Iveco Stralis at Ad Repair Manual
Iveco Stralis at Ad Repair Manual
Iveco Stralis at Ad Repair Manual
STRALIS AT/AD
REPAIR MANUAL
MECHANICAL
ELECTRIC
ELECTRONIC
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STRALIS AT/AD
REPAIR MANUAL
This publication describes the characteristics, the data, the
correct methodology of the repairs that can be made on each
individual component of the vehicle.
By complying with the instructions supplied and using the
specific tools it is possible to perform any repair intervention
correctly, within the specified time frames, while protecting the
technicians against incidents.
Before starting any repair work, make sure that all accident
prevention devices are ready at hand.
Check and wear the protective personal equipment provided
for by the safety standards: goggles, helmet, gloves, shoes.
Check the efficiency of all processing, lifting and transport tools
before using them.
Produced by:
Example
Furthermore, within each section, every heading or sub-heading concerning the operations to be carried out is preceded by a six
digit number. This number is the Product Code that is to be found in the repair operation described in the REPAIR TIMES CHARTS
and in the FAULT CODES.
For quick reference the indication of how to read this code is described below (see the Repair time charts also).
Product Code: 5 0
PRODUCT UNIT SUB-ASSEMBLY
COMPONENT
Example:
Product 50 = Frame;
Product 52 = Axles;
Product 53 = Gears etc.
Unit Code: 0 1
PRODUCT UNIT SUB-ASSEMBLY
COMPONENT
Figures three and four identify the ASSEMBLY within the PRODUCT
Example:
Product 50 = Frame;
Unit 01 = Chassis;
Unit 02 = Bumpers etc .
Sub-assembly Code: 4 0
PRODUCT UNIT SUB-ASSEMBLY
COMPONENT
Example:
Product 50 = Frame;
Unit 01 = Chassis;
Sub-assembly 40 = Chassis cross members etc.
Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fitting in place
Assembly ρ Compression ratio
Tolerance
Tighten to torque
Weight difference
Replacement
Press or caulk
Original spare parts
Regulation
Rotation
Adjustment
Warning Angle
! Note Angular value
Visual inspection
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Oversized
Interference
Higher than….
Strained assembly
Maximum, peak
Undersized
Thickness
Less than….
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0°
Sealant
Cold
Adhesive
Winter
Temperature > 0°
Air bleeding Hot
Summer
STRALIS AT/AD
UPDATE DATA
Section
General information 1
Engine 2
Clutch 3
Gearbox 4
Hydraulic retarder 5
Propeller shafts 6
Rear axles 7
Front axle 8
Steering system 11
Maintenance 14
SECTION 1
General
Page
COMPOSITION OF MODELS . . . . . . . . . . . . . . 5
REPLENISHING FLUIDS . . . . . . . . . . . . . . . . . . . 13
Print 603.43.671
Manufacturer’s
plate
To identify the vehicle in accordance with the
E.E.C. directive
(under the front radiator cowling).
l) absorption
value
o) No. of axles.
Engine type Engine power KW
p) Place of manufacture. m) n)
Made in
p)
9843 8247
COMPOSITION OF MODELS
CHASSIS CABS - 4x2 MODELS
AT 190 S 40/FP-CT
AT 190 S 43/FP-CT
AD 190 S 27/FP-D
AD 190 S 31/FP-D
AD 190 S 35/FP-D
AD 190 S 40/FP-D
AD 190 S 43/FP-D
T = 4x2 tractor
AT 190 S 27/FP-D
AT 190 S 31/FP-D
AT 190 S 35/FP-D
AT 190 S 40/FP-D
AT 190 S 43/FP-D
AD 190 S 27/P
AD 190 S 30/P
AD 190 S 31/P
AD 190 S 35/P
AD 190 S 40/P
AD 190 S 43/P
AT 190 S 27/P
AT 190 S 31/P
AT 190 S 35/P
AT 190 S 40/P
AT 190 S 43/P
TX = 6x2 C tractor (central added axle cannot
AT 190 S S31
AD 190 S 27
AD 190 S 30
AD 190 S 31
AD 190 S 35
AD 190 S 40
AD 190 S 43
AT 190 S 27
AT 190 S 35
AT 190 S 40
AT 190 S 43
be lifted)
TY = 6x2 P tractor (rear added axle can be
lifted)
ASSEMBLIES TN = 6x2 vehicles with mechanical rear
f f f f f f suspensions and raisable rigid rear added
F2BE0681F (270 CV)
axle
F2BE0681E (300 CV) f f
TZ = 6x4 tractor (bogie rear axle)
F2BE0681B (310 CV) f f f f f f
P = 4x2 — 6x2P — 6x2C vehicles with air
F2BE0681A (350 CV) f f f f f f suspension on rear axle and 6x2P vehicles
F3AE0681B (400 CV) f f f f f f f with rigid rear axle that can be lifted with
F3AE0681D (430 CV) f f f f f f f single wheels
PT = 6x2P vehicles with air suspension on rear
Single disc 16” f f f f f f f f f f f f f f f f f f f f axle and rigid rear added axle that can be
lifted with twin wheels
Single disc 17” f f f f f f f f f f f f f f
PS = 6x2P vehicles with air suspension on rear
ZF 9 S 109 D.D. f f f f f f f f f f f f axle and on steering rear added axle that
can be lifted with single wheels
ZF 16 S 151 D.D. f f f f f f
FP = 4x2 — 6x4 — 6x2P — 6x2C vehicles with
ZF 16 S 181 O.D. front and rear air suspensions
ZF 16 S 181 D.D. f f f f f f f f f f f f f f
FS = 6x2P vehicles with front and rear air
ZF 16 S 221 O.D. suspensions, steering rear added axle can
EuroTronic Automated 12 AS 2301 O.D. be lifted with single wheels
EuroTronic Automated 12 AS 2301 D.D. f f f f f f f f f f f f f f f f f f f f f f 4x2 = Vehicles with two axles with rear driving
Allison MD 3060 P - MD 3066 P f f f f axle
FRONT AXLE: 5876/4 (F 8021) ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ 6x2P = Vehicles with three axles with rear driving
axle and rear added third axle that can be
5876/5 (F 8021) F F F F F F F F F F F F F F F F F F F F F F F F lifted
5886/5 (F 9021) f f f f f f f f f f 6x2C = Vehicles with three axles with rear driving
ADDED AXLE: axle and central added third axle that
Steering central 5876/4 (F 8021) cannot be lifted
Rigid rear 55080/D1 (N 8071) * 6x4 = Vehicles with three axles with two rear
Rigid rear 56082/D1 (N 9171) * driving axles (in tandem)
Steering rear 57080/D1 (N 8072) * CM = Movable Boxes
MERITOR MS 13-175/T - MS 13-175/D f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f LT = Tractor with lowered chassis frame
MERITOR RT 160/1 CT = Chassis cab with lowered chassis frame
451391 HR RR = Rough Roads
D = Distribution
ZF 8098 f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f
HR = Hub Reduction
AT = Active Time
FRONT MECHANICAL Front j j j j j j j j j j j j j f j j j j j j j j
AD = Active Day
Rear j j j j j j j j j j j
PNEUMATIC Front f f f f f f f f f f f f
Rear f f f f f f f f f f f f f f f f f f f f f f f
Added axle
⊗ = With brake calliper assembly at 57° without parking brake j = With parabolic leaf springs
F = With brake calliper assembly at 0° with parking brake * = TI with drum brakes
Z = With longitudinal and transversal bars
COMPOSITION OF MODELS
CHASSIS CABS - 6x2 P MODELS
T = 4x2 tractor
AD 260 S 35Y/FP-D
AD 260 S 31Y/FP-D
AD 260 S 31Y/FS-D
AD 260 S 35Y/FS-D
AD 260 S 27Y/FS-D
AT 260 S 31Y/FP-D
AT 260 S 35Y/FP-D
AD 260 S 27Y/FP-D
AT 260 S 27Y/FS-D
AT 260 S 30Y/FS-D
AT 260 S 31Y/FS-D
AT 260 S 35Y/FS-D
AT 260 S 27Y/FP-D
AD 260 S 27Y/TN
AD 260 S 31Y/TN
AD 260 S 35Y/TN
AT 260 S 27Y/TN
AT 260 S 31Y/TN
AT 260 S 35Y/TN
AD 260 S 27Y/PT
AD 260 S 31Y/PT
AD 260 S 35Y/PT
AT 260 S 31Y/PT
AT 260 S 27Y/PT
AT 260 S 35Y/PT
AD 260 S 31Y/PS
AD 260 S 35Y/PS
TX = 6x2 C tractor (central added axle cannot
AD 260 S 27Y/PS
AD 260 S 30Y/PS
AT 260 S 27Y/PS
AT 260 S 31Y/PS
AT 260 S 35Y/PS
AT 260 S 30Y/PS
AD 260 S 31Y/P
AD 260 S 35Y/P
AD 260 S 27Y/P
AT 260 S 35Y/P
AT 260 S 27Y/P
AT 260 S 31Y/P
be lifted)
TY = 6x2 P tractor (rear added axle can be lifted)
TN = 6x2 vehicles with mechanical rear
suspensions and raisable rigid rear added
ASSEMBLIES axle
F2BE0681F (270 CV) f f f f f f f f f f f f TZ = 6x4 tractor (bogie rear axle)
F2AE0681E (300 CV) f f f P = 4x2 — 6x2P — 6x2C vehicles with air
F2BE0681B (310 CV) f f f f f f f f f f f f suspension on rear axle and 6x2P vehicles
F2BE0681A (350 CV) f f f f f f f f f f f f with rigid rear axle that can be lifted with
single wheels
F3AE0681B (400 CV)
F3AE0681D (430 CV) PT = 6x2P vehicles with air suspension on rear
axle and rigid rear added axle that can be
Single disc 16” f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f lifted with twin wheels
PS = 6x2P vehicles with air suspension on rear
Single disc 17” axle and on steering rear added axle that
can be lifted with single wheels
ZF 9S 109 D.D. f f f f f f f f f f f f f f f f f f f f f f f f f
FP = 4x2 — 6x4 — 6x2P — 6x2C vehicles with
ZF 16S 151 O.D. f f f f f f f f f f f f front and rear air suspensions
ZF 16S 181 O.D. FS = 6x2P vehicles with front and rear air
ZF 16S 181 D.D. suspensions, steering rear added axle can
ZF 16S 221 D.D. be lifted with single wheels
EuroTronic Automated 12 AS 2301 D.D. 4x2 = Vehicles with two axles with rear driving
EuroTronic Automated 12 AS 2301 O.D. f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f axle
Allison MD 3060 P - MD 3066 P f f f f f f f f f f f 6x2P = Vehicles with three axles with rear driving
axle and rear added third axle that can be
FRONT AXLE: 5876/4 (F 8021) ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗
lifted
5876/5 (F 8021) F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F F
6x2C = Vehicles with three axles with rear driving
5886/5 (F 9021) f f f f f f f f axle and central added third axle that
cannot be lifted
ADDED AXLE:
Steering central 5876/2 (F 8021) 6x4 = Vehicles with three axles with two rear
driving axles (in tandem)
Rigid rear 55080/D1 (N 8071) * f f f f f f f f f f f f
CM = Movable Boxes
Rigid rear 56082/D1 (N 9171) * f f f f f f f f f f f f
HM = Heavy Mission
Steering rear 57080/D1 (N 8072) * f f f f f f f f f f f f f f f
LT = Tractor with lowered chassis frame
MERITOR MS 13-175/T - MS 13-175/D f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f f
CT = Chassis cab with lowered chassis frame
MERITOR RT 160/1
RR = Rough Roads
451391 HR
D = Distribution
COMPOSITION OF MODELS
CHASSIS CABS - 6x2 P MODELS
AD 260 S 43Y/FS-CM
AD 260 S 40Y/FS-CM
AT 260 S 43Y/FS-CM
T = 4x2 tractor
AT 260 S 40Y/FS-CM
AD 260 S 43Y/FP-D
AD 260 S 43Y/FS-D
AD 260 S 40Y/FS-D
AT 260 S 43Y/FP-D
AD 260 S 40Y/FP-D
AT 260 S 40Y/FS-D
AT 260 S 43Y/FS-D
AT 260 S 40Y/FP-D
AD 260 S 40Y/TN
AD 260 S 43Y/TN
AT 260 S 40Y/TN
AT 260 S 43Y/TN
AD 260 S 40Y/PT
AD 260 S 43Y/PT
AT 260 S 40Y/PT
AT 260 S 43Y/PT
AD 260 S 43Y/PS
TX = 6x2 C tractor (central added axle cannot
AD 260 S 40Y/PS
AT 260 S 40Y/PS
AT 260 S 43Y/PS
AD 260 S 43Y/P
AD 260 S 40Y/P
AT 260 S 40Y/P
AT 260 S 43Y/P
be lifted)
TY = 6x2 P tractor (rear added axle can be lifted)
TN = 6x2 vehicles with mechanical rear
suspensions and raisable rigid rear added
ASSEMBLIES axle
F2BE0681F (270 CV) TZ = 6x4 tractor (bogie rear axle)
F2AE0681E (300 CV) P = 4x2 — 6x2P — 6x2C vehicles with air
F2BE0681B (310 CV) suspension on rear axle and 6x2P vehicles
F2BE0681A (350 CV) with rigid rear axle that can be lifted with
single wheels
F3AE0681B (400 CV) f f f f f f f f f f f f f f
F3AE0681D (430 CV) f f f f f f f f f f f f f f PT = 6x2P vehicles with air suspension on rear
axle and rigid rear added axle that can be
Single disc 16” lifted with twin wheels
PS = 6x2P vehicles with air suspension on rear
Single disc 17” f f f f f f f f f f f f f f f f f f f f f f f f f f f f axle and on steering rear added axle that
can be lifted with single wheels
ZF 9S 109 D.D.
FP = 4x2 — 6x4 — 6x2P — 6x2C vehicles with
ZF 16S 151 O.D. front and rear air suspensions
ZF 16S 181 O.D. FS = 6x2P vehicles with front and rear air
ZF 16S 181 D.D. f f f f f f f f f f f f f f f f f f f f f f f f f f f f suspensions, steering rear added axle can
ZF 16S 221 D.D. be lifted with single wheels
EuroTronic Automated 12 AS 2301 D.D. 4x2 = Vehicles with two axles with rear driving
EuroTronic Automated 12 AS 2301 O.D. f f f f f f f f f f f f f f f f f f f f f f f f axle
Allison MD 3060 P - MD 3066 P 6x2P = Vehicles with three axles with rear driving
axle and rear added third axle that can be
FRONT AXLE: 5876/4 (F 8021) ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗
lifted
5876/5 (F 8021) F F F F F F F F F F F F F F F F F F F F F F
6x2C = Vehicles with three axles with rear driving
5886/5 (F 9021) f f f f f f axle and central added third axle that
cannot be lifted
ADDED AXLE:
Steering central 5876/4 (F 8021) 6x4 = Vehicles with three axles with two rear
driving axles (in tandem)
Rigid rear 55080/D1 (N 8071) * f f f f f f
CM = Movable Boxes
Rigid rear 56082/D1 (N 9171) * f f f f f f f f
LT = Tractor with lowered chassis frame
Steering rear 57080/D1 (N 8072) * f f f f f f f f f f f f f f
CT = Chassis cab with lowered chassis frame
MERITOR MS 13-175/T - MS 13-175/D f f f f f f f f f f f f f f f f f f f f f f
RR = Rough Roads
MERITOR RT 160/1
D = Distribution
451391 HR
HR = Hub Reduction
COMPOSITION OF MODELS
TRACTORS - MODELS 4x2 6x2 C 6x4
T = 4x2 tractor
AT 440 S 40T/FP-CT
AT 440 S 43T/FP-CT
AD 440 S 40T/P-HR
AD 440 S 43T/P-HR
AT 440 S 40T/FP-LT
AT 440 S 43T/FP-LT
TX = 6x2 C tractor (central added axle cannot
AD 440 S 43T/P-RR
AT 440 S 43T/P-HR
AD 440 S 35T/P-HR
AD 440 S 40T/P-RR
AT 440 S 35T/P-HR
AT 440 S 43T/P-RR
AT 440 S 40T/P-HR
AT 440 S 40T/P-RR
AD 440 S 40TX/P
AD 440 S 43TX/P
AT 440 S 40TX/P
AT 440 S 43TZ/P
be lifted)
AT 440 S 43TXP
AD 440 S 43T/P
AD 440 S 31T/P
AD 440 S 35T/P
AD 440 S 40T/P
AT 440 S 35T/P
AT 440 S 40T/P
AT 440 S 43T/P
AT 440 S 31T/P
TY = 6x2 P tractor (rear added axle can be lifted)
TN = 6x2 vehicles with mechanical rear
suspensions and raisable rigid rear added
axle
ASSEMBLIES
TZ = 6x4 tractor (bogie rear axle)
F2BE0681F (270 CV)
F2AE0681E (300 CV) P = 4x2 — 6x2P — 6x2C vehicles with air
F2BE0681B (310 CV) f f suspension on rear axle and 6x2P vehicles
with rigid rear axle that can be lifted with
F2BE0681A (350 CV) f f f f single wheels
F3AE0681B (400 CV) f f f f f f f f f f
F3AE0681D (430 CV) f f f f f f f f f f f PT = 6x2P vehicles with air suspension on rear
axle and rigid rear added axle that can be
Single disc 16” lifted with twin wheels
PS = 6x2P vehicles with air suspension on rear
Single disc 17” f f f f f f f f f f f f f f f f f f f f f f f f f f f axle and on steering rear added axle that
can be lifted with single wheels
ZF 9S 109 D.D.
ZF 16S 151 O.D. f f f f f f FP = 4x2 — 6x4 — 6x2P — 6x2C vehicles with
ZF 16S 181 O.D. f f f f f f f f front and rear air suspensions
ZF 16S 181 D.D. f f f f f f f f f f f f FS = 6x2P vehicles with front and rear air
ZF 16S 221 D.D. f suspensions, steering rear added axle can
EuroTronic Automated 12 AS 2301 D.D. f f f f be lifted with single wheels
EuroTronic Automated 12 AS 2301 O.D. f f f f f f f f f f f f f f f f f f f f 4x2 = Vehicles with two axles with rear driving
Allison MD 3060 P - MD 3066 P axle
FRONT AXLE: 5876/4 (F 8021) ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ ⊗ 6x2P = Vehicles with three axles with rear driving
5876/5 (F 8021) F F F F F F F F F F F F F F F F F F F F F F F F F F F axle and rear added third axle that can be
lifted
5886/5 (F 9021)
6x2C = Vehicles with three axles with rear driving
ADDED AXLE: axle and central added third axle that
Steering central 5876/4 (F 8021) f f f f cannot be lifted
Rigid rear 55080/D1 (N 8071) * 6x4 = Vehicles with three axles with two rear
driving axles (in tandem)
Rigid rear 56082/D1 (N 9171) *
CM = Movable Boxes
Steering rear 57080/D1 (N 8072) *
HM = Heavy Mission
MERITOR MS 13-175/T - MS 13-175/D f f f f f f f f f f f f f f f f f f f f f f
LT = Tractor with lowered chassis frame
MERITOR RT 160/1 f
451391 HR f f f f CT = Chassis cab with lowered chassis frame
RR = Rough Roads
ZF 8098 f f f f f f f f f f f f f f f f f f f f f f f f f f f D = Distribution
AT = Active Time
FRONT MECHANICAL Front j j j j j j j j j j j j j j j j j j j j j j j AD = Active Day
Rear j
PNEUMATIC Front f f f f
Rear f f f f f f f f f f f f f f f f f f f f f f f f f f f
Added axle
⊗ = With brake calliper assembly at 57° without parking brake j = With parabolic leaf springs
F = With brake calliper assembly at 0° with parking brake * = TI with drum brakes
Z = With longitudinal and transversal bars
CAB LIVEABILITY
A A A B B C C D
A A A B B C C D
C = 4x2; 18-20 ton.
E = 6x2C; 26 ton.
F = 6x2P; 26 ton.
G = 6x2P; 26 ton.
H = 4x2T; 19-20 ton.
J = 6x2C; 26 ton.
K = 6x4; 26 ton.
L = 4x2P; 19-20 ton.
M = 6x2P; 26 ton.
N = 6x2P; 26 ton.
ENGINE
A A A B B C C D
H E 270
L E 400
K E 430
P E 310
Q E 300
R E 352
A A A B B C C D
A Mechanical - SR - TWIN
B Pneumatic - SR - CENT/SING/TWIN
C - SR - CENT/SING
F - SR - STER
G (*) - SR - SING
H (*) - SR - STER
A A A B B C C D
2 = Tractor - STD
H = Tractor - GRAV
T = LOW TR - STD
WHEELBASE
A A A B B C C D
T6x4 3200 2
6x2P T 4x2
3805 3800 3
C 4x2 C 6x2C
C 4x2
C 6x2C 4200 4
6x2P
C 4x2
C 6x 2 4500 5
6 x 2P
C 4x2
6x2P
4800 6
C 4x2
6x2P
5100 7
C 4x2 8
5700
6x2P
C4x2 5500 L
C4x2 6300 M
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