake systems, ABS (Anti-lock Braking System), EBS (Electronic Braking System), and drum/disc brake components, including service and adjustment.
Anti Skid System:
Detailed diagnostics and troubleshooting for traction control and stability systems.
Passive Features
Bodywork And Chassis:
Information on frame construction, body panels, and associated structural integrity aspects.
💡 Technology Features
Infotainment
Control Panel:
Covers the operation and diagnostics of the driver's control panel, including display functions and warning indicators.
Driver Assistance
Electronic Control:
Detailed coverage of EDC (Engine Control Data) / ECM (Engine Control Module) systems, including parameter monitoring and fault diagnosis.
Electrical System
Components:
Extensive electrical schematics, wiring diagrams, junction connectors, remote switches, and body controller modules.
Charging System:
Alternator system diagnostics and repair.
Starting System:
Starter motor diagnostics and repair.
Security
Immobilizer System:
Details on the immobilizer system operation and troubleshooting.
Climate Control
Air Conditioning And Heating:
Covers HVAC system components, operation, service, and refrigerant handling.
Suspension
Air Suspension System:
Detailed information on air suspension components, operation, diagnostics, and repair procedures.
Steering
Hydraulic Steering:
Coverage of the power steering system, including pump, steering gear, and hydraulic circuits.
🔧 Maintenance
Service Intervals
General Recommendations:
The manual provides detailed service intervals for all major components, including oil changes, filter replacements, and inspections, tailored for heavy-duty usage.
Fluid Specifications
Engine Oil:
Specific API or ACEA rated engine oils required for the F3A and F3B engines, with viscosity grades (e.g., 15W-40, 10W-40) and capacity.
Coolant:
Type and concentration of antifreeze/coolant required, typically OAT or HOAT for modern diesel engines.
Brake Fluid:
DOT specification for brake fluid and clutch fluid.
Transmission Fluid:
Specific gear oil or ATF for ZF manual and automated transmissions, critical for longevity and performance.
Known Issues
Typical Considerations:
While not explicitly listed as 'known issues,' the manual's troubleshooting sections address common problems related to EGR systems, DPF (Diesel Particulate Filter) regeneration, SCR system faults, and turbocharger issues prevalent in Euro 4/5 vehicles.
Filters
Part Numbers:
Includes part numbers for oil filters, fuel filters, air filters, and cabin filters.
Lubrication
Chassis Points:
Details lubrication points for suspension, steering, and driveline components.
📚 Vehicle History
Brand Heritage
Iveco Profile:
Iveco is an Italian industrial vehicle manufacturer with a long history in producing trucks, buses, and commercial vehicles.
Model Evolution
Stralis Family:
The STRALIS range represents Iveco's commitment to modern heavy-duty truck design, focusing on efficiency, comfort, and performance for long-haul and distribution.
Production
Euro Standards Era:
Euro 4 and Euro 5 standards dictated significant changes in engine technology, emission control systems (like SCR), and powertrain management.
📄 Technical Specifications
Torque Values
Tightening Specifications:
Comprehensive list of torque specifications for critical fasteners across all major component groups, essential for proper assembly and safety.
Special Tools
Required Tools:
Lists specialized tools required for specific maintenance and repair procedures, enabling accurate work.
Wheel And Tires
Specifications:
Information on tire sizes, inflation pressures, and wheel bolt patterns relevant to various STRALIS AS configurations.
Wheel Alignment
Parameters:
Provides specifications for wheel alignment angles (camber, caster, toe) to ensure proper handling and tire wear.
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