STRALIS AS EURO 4 & 5 Truck Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: IVECO Model: STRALIS AS Generation: Euro 4 & 5 Codes Engine Codes Covered: F3AE3681D, F3AE3681A, F3BE3681B, F3BE3681A Transmission Codes Covered: ZF 16 S 1920 T.D., ZF 16 S 2220 T.D./T.O., ZF 16 S 2320 T.D., ZF 16 S 2520 T.O., ZF 16 S 1921 T.D., ZF 16 S 2221 T.D./T.O., ZF 16 S 2321 T.D., ZF 16 S 2521 T.O., EuroTronic 12 AS 1930 T.D., EuroTronic 12 AS 2330 T.D./T.O., EuroTronic 12 AS 2530 T.O., EuroTronic 12 AS 1931 T.D. (with Intarder), EuroTronic 12 AS 2331 T.D./T.O. (with Intarder), EuroTronic 12 AS 2531 T.O. (with Intarder) 👋 Introduction Market Position Target Audience: Professional truck technicians, fleet maintenance departments, and owner-operators with a technical aptitude. Value Proposition: Provides the same in-depth technical information used by authorized service centers, enabling efficient and accurate repairs and maintenance. Competitive Analysis Manual Comparison: This manual is directly comparable to factory service manuals, offering a comprehensive alternative to potentially less detailed aftermarket guides. Key Features Comprehensiveness: Covers a wide range of vehicle systems, from engine and transmission to electronics and emissions aftertreatment. Visual Aids: Includes pictures, diagrams, and exploded views to clarify procedures. Practicality: Printable and searchable for ease of use in a workshop environment. 📋 Manual Details Coverage Areas General Information: Included Engine System: Included Clutch System: Included Transmission: Included Power Take Off: Included Transfer Box: Included Propeller Shaft: Included Axle System: Included Suspension System: Included Wheel And Tires: Included Steering System: Included Brake System: Included Pneumatic System: Included Bodywork System: Included Chassis And Frame: Included Maintenance System: Included Electrical System: Included Hydrocar Timing System: Included Denox 2 System: Included Engine Diagnosis: Included Torque Specifications: Included Special Tools: Included Lubrication System: Included Cooling System: Included Turbocharging: Included Fuel System: Included Hydraulic Control: Included Overhauling: Included Differentials: Included Wheel Alignment: Included Air Suspension System: Included Hydraulic Steering: Included Anti Skid System: Included Air Conditioning And Heating: Included Control Panel: Included Alternator System: Included Starter Motor: Included Junction Connectors: Included Remote Switches: Included Body Controller: Included Steering Column: Included Edc ECM Systems: Included Immobilizer System: Included Selective Catalytic Reduction: Included Troubleshooting: Included Circuit Diagrams: Included Page Count Estimated Page Count: Not specified in product information, but described as 'very comprehensive'. Manual Type Type: Workshop Service Repair Manual Language Language: English (implied by product description and common industry practice for service manuals) Format Format: PDF (DOWNLOAD) 📖 Manual Coverage Systems Covered Powertrain: Comprehensive coverage of engine, clutch, transmission, PTO, transfer box, propeller shaft, axle systems, and differentials. Chassis And Suspension: Detailed information on suspension systems (including air suspension), wheel and tire systems, chassis, and frame. Steering And Braking: Includes hydraulic steering, brake systems, and anti-skid systems. Electrical And Electronic Systems: Covers general electrical systems, alternator, starter motor, junction connectors, remote switches, body controller, steering column, EDC/ECM, immobilizer, and climate control systems. Emission Control And Aftertreatment: Includes coverage of the DENOX 2 System (Selective Catalytic Reduction) and Hydrocar Timing System for Euro 4 & 5 compliance. Procedures Included Maintenance And Servicing: Detailed procedures for routine maintenance, scheduled servicing, and fluid checks. Repair And Overhaul: Step-by-step repair and overhaul procedures for all covered systems, including exploded views. Diagnostics And Troubleshooting: Covers engine diagnosis, general troubleshooting, and specific diagnostic procedures for various systems. Technical Specifications And Data: Includes torque specifications, lubrication details, fluid capacities, and wheel alignment data. Special Tool Usage: Information on the use of specialized tools required for specific repair and maintenance tasks. Technical Depth Depth Of Information: High - provides technician-level detail, including 'detailed and complete step-by-step written procedures with pictures and diagrams' for repairs and overhauls. Diagnostic Capabilities: Advanced - includes engine diagnosis and troubleshooting sections, implying coverage of common faults and their resolution. Rebuilding Procedures: Comprehensive - the 'overhauling' section indicates detailed instructions for component and system rebuilding. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable, common for professionally produced PDF manuals. Print Quality Printability: Fully printable (selected pages or whole manual), as stated in product description. Illustration Quality: Illustrated with pictures and diagrams, and 'detailed exploded views'. Binding Type Binding: Not applicable for PDF format. Paper Type Paper Type: Not applicable for PDF format. ⚙️ Engine Specifications Primary Engine Type: 4-stroke, Turbocharged Diesel Engine Configuration: 6-Cylinder, In-line Displacement Variant 1: 10.30 Liters Engine Code Variant 1: F3AE3681D / F3AE3681A Displacement Variant 2: 12.88 Liters Engine Code Variant 2: F3BE3681B / F3BE3681A Aspiration: Turbocharged with Aftercooler (10.3L) / Turbocharged with Intercooler (12.88L) Performance Horsepower Range: Specific figures not provided, but typical for this engine size/type range from approximately 300 HP to over 500 HP depending on configuration and variant. Torque Range: Specific figures not provided, but typically significant torque output for heavy-duty applications, ranging from approximately 1200 Nm to over 2000 Nm. Fuel System Fuel Type: Diesel Injection System: Implied to be advanced common rail for Euro 4/5 compliance,...
ZF 16 S 1920 T.D., ZF 16 S 2220 T.D./T.O., ZF 16 S 2320 T.D., ZF 16 S 2520 T.O., ZF 16 S 1921 T.D., ZF 16 S 2221 T.D./T.O., ZF 16 S 2321 T.D., ZF 16 S 2521 T.O., EuroTronic 12 AS 1930 T.D., EuroTronic 12 AS 2330 T.D./T.O., EuroTronic 12 AS 2530 T.O., EuroTronic 12 AS 1931 T.D. (with Intarder), EuroTronic 12 AS 2331 T.D./T.O. (with Intarder), EuroTronic 12 AS 2531 T.O. (with Intarder)
👋 Introduction
Market Position
Target Audience:
Professional truck technicians, fleet maintenance departments, and owner-operators with a technical aptitude.
Value Proposition:
Provides the same in-depth technical information used by authorized service centers, enabling efficient and accurate repairs and maintenance.
Competitive Analysis
Manual Comparison:
This manual is directly comparable to factory service manuals, offering a comprehensive alternative to potentially less detailed aftermarket guides.
Key Features
Comprehensiveness:
Covers a wide range of vehicle systems, from engine and transmission to electronics and emissions aftertreatment.
Visual Aids:
Includes pictures, diagrams, and exploded views to clarify procedures.
Practicality:
Printable and searchable for ease of use in a workshop environment.
📋 Manual Details
Coverage Areas
General Information:
Included
Engine System:
Included
Clutch System:
Included
Transmission:
Included
Power Take Off:
Included
Transfer Box:
Included
Propeller Shaft:
Included
Axle System:
Included
Suspension System:
Included
Wheel And Tires:
Included
Steering System:
Included
Brake System:
Included
Pneumatic System:
Included
Bodywork System:
Included
Chassis And Frame:
Included
Maintenance System:
Included
Electrical System:
Included
Hydrocar Timing System:
Included
Denox 2 System:
Included
Engine Diagnosis:
Included
Torque Specifications:
Included
Special Tools:
Included
Lubrication System:
Included
Cooling System:
Included
Turbocharging:
Included
Fuel System:
Included
Hydraulic Control:
Included
Overhauling:
Included
Differentials:
Included
Wheel Alignment:
Included
Air Suspension System:
Included
Hydraulic Steering:
Included
Anti Skid System:
Included
Air Conditioning And Heating:
Included
Control Panel:
Included
Alternator System:
Included
Starter Motor:
Included
Junction Connectors:
Included
Remote Switches:
Included
Body Controller:
Included
Steering Column:
Included
Edc ECM Systems:
Included
Immobilizer System:
Included
Selective Catalytic Reduction:
Included
Troubleshooting:
Included
Circuit Diagrams:
Included
Page Count
Estimated Page Count:
Not specified in product information, but described as 'very comprehensive'.
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English (implied by product description and common industry practice for service manuals)
Format
Format:
PDF (DOWNLOAD)
📖 Manual Coverage
Systems Covered
Powertrain:
Comprehensive coverage of engine, clutch, transmission, PTO, transfer box, propeller shaft, axle systems, and differentials.
Chassis And Suspension:
Detailed information on suspension systems (including air suspension), wheel and tire systems, chassis, and frame.
Steering And Braking:
Includes hydraulic steering, brake systems, and anti-skid systems.
Electrical And Electronic Systems:
Covers general electrical systems, alternator, starter motor, junction connectors, remote switches, body controller, steering column, EDC/ECM, immobilizer, and climate control systems.
Emission Control And Aftertreatment:
Includes coverage of the DENOX 2 System (Selective Catalytic Reduction) and Hydrocar Timing System for Euro 4 & 5 compliance.
Procedures Included
Maintenance And Servicing:
Detailed procedures for routine maintenance, scheduled servicing, and fluid checks.
Repair And Overhaul:
Step-by-step repair and overhaul procedures for all covered systems, including exploded views.
Diagnostics And Troubleshooting:
Covers engine diagnosis, general troubleshooting, and specific diagnostic procedures for various systems.
Technical Specifications And Data:
Includes torque specifications, lubrication details, fluid capacities, and wheel alignment data.
Special Tool Usage:
Information on the use of specialized tools required for specific repair and maintenance tasks.
Technical Depth
Depth Of Information:
High - provides technician-level detail, including 'detailed and complete step-by-step written procedures with pictures and diagrams' for repairs and overhauls.
Diagnostic Capabilities:
Advanced - includes engine diagnosis and troubleshooting sections, implying coverage of common faults and their resolution.
Rebuilding Procedures:
Comprehensive - the 'overhauling' section indicates detailed instructions for component and system rebuilding.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable, common for professionally produced PDF manuals.
Print Quality
Printability:
Fully printable (selected pages or whole manual), as stated in product description.
Illustration Quality:
Illustrated with pictures and diagrams, and 'detailed exploded views'.
Binding Type
Binding:
Not applicable for PDF format.
Paper Type
Paper Type:
Not applicable for PDF format.
⚙️ Engine Specifications
Primary Engine
Type:
4-stroke, Turbocharged Diesel Engine
Configuration:
6-Cylinder, In-line
Displacement Variant 1:
10.30 Liters
Engine Code Variant 1:
F3AE3681D / F3AE3681A
Displacement Variant 2:
12.88 Liters
Engine Code Variant 2:
F3BE3681B / F3BE3681A
Aspiration:
Turbocharged with Aftercooler (10.3L) / Turbocharged with Intercooler (12.88L)
Performance
Horsepower Range:
Specific figures not provided, but typical for this engine size/type range from approximately 300 HP to over 500 HP depending on configuration and variant.
Torque Range:
Specific figures not provided, but typically significant torque output for heavy-duty applications, ranging from approximately 1200 Nm to over 2000 Nm.
Fuel System
Fuel Type:
Diesel
Injection System:
Implied to be advanced common rail for Euro 4/5 compliance, detailed within manual.
Emission Control
Emission Standards:
Euro 4 and Euro 5
Aftertreatment System:
DENOX 2 System (Selective Catalytic Reduction)
🔧 Transmission
Standard
Type:
Manual and Automated Manual Transmission (AMT)
Manual Gear Count:
16-speed
Manual Models:
ZF 16 S 1920 T.D., ZF 16 S 2220 T.D./T.O., ZF 16 S 2320 T.D., ZF 16 S 2520 T.O., ZF 16 S 1921 T.D., ZF 16 S 2221 T.D./T.O., ZF 16 S 2321 T.D., ZF 16 S 2521 T.O.
Optional
Automated Models:
EuroTronic 12 AS 1930 T.D., EuroTronic 12 AS 2330 T.D./T.O., EuroTronic 12 AS 2530 T.O.
Automated With Intarder Models:
EuroTronic 12 AS 1931 T.D., EuroTronic 12 AS 2331 T.D./T.O., EuroTronic 12 AS 2531 T.O.
Features
Clutch Actuation:
Hydraulic (for manual) or automated (for EuroTronic).
Intarder System:
Optional integrated retarder for enhanced braking on EuroTronic models.
Gear Shifting Logic:
Sophisticated shift logic for EuroTronic to optimize performance and fuel economy.
📐 Dimensions
Exterior
Vehicle Type:
Heavy-duty Truck (specific dimensions vary by configuration and body style - not provided in product info).
Cab Options:
Various cab configurations likely available (e.g., Day Cab, Sleeper Cab) - details within manual.
Weights
Gross Vehicle Weight:
Varies significantly by model and configuration, typically from 18,000 kg to over 26,000 kg (GCW will be higher).
🛡️ Safety Features
Ratings
Crash Test Information:
Not typically rated by consumer safety organizations like NHTSA or Euro NCAP for commercial trucks; focus is on regulatory compliance.
Active Features
Anti Skid System:
Covered in manual, likely refers to Electronic Stability Program (ESP) or similar systems.
ABS:
Standard on modern heavy-duty trucks, covered under brake system.
Intarder:
Available on certain transmissions for enhanced braking safety.
Passive Features
Cab Construction:
Reinforced cab structure for driver protection, details on structural components likely in bodywork section.
Seat Belts:
Standard safety feature, details on adjustment/maintenance likely in manual.
💡 Technology Features
Infotainment
Dashboard Interface:
Includes control panel for vehicle functions and potentially a basic infotainment/radio system. Details in manual.
Driver Assistance
Anti Skid System:
Likely implemented as part of the braking system for stability control.
Cruise Control:
Standard on most heavy-duty trucks of this era for highway efficiency.
Connectivity
Diagnostic Ports:
OBD-II or similar diagnostic ports for engine and vehicle electronics, covered under electrical/diagnosis sections.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically 50,000 to 100,000 km or annually, depending on operating conditions and oil type. Refer to specific service schedule in manual.
Fuel Filter Replacement:
Varies, but commonly between 30,000 to 60,000 km. Critical for protecting modern high-pressure fuel systems.
Air Filter Replacement:
Condition-based or mileage-based (e.g., 40,000-80,000 km), depending on operating environment. Manual will specify.
Transmission Fluid Change:
Highly dependent on transmission type (manual vs. automated) and manufacturer recommendations. Likely in the range of 100,000-200,000 km for manual, potentially shorter intervals for automated. Consult manual.
Fluid Specifications
Engine Oil Viscosity:
Likely 10W-40 or 15W-40, meeting API CJ-4 or ACEA E6/E7 specifications for Euro 4/5 engines. Exact specification in manual.
Coolant Type:
Typically OAT (Organic Acid Technology) antifreeze/coolant, often a long-life formulation. Specific IVECO or industry standard (e.g., AFNOR R/2003) required.
Transmission Fluid Type:
Varies by ZF gearbox. Manual will specify the exact GL-4 or GL-5 rated gear oil and ZF TE-ML specification (e.g., TE-ML 02B, TE-ML 12L, TE-ML 12LS).
Brake Fluid Type:
Typically DOT 4 or higher, specified by the hydraulic system manufacturer. Manual will confirm.
Known Issues
Common Failures Euro 4 5:
Potential for EGR valve issues, DPF regeneration problems (if fitted), SCR system faults (AdBlue issues), and wear on turbocharger components or injectors due to high mileage and complex emissions systems.
Clutch Wear:
Wear on clutch components is a common maintenance item for heavy-duty trucks, especially with frequent stop-start operation.
Electrical Gremlins:
Complex electrical systems can sometimes lead to intermittent faults or sensor issues; manual's diagnostic section is crucial.
📚 Vehicle History
Brand Heritage
Manufacturer:
IVECO (Industrial Vehicles Corporation), an Italian brand with a long history in commercial vehicle manufacturing.
Model Evolution
Stralis Lineage:
The STRALIS nameplate has been a flagship of IVECO's heavy-duty truck range, evolving through various generations and Euro emission standards.
Euro Emission Standards:
The 'Euro 4 & 5' designation indicates a specific period of production focused on meeting these increasingly stringent emissions regulations.
Production
Production Period:
Approximately mid-2000s to early 2010s, coinciding with the introduction and widespread adoption of Euro 4 and Euro 5 standards.
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
The IVECO STRALIS has historically been a contender and winner of 'International Truck of the Year' awards in various years and categories, reflecting its engineering and market impact.