IVECO STRALIS AT, STRALIS AD REPAIR MANUAL

Name: IVECO STRALIS AT
Brand: IVECO
SKU: 16368129
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STRALIS AT/AD

REPAIR MANUAL

MECHANICAL

ELECTRIC

ELECTRONIC

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.

The data contained in this publication might fail to reflect the latest changes which the Manufacturer may introduce at any time, for technical or sales purposes, or to meet the requirements of local legislation.

Copy, even partial, of text and drawings is forbidden.

Publication Edited by: IVECO S.p.A.

T.C.O. - B.U. Customer Service Lungo Stura Lazio, 15/19 10156 Torino (Italy)

Printed 603.93.141 - 1st Ed. 2003

Produced by:

B.U. TECHNICAL PUBLISHING

C.so Svizzera, 185

10149 Torino (Italy)

SPECIAL REMARKS

The workshop manuals for mechanical parts have been divided into Sections, each of which has a number and its relevant contents are indicated in the General Specifications. Each section features a main Unit (e.g. engine, gears etc.).

The subjects usually dealt with in each section are:

Technical data table, Driving torques, Equipment, Diagnostic, Removal and Fitting in place, Repair operations. Where possible, the same sequence of procedures has been followed for easy reference.

Diagrams and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with, (see next page) instead of giving descriptions of some operations or procedures.

Example

1	Ø 1	= housing for connecting rod small end bush
1
				Tighten to torque
	Ø 2	= housing for connecting rod bearings	α	Tighten to torque +
2	Ø 2	= housing for connecting rod bearings	α	angular value
2

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.

Print 603.93.141

Base - January 2003

Graphs and symbols

Removal

Disconnection

Refitting

Connection

Removal

Disassembly

Fitting in place

Assembly

Tighten to torque

Tighten to torque + angle value

Press or caulk

Regulation

Adjustment

Warning

!Note

Visual inspection Fitting position check

Measurement

Value to find

Check

Equipment

Surface for machining

Machine finish

Interference

Strained assembly

Thickness

Clearance

Lubrication

Damp

Grease

Sealant

Adhesive

Air bleeding

Intake

Exhaust

Operation

ρCompression ratio

Tolerance

Weight difference

Rolling torque

Replacement

Original spare parts

Rotation

Angle

Angular value

Preload

Number of revolutions

Temperature

Pressure

bar

Oversized

Higher than….

Maximum, peak

Undersized

Less than….

Minimum

Selection

Classes

Oversizing

Temperature < 0°

Cold

Winter

Temperature > 0°

Hot

Summer

Base - January 2003

Print 603.93.141

STRALIS AT/AD

Print 603.93.141 — 1st edition

Base — January 2003

UPDATE DATA

Section	Description	Page	Revision date

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Print 603.93.141

INDEX OF SECTIONS

	Section
General information	1

Engine	2

Clutch	3

Gearbox	4

Hydraulic retarder	5

Propeller shafts	6

Rear axles	7

Front axle	8

Front and rear suspensions	9

Wheels and tyres	10

Steering system	11

Pneumatic system - brakes	12

Bodywork and chassis frame	13

Maintenance	14

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STRALIS AT/AD	GENERAL	1

SECTION 1
General
	Page
VEHICLE IDENTIFICATION DATA . . . . . . . . . .	3
- Vehicle identification plate . . . . . . . . . . . . . . . .	4
- Production identification plate . . . . . . . . . . . . .	4
COMPOSITION OF MODELS . . . . . . . . . . . . . .	5
P.I.C. NUMBER CODING . . . . . . . . . . . . . . . . . .	9
REPLENISHING FLUIDS . . . . . . . . . . . . . . . . . . .	13

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2	GENERAL	STRALIS AT/AD

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IVECO STRALIS AT, STRALIS AD REPAIR MANUAL

STRALIS AT/AD	GENERAL	3

VEHICLE IDENTIFICATION DATA

The type and number of engine, type and number of chassis and manufacturer’s plate comprise the vehicle identification data.

Manufacturer’s

plate

To identify the vehicle in accordance with the E.E.C. directive

(under the front radiator cowling).

Chassis frame

Punching (front on right side member of chassis frame).

Engine

Plate on the left rear side of the crankcase

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4	GENERAL	STRALIS AT/AD

Vehicle Identification Plate

Plate legend

a)Type-approval number marking (if applicable).

b)Vehicle identification code number (V.I.N.).

c)Total tractor weight.

d)Total weight of tractor + trailer (if applicable).

e)Permissible weight limit on 1st axle.

f)Permissible weight limit on 2nd axle (if applicable).

g)Permissible weight limit on 3rd axle.

h)Permissible weight limit on 4th axle (if applicable).

i)Specific identification of type.

l)Wheelbase in mm.

m)Engine type.

n)Engine power.

o)No. of axles.

p)Place of manufacture.

Production identification plate

This plate shows the P.I.C. (production identification code number), which is needed when referring to the spare parts catalogue (electronic and/or microfiche catalogue). The P.I.C. is also given on the vehicle warranty card.

Note: When consulting the catalogues, use only the first 8 digits of the product identification code number.

	IVECO MAGIRUS AG
a)
b)
c)		Kg
d)		Kg
e)	1-	Kg
f)	2-	Kg
g)	3-	Kg
h)	4-	Kg
i)	Type	No of axles
i)		o)
		o)
l)	Wheelbase	Corrected
l)		absorption
		value
m) Engine type		Engine power KW
		n)
	Made in
p)
	Unit No	Permissible
	Unit No	grade of
	Part No	smoke
	Part No

Serial No

P.I.C. No

Made in Germany-Iveco Magirus AG

9843 8247

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STRALIS AT/AD GENERAL 5

COMPOSITION OF MODELS

CHASSIS CABS - 4x2 MODELS

<![if ! IE]>

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<![if ! IE]>

<![endif]>27/FP-D

<![if ! IE]>

<![endif]>31/FP-D

<![if ! IE]>

<![endif]>31/FP-D

<![if ! IE]>

<![endif]>35/FP-D

<![if ! IE]>

<![endif]>35/FP-D

<![if ! IE]>

<![endif]>40/FP-D

<![if ! IE]>

<![endif]>40/FP-D

<![if ! IE]>

<![endif]>40/FP-CT

<![if ! IE]>

<![endif]>43/FP-D

<![if ! IE]>

<![endif]>43/FP-D

<![if ! IE]>

<![endif]>43/FP-CT

<![if ! IE]>

<![endif]>27

<![if ! IE]>

<![endif]>27

<![if ! IE]>

<![endif]>27/P

<![if ! IE]>

<![endif]>27/P

<![if ! IE]>

<![endif]>30

<![if ! IE]>

<![endif]>30/P

<![if ! IE]>

<![endif]>31

<![if ! IE]>

<![endif]>S31

<![if ! IE]>

<![endif]>31/P

<![if ! IE]>

<![endif]>31/P

<![if ! IE]>

<![endif]>35

<![if ! IE]>

<![endif]>35

<![if ! IE]>

<![endif]>35/P

<![if ! IE]>

<![endif]>35/P

<![if ! IE]>

<![endif]>40

<![if ! IE]>

<![endif]>40

<![if ! IE]>

<![endif]>40/P

<![if ! IE]>

<![endif]>40/P

<![if ! IE]>

<![endif]>43

<![if ! IE]>

<![endif]>43

<![if ! IE]>

<![endif]>43/P

<![if ! IE]>

<![endif]>43/P

ASSEMBLIES

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

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<![if ! IE]>

<![endif]>AT 190 S

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<![endif]>AD 190 S

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<![endif]>AT 190 S

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<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AD 190 S

<![if ! IE]>

<![endif]>AT 190 S

<![if ! IE]>

<![endif]>AT 190 S

F2BE0681F (270 CV)

F2BE0681E (300 CV)

F2BE0681B (310 CV)

F2BE0681A (350 CV)

F3AE0681B (400 CV)

F3AE0681D (430 CV)

Single disc 16”

Single disc 17”

ZF 9 S 109 D.D.

ZF 16 S 151 D.D.

ZF 16 S 181 O.D.

ZF 16 S 181 D.D.

ZF 16 S 221 O.D.

EuroTronic Automated 12 AS 2301 O.D.

EuroTronic Automated 12 AS 2301 D.D.

Allison MD 3060 P - MD 3066 P

FRONT AXLE:

5876/4 (F 8021)

5876/5 (F 8021)

5886/5 (F 9021)

ADDED AXLE:

Steering central

5876/4 (F 8021)

Rigid rear

55080/D1 (N 8071) *

Rigid rear

56082/D1 (N 9171) *

Steering rear

57080/D1 (N 8072) *

MERITOR MS 13-175/T - MS 13-175/D

MERITOR RT 160/1

451391 HR

ZF 8098

FRONT MECHANICAL

Front

Rear

PNEUMATIC

Front

Rear

Added axle

= With brake calliper assembly at 57° without parking brake

= With parabolic leaf springs

= With brake calliper assembly at 0° with parking brake

= TI with drum brakes

= With longitudinal and transversal bars

T	= 4x2 tractor
TX	= 6x2 C tractor (central added axle cannot
	be lifted)
TY	= 6x2	P tractor (rear added axle can be
	lifted)
TN	= 6x2	vehicles with mechanical rear
	suspensions and raisable rigid rear added
	axle
TZ	= 6x4 tractor (bogie rear axle)

P= 4x2 — 6x2P — 6x2C vehicles with air suspension on rear axle and 6x2P vehicles with rigid rear axle that can be lifted with single wheels

PT	=	6x2P vehicles with air suspension on rear
		axle and rigid rear added axle that can be
		lifted with twin wheels
PS	=	6x2P vehicles with air suspension on rear
		axle and on steering rear added axle that
		can be lifted with single wheels
FP	= 4x2 — 6x4 — 6x2P — 6x2C vehicles with
		front and rear air suspensions
FS	= 6x2P vehicles with front and rear air
		suspensions, steering rear added axle can
		be lifted with single wheels
4x2	=	Vehicles with two axles with rear driving
		axle
6x2P	= Vehicles with three axles with rear driving
		axle and rear added third axle that can be
		lifted
6x2C	= Vehicles with three axles with rear driving
		axle and central added third axle that
		cannot be lifted
6x4	=	Vehicles with three axles with two rear
		driving axles (in tandem)
CM	= Movable Boxes
LT	=	Tractor with lowered chassis frame
CT	= Chassis cab with lowered chassis frame
RR	= Rough Roads
D	=	Distribution
HR	= Hub Reduction
AT	= Active Time
AD	= Active Day

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6 GENERAL STRALIS AT/AD

COMPOSITION OF MODELS

CHASSIS CABS - 6x2 P MODELS

ASSEMBLIES

<![if ! IE]>

<![endif]>AD 260 S 27Y/P

<![if ! IE]>

<![endif]>AT 260 S 27Y/P

<![if ! IE]>

<![endif]>AD 260 S 27Y/PS

<![if ! IE]>

<![endif]>AT 260 S 27Y/PS

<![if ! IE]>

<![endif]>AD 260 S 27Y/FP-D

<![if ! IE]>

<![endif]>AT 260 S 27Y/FP-D

<![if ! IE]>

<![endif]>AD 260 S 27Y/FS-D

<![if ! IE]>

<![endif]>AT 260 S 27Y/FS-D

<![if ! IE]>

<![endif]>AD 260 S 30Y/PS

<![if ! IE]>

<![endif]>AT 260 S 30Y/PS

<![if ! IE]>

<![endif]>AT 260 S 30Y/FS-D

<![if ! IE]>

<![endif]>AD 260 S 31Y/P

<![if ! IE]>

<![endif]>AT 260 S 31Y/P

<![if ! IE]>

<![endif]>AD 260 S 31Y/PS

<![if ! IE]>

<![endif]>AT 260 S 31Y/PS

<![if ! IE]>

<![endif]>AD 260 S 31Y/FP-D

<![if ! IE]>

<![endif]>AT 260 S 31Y/FP-D

<![if ! IE]>

<![endif]>AD 260 S 31Y/FS-D

<![if ! IE]>

<![endif]>AT 260 S 31Y/FS-D

<![if ! IE]>

<![endif]>AD 260 S 35Y/P

<![if ! IE]>

<![endif]>AT 260 S 35Y/P

<![if ! IE]>

<![endif]>AD 260 S 35Y/PS

<![if ! IE]>

<![endif]>AT 260 S 35Y/PS

<![if ! IE]>

<![endif]>AD 260 S 35Y/FP-D

<![if ! IE]>

<![endif]>AT 260 S 35Y/FP-D

<![if ! IE]>

<![endif]>AD 260 S 35Y/FS-D

<![if ! IE]>

<![endif]>AT 260 S 35Y/FS-D

<![if ! IE]>

<![endif]>AD 260 S 27Y/PT

<![if ! IE]>

<![endif]>AT 260 S 27Y/PT

<![if ! IE]>

<![endif]>AD 260 S 27Y/TN

<![if ! IE]>

<![endif]>AT 260 S 27Y/TN

<![if ! IE]>

<![endif]>AD 260 S 31Y/PT

<![if ! IE]>

<![endif]>AT 260 S 31Y/PT

<![if ! IE]>

<![endif]>AD 260 S 31Y/TN

<![if ! IE]>

<![endif]>AT 260 S 31Y/TN

<![if ! IE]>

<![endif]>AD 260 S 35Y/PT

<![if ! IE]>

<![endif]>AT 260 S 35Y/PT

<![if ! IE]>

<![endif]>AD 260 S 35Y/TN

<![if ! IE]>

<![endif]>AT 260 S 35Y/TN

F2BE0681F (270 CV)

F2AE0681E (300 CV)

F2BE0681B (310 CV)

F2BE0681A (350 CV)

F3AE0681B (400 CV)

F3AE0681D (430 CV)

Single disc 16”

Single disc 17”

ZF 9S 109 D.D.

ZF 16S 151 O.D.

ZF 16S 181 O.D.

ZF 16S 181 D.D.

ZF 16S 221 D.D.

EuroTronic Automated 12 AS 2301 D.D.

EuroTronic Automated 12 AS 2301 O.D.

Allison MD 3060 P - MD 3066 P

FRONT AXLE:

5876/4 (F 8021)

5876/5 (F 8021)

5886/5 (F 9021)

ADDED AXLE:

Steering central

5876/2 (F 8021)

Rigid rear

55080/D1 (N 8071) *

Rigid rear

56082/D1 (N 9171) *

Steering rear

57080/D1 (N 8072) *

MERITOR MS 13-175/T - MS 13-175/D

MERITOR RT 160/1

451391 HR

ZF 8098

FRONT MECHANICAL

Front

Rear

PNEUMATIC

Front

Rear

Added axle

= With brake calliper assembly at 57° without parking brake

= With parabolic leaf springs

= With brake calliper assembly at 0° with parking brake

= TI with drum brakes

= With longitudinal and transversal bars

T	= 4x2 tractor
TX	= 6x2 C tractor (central added axle cannot
	be lifted)
TY	= 6x2 P tractor (rear added axle can be lifted)
TN	= 6x2 vehicles with mechanical rear
	suspensions and raisable rigid rear added
	axle
TZ	= 6x4 tractor (bogie rear axle)

P= 4x2 — 6x2P — 6x2C vehicles with air suspension on rear axle and 6x2P vehicles with rigid rear axle that can be lifted with single wheels

PT	=	6x2P vehicles with air suspension on rear
		axle and rigid rear added axle that can be
		lifted with twin wheels
PS	=	6x2P vehicles with air suspension on rear
		axle and on steering rear added axle that
		can be lifted with single wheels
FP	= 4x2 — 6x4 — 6x2P — 6x2C vehicles with
		front and rear air suspensions
FS	= 6x2P vehicles with front and rear air
		suspensions, steering rear added axle can
		be lifted with single wheels
4x2	=	Vehicles with two axles with rear driving
		axle
6x2P	=	Vehicles with three axles with rear driving
		axle and rear added third axle that can be
		lifted
6x2C	=	Vehicles with three axles with rear driving
		axle and central added third axle that
		cannot be lifted
6x4	= Vehicles with three axles with two rear
		driving axles (in tandem)
CM	= Movable Boxes
HM	= Heavy Mission
LT	=	Tractor with lowered chassis frame
CT	= Chassis cab with lowered chassis frame
RR	= Rough Roads
D	=	Distribution
AT	= Active Time
AD	= Active Day

Base - January 2003

Print 603.93.141

STRALIS AT/AD GENERAL 7

COMPOSITION OF MODELS

CHASSIS CABS - 6x2 P MODELS

<![if ! IE]>

<![endif]>AD 260 S 40Y/FS-CM

<![if ! IE]>

<![endif]>AT 260 S 40Y/FS-CM

<![if ! IE]>

<![endif]>AD 260 S 43Y/FS-CM

<![if ! IE]>

<![endif]>AT 260 S 43Y/FS-CM

ASSEMBLIES

<![if ! IE]>

<![endif]>AD 260 S 40Y/P

<![if ! IE]>

<![endif]>AT 260 S 40Y/P

<![if ! IE]>

<![endif]>AD 260 S 40Y/PS

<![if ! IE]>

<![endif]>AT 260 S 40Y/PS

<![if ! IE]>

<![endif]>AD 260 S 40Y/FP-D

<![if ! IE]>

<![endif]>AT 260 S 40Y/FP-D

<![if ! IE]>

<![endif]>AD 260 S 40Y/FS-D

<![if ! IE]>

<![endif]>AT 260 S 40Y/FS-D

<![if ! IE]>

<![endif]>AD 260 S 43Y/P

<![if ! IE]>

<![endif]>AT 260 S 43Y/P

<![if ! IE]>

<![endif]>AD 260 S 43Y/PS

<![if ! IE]>

<![endif]>AT 260 S 43Y/PS

<![if ! IE]>

<![endif]>AD 260 S 43Y/FP-D

<![if ! IE]>

<![endif]>AT 260 S 43Y/FP-D

<![if ! IE]>

<![endif]>AD 260 S 43Y/FS-D

<![if ! IE]>

<![endif]>AT 260 S 43Y/FS-D

<![if ! IE]>

<![endif]>AD 260 S 40Y/PT

<![if ! IE]>

<![endif]>AT 260 S 40Y/PT

<![if ! IE]>

<![endif]>AD 260 S 40Y/TN

<![if ! IE]>

<![endif]>AT 260 S 40Y/TN

<![if ! IE]>

<![endif]>AD 260 S 43Y/PT

<![if ! IE]>

<![endif]>AT 260 S 43Y/PT

<![if ! IE]>

<![endif]>AD 260 S 43Y/TN

<![if ! IE]>

<![endif]>AT 260 S 43Y/TN

F2BE0681F (270 CV)

F2AE0681E (300 CV)

F2BE0681B (310 CV)

F2BE0681A (350 CV)

F3AE0681B (400 CV)

F3AE0681D (430 CV)

Single disc 16”

Single disc 17”

ZF 9S 109 D.D.

ZF 16S 151 O.D.

ZF 16S 181 O.D.

ZF 16S 181 D.D.

ZF 16S 221 D.D.

EuroTronic Automated 12 AS 2301 D.D.

EuroTronic Automated 12 AS 2301 O.D.

Allison MD 3060 P - MD 3066 P

FRONT AXLE:

5876/4 (F 8021)

5876/5 (F 8021)

5886/5 (F 9021)

ADDED AXLE:

Steering central

5876/4 (F 8021)

Rigid rear

55080/D1 (N 8071) *

Rigid rear

56082/D1 (N 9171) *

Steering rear

57080/D1 (N 8072) *

MERITOR MS 13-175/T - MS 13-175/D

MERITOR RT 160/1

451391 HR

ZF 8098

FRONT MECHANICA0L

Front

Rear

PNEUMATIC

Front

Rear

Added axle

= With brake calliper assembly at 57° without parking brake

= With parabolic leaf springs

= With brake calliper assembly at 0° with parking brake

= TI with drum brakes

= With longitudinal and transversal bars

T	= 4x2 tractor
TX	= 6x2 C tractor (central added axle cannot
	be lifted)
TY	= 6x2 P tractor (rear added axle can be lifted)
TN	= 6x2 vehicles with mechanical rear
	suspensions and raisable rigid rear added
	axle
TZ	= 6x4 tractor (bogie rear axle)

P= 4x2 — 6x2P — 6x2C vehicles with air suspension on rear axle and 6x2P vehicles with rigid rear axle that can be lifted with single wheels

PT	=	6x2P vehicles with air suspension on rear
		axle and rigid rear added axle that can be
		lifted with twin wheels
PS	=	6x2P vehicles with air suspension on rear
		axle and on steering rear added axle that
		can be lifted with single wheels
FP	= 4x2 — 6x4 — 6x2P — 6x2C vehicles with
		front and rear air suspensions
FS	= 6x2P vehicles with front and rear air
		suspensions, steering rear added axle can
		be lifted with single wheels
4x2	=	Vehicles with two axles with rear driving
		axle
6x2P	=	Vehicles with three axles with rear driving
		axle and rear added third axle that can be
		lifted
6x2C	=	Vehicles with three axles with rear driving
		axle and central added third axle that
		cannot be lifted
6x4	= Vehicles with three axles with two rear
		driving axles (in tandem)
CM	= Movable Boxes
LT	=	Tractor with lowered chassis frame
CT	= Chassis cab with lowered chassis frame
RR	= Rough Roads
D	=	Distribution
HR	= Hub Reduction
AT	= Active Time
AD	= Active Day

Print 603.93.141

Base - January 2003

8 GENERAL STRALIS AT/AD

COMPOSITION OF MODELS

TRACTORS - MODELS

4x2

6x2 C

6x4

ASSEMBLIES

<![if ! IE]>

<![endif]>AD 440 S 31T/P

<![if ! IE]>

<![endif]>AT 440 S 31T/P

<![if ! IE]>

<![endif]>AD 440 S 35T/P

<![if ! IE]>

<![endif]>AT 440 S 35T/P

<![if ! IE]>

<![endif]>AD 440 S 35T/P-HR

<![if ! IE]>

<![endif]>AT 440 S 35T/P-HR

<![if ! IE]>

<![endif]>AD 440 S 40T/P

<![if ! IE]>

<![endif]>AT 440 S 40T/P

<![if ! IE]>

<![endif]>AD 440 S 40T/P-RR

<![if ! IE]>

<![endif]>AT 440 S 40T/P-RR

<![if ! IE]>

<![endif]>AD 440 S 40T/P-HR

<![if ! IE]>

<![endif]>AT 440 S 40T/P-HR

<![if ! IE]>

<![endif]>AT 440 S 40T/FP-CT

<![if ! IE]>

<![endif]>AT 440 S 40T/FP-LT

<![if ! IE]>

<![endif]>AD 440 S 43T/P

<![if ! IE]>

<![endif]>AT 440 S 43T/P

<![if ! IE]>

<![endif]>AD 440 S 43T/P-RR

<![if ! IE]>

<![endif]>AT 440 S 43T/P-RR

<![if ! IE]>

<![endif]>AD 440 S 43T/P-HR

<![if ! IE]>

<![endif]>AT 440 S 43T/P-HR

<![if ! IE]>

<![endif]>AT 440 S 43T/FP-CT

<![if ! IE]>

<![endif]>AT 440 S 43T/FP-LT

<![if ! IE]>

<![endif]>AD 440 S 40TX/P

<![if ! IE]>

<![endif]>AT 440 S 40TX/P

<![if ! IE]>

<![endif]>AD 440 S 43TX/P

<![if ! IE]>

<![endif]>AT 440 S 43TXP

<![if ! IE]>

<![endif]>AT 440 S 43TZ/P

F2BE0681F (270 CV)

F2AE0681E (300 CV)

F2BE0681B (310 CV)

F2BE0681A (350 CV)

F3AE0681B (400 CV)

F3AE0681D (430 CV)

Single disc 16”

Single disc 17”

ZF 9S 109 D.D.

ZF 16S 151 O.D.

ZF 16S 181 O.D.

ZF 16S 181 D.D.

ZF 16S 221 D.D.

EuroTronic Automated 12 AS 2301 D.D.

EuroTronic Automated 12 AS 2301 O.D.

Allison MD 3060 P - MD 3066 P

FRONT AXLE:

5876/4 (F 8021)

5876/5 (F 8021)

5886/5 (F 9021)

ADDED AXLE:

Steering central

5876/4 (F 8021)

Rigid rear

55080/D1 (N 8071) *

Rigid rear

56082/D1 (N 9171) *

Steering rear

57080/D1 (N 8072) *

MERITOR MS 13-175/T - MS 13-175/D

MERITOR RT 160/1

451391 HR

ZF 8098

FRONT MECHANICAL

Front

Rear

PNEUMATIC

Front

Rear

Added axle

= With brake calliper assembly at 57° without parking brake

= With parabolic leaf springs

= With brake calliper assembly at 0° with parking brake

= TI with drum brakes

= With longitudinal and transversal bars

T	= 4x2 tractor
TX	= 6x2 C tractor (central added axle cannot
	be lifted)
TY	= 6x2 P tractor (rear added axle can be lifted)
TN	= 6x2 vehicles with mechanical rear
	suspensions and raisable rigid rear added
	axle
TZ	= 6x4 tractor (bogie rear axle)

P= 4x2 — 6x2P — 6x2C vehicles with air suspension on rear axle and 6x2P vehicles with rigid rear axle that can be lifted with single wheels

PT	=	6x2P vehicles with air suspension on rear
		axle and rigid rear added axle that can be
		lifted with twin wheels
PS	=	6x2P vehicles with air suspension on rear
		axle and on steering rear added axle that
		can be lifted with single wheels
FP	= 4x2 — 6x4 — 6x2P — 6x2C vehicles with
		front and rear air suspensions
FS	= 6x2P vehicles with front and rear air
		suspensions, steering rear added axle can
		be lifted with single wheels
4x2	=	Vehicles with two axles with rear driving
		axle
6x2P	=	Vehicles with three axles with rear driving
		axle and rear added third axle that can be
		lifted
6x2C	=	Vehicles with three axles with rear driving
		axle and central added third axle that
		cannot be lifted
6x4	= Vehicles with three axles with two rear
		driving axles (in tandem)
CM	= Movable Boxes
HM	= Heavy Mission
LT	=	Tractor with lowered chassis frame
CT	= Chassis cab with lowered chassis frame
RR	= Rough Roads
D	=	Distribution
AT	= Active Time
AD	= Active Day

Base - January 2003

Print 603.93.141

STRALIS AT/AD	GENERAL	9

P.I.C. NUMBER CODING

CAB LIVEABILITY

= Stralis AD (Active Day)

= Stralis AT (Active Time)

CONFIGURATION

TO TAL

WEI GH T

O N

G RO UN D

AXL ES

= 4x2; 18-20 ton.

= 4x2T; 19-20 ton.

E = 6x2C; 26 ton.

F = 6x2P; 26 ton.

G	= 6x2P; 26 ton.

H	= 4x2T; 19-20 ton.
J	= 6x2C; 26 ton.
	= 6x2C; 26 ton.
K	= 6x4; 26 ton.
	= 6x4; 26 ton.
L	= 4x2P; 19-20 ton.
	= 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

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10	GENERAL	STRALIS AT/AD

SUSPENSION TYPE - REAR AXLE TYPE - TYPE OF ADDITIONAL AXLE

A	A	A	B
A	A	A	B


			A


			B


			C


			E


			E


			F


			G


			H

*	=	Suspensions with 5886/D front axle
TWIN	=	Twin rear wheels
CENT	=	Middle axle (6x2C vehicles)
SING	=	Added axle with rear single wheels
STER	=	Added axle with rear steering single wheels
HR	=	Double reduction rear axle
SR	=	Simple reduction rear axle

B		C		C		D

Mechanical - SR - TWIN

Pneumatic - SR - CENT/SING/TWIN

-SR - CENT/SING Pneumatic - HR (Tractor 4x2)

Pneumatic - HR - SR - STER (Chassis cab 6x2P)

-SR - STER

(*)- SR - SING

(*)- SR - STER

VERSION COMBINATION - USE

= Chassis cab - STD

= Tractor - STD

= Tractor - GRAV

= Cartran - STD -Tractor

= Cartran - STD - Chassis cab

= LOW TR - STD

Cartran

Car transport

LOW TR

Lowered tractor

STD

Standard use

GRAV

Heavy duty use

Base - January 2003

Print 603.93.141

STRALIS AT/AD	GENERAL	11

WHEELBASE

VERSION

WHEELBASE

VERSION

WHEELBASE

VERSION

WHEELBASE

VERSION

WHEELBASE

T 6 x 2 C

3800

T 4 x 2

3650

6 x 2 P

3120

T 6 x 4

2800

6 x 2 P

3805

C 4 x 2

C 4 x 2	6300

	T 6 x 4	3200


T	4 x 2	3800
C	6 x 2 C	3800
C	6 x 2 C


C	4 x 2
C	6 x 2 C	4200
	6 x 2 P


C	4 x 2
C	6 x 2	4500
	6 x 2P


C	4 x 2	4800
	6 x 2 P	4800
	6 x 2 P


C	4 x 2	5100
	6 x 2 P	5100
	6 x 2 P


C	4 x 2	5700
	6 x 2 P	5700
	6 x 2 P


	6 x 2 P	6050


	C 4 x 2	5500


	C 4 x 2	6300

Print 603.93.141

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12	GENERAL	STRALIS AT/AD

	GEARBOX - BRAKES COMBINATION
A	A	A	B	B	C	C	D

	GEARBOX			BRAKES
	GEARBOX			NO	YES
				NO	YES
	Mechanical			Disc	Disc		A
	Mechanical			Disc	Drum		B
	ALLISON			Disc	Drum		D
							D
	EuroTronic 12 A S 2301			Disc	Disc		E
							E
	EuroTronic 12 A S 2301			Disc	Drum		F
		CAB - DRIVE - BRAKES COMBINATION
A	A	A	B	B	C	C	D
					DRIVE
					Left		1
					Right		A

Base - January 2003

Print 603.93.141

STRALIS AT/AD GENERAL 13

REPLENISHING FLUIDS

LUBRICANTS RECOMMENDED BY IVECO	PARTS TO BE FILLED UP	Quantity
		Litres	Kg
Urania FE 5W30(1)
Urania LD5	Engine F2B
Urania Turbo LD
	Total capacity for first filling	28	25,2
		28	25,2
	Capacity:
	- engine sump min level	12.5	11,2
	- engine sump max level	23	21
	- quantity in circulation that	5	4.5
	does not flow back to the en-
	gine sump	2.5	2.3
		2.5	2.3

-quantity contained in the cartridge filter (which has to be added to the cartridge filter refill)

Urania FE 5W30(1)	Engine F3A
Urania LD5
Urania Turbo LD	Total capacity 1st filling	30	29.8
	Total capacity 1st filling	30	29.8
	Capacity:
	- engine sump at minimum level	17	15.3
	- engine sump at maximum level	25	22.5
	- quantity in circulation that does not re-	7	6.3
	turn to sump	7	6.3
	- quantity contained in cartridge filter (to	2.5	2.3
	add when changing the cartridge filter)	2.5	2.3
	Gearbox
	ZF 9 S 109 *	8	7.2
	ZF 16 S 151 *	11	10
Tutela Truck FE-Gear1	ZF 16 S 151 + Intarder *	18.5	16.65
Tutela Truck FE-Gear1	ZF 16 S 181 *	13	12
Tutela ZC 90	ZF 16 S 181 + Intarder*	21.5	19.35
	ZF 16 S 221 *	13	12
	ZF 16 S 221 + Intarder*	21.5	19.35
* Quantity 1st filling	EuroTronic automated 12 AS 2301*	12	11
	EuroTronic automated 12 AS 2301* + intarder	23	21
Tutela GI/A	Allison MD 3060 P - MD 3066 P	18	16
Tutela Truck FE-Gear1	Power take off (Multipower)	2.5
Tutela ZC 90	Power take off (Multipower)	2.5
Tutela ZC 90

(1)IVECO recommends using these oils for reasons of fuel economy. IVECO provides new vehicles already with these types of lubricants. Also suited for cold climates (minimum temperature down to -30ºC)

These quantities are not decisive. An exact check must be made by verifying the levels

Print 603.93.141

Base - January 2003

14 GENERAL STRALIS AT/AD

REPLENISHING FLUIDS

LUBRICANTS RECOMMENDED BY IVECO	PARTS FOR REPLENISHING		Quantity
LUBRICANTS RECOMMENDED BY IVECO	PARTS FOR REPLENISHING		Litres	kg
			Litres	kg
	Front hubs (single)		0.35	0.32
	FRONT AXLE	5876/4-/5 (F8021)	0.35	0.32
Tutela Truck FE-Axle(2)	FRONT AXLE	5886/5	0.35	0.32
Tutela Truck FE-Axle(2)	ADDED AXLE::
Tutela W140/M-DA	ADDED AXLE::		0.35	0.32
Tutela W140/M-DA	Steering central	5876/4 (F 8021)	0.35	0.32
Tutela W90/M-DA3	Rigid rear	55080/D1 (N 8071)	0.35	0.32
	Rigid rear	56082/D1 (N 9171)	0.35	0.32
	Steering rear	57080/DI (N 8072)	0.35	0.32

Tutela Truck

FE-Axle(2)

Tutela W140/M-DA

Tutela W90/M-DA3

Bridge Meritor MS 13-175/T - MS 13-175/D:
V	(mechanical suspension)	18.5	16.5
V	(pneumatic suspension)	17	15.5
Bridge 451391 HR		16	14.5
Rear axle Meritor in tandem RT 160E/1		18.5	16.6
- middle		18.5	16.6
- rear		16.5	14.8

Tutela GI/A	Power steering	2.7*	2.4
		13.5**	12

*Excluding vehicles with steering rear axle

**For vehicles with steering rear axle only

Tutela TRUCK	Clutch circuit		0.5	0.45
Tutela TRUCK	Clutch circuit
DOT SPECIAL	(excluding vehicles with Euro Tronic gearbox)
DOT SPECIAL	(excluding vehicles with Euro Tronic gearbox)

	Cooling system		µ34	µ23.4
	Engine F2B	Total capacity*	µ34	µ23.4
Water+Paraflu11	Engine F2B with Intarder	Total capacity*	µ50	µ27
	Engine F3A	Total capacity*	µ38	µ39.6
	Engine F3A	Total capacity*	µ38	µ39.6
	Engine F3A with Intarder	Total capacity*	µ58	µ57.6
	* = Protective anti-freeze
	(concentration 50% freezing point —35°C)
Tutela LHM	Cab tilting system		0.6	0.54
Tutela LHM	Cab tilting system		0.6	0.54

(2)Only on axles with disc brakes, IVECO recommends using these oils for reasons of fuel economy. IVECO provides new vehicles already with these types of lubricants. Also suited for cold climates (minimum temperature down to -30ºC)

(3)Specific for cold climates

These quantities are not decisive. An exact check must be made by verifying the levels

Base - January 2003

Print 603.93.141

STRALIS AT/AD	GENERAL	15

International lubricant designation		FL products
Engine oil
Meets the specifications:
ACEA E4 with a totally synthetic base	SAE 50W 30	URANIA FE 5W30
ACEA E5 with a mineral base	SAE 15W 40	Urania LD5
ACEA E3 with a mineral base	SAE 15W 40	Urania Turbo LD

Oil for differential gear and wheel hubs
Meets the specifications:
API GL5, MT-1 with a totally synthetic base	SAE 75W 90	Tutela Truck FE-Axle
API GL5 with a mineral base	SAE 85W 140	Tutela W140/M-DA
API GL5 with a mineral base	SAE 80W 90	Tutela W90/M-DA

Oil for mechanical gearboxes
Containing non-EP anti-wear additives
Meets the specifications:
API GL4 with a totally synthetic base	SAE 75W 85	Tutela Truck FE-Gear
API GL3 with a mineral base	SAE 80W 90	Tutela ZC90

Oil for power steering and hydrostatic transmissions
A.T.F. DEXRON II D		Tutela GI/A

Grease for general greasing		Tutela MR 2
based on lithium soaps, N.L.G.I. consistency no. 2		Tutela MR 2
based on lithium soaps, N.L.G.I. consistency no. 2

Specific grease for bearings and wheel hubs		Tutela MR 3
based on lithium soaps, N.L.G.I. consistency no. 3		Tutela MR 3
based on lithium soaps, N.L.G.I. consistency no. 3

Clutch drive fluid		Tutela TRUCK DOT SPECIAL
Conforming to N.H.T.S.A. standards 116, ISO 4925, Std. SAEJ 1703,		Tutela TRUCK DOT SPECIAL
IVECO STANDARD 18-1820

Mineral oil for hydraulic circuits		Tutela LHM
In compliance with IVECO STANDARD 18-1823		Tutela LHM
In compliance with IVECO STANDARD 18-1823

Windscreen washer fluid, mixture of spirit, water and surfactants		Tutela PROFESSIONAL SC 35
CUNA NC 956-11		Tutela PROFESSIONAL SC 35
CUNA NC 956-11

Grease for central lubrication systems based on lithium soaps,		Tutela COMAR 2
with synthetic base, N.L.G.I. no. 2.		Tutela COMAR 2
Working temperatures: from —30°C to +140°C

Concentrated protective fluid for radiators		Paraflu11
based on ethylene glycol containing corrosion inhibitors, conforming to the		Paraflu11

standard: IVECO-STANDARD 18-1830

Print 603.93.141

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16	GENERAL	STRALIS AT/AD

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Print 603.93.141

STRALIS AT/AD	ENGINE	1

SECTION 2
Engine
	Page
- F2B Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3
- F3A Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .	113
- Hidrocar pressure take-off on timing system
(P.T.O. - Optional) . . . . . . . . . . . . . . . . . . . . .	223

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2	ENGINE	STRALIS AT/AD

Base - January 2003

Print 603.93.141

STRALIS AT/AD	ENGINE F2B	3
	Print 603.43.671
	F2B Engine
		Page
	VIEWS OF THE ENGINE . . . . . . . . . . . . . . . . . .	8
	GENERAL CHARACTERISTICS . . . . . . . . . . . . .	13
	ASSEMBLY CLEARANCE DATA . . . . . . . . . . . .	16
	TIGHTENING TORQUES . . . . . . . . . . . . . . . . .	22
	TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	28
	DISMANTLING THE ENGINE ON THE BENCH	40
	REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . .	47
	CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . .	47
	- Checks and measurements . . . . . . . . . . . . . . .	47
	CYLINDER LINERS . . . . . . . . . . . . . . . . . . . . . . .	48
	- Fitting and checking protrusion . . . . . . . . . . . .	49
	- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	49
	- Replacing cylinder liners . . . . . . . . . . . . . . . . . .	49
	CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .	50
	- Measuring main journals and crank pins . . . . . .	51
	PRELIMINARY MEASUREMENT OF MAIN AND BIG
	END BEARING SHELL SELECTION DATA . .	52
	- Replacing the timing control gear and
	the oil pump . . . . . . . . . . . . . . . . . . . . . . . . . .	59
	- Checking main journal installation clearance . . .	59
	- Checking crankshaft end float . . . . . . . . . . . . .	60
	PISTON-CONNECTING ROD ASSEMBLY . . . .	61
	- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	61
	- Measuring the diameter of the pistons . . . . . . .	62
	- Conditions for correct gudgeon pin-piston
	coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	62
	- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . .	63
	CONNECTING ROD . . . . . . . . . . . . . . . . . . . . .	64
	- Checking connecting rod alignment . . . . . . . . .	65

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4	ENGINE F2B	STRALIS AT/AD

	Page
- Mounting the connecting rod-piston assembly .	65
- Mounting the piston rings . . . . . . . . . . . . . . . . .	65
- Fitting the connecting rod-piston assembly into
the piston liners . . . . . . . . . . . . . . . . . . . . . . . .	66
- Piston protrusion check . . . . . . . . . . . . . . . . . .	66
- Checking assembly clearance of big end pins . .	67
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .	67
- Valve removal . . . . . . . . . . . . . . . . . . . . . . . . . .	67
- Checking the planarity of the head on
the cylinder block . . . . . . . . . . . . . . . . . . . . . . .	67
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	67
- Removing deposits and checking the valves . . .	67
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . .	68
- Replacing of valve guides . . . . . . . . . . . . . . . . .	69
- Replacing - Reaming the valve seats . . . . . . . . .	69
REPLACING INJECTOR HOLDER CASES . . . . .	69
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	69
- Checking protrusion of injectors . . . . . . . . . . . .	71
TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . .	72
- Checking cam lift and pin alignment . . . . . . . . .	72
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	73
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	73
- Replacing camshaft bushes using
beater 99360487 . . . . . . . . . . . . . . . . . . . . . . .	74
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	74
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	74
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .	75
- Fitting the valves and oil seal ring . . . . . . . . . . .	75
ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . .	76
- Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	76
- Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	76
ASSEMBLING THE ENGINE ON THE BENCH .	77
DIAGRAM SHOWING THE UNDERBLOCK FIXING
SCREWS TIGHTENING ORDER . . . . . . . . . .	79

	Page
- Fitting the connecting rod-piston assembly into
the cylinder liners . . . . . . . . . . . . . . . . . . . . . . .	80
ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . .	83
- Fitting engine flywheel . . . . . . . . . . . . . . . . . . .	83
- Fitting camshaft . . . . . . . . . . . . . . . . . . . . . . . . .	84
- Fitting pump-injectors . . . . . . . . . . . . . . . . . . . .	85
- Fitting rocker-arm shaft assembly . . . . . . . . . . .	85
- Camshaft timing . . . . . . . . . . . . . . . . . . . . . . . .	86
- Phonic wheel timing . . . . . . . . . . . . . . . . . . . . .	88
- Intake and exhaust rocker play adjustment and
pre-loading of rockers controlling pump injectors.	89
ENGINE COMPLETION . . . . . . . . . . . . . . . . . .	90
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .	93
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
- Overpressure valve . . . . . . . . . . . . . . . . . . . . .	95
- Oil pressure control valve . . . . . . . . . . . . . . . .	96
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . .	96
- By-pass valve . . . . . . . . . . . . . . . . . . . . . . . . . .	97
- Thermostatic valve . . . . . . . . . . . . . . . . . . . . . .	97
- Engine oil filters . . . . . . . . . . . . . . . . . . . . . . . .	97
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	99
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .	99
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .	99
- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . .	101
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .	101
- Electromagnetic coupling . . . . . . . . . . . . . . . . .	101
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . .	102
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . .	102
TURBO COMPRESSOR HOLSET HX 40V . . . . .	104
- Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	107
- Solenoid valve for VGT control . . . . . . . . . . . .	107

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Print 603.93.141

STRALIS AT/AD		ENGINE F2B	5

	Page
FUEL FEED	108
FUEL FEED	108

- Replacing injectors-pump . . . . . . . . . . . . . . . . .	109

- Injector-pump . . . . . . . . . . . . . . . . . . . . . . . . . .	109

- Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .	109

- Injector Phases . . . . . . . . . . . . . . . . . . . . . . . . .	110

Print 603.93.141

Base - January 2003

+ 120 hidden pages

IVECO STRALIS AT, STRALIS AD REPAIR MANUAL

SPECIAL REMARKS

Graphs and symbols

INDEX OF SECTIONS

GENERAL

VEHICLE IDENTIFICATION DATA

Vehicle Identification Plate

Production identification plate

P.I.C. NUMBER CODING

REPLENISHING FLUIDS

ENGINE

F2B Engine