Iveco Stralis (AT-AD) - Repair, Service Manual and Electrical Wiring Diagrams

CLICK HERE FOR SAMPLE MANUAL

IVECO STRALIS (AT-AD) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to vehicles Iveco Stralis (AT-AD).
 

CONTENTS:

SECTION 1 - GENERAL
General
- Vehicle identification data
- Vehicle identification plate
- Production identification plate
- Composition of model
- P.i.c. Number coding
- Replenishing fluids
SECTION 2 - ENGINE
Engine
- F2b engine
- General characteristics
- Views of the engine
- Assembly clearance data
- Tightening torques
- Tools
- Dismantling the engine on the bench
- Repair operations
- Cylinder block
- Cylinder liners
- Crankshaft
- Preliminary measurement of main and big end bearing shell selection data
- Piston-connecting rod assembly
- Connecting rod
- Cylinder head
- Valve
- Valve guides
- Replacing injector holder cases
- Timing gear
- Valve springs
- Rocker shaft
- Assembling the engine on the bench
- Diagram showing the underblock fixing screws tightening order
- Engine flywheel
- Engine completion
- Lubrication
- Cooling
- Turbocharging
- Turbocharger
- Turbo compressor holset hx 40v
- Fuel feed
- F3a engine
- Views of the engine
- Technical designation
- Characteristic curves
- General characteristics
- Assembly clearance data
- Tightening torque
- Tools
- Dismantling the engine on the bench
- Repair operations
- Cylinder block
- Cylinder liners
- Crankshaft
- Piston connecting rod assembly
- Connecting rods
- Cylinder head
- Rocker shaft
- Engine assembly on bench
- Engine flywheel
- Lubrication
- Cooling
- Turbocharging
- Feeding
- Hydrocar pressure take-off on timing system
- Hydrocar pressure take-off on timing system - p.t.o. (optional)
- Specifications and data
- Tightening torques
- Engaging power take-off
- Removing-refitting power take-off
SECTION 3 - CLUTCH
Clutch
- Description
- Clutch
- Characteristics and data
- Diagnostics
- 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
- Removal (vehicles with eurotronic automated gearbox)
- Removal (vehicles with zf 16 s... Gearbox)
- Refitting
- Pedal
- Unit removal-assembly
- Checking and adjusting stops on clutch pedal
- Hydraulic control (vehicles with zf 9 s 109 - zf 16s 151/181/221 gearboxes)
- Clutch actuator for zf 16 s 151/181/221 gearboxes
- Fitting and adjusting the clutch wear indicator
- Push rod adjustment
- Operator cylinder (new clutch)
- Bleeding clutch circuit
- Clutch actuator for eurotronic automated gearbox
- Clutch actuator push rod adjustment (new clutch)
- Fitting the clutch actuator
- Replacing the clutch actuator
SECTION 4 - GEARBOXES
Gearboxes
- Gearbox zf 9 s 109 d.d.
- General specifications
- Specifications and data
- Diagnostics
- Tightening torque
- Equipment
- Removal
- Disassembling the e.r.u. Box
- Disassembling the e.r.u.
- Checks
- Assembling the e.r.u.
- Assembling the e.r.u. Box
- Disassembling the gearbox
- Removing the input shaft
- Removing the main shaft
- Removing the transmission shaft
- Removing the gearchange case of gearbox
- Oil pump
- Checks
- Assembling the gearchange case
- Assembling the transmission shaft
- Assembling the input shaft
- Assembling the gearbox
- Adjusting the transmission shaft bearings
- Gearboxes: zf 16 s 181 d.d. - zf 16 s 181 o.d. - zf 16 s 221 d.d.
- Location of gearbox description plate
- Description
- Operation
- Epicyclic reduction gear control
- Specifications and data
- Tightening torques
- Tools
- Gearbox fault diagnosis
- Removing-refitting the gearbox
- Overhauling the gearbox
- Checks
- Pneumatic control of gearbox
- Zf gearboxes with intarder hydraulic retarder, types: 16 s 151 d.d. 16 s 181 d.d. 16 s 221 d.d.
- Specifications and data
- Tools
- Gearbox eurotronic 12 as 2301 d.d./o.d.
- Description
- Specifications and data
- Tightening torques
- Tools
- Overhauling the gearbox
- Gearbox eurotronic 12 as 2301 d.d./o.d. With intarder (it)
- Specifications and data
- Overhauling the gearbox
- Experimental tools
- Gearboxes allison md 3060 pr - allison md 3066 pr
- Description
- Technical designation
- Characteristics and data
- Main operation anomalies
- Tightening torques
- Tools
- Removal and refitting of the transmission
- Disconnecting and connecting gearbox control module again
- Replacing speed sensors
- Replacing oil level sensor
- Replacing oil suction filter
- Replacing the solenoid valves
- Replacing plane gaskets in gearbox control module
- Replacing pressure switch f3
- Replacing the seal ring on the output shaft
- Transmission external control (except for vehicles equipped with eurotronic - allison gearshift)
- Transmission external control
- Side tie rod
- Telescopic tie rod
- Transmission idler arm
- Cross tie rod
- Power take-off
- Zf power take-off
- Hydrocar power take-off
- Power take off (optional 2395)
- Description
- Features and data
- Tightening torque
- Equipment
- Removing - refitting total power take-off assembly
- Overhauling
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 s 181/221-od gearbox
- Removal
- Refitting
- Filling with oil
- Specifications and data
- Tightening torques
- Tools
- Fault diagnosis
- 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
SECTION 6 - PROPELLER SHAFTS
Propeller shafts
- Characteristics and data
- Diagnostic
- 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
- Fault diagnosis
- Removing-refitting the rear axle
- Removal
- Refitting
- Removing-refitting the differential from the rear axle on the vehicle
- Removal
- Refitting
- Rear axle meritor ms 13-175 with disc brakes
- Description
- Characteristics and data
- Tightening torques
- Tools
- Overhauling the rear axle assembly
- Overhauling thewheel hubs
- Removing and refitting the differential
- Repairing the differential
- Removing the bevel pinion from the support
- Fitting the mount on the bevel pinion
- Adjusting the cap gap
- Correcting the crown wheel and pinion contacts (after assembly)
- Work on the vehicle
- Replacing the bevel pinion mount seal
- Rear axle meritor ms 13-175 whit drum brakes
- Description
- Characteristics and data
- Tightening torques
- Tools
- Overhauling the rear axle assembly
- Overhauling thewheel hubs
- Replacing thewheel hub bolts
- Removing and reassembling the differential
- Rear axle 451391 (r 8284)
- Description
- Specifications and data
- Tightening torques
- Tools
- Rear axles assembly overhaul
- Checking the wheel hub and epicycloid reduction gear unit parts
- Wheel hub assembly
- Removing-refitting the differential
- Repairing the differential
- Checking the differential components
- Axles in tandem meritor rt 160 e/1
- Axles in tandem (intermediate) meritor rp 160 e (r 2478)
- Checking wheel hub components
- Dismantling inter-axle unit
- Checking inter-axle unit components
- Fitting inter-axle unit
- Adjusting drive input shaft bearing end float
- Adjusting differential lock and inter-axle control pin end-stop
- Dismantling gear cage
- Checking differential components
- Assembling gear cage
- Calculating bevel pinion positionin differential casing
- Determining the thickness of the bevel pinion bearing clearance adjustment rings
- Adjusting the cap gap
- Axles in tandem (rear) meritor rr 167 e (r 0878)
SECTION 8 - AXLES
Axles
- Front axle 5876/4 (f 8021) 5876/5 (f 8021) 5886/5 (f9021) steering central added axle 5876/2 (f 8021)
- Description
- Specifications and data
- Fault diagnosis
- Tightening torques
- Tools
- Removing and refitting axle
- Removing and refitting axle
- Vehicle checks
- Checking swivel head play
- Front axle assembly overhaul
- Removing - refitting wheel hubs
- 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
- Checking and measuring the axle body
- Rigid rear added axle 55080/di (n 8071)
- Description
- Characteristics and data
- Tightening torque
- Tools
- Removing-refitting
- Repairs
- Rigid rear added axle 55080/ti (n 8071)
- Description
- Characteristics and data
- Tightening torques
- Tools
- Removing - refitting wheel hubs
- Rigid rear added axle with hydraulic lifting 56082/d1 (n 9171)
- Description
- Characteristics and data
- Tightening torque
- Tools
- Removing-refitting
- Repairs
- Rigid rear added axle with hydraulic lifting 56082/t1 (n 9171)
- Description
- Characteristics and data
- Tightening torque
- Tools
- Removing-refitting
- Repair operations
- Vehicles with mechanical suspension and hydraulic lifting
- Fault diagnosis
- Specifications
- Electro-hydraulic pump
- Lifting cylinders (vehicleswith mechanical suspension)
- Steering rear added axle 57080/di (n 8072)
- Description
- Characteristics and data
- Tightening torques
- Tools
- Repairs
- Pneumatic lift
- General
- Location on the vehicle of the main components of the hydraulic system
- Hydraulic system
- Hydraulic system working diagram
- Vehicles with pneumatic rear suspensions and pneumatic lifting
- Tightening torques (steering and lifting device linkage)
- Characteristics and data
- Main hydraulic system components
- Hydraulic accumulator
- Operator cylinder
- Centring cylinder
- Additional axle pneumatic lifting device removal and refitting
- Air bleeding from the hydraulic circuit
- Steering rear added axle 57080/ti (n 8072)
- Description
- Characteristics and data
- Tightening torques
- Tools
- Repair operations
- Wheel geometry
- General information
- Frontwheel geometry (4x2 vehicles)
- Vehicle wheel geometry with central added axle (6x2 c)
SECTION 9 - SUSPENSIONS
Suspensions
- Suspensions
- Description
- Mechanical front suspension
- Pneumatic front suspension
- Pneumatic rear suspension
- Rear mechanical suspension
- Specifications and data
- Mechanical front suspension assembly drawing
- Rear mechanical suspension assembly
- “cantilever” rear suspension (vehicles 6x2)
- Procedure for assembly of the slipper block and mounting brackets for the longitudinal bars
- Tightening the u-bolts clamping the leaf spring to the central pivot
- Removing the central support
- Removing the central support shaft
- Replacing the bracket
- Replacing the half bearings
- Reassembling the bracket
- Reassembling the central support shaft
- Reassembling the central support
- Front shock absorbers
- Additional axle shock absorbers
- Rear shock absorbers
- Air suspension
- Chassis frame lifting, lowering and self-levelling with remote control
- Saving levels
- Air suspension system diagrams
- Rear air suspension main diagram for 4x2p vehicles
- Working diagram of pneumatic rear suspensions for 4x2t/p tractors
- Suspension diagram for tractors and cabin vehicles 4x2t/fp
- Working diagram of air suspensions for 6x2y/fp/fs-d/fp-d vehicles
- Working diagram of air suspensions for 6x2y/fp/fs-d/fp-d vehicles (without lifting the additional axle)
- Working diagram of air suspensions for 6x2y/fp/fs-cm vehicles
- Working diagram of air suspensions for 6x2y/fp/fs-cm vehicles (without lifting the additional axle)
- Working diagram of rear air suspensions for 6x2y/pt vehicles
- Working diagram of rear air suspensions for 6x2y/pt vehicles (without lifting the additional axle)
- Working diagram of rear air suspensions for 6x2y/ps vehicles
- Working diagram of rear air suspensions for 6x2y/ps vehicles (without lifting the additional axle)
- Working diagram of air suspensions for 6x2tx/p vehicles
- Working diagram of pneumatic rear suspensions for 6x4 tz/p vehicles
- Characteristics and data
- Pneumatic system
- Main components of the pneumatic system
- Controlled pressure valve
- Fault diagnosis
- Level sensor
- Electro-pneumatic control valve
- Load detector pressure sensor
- Low air pressure switch
- Air spring
- Ecas control unit
- Fault diagnosis
- Diagnosis instruments
- Cluster diagnosis
- Tools
- Tightening torques
- Mechanical front suspension
- Pneumatic front suspension
- Pneumatic front suspension with bars
- Central added axle pneumatic suspensions 6x2 c vehicles
- Pneumatic rear suspension 4x2 - 6x2 c vehicles
- Pneumatic rear suspension 6x2 p/pt/ft vehicles
- Pneumatic rear suspension 6x2 p/fp/fs vehicles
- Pneumatic rear suspension 6x2 p/ps vehicles
- Pneumatic rear suspension 6x4 p vehicles
- Removal-refitting of front leaf spring
- Removal
- Refitting
- Removing-refitting front suspension bars
- Removing longitudinal bars
- Removing transverse bar
- Refitting
- Rear suspensions
- Removal
- Refitting
- Removing-refitting the rear axle longitudinal suspension arm
- Removing refitting the rear added axle longitudinal suspension arm
- Removing-refitting the rear axle triangular suspension arm
- Removing-refitting the rear added axle triangular suspension arm
- Removal
- Refitting
- Replacing the suspension arm flexible pin
- Removal
- Refitting
- Stabilizer bar
- Front stabilizer bar
- Central added axle stabilizer bar (6x2 c vehicles)
- Rear stabilizer bar
- Removal
- Refitting
- Rubber bushings
- Replacing front stabilizer bar rubber bushings
- Replacing rear stabilizer bar rubber bushings
- Shock absorbers
- Removal-refitting
- Front axle shock absorbers (6x2 c vehicles)
- Central added axle shock absorbers
- Rear axle shock absorbers
- Rear added axle shock absorbers (6x2 p vehicles)
- Removal
- Refitting
- Chassis frame adjustment
SECTION 10 - WHEELS AND TYRES
Wheels and tyres
- Description
- Characteristics and data
- Tyre inflation pressures
- Tools
- Fault diagnosis
- Static balancing of the wheels
- Correcting residual static imbalance
- Tyre pressure
- How tyre behaviour depends on pressure
SECTION 11 - STEERING
Steering
- Description
- Specifications and data
- Fault diagnosis
- Tightening torques
- Tools
- Removing-refitting the power steering system
- Removal
- Refitting
- Removing-fitting the steering lever
- Steering control
- Removing-refitting the steering control assembly
- Removal
- Refitting
- Changing the pneumatic cylinder
- Removal
- Refitting
- Bleeding the power steering system
- Measuring steering box play at the steering wheel
- Checking the maximum pressure of the power steering system
- Setting the automatic hydraulic steering limit
SECTION 12 - AIR SYSTEM - BRAKES
Air system - brakes
- Symbols for air/hydraulic system circuit diagrams (tanks and accumulators)
- Symbols for air/hydraulic system circuit diagrams (valves)
- Symbols for air-hydraulic system diagrams (tanks and accumulators)
- Symbols for air/hydraulic system circuit diagrams (converters, cylinders and callipers)
- Symbols for air/hydraulic system circuit diagrams (callipers and cylinders)
- Symbols for air/hydraulic system circuit diagrams (semi-couplings and coupling connectors)
- Symbols for air/hydraulic system circuit diagrams (semi-couplings and coupling connectors)
- Symbols for air/hydraulic system circuit diagrams (indicators and switches)
- Symbols for air/hydraulic system circuit diagrams (brakes)
- Pipings and fittings
- In general
- Rigid pipings reflanging
- Rigid pipings bending
- Rigid pipings cutting
- Flexible pipings replacementwith traditional fittings
- Flexible pipings replacement with quick connection fittings
- Ebs (electronic brake system)
- Ebs benefits
- Tractor and trailer compatibility at any time
- Complete fault-diagnosis structures
- Operating logic
- Brake system
- Auxiliary brake integration
- “abs-ebl” system (anti-lock brake system — electronic brake limiter)
- “abs” (anti-lock brake system)
- Ebl (electronic brakes limiter)
- Operating logic
- Ebs working diagram for 4x2 vehicles (tractors)
- Ebs working diagram for 4x2 vehicles (models: at440s.. /fp-ct/fp-lt)
- Ebs working diagram for 6x2 vehicles (tractors)
- Ebs working diagram for 6x2 vehicles (trucks)
- Ebs working diagram for 6x2 vehicles (trucks)
- Abs-ebl working diagram for 4x2 vehicles (trucks and tractors)
- Abs-ebl working diagram for 6x2c vehicles
- Abs-ebl working diagram for 6x4 vehicles
- Abs-ebl working diagram for stand alone 4x2 vehicles (trucks)
- Abs-ebl working diagram for 6x2 vehicles (trucks)
- Abs-ebl working diagram for stand alone 6x2 vehicles (trucks)
- Description
- Service braking
- Emergency braking
- Exhaust brake
- Parking brake
- Brakes
- Disc brakes
- Drum brakes
- Fault diagnosis
- Diagnosis instruments
- Cluster diagnosis
- Tightening torques
- Tools
- Specifications and data - pneumatic system
- Specifications and data - brakes
- Checks on main components of brake system
- Main components of the braking system
- Compressor
- Head locking screw tightness
- Fault diagnosis
- A.p.u. (air processing unit)
- Duplex control valve (vehicles without ebs)
- Duplex control valve with electric transmitter (vehicles with ebs)
- Fault diagnosis (vehicles without ebs)
- Relay valve (vehicles without ebs)
- Proportional relay valve for front axle (vehicles with ebs)
- Fault diagnosis (vehicles without ebs)
- Coupling heads
- Rear axle electro-pneumatic modulator (for vehicles with ebs)
- Fault diagnosis
- Redundancy valve (for 4x2 and 6x2 trucks)
- Abs-ebs solenoid valve
- Dual stop valve
- Triple servo control valve (vehicles without ebs)
- Predominance control
- Fault diagnosis
- Trailer servo control valve (vehicles with ebs)
- Pressure test point valve
- Parking brake hand control valve (vehicles suited to towing)
- Fault diagnosis (parking brake control valve)
- Parking brake control manual distributor (standby vehicles)
- Manual control valve to slow down the trailer (optional extra)
- Fault diagnosis (parking brake control valve)
- Controlled pressure valve
- Fault diagnosis
- Check valve (vehicles suited to towing)
- Low-pressure switch
- Electro-pneumatic valve for asr
- Speed sensor
- Phonic wheels
- Electronic control unit
- Pressure sensor
- Diaphragm brake cylinder (for front and added front axle disc brake)
- Diaphragm brake cylinder (for front and added front axle drum brake)
- Combined brake cylinder (for front and rear disc brake)
- Combined brake cylinder (for front and rear drum brake)
- Combined cylinder emergency brake release device
- Repairs
- Fault diagnosis
- Disc brakes knorr type (caliper sn7)
- Operation (see previous figure)
- Checks
- Checking the automatic play recovery system efficiency
- Brake caliper components
- Check of braking seals thickness
- Overhauling front disc brakes
- Replacing brake linings
- Removing and refitting brake callipers
- Removal
- Refitting
- Removing and refitting wheel hubs
- Removal
- Refitting
- Brake caliper overhaul
- Disassembly
- Component part cleaning and check
- Assembly
- Overhauling rear disc brakes
- Replacing brake linings
- Overhauling brake discs
- Turning and grinding brake discs
- Drum brakes
- Overhauling the drum brakes
- Removing the rear drum brakes
- Turning drums
- Replacing brake linings
- Assembly
SECTION 13 - BODYWORK - CHASSIS FRAME
Bodywork - chassis frame
- Cab
- General information
- Cab tilting
- Cab mechanic suspension
- Cab driving position adjustment
- Cab pneumatic suspension
- Adjusting the levelling valve linkage
- Cab air-conditioning
- General
- Ventilation
- Description
- Air-conditioning and heating
- Description
- Air-conditioning
- Air-conditioning controls assembly
- Manual
- Heating and ventilation
- Heating
- Component layout (webasto air conditioner)
- Heater assembly component layout (webasto)
- Outside temperature sensor
- Compressor
- Condenser and safety pressure switches
- Geared motors
- Evaporator temperature sensor
- Expansion valve
- Procedure for emptying and refilling the air-conditioning systems with r134a refrigerant
- R134a refrigerant recovery and refilling station (99305146)
- Safety standards
- Control fascia
- Operation flow chart
- Recovering refrigerant from the vehicle system
- Creating a vacuum in the system
- Restoring oil in the system
- Filling the system with refrigerant
- Checking the pressures in the system
- Operations prior to disconnecting the station from the system
- Leak finder for air-conditioning systems with hfc r134a (9905147)
- Repair operations
- Heater
- Removal
- Refitting
- Additional air heater system
- Removal
- Refitting
- Defrost control motor
- Removal
- Refitting
- Air recirculation door control motor
- Removal
- Refitting
- Electric fan
- Removal
- Refitting
- Heater radiator
- Removal
- Refitting
- Pollen filter
- Removal
- Refitting
- Air-conditioner compressor
- Removal
- Refitting
- Air-conditioner condenser
- Removal
- Refitting
- Outside air temperature sensor
- Removal
- Refitting
SECTION 14 - SCHEDULED MAINTENANCE
Scheduled maintenance
- Vehicle with motor cursor 8 (f2b)
- Maintenance
- Maintenance services chart
- Checks and/or maintenancework
- Off-plane operations
- Maintenance work
- M1 service
- M2 service
- M3 service
- M4 service
- Ep1 service
- T1 service
- T2 service
- T3 service
- T4 service
- T5 service
- T6 service
- Vehicle with motor cursor 10 (f3a)
- Maintenance

AND MORE....