Iveco Stralis AT/AD Workshop Service Repair Manual

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This Workshop Service Repair manual PDF download for the Iveco Stralis AT/AD Mechanical Electric/Electronic has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


TABLE OF CONTENTS :

SECTION 1 - General
SECTION 2 - Engine
SECTION 3 - Clutch
SECTION 4 - Gearboxes
SECTION 5 - Intarder - ZF hydraulic retarder
SECTION 6 - Propeller shafts
SECTION 7 - Rear axles
SECTION 8 - Axles
SECTION 9 - Suspensions
SECTION 10 - Wheels and tyres
SECTION 11 - Steering
SECTION 12 - Air system - Brakes
SECTION 13 - Bodywork - Chassis frame
SECTION 14 - Scheduled maintenance

ELECTRIC/ELECTRONIC SYSTEM


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 603.93.141
Total Pages : 1507


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STRALIS AT/AD
REPAIR MANUAL :
MECHANICAL
SPECIAL REMARKS
Graphs and symbols
INDEX OF SECTIONS
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
Checks and measurements
CYLINDER LINERS
Replacing cylinder liners
Removal
Fitting and checking protrusion
CRANKSHAFT
Measuring main journals and crank pins
PRELIMINARY MEASUREMENT OF MAIN AND BIG END BEARING SHELL SELECTION DATA
Replacing the timing control gear and the oil pump
Checking main journal installation clearance
Checking crankshaft end float
PISTON-CONNECTING ROD ASSEMBLY
Removal
Measuring the diameter of the pistons
Conditions for correct gudgeon pin-piston coupling
Piston rings
CONNECTING ROD
Checking connecting rod alignment
Mounting the connecting rod - piston assembly
Mounting the piston rings
Fitting the connecting rod-piston assembly into the piston liners
Piston protrusion check
Checking assembly clearance of big end pins
CYLINDER HEAD
Valve removal
Checking the planarity of the head on the cylinder block
VALVE
Removing deposits and checking the valves
VALVE GUIDES
Replacing of valve guides
Replacing - Reaming the valve seats
REPLACING INJECTOR HOLDER CASES
Removal
Checking protrusion of injectors
TIMING GEAR
Checking cam lift and pin alignment
Camshaft
Bushes
Replacing camshaft bushes using beater 99360487
Removal
Assembly
VALVE SPRINGS
Fitting the valves and oil seal ring
ROCKER SHAFT
Shaft
Rocker
ASSEMBLING THE ENGINE ON THE BENCH
DIAGRAM SHOWING THE UNDERBLOCK FIXING SCREWS TIGHTENING ORDER
Fitting the connecting rod-piston assembly into the 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.
ENGINE COMPLETION
LUBRICATION
Oil pump
Overpressure valve
Oil pressure control valve
Heat exchanger
By-pass valve
Thermostatic valve
Engine oil filters
COOLING
Description
Operation
Water pump
Thermostat
Electromagnetic coupling
TURBOCHARGING
TURBOCHARGER
TURBO COMPRESSOR HOLSET HX 40V
Actuator
Solenoid valve for VGT control
FUEL FEED
Fuel pump
Injector-pump
Replacing injectors-pump
Injector Phases
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
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
Removing valves
Checking the planarity of the head on the 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 system
Camshaft
Bushings
Valve springs
Fitting valves and oil seal
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
COOLING
Description
Operation
Water pump
Thermostat
Electromagnetic coupling
TURBOCHARGING
Turbocharger HOLSET HY55V
Actuator
Solenoid valve for VGT control
FEEDING
Fuel pump
Injector-pump
Replacing injectors-pump
Injector Phases
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
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
Description of gearbox 9 S 109 D.D.
SPECIFICATIONS AND DATA
DIAGNOSTICS
TIGHTENING TORQUE
EQUIPMENT
REMOVAL
Removing the E.R.U.box
Reassembling the E.R.U.box
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
Adjusting the main 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
Slow range
Fast range
EPICYCLIC REDUCTION GEAR CONTROL
Reduced speeds
Normal speeds
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
GEARBOX FAULT DIAGNOSIS
REMOVING-REFITTING THE GEARBOX
Removal
Refitting
OVERHAULING THE GEARBOX
Servoshift gear box
Removal
Refitting
Disassembly
Assembly
Removing the rear box
Removing the epicyclic reduction gear unit (ERG)
Fitting the epicyclic reduction gear unit (ERG)
Refitting the epicyclic reduction gear unit (ERG) rear box
Removing the gearbox
Removing the main shaft
Removing the drive input shaft
Removing the transmission shaft
CHECKS
Gearbox
Hubs - sliding sleeves - forks
Bearings
Shafts - gears
Synchronizing devices
BK-type single-cone synchronizing devices
Fitting the drive input shaft
Fitting the drive input shaft
Fitting the main shaft
Adjusting the main shaft
Fitting the gearbox
Oil pump
Adjusting the transmission shaft bearing end float
Drive input shaft cover
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
Removing the hydraulic retarder from the gearbox on the stand
Refitting the hydraulic retarder
Removing the epicyclic reduction gear unit (ERG) rear box
Removing the epicyclic reduction gear unit (ERG)
Component parts of the epicyclic reduction gear unit
Fitting the epicyclic reduction gear unit (ERG)
Refitting the epicyclic reduction gear unit (ERG) rear box
Gearbox EuroTronic 12 AS 2301 D.D./O.D.
DESCRIPTION
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
OVERHAULING THE GEARBOX
Checks
Gearbox actuator
Removal
Refitting
Removing the rear box
Removing the rear box
Removing the epicyclic reduction gear train (E.R.G.)
Fitting the epicyclic reduction gear train (E.R.G.)
Adjusting epicyclic reduction gear train bearing end float
Adjusting main shaft end float
Synchronizing device assembly for engaging normal or reduced gears
Removal
Fitting
Removing the middle box
Removing the main shaft
Removing the drive input shaft
Removing the splitter synchronizing device
Fitting the splitter synchronizing device
Fitting the main shaft
Fitting the drive input shaft
Splitter control fork
Disassembly - Assembly
Gear control forks
Removal
Fitting
Transmission shafts
Disassembly - Assembly
Fitting the middle box
Fitting the front box
Front cover
Removal
Fitting the front cover
Adjusting drive input shaft bearing end float
Adjusting transmission shaft bearing end float
Clutch release lever
Gearbox EuroTronic 12 AS 2301 D.D./O.D. with Intarder (IT)
SPECIFICATIONS AND DATA
OVERHAULING THE GEARBOX
Removing the hydraulic retarder
Refitting the hydraulic retarder
Adjusting epicyclic reduction gear train bearing end float
Adjusting stator end float
Removing the rear box
Removing the E.R.G.
Fitting the E.R.G.
EXPERIMENTAL TOOLS
Gearboxes Allison MD 3060 PR - Allison MD 3066 PR
DESCRIPTION
TECHNICAL DESIGNATION
Identification plate
CHARACTERISTICS AND DATA
MAIN OPERATION ANOMALIES
TIGHTENING TORQUES
TOOLS
REMOVAL AND REFITTING OF THE TRANSMISSION
Removal
Refitting
DISCONNECTING AND CONNECTING GEARBOX CONTROL MODULE AGAIN
Disconnecting
Refitting
REPLACING SPEED SENSORS
Replacing turbine speed sensor
Engine revolutions sensor replacement
Replacing the output speed sensor
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
Transmission tie rod adjustment
SIDE TIE ROD
Removal
Refitting
TELESCOPIC TIE ROD
Removal
Refitting
TRANSMISSION IDLER ARM
Removal
Disassembly
Assembly
Refitting
CROSS TIE ROD
Removal
Refitting
Power take-off
ZF POWER TAKE-OFF
HYDROCAR POWER TAKE-OFF
Power take off (Optional 2395)
DESCRIPTION
FEATURES AND DATA
TIGHTENING TORQUE
EQUIPMENT
Operation (power take off disengaged)
Operation (power take off engaged)
REMOVING - REFITTING TOTAL POWER TAKE-OFF ASSEMBLY
Removal
Refitting
OVERHAULING
Removing main box
Removing drive assembly
Removing bearing for shaft with gear wheel
Removing oil pump
Cleaning and checking parts
Fitting the oil pump
Fitting bearing for shaft with gear wheel
Fitting drive assembly
Adjusting drive output shaft tapered bearings
Fitting the main housing
Adjusting ball bearing
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
Removal
Replacing wheel hub bearings
Checking the parts forming the wheel hubs
Replacing the wheel fixing pins
REMOVING AND REFITTING THE DIFFERENTIAL
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 CROWN WHEEL AND PINION CONTACTS (AFTER ASSEMBLY)
WORK ON THE VEHICLE
REPLACING THE BEVEL PINION MOUNT SEAL
Disassembly
Assembly
Rear axle MERITOR MS 13-175 whit drum brakes
DESCRIPTION
CHARACTERISTICS AND DATA
TIGHTENING TORQUES
TOOLS
OVERHAULING THE REAR AXLE ASSEMBLY
OVERHAULING THEWHEEL HUBS
Removal
Wheel hub component check
REPLACING THEWHEEL HUB BOLTS
Wheel hub reassembly
REMOVING AND REASSEMBLING THE DIFFERENTIAL
Removal
Axle casing check
Rear axle 451391 (R 8284)
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 MERITOR RT 160 E/1
Axles in Tandem (Intermediate) Meritor RP 160 E (R 2478)
DESCRIPTION
SPECIFICATIONS AND DATA
TIGHTENING TORQUES
TOOLS
EXPERIMENTAL TOOLS
SERVICING INTERMEDIATE AXLEASSEMBLY RP 160 E (R2478)
AIR BREATHER REMOVAL-REFITTING
SERVICING WHEEL HUBS
Checking wheel hub components
ASSEMBLING WHEEL HUBS
REMOVING DIFFERENTIAL GEAR — TRANSFER BOX(with rear axle on stand 99322215)
REFITTING DIFFERENTIAL GEAR — TRANSFER BOX (with rear axle on stand 99322215)
REPAIRING INTER-AXLE UNIT
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
REPAIRING MAIN DIFFERENTIAL - DISMANTLING DIFFERENTIAL CASING
Dismantling gear cage
Checking differential components
Assembling gear cage
ASSEMBLING DIFFERENTIAL CASING
Calculating bevel pinion positionin differential casing
COMPUTATIONAL EXAMPLES
Determining the thickness of the bevel pinion bearing clearance adjustment rings
Adjusting the cap gap
CORRECTING THE CROWNWHEEL AND PINION CONTACTS (AFTER ASSEMBLY)
REMOVING-SERVICING-REFITTING INTER-AXLEOUTPUT SHAFT
Axles in Tandem (Rear) MERITOR RR 167 E (R 0878)
DESCRIPTION
CHARACTERISTICS AND DATA
TIGHTENING TORQUES
TOOLS
OVERHAULING REAR AXLE ASSEMBLY 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
Removal
Refitting
REMOVING AND REFITTING AXLE
Vehicles with pneumatic front suspension and longitudinal bars
Removal
Refitting
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
Rigid rear added axle 55080/DI (N 8071)
DESCRIPTION
CHARACTERISTICS AND DATA
TIGHTENING TORQUE
TOOLS
REMOVING-REFITTING
Removal
Refitting
REPAIRS
Rigid rear added axle 55080/TI (N 8071)
DESCRIPTION
CHARACTERISTICS AND DATA
TIGHTENING TORQUES
TOOLS
REMOVING - REFITTING WHEEL HUBS
Removal
Replacing wheel hub bearings
Replacing wheel fixing pins
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
Location of main system components
Hydraulic system circuit diagram
FAULT DIAGNOSIS
SPECIFICATIONS
ELECTRO-HYDRAULIC PUMP
Removal
Refitting
LIFTING CYLINDERS (VEHICLESWITH MECHANICAL SUSPENSION)
Removal
Refitting
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
Location on the vehicle of the main components
Pneumatic working diagram, rear air suspensions and air lift for added axles with single wheels
TIGHTENING TORQUES (Steering and lifting device linkage)
CHARACTERISTICS AND DATA
Steering and third axle hydraulic system
MAIN HYDRAULIC SYSTEM COMPONENTS
HYDRAULIC ACCUMULATOR
Nitrogen pressure checking and recharging
OPERATOR CYLINDER
Disassembly
Assembly
Checking cylinder oil sealing on the vehicle
CENTRING CYLINDER
Disassembly
Assembly
Checking cylinder oil sealing on the vehicle
ADDITIONAL AXLE PNEUMATIC LIFTING DEVICE REMOVAL AND REFITTING
Removal
Refitting
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)
Steering rear added axle 57080/TI (N 8072)
DESCRIPTION
CHARACTERISTICS AND DATA
TIGHTENING TORQUES
TOOLS
REPAIR OPERATIONS
Wheel geometry
GENERAL INFORMATION
Steering wheel angles
FRONTWHEEL GEOMETRY (4X2 vehicles)
Positioning clips and headlights
Electronic compensation of rim eccentricity
Wheel alignment
Checking wheel toe-in
Checking wheel deviation
Checking camber
Checking kingpin angle and caster
Checking rear axle alignment
VEHICLE WHEEL GEOMETRY WITH CENTRAL ADDED AXLE (6X2 C)
Checking steering angles
Vehicle wheel geometry with steering rear added axle and pneumatic lifting
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
Maintenance services chart
CHECKS AND/OR MAINTENANCE WORK
OFF-PLANE OPERATIONS
MAINTENANCE WORK
M1 SERVICE
M2 SERVICE
EXTRA PLAN MAINTENANCE
EP1 SERVICE
EP2 SERVICE
EP3 SERVICE
T1 SERVICE
T2 SERVICE
T3 SERVICE
T4 SERVICE
ELECTRIC/ELECTRONIC SYSTEM
UPDATE DATA
GENERAL LIST OF CONTENTS
Introduction
General warnings for electrical/electronic components
Component Code
VARIATIONS WITH RESPECT TO STRALIS “AS”
General
GENERAL DESCRIPTION OF THE MULTIPLEX SYSTEM
POWER NETWORK
MASS POINTS
LIST OF ST JUNCTION CONNECTOR ON BOARD THE VEHICLE
Components
REMOTE CONTROL/FUSE HOLDER CENTER
SUPPLEMENTARY REMOTE SWITCHES
SUPPLEMENTARY FUSES
INSTRUMENT-HOLDER DASHBOARD
CENTRAL DASHBOARD CONTROLS
CONTROLS ON THE STEERING WHEEL
REARVIEW MIRRORS AND WINDOW REGULATOR CONTROL ADJUSTMENT (OPT)
LEFT LIGHT CONTROL
DIAGNOSIS CONNECTOR
“VDI” ELECTRONIC CENTER
WALL PASS
ALTERNATOR
STARTER MOTOR
Elektronic systems
LOCATION OF MULTIPLEX SYSTEM COMPONENTS ON BOARD THE VEHICLE
Cluster
Body computer
Front Frame Computer (F.F.C.)
Rear Frame Computer (R.F.C.)
Driver door module (D.D.M.)
Passanger Door Module (P.D.M.)
C.B. (Cab module) Opt
S.W.I. (Steering wheel / steervator interface)
SPIRALED CONTACT
B.M. (BED MODULE) OPT
AUTOMATIC AIR CONDITIONER
MANUAL AIR CONDITIONER
HYDRONIC D 10 WATER HEATER
IMMOBILIZER
EDC
EBS
ABS-EBL
ECAS SUSPENSIONS
EUROTRONIC AUTOMATIC TRANSMISSION
INTARDER
Diagnosis
Circuit charts
Card 1: Battery positive
Card 2: Positive after TGC (+30)
Card 3: Positive after TGC (+30)
Card 4: Positive after TGC (+30)
Card 5: Services supply (+15)
Card 6: Services supply (+15)
Card 7: BC unit (J7)
Card 8: BC unit (J6)
Card 9: BC unit (J4-J5)
Card 10: BC unit (J2-J3)
Card 11: SWI unit
Card 12: FFC unit (J2)
Card 13: FFC unit (J1)
Card 14: RFC unit (J1)
Card 15: RFC unit (J2)
Card 16: CM unit
Card 17: DDM-BM unit
Card 18: PDM unit
Card 19: IC unit
Card 20: CAN-ICB/IDB line
Card 21: CAN-SB (EBS/ABS) line
Card 22: CAN-BCB line
Card 23: VDI unit / CAN-VDB line
Card 24: ECAS 4x2 FP
Card 25: ECAS 6x4 P
Card 26: ECAS 6x2 P/FP
Card 27: ECAS 4x2 Tractor
Card 28: ECAS 6x2C
Card 29: ZF retarder
Card 30: ABS
Card 31: EBS
Card 32: EuroTronic II
Card 33: Immobilizer
Card 34: Manually controlled air conditioning system
Card 35: Automatically controlled air conditioning system
Card 36: Automatically controlled supplementary water heater
Card 37: Manually controlled supplementary water heater
Card 38: Manually controlled supplementary air heater
Card 39: EDC (Connector A) for F3A engines
Card 40: EDC (Connector A) for F2B engines
Card 41: EDC (Connector B)
Card 42: PTO with mechanical gearbox
Card 43: Radioreceiver
Block diagrams
Chart 1: Start-up - recharge warning light
Chart 2: EDC power supply - Immobilizer -Warning light - EDC Blink code - (warning light) - Four wheel drive on warning light
Chart 3: Cruise Control - Accelerator pedal sensor (potentiometer) - Pre-post heating warning light
Chart 4: Intarder
Chart 5: Voltmeter - Rev counter - Engine water temperature - Fuel level
Chart 6: Engine oil pressure - Engine oil level - window winder level - Hydraulic power steering fluid level - Engine water level
Chart 7: Chock wear indicator - Pad wear indicator - Reduced gear on indicator- Clogged oil filter indicator - Clogged air filter indicator
Chart 8: Differential block -Water presence in fuel indicator
Chart 9: Exterior lights
Chart 10: Exterior lights
Chart 11: Exterior lights - Reverse light
Chart 12: Hazard lights - Headlight beam orientation
Chart 13: Internal lights
Chart 14: Windscreen wiper - Horn - Hour counter
Chart 15: TGC
Chart 16: Sunroof - Windscreen washer
Chart 17: Tachograph
Chart 18: Engine electric fan
Chart 19: Rearview mirror control - Power windows
Chart 20: Central door lock
Chart 21: ECAS (warning lights) - ABS (warning lights)
Chart 22: EBS (warning lights) - Heated windscreen - PTO
Chart 23: Retarder (warning light) - Cabin tilting
Chart 24: Brake air pressure - ECAS - Outside temperature
Chart 25: Trip odometer / Total odometer - Speed limiter
Chart 26: Engine oil temperature - Beacon lights - Sun visor

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