Iveco Stralis As (Euro 4-5) - Service Repair Manual - Wiring Diagrams

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IVECO STRALIS AS (EURO 4/5) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING SCHEMATICS

- English Workshop Manual and Wiring Schematics, to vehicles Iveco Stralis AS (Euro 4/5).

 INDEX:

STRALIS AS EURO 4/5
- REPAIR MANUAL
-- MECHANICAL ELECTRIC/ELECTRONIC
-- PRELIMINARY REMARKS
-- SYMBOLS -WARNINGS
-- SYMBOLS - ASSISTANCE OPERATIONS
-- PRODUCT CODE
-- GENERAL WARNINGS
-- GENERAL WARNINGS ON THE ELECTRIC SYSTEM
-- Bonding and screening
-- OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS
-- CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
-- UPDATE DATA
-- INDEX OF SECTIONS
-- SECTION 1 - General
-- General
-- VEHICLE IDENTIFICATION DATA
-- Vehicle Identification Plate
-- Production identification plate
-- COMMERCIAL CODES
-- COMPOSITION OF MODELS
-- P.I.C. NUMBER CODING
-- REPLENISHING FLUIDS
-- International lubricant designation
-- SECTION 2 - Engine
-- Engine
-- F3A Engine
-- VIEWS OF THE ENGINE
-- TECHNICAL DESIGNATION
-- CHARACTERISTIC CURVES
-- GENERAL CHARACTERISTICS
-- ASSEMBLY CLEARANCE DATA
-- TIGHTENING TORQUE F3A ENGINE
-- TOOLS
-- ENGINE REMOVAL - REFITTING
-- Removal
-- Refitting
-- Filling the cooling system
-- Bleeding air from the supply system
-- Checks and tests
-- ELECTRO-MAGNETIC JOINT REPLACEMENT
-- Removal
-- Refitting
-- DISMANTLING THE ENGINE ON THE BENCH
-- REPAIR OPERATIONS
-- CYLINDER BLOCK
-- Checks and measurements
-- Cylinder liners
-- Replacing cylinder liners
-- Crankshaft
-- Measuring the main journals and crankpins
-- Preliminary measurement of main and big end bearing shell selection data
-- Selecting the main and big end bearing shells
-- Replacing the timing gear and oil pump
-- Checking main journal assembly clearance
-- Checking crankshaft end float
-- Piston connecting rod assembly
-- Piston rings
-- Connecting rods
-- Bushings
-- Checking connecting rods
-- Mounting the connecting rod — piston assembly
-- Mounting the piston rings
-- Fitting the big end bearing shells
-- Fitting connecting rod - piston assemblies in the cylinder liners
-- Checking piston protrusion
-- Checking crankpin assembly clearance
-- CYLINDER HEAD
-- Disassembly the valves
-- Checking head bearing surface on cylinder block
-- Valves
-- Removing deposits and checking the valves
-- Valve seats
-- Checking clearance between valve-stem and associated valve guide
-- Valve guides
-- Replacing injector cases
-- Checking injector protrusion
-- TIMING GEAR
-- Camshaft drive
-- Idler gear pin
-- Idler gear
-- Twin intermediategearpin
-- Twin idler gear
-- Replacing the bushings
-- Timing system
-- Checking cam lift and pin alignment
-- Bushings
-- Replacing camshaft bushings with drift 99360499
-- Removal
-- Assembly
-- Valve springs
-- ROCKER SHAFT
-- Shaft
-- Rocker arms
-- ENGINE ASSEMBLY ON BENCH
-- Fitting connecting rod - piston assemblies in cylinder liners
-- ENGINE FLYWHEEL
-- Fitting engine flywheel
-- Fitting camshaft
-- Fitting pump-injectors
-- Fitting rocker-arm shaft assembly
-- Camshaft timing
-- Phonic wheel timing
-- Intake and exhaust rocker play adjustment and pre-loading of rockers controlling pump injectors
-- Completing Engine Assembly
-- LUBRICATION
-- Oil pump
-- Overpressure valve
-- Oil pressure control valve
-- Heat exchanger
-- By-pass valve
-- Thermostatic valve
-- Engine oil filters
-- Valve integrated in piston cooling nozzle
-- COOLING
-- Description
-- Operation
-- Electromagnetic coupling
-- Water pump
-- Thermostat
-- View of thermostat operation for versions with Intarder
-- TURBOCHARGING
-- Turbocharger HOLSET HE 531 V
-- Actuator
-- Solenoid valve for VGT control
-- REPAIRING ACTIONS
-- Variable geometry movement control
-- Checking the actuator
-- Checking actuator travel
-- Cleaning turbine body
-- FEEDING
-- Overpressure valve
-- Feed pump
-- Injector-pump
-- Replacing injectors-pump
-- Pressure damper
-- F3B Engine
-- VIEWS OF THE ENGINE
-- TECHNICAL DESCRIPTION
-- CHARACTERISTIC CURVES
-- GENERAL SPECIFICATIONS
-- ASSEMBLY DATA - CLEARANCE
-- TIGHTENING TORQUE
-- DIAGRAMS OF TIGHTENING SEQUENCE OF MAIN ENGINE COMPONENTS
-- TOOLS
-- ENGINE REMOVAL-REFITTING
-- Removal
-- Refitting
-- Filling the cooling system
-- Bleeding air from the supply system
-- Checks and tests
-- ELECTRO-MAGNETIC JOINT REPLACEMENT
-- Removal
-- Refitting
-- DISASSEMBLY THE ENGINE ON THE BENCH
-- REPAIRS
-- CYLINDER BLOCK
-- Checks and measurements
-- Cylinder liners
-- Replacing the cylinder liners
-- Crankshaft
-- Measuring the main journals and crankpins
-- Preliminary measurement of data to select main bearing and big end bearing shells
-- Selecting the main bearing and big end bearing shells
-- Replacing the timing gear and oil pump
-- Checking main journal assembly clearance
-- Checking crankshaft end float
-- Connecting rod piston assembly
-- Piston rings
-- Connecting rod
-- Bushings
-- Checking connecting rods
-- Mounting the connecting rod — piston assembly
-- Mounting the piston rings
-- Fitting the big end bearing shells
-- Fitting connecting rod - piston assemblies in the cylinder liners
-- Checking piston protrusion
-- Checking crankpin assembly clearance
-- CYLINDER HEAD
-- Disassembly the valves
-- Checking head bearing surface on cylinder block
-- Valves
-- Valve seats
-- Checking clearance between valve-stem and associated valve guide
-- Valve guides
-- Replacing injector cases
-- Checking injector protrusion
-- TIMING GEAR
-- Camshaft drive
-- Idler gear pin
-- Idler gear
-- Twin intermediate gear pin
-- Twin idler gear
-- Replacing the bushings
-- Timing system
-- Checking cam lift and pin alignment
-- Bushings
-- Valve springs
-- ROCKER SHAFT
-- Shaft
-- Rocker arms
-- ENGINE ASSEMBLY ON BENCH
-- Fitting connecting rod - piston assemblies in cylinder liners
-- Fitting the cylinder head
-- Fitting flywheel box
-- ENGINE FLYWHEEL
-- Fitting engine flywheel
-- Fitting camshaft
-- Fitting pump-injectors
-- Fitting rocker-arm shaft assembly
-- Camshaft timing
-- Phonic wheel timing
-- Adjusting rocker arm clearance, intake, exhaust and pre-load of pump injector governing rocker arms
-- Completing Engine Assembly
-- LUBRICATION
-- Oil pump
-- Overpressure valve
-- Oil pressure control valve
-- Heat exchanger
-- By-pass valve
-- Thermostatic valve
-- Engine oil filters
-- Valve integrated in piston cooling nozzle
-- COOLING
-- Description
-- Operation
-- Electromagnetic coupling
-- Water pump
-- Thermostat
-- View of thermostat operation for versions with Intarder
-- TURBOCHARGING
-- Turbocharger HOLSET HE 551 V
-- Actuator
-- Solenoid valve for VGT control
-- REPAIR
-- Variable geometry movement control
-- Checking the actuator
-- Checking actuator travel
-- Cleaning turbine body
-- FEEDING
-- Overpressure valve
-- Feed pump
-- Injector-pump
-- Pressure damper
-- Hydrocar pressure take-off on timing system
-- HYDROCAR PRESSURE TAKE-OFF ON TIMING SYSTEM - P.T.O. (OPTIONAL)
-- Description
-- SPECIFICATIONS AND DATA
-- TIGHTENING TORQUES
-- ENGAGING POWER TAKE-OFF
-- REMOVING-REFITTING POWER TAKE-OFF
-- Denox System 2
-- DeNOx2 SYSTEM
-- General remarks
-- Tank
-- Ad Blue fluid level gauge control
-- By-pass valve
-- Pump module
-- Dosing module
-- Catalyst
-- Exhaust gas temperature sensor
-- Humidity detecting sensor
-- REPAIR INTERVENTIONS ON DeNox SYSTEM
-- Ad Blue tank
-- Disconnection
-- Reconnection
-- Tank level indicator
-- Disconnection
-- Reconnection
-- Pump module
-- Disconnection
-- Filter + Pre-Filter
-- Disconnection
-- Reconnection
-- Deflecting valve
-- Disconnection
-- Inlet exhaust gas temperature sensor
-- Disconnection
-- Reconnection
-- Outlet exhaust gas temperature sensor
-- Disconnection
-- Reconnection
-- Nitrogen oxides detecting sensor (IF PRESENT)
-- Disconnection
-- Reconnection
-- Sucked air humidity detecting sensor
-- Disconnection
-- Reconnection
-- Measuring out module
-- Disconnection
-- Reconnection
-- Fault Diagnosis
-- FAULT DIAGNOSIS
-- Diagnosis Instruments
-- Cluster Diagnosis
-- DTC - FMI error codes
-- SECTION 3 - Clutch
-- Clutch
-- DESCRIPTION
-- Clutch
-- SPECIFICATIONS AND DATA
-- DIAGNOSTICS
-- Main operating faults of a mechanical nature
-- TIGHTENING TORQUES
-- TOOLS
-- REMOVING AND REFITTING THE CLUTCH
-- Removal
-- CHECKS
-- Refitting
-- REMOVING-REFITTING THE THRUST BEARING
-- REPLACING THE SUPPORT BEARING OF THE CLUTCH SHAFT
-- REMOVING-REFITTING THE PEDAL UNIT SATA
-- Removal (vehicles with EuroTronic Automated gearbox)
-- Removal (vehicles with ZF 16 S... gearbox)
-- Refitting
-- PEDAL TYPE SATA (Vehicles with ABS)
-- Unit removal-assembly
-- CHECKING AND ADJUSTING STOPS ON CLUTCH PEDAL (vehicles with ABS)
-- Clutch stop
-- Idle travel of clutch pedal
-- Pedal control valve stroke
-- PEDAL TYPE WABCO vehicles with EBS)
-- Clutch stop
-- Clutch pedal idle travel
-- Pedal control valve stroke
-- HYDRAULIC CONTROL vehicles with ZF 16 S... gearboxes)
-- Clutch actuator
-- SPECIFICATIONS FOR MANUAL GEARBOX PREASSEMBLY
-- Spring pin adjustment
-- BLEEDING CLUTCH CIRCUIT
-- SPECIFICATIONS FOR AUTOMATIC TRANSMISSION ASSEMBLY
-- SECTION 4 - Gearboxes
-- Gearboxes
-- Gearboxes: 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.
-- DESCRIPTION
-- LOCATION OF GEARBOX DESCRIPTION PLATE
-- SPECIFICATIONS AND DATA
-- SPECIFICATIONS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- REMOVING-REFITTING THE GEARBOX
-- Removal
-- Refitting
-- ZF gearboxes with Intarder (IT), hydraulic retarder, types: 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.
-- SPECIFICATIONS AND DATA
-- TOOLS
-- OVERHAULING THE GEARBOX
-- Removing the hydraulic retarder from the gearbox on the stand
-- Refitting the hydraulic retarder
-- Adjusting stator end float
-- Removing the epicyclic reduction gear unit ERG) rear box
-- Removing the epicyclic reduction gear unit (ERG)
-- Refitting the epicyclic reduction gear unit (ERG) rear box
-- Gearboxes EuroTronic Automated: - 12 AS 1930 T.D. - 12 AS 2330 T.D./T.O. - 12 AS 2530 T.O.
-- DESCRIPTION
-- LOCATION OF GEARBOX DESCRIPTION PLATE
-- GEARBOX ELECTRONIC MANAGEMENT
-- Theoretical scheme
-- SPECIFICATIONS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- REMOVING-REFITTING GEARBOX
-- Removal
-- Refitting
-- Gearboxes EuroTronic Automated with Intarder: - 12 AS 1931 T.D. - 12 AS 2331 T.D./T.O. - 12 AS 2531 T.O.
-- SPECIFICATIONS AND DATA
-- TOOLS
-- EXPERIMENTAL TOOLS
-- OVERHAULING THE GEARBOX
-- Removing the hydraulic retarder
-- Refitting the hydraulic retarder
-- Adjusting epicyclic reduction gear train bearing end float
-- Adjusting stator end float
-- Adjusting stator end float
-- Removing the rear box
-- Disassembling the E.R.G.
-- Assembling the E.R.G.
-- EuroTronic gearboxes diagnostics
-- DIAGNOSTICS
-- Diagnosis Instruments
-- Cluster Diagnosis
-- Troubleshooting via DTC-FMI codes
-- SECTION 5 - Intarder - ZF hydraulic retarder
-- Intarder - ZF hydraulic retarder
-- LOCATION OF INTARDER HYDRAULIC RETARDER DESCRIPTION PLATE
-- GENERAL INFORMATION
-- OPERATION
-- Retarder engaged
-- Retarder disengaged
-- LAYOUT OF MAIN SYSTEM COMPONENTS ON THE RETARDER
-- REMOVING AND REFITTING THE RETARDER ON THE ZF 16 S 1621/1921/2221 GEARBOX
-- Removal
-- Refitting
-- Filling with oil
-- SPECIFICATIONS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- DIAGNOSTICS
-- Main operating faults of a mechanical nature
-- OVERHAULING THE INTARDER HYDRAULIC RETARDER
-- Hydraulic accumulator
-- Removal
-- Fitting
-- Removing hydraulic retarder
-- Checking the component parts of the hydraulic retarder
-- Fitting the hydraulic retarder
-- Stator end float adjustment
-- Only for EuroTronic Automated gearboxes, operate as below
-- SECTION 6 - Propeller shafts
-- Propeller shafts
-- CHARACTERISTICS AND DATA
-- STRALIS (Tractors) - CHARACTERISTICS AND DATA (vehicles 4x2/6x2C/6x4/6x2p)
-- STRALIS AS (Cabs) - CHARACTERISTICS AND DATA (vehicles 4x2/6x2P/6x4)
-- DIAGNOSTIC
-- Main operating faults of a mechanical nature
-- TIGHTENING TORQUES
-- TOOLS
-- REMOVING AND REASSEMBLING THE PROPELLER SHAFT
-- Removal
-- Reassembly
-- CHECKING THE PROPELLER SHAFT ON THE VEHICLE
-- REMOVING AND FITTING BACK THE UNIVERSAL JOINTS
-- REMOVING AND REASSEMBLING THE SUPPORT
-- SECTION 7 - Rear axles
-- Rear axles
-- DIAGNOSTICS
-- Main operating faults of a mechanical nature
-- REMOVING-REFITTING THE REAR AXLE
-- Removal
-- Refitting
-- REMOVING-REFITTING THE DIFFERENTIAL FROM THE REAR AXLE ON THE VEHICLE
-- Removal
-- Refitting
-- Rear Axle ARVINMERITOR MS 13-175 with disc brakes
-- LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE
-- DESCRIPTION
-- CHARACTERISTICS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- OVERHAULING THE REAR AXLE ASSEMBLY
-- OVERHAULING THE WHEEL HUBS
-- Removal
-- Replacing wheel hub bearings
-- Checking the parts forming the wheel hubs
-- Replacing the wheel fixing pins
-- REMOVING AND REFITTING THE DIFFERENTIAL with axle on stand 99322215)
-- Removal
-- Refitting
-- REPAIRING THE DIFFERENTIAL
-- Removing the differential
-- Removing the gearcase
-- REMOVING THE BEVEL PINION FROM THE SUPPORT
-- Differential component check
-- Fitting the gear housing
-- FITTING THE MOUNT ON THE BEVEL PINION
-- Reassembling the differential housing
-- ADJUSTING THE CAP GAP
-- CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)
-- WORK ON THE VEHICLE
-- REPLACING THE BEVEL PINION MOUNT SEAL
-- Disassembly
-- Assembly
-- Rear axle 451391
-- DESCRIPTION
-- SPECIFICATIONS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- REAR AXLES ASSEMBLY OVERHAUL
-- Disassembly
-- Epicycloid reduction gear disassembly
-- Wheel hub disassembly
-- CHECKING THE WHEEL HUB AND EPICYCLOID REDUCTION GEAR UNIT PARTS
-- WHEEL HUB ASSEMBLY
-- Assembling the epicycloid reduction gear
-- REMOVING-REFITTING THE DIFFERENTIAL
-- REPAIRING THE DIFFERENTIAL
-- Disassembly
-- Gear housing disassembly
-- Removing the bevel pinion from the support
-- CHECKING THE DIFFERENTIAL COMPONENTS
-- Gear housing assembly
-- Assembling the bevel pinion support
-- Procedure to follow to determine the thickness of the bevel pinion rolling torque adjusting ring
-- Differential housing assembly
-- Gear housing bearings rolling torque adjustment
-- Axles in tandem ARVINMERITOR MT23-155/2D
-- Axles Intermediate ARVINMERITOR MD11-155/2D
-- DESCRIPTION
-- SPECIFICATIONS ANDA DATA
-- LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE
-- SPECIFICATIONS AND DATA
-- TIGHTENING TORQUES
-- TOOLS
-- SPECIAL PURPOSE TOOLS
-- INTERMEDIATE REAR AXLE ASSEMBLY OVERHAUL
-- OVERHAULING THEWHEEL HUBS
Removal
Replacing wheel hub bearings
Checking the parts forming the wheel hubs
Replacing the wheel fixing pins
Wheel hub reassembly
-- DIFFERENTIAL CASE REMOVAL
Case removal
Gearing case removal
Checking the differential components
Gearing case refitting
-- ASSEMBLING DIFFERENTIAL CASING
Calculating bevel pinion position in differential casing
-- EXAMPLES
Adjust the limit switch of the differential - distributor lock control pin
Adjusting drive input shaft bearing end float
-- ADJUSTING THE CAP ANGLE
-- CORRECTING THE BEVEL GEAR PAIR CONTACTS (AFTER FITTING IN PLACE)
-- REMOVAL-OVERHAUL-REFITTING OF DISTRIBUTOR OUTPUT SHAFT
Adjustment of motion output shaft bearing end play
-- Rear axles ARVINMERITOR MR11-155/D
-- DESCRIPTION
-- LOCATION OF DIFFERENTIAL UNIT PLATES - REAR AXLE
-- CHARACTERISTICS AND DATA
-- TIGHTENING TORQUES
-- REPAIR OPERATIONS
-- SECTION 8 - Axles
-- Axles
-- Front axles
-- Front axle 5876 5876/4 5876/5 Steering central added axle 5876/4
-- DESCRIPTION
-- SPECIFICATIONS AND DATA
-- DIAGNOSTICS
Main operating faults of a mechanical nature
-- TIGHTENING TORQUES
-- TOOLS
-- REMOVING AND REFITTING AXLE
Vehicles with mechanical front suspension
Removal
Refitting
-- REMOVING AND REFITTING AXLE
Vehicles with pneumatic front suspension and longitudinal bars
Removal
Refitting
-- HYDRAULIC SYSTEM FOR CENTRAL ADDED AXLE STEERING (vehicles 6X2C)
Hydraulic system working diagram
-- CHARACTERISTICS AND DATA
-- CENTRING CYLINDER OPERATING DIAGRAM
Added central axle
Location on the vehicle of the main components of the hydraulic system
Hydraulic system
-- AIR BLEEDING FROM THE HYDRAULIC CIRCUIT
Filling up and bleeding the power steering hydraulic circuit (circuit 1)
Filling up and bleeding the power steering hydraulic circuit (circuit 2)
-- REPAIRS
-- CENTRAL ADDED AXLE AIR LIFT, 6X2C VEHICLES
-- GENERAL
Location on the vehicle of the main components
Pneumatic principle scheme, rear pneumatic suspensions and pneumatic lifting device for central added axle with single wheels
-- VEHICLE CHECKS
Tie rods
Swivel heads
-- CHECKING SWIVEL HEAD PLAY
-- FRONT AXLE ASSEMBLY OVERHAUL
-- REMOVING - REFITTING WHEEL HUBS
Removal
Replacing wheel hub bearings
Replacing wheel fixing pins
Refitting wheel hubs
Checking wheel hub bearing end float
Measuring rolling torque
-- REMOVING AND REFITTING TRANSVERSE TIE ROD
-- REPLACING TRANSVERSE TIE ROD SWIVEL HEADS
-- LONGITUDINAL TIE ROD LEVER REMOVAL/REFITTING
-- CROSS TIE ROD LEVER REMOVAL/REFITTING
-- REMOVING AND REFITTING PIN FOR STUB AXLE
Removal
Replacing kingpin bearing
Checking and adjusting clearance between stub axle and axle
-- CHECKING AND MEASURING THE AXLE BODY
Checking levelness of leaf spring supporting surfaces with respect to the holes for the kingpins
Checking angle of holes for kingpins
-- Additional rear axle

AND MORE.....