Iveco Stralis AS Euro 4-5 18-44T 2006-2013 Service & Repair Workshop Manual
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๐ท๏ธ Basic Information Identification Make: Iveco Model: Stralis AS Model Variant: AS (Active Space) Codes Emission Standard: Euro 4-5 Gvwr Range: 18-44 Tonnes ๐ Introduction Market Position Segment: Heavy-duty truck, long-haul transport Target User: Commercial fleet maintenance, independent repair shops, owner-operators Competitive Analysis Competitors: DAF XF, Volvo FH, Scania R-series, Mercedes-Benz Actros (for the period) Key Features Value Proposition: Comprehensive factory-level repair information for specific Euro 4-5 Stralis AS models, accessible and permanent digital format. ๐ Manual Details Coverage Areas Region Covered: Global (Euro emission standards imply European focus, but principles apply broadly) Page Count Estimated Page Count: Hundreds (stated as 'hundreds of pages') Manual Type Type: Service & Repair Workshop Manual Language Language: English (assumed from product description and common industry practice for downloaded manuals) Format Format: PDF Download ๐ Manual Coverage Systems Covered Engine: Engine repair, diagnosis, performance tuning, emission control systems Transmission: Manual and Automated Manual Transmissions (e.g., ZF AS-Tronic), clutch, driveline Chassis: Frame, suspension (front and rear), steering system Brakes: Air brake system, ABS, EBS, parking brake, brake pad/disc replacement Electrical: Wiring diagrams, ECU diagnostics, lighting systems, charging system, starter system HVAC: Heating, Ventilation, and Air Conditioning system diagnosis and repair Bodywork: Cab interior and exterior trim, doors, latches, glass replacement Fuel System: Fuel tank, fuel lines, injectors, fuel filters Cooling System: Radiator, fan, coolant hoses, water pump Exhaust System: Diesel Particulate Filter (DPF) regeneration, SCR systems (if applicable to later Euro 5 variants), muffler Pneumatic System: Air compressor, air dryer, air tanks, air circuits for brakes and suspension Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication points Troubleshooting: Diagnostic procedures, fault code interpretation, symptom-based troubleshooting Repair: Component removal and installation, adjustments, system overhauls Diagnostics: ECU diagnostic tool usage, live data interpretation, specific system diagnostics Disassembly Assembly: Detailed step-by-step instructions with exploded diagrams for major components Calibration Adjustment: Calibration of sensors, adjustments to braking systems, engine control adjustments Technical Depth Depth: Comprehensive (covers all repairs, servicing, and troubleshooting) Detail Level: High (detailed photos & diagrams, step-by-step instructions, exploded diagrams) User Level: Professional Mechanics and Technicians ๐ Manual Specifications File Format Format: PDF Searchability: Likely text-searchable if properly generated PDF (implied by professional use) Print Quality Printability: Yes, single pages or entire manual Binding Type Binding: Not applicable (Digital Download) Paper Type Paper Type: Not applicable (Digital Download) Licensing License: Lifetime use, no expiry dates, no renewal fees Compatibility Os Compatibility: Windows & MAC Computers Device Compatibility Devices: Computer, tablet, smartphone โ๏ธ Engine Specifications Primary Engine Engine Family: Iveco Cursor (likely FPT Industrial Cursor family) Displacement Range: Typically 9.5L to 12.9L (common for Stralis models in this GVWR range) Performance Horsepower Range: Approx. 360 HP to 560 HP (depending on specific engine variant and tune) Torque Range: Approx. 1700 Nm to 2500 Nm (depending on specific engine variant and tune) Fuel System Injection Type: Common Rail Direct Injection (CRDi) Emission Controls: Exhaust Gas Recirculation (EGR), Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), Selective Catalytic Reduction (SCR) for some Euro 5 variants Engine Management ECU: Bosch EDC (Electronic Diesel Control) or similar, integrated with vehicle systems ๐ง Transmission Standard Type: ZF 12-speed AS-Tronic (Automated Manual Transmission) is common for this era Stralis, but manual options may exist. Optional Type: Potentially Eaton manual transmissions or other automated systems depending on specific configuration. Features Shift Modes: Fully automatic, manual override, economy and power modes (for AMT) Fluid Specifications Transmission Fluid: Specific ATF or gear oil as per Iveco specification (e.g., ZF TE-ML 01/02/04 series for AS-Tronic, GL-5 gear oil for manual). ๐ Dimensions Exterior Configurations: Tractor unit (4x2, 6x2, 6x4), rigid chassis (various axle configurations) Weights Gvwr: Gross Vehicle Weight Rating up to 44,000 kg (44 Tonnes) for tractor units, Gross Combination Weight (GCW) higher. Curb Weight: Varies significantly by configuration, typically 7-10 Tonnes for tractor units. ๐ก๏ธ Safety Features Ratings Crash Safety: Not typically rated by organizations like NHTSA or Euro NCAP in the same way as passenger cars, but built to strict ECE regulations for commercial vehicles. Cab structural integrity is paramount. Active Features ABS: Standard Anti-lock Braking System Ebs: Electronic Braking System (often integrated with ABS and Trailer EBS) Esp: Electronic Stability Program (may be optional or standard on higher GVWR models) Passive Features Cab Construction: Reinforced safety cab, crumple zones, side impact protection Seatbelts: Seatbelt pre-tensioners Lighting: Halogen or Xenon headlights, integrated fog lights, daytime running lights (DRLs) ๐ก Technology Features Infotainment Head Unit: Integrated digital radio, CD player, potentially optional Bluetooth and navigation. Driver Assistance Cruise Control: Standard adaptive cruise control (ACC) or standard cruise control. Telematics: Optional fleet management integration, GPS tracking. Connectivity Diagnostic Interface: OBD-II compliant, often with proprietary diagnostic connectors for deeper system access. ๐ง Maintenance Service Intervals Oil Change Interval: Typically 60,000 - 100,000 km or annually, depending on operating conditions and oil type. Refer to manual for...
Typically 9.5L to 12.9L (common for Stralis models in this GVWR range)
Performance
Horsepower Range:
Approx. 360 HP to 560 HP (depending on specific engine variant and tune)
Torque Range:
Approx. 1700 Nm to 2500 Nm (depending on specific engine variant and tune)
Fuel System
Injection Type:
Common Rail Direct Injection (CRDi)
Emission Controls:
Exhaust Gas Recirculation (EGR), Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), Selective Catalytic Reduction (SCR) for some Euro 5 variants
Engine Management
ECU:
Bosch EDC (Electronic Diesel Control) or similar, integrated with vehicle systems
๐ง Transmission
Standard
Type:
ZF 12-speed AS-Tronic (Automated Manual Transmission) is common for this era Stralis, but manual options may exist.
Optional
Type:
Potentially Eaton manual transmissions or other automated systems depending on specific configuration.
Features
Shift Modes:
Fully automatic, manual override, economy and power modes (for AMT)
Fluid Specifications
Transmission Fluid:
Specific ATF or gear oil as per Iveco specification (e.g., ZF TE-ML 01/02/04 series for AS-Tronic, GL-5 gear oil for manual).
๐ Dimensions
Exterior
Configurations:
Tractor unit (4x2, 6x2, 6x4), rigid chassis (various axle configurations)
Weights
Gvwr:
Gross Vehicle Weight Rating up to 44,000 kg (44 Tonnes) for tractor units, Gross Combination Weight (GCW) higher.
Curb Weight:
Varies significantly by configuration, typically 7-10 Tonnes for tractor units.
๐ก๏ธ Safety Features
Ratings
Crash Safety:
Not typically rated by organizations like NHTSA or Euro NCAP in the same way as passenger cars, but built to strict ECE regulations for commercial vehicles. Cab structural integrity is paramount.
Active Features
ABS:
Standard Anti-lock Braking System
Ebs:
Electronic Braking System (often integrated with ABS and Trailer EBS)
Esp:
Electronic Stability Program (may be optional or standard on higher GVWR models)
Passive Features
Cab Construction:
Reinforced safety cab, crumple zones, side impact protection
Seatbelts:
Seatbelt pre-tensioners
Lighting:
Halogen or Xenon headlights, integrated fog lights, daytime running lights (DRLs)
๐ก Technology Features
Infotainment
Head Unit:
Integrated digital radio, CD player, potentially optional Bluetooth and navigation.
Driver Assistance
Cruise Control:
Standard adaptive cruise control (ACC) or standard cruise control.
OBD-II compliant, often with proprietary diagnostic connectors for deeper system access.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically 60,000 - 100,000 km or annually, depending on operating conditions and oil type. Refer to manual for specifics.
Air Filter Interval:
Condition-based or every 2-3 services, depending on dust levels.
Fuel Filter Interval:
Typically 40,000 - 60,000 km, or as recommended by the manual for specific engine types.
Fluid Specifications
Engine Oil Grade:
API CI-4/CJ-4 or ACEA E4/E6/E7, SAE 10W-40 or 15W-40 common. Specific viscosity depends on climate.
Coolant:
Ethylene glycol-based antifreeze with corrosion inhibitors, typically pink or yellow (e.g., Paraflu UP).
Brake Fluid:
DOT 4, or DOT 5.1 for systems with higher temperature requirements. Air brake systems use specific air system lubricants/driers.
Known Issues
Common Problems:
DPF regeneration issues, AdBlue system faults (for Euro 5 SCR), EGR valve clogging, clutch wear (especially on AMT), electrical connector corrosion.
๐ Vehicle History
Brand Heritage
Manufacturer:
Iveco (Industrial Vehicles Corporation), part of CNH Industrial.
Model Evolution
Predecessor:
Iveco EuroStar, EuroTech
Generation:
First generation Stralis, launched in 2002, with significant updates leading to Euro 4-5 models in this range.
Production
Production Period:
2006-2013 (specific to this manual's coverage)
Manufacturing Locations:
Primary manufacturing in Spain (Valladolid) and Italy (Suzzara), with global assembly plants.
๐ Awards & Recognition
Recognitions
Awards:
The Stralis range has received numerous industry awards over its lifecycle for design, innovation, and efficiency, though specific accolades for the 2006-2013 Euro 4-5 models are varied.