Iveco Stralis AS Euro 4/5 2006–2013 Repair Manual Set (P/N 603.93.531)
1,916 Pages • ZIP Download: 3 Printable PDFs (English)
Iveco Models Covered & Key Technical Specifications
Models: Stralis AS Euro 4/5 (AS 190, AS 260, AS 440), Stralis AT Euro 4/5, Stralis AD Euro 4/5
Models & Model Codes:
Stralis AS 190 — AS 190S 42/P, AS 190S 42/FP-CM, AS 190S 42/FP-GV, AS 190S 45/P, AS 190S 45/FP-CM, AS 190S 45/FP-GV, AS 190S 50/P, AS 190S 50/FP-CM, AS 190S 50/FP-GV.
Stralis AS 260 — AS 260S 42Y/FP-CM, AS 260S 42Y/FP-GV, AS 260S 42Y/FS-CM, AS 260S 42Y/FS-GV, AS 260S 42Y/P, AS 260S 42Y/PS, AS 260S 42Y/PT, AS 260S 45Y/FP-CM, AS 260S 45Y/FP-GV, AS 260S 45Y/FS-CM, AS 260S 45Y/FS-GV, AS 260S 45Y/P, AS 260S 45Y/PS, AS 260S 45Y/PT, AS 260S 50Y/FP-CM, AS 260S 50Y/FP-GV, AS 260S 50Y/FS-CM, AS 260S 50Y/FS-GV, AS 260S 50Y/P, AS 260S 50Y/PS, AS 260S 50Y/PT, AS 260S 56Y/FP-CM, AS 260S 56Y/FS-CM, AS 260S 56Y/P, AS 260S 56Y/PS, AS 260S 56Y/PT, AS 260S 50Z/P-HM, AS 260S 56Z/P-HM, AS 260S 50TZ/P-HM, AS 260S 56TZ/P-HM.
Stralis AS 440 — AS 440S 42T/P+T/P-RR, AS 440S 42T/P-HR, AS 440S 42T/FP-LT, AS 440S 45T/P+T/P-RR, AS 440S 45T/P-HR, AS 440S 45T/FP-LT, AS 440S 50T/P, AS 440S 50T/P-HR, AS 440S 50T/FP-LT, AS 440S 56T/P, AS 440S 56T/P-HR, AS 440S 56T/FP-LT, AS 440S 42TX/P, AS 440S 45TX/P, AS 440S 50TX/P, AS 440S 56TX/P, AS 440S 50TY/PT.
Stralis AT Euro 4/5 — EBS 2/ESP/EBL braking and BC2 electrical coverage only.
Stralis AD Euro 4/5 — EBS 2/ESP/EBL braking and BC2 electrical coverage only.
Sub-models / Variants: Active Space (AS), Active Time (AT), Active Duty (AD), 4x2, 6x2 C, 6x2 P, 6x4, Tractor, Lorry, Low Cab, Heavy Duty, Rough Road
Engine Variants (Stralis AS): S 42 — F3AE3681D; S 45 — F3AE3681A; S 50 — F3BE3681B; S 56 — F3BE3681A.
Manual Transmissions (Stralis AS): S 42 except HR — ZF 16 S 1920 T.D.; S 45 except HR — ZF 16 S 2220 T.D.; S 50 except HR — ZF 16 S 2320 T.D.; S 56 — ZF 16 S 2520 T.O.; S 42/S 45 HR — ZF 16 S 2220 T.O.; S 50 HR — ZF 16 S 2520 T.O.
Automated Transmissions (Stralis AS): S 42 except HR — EuroTronic 12 AS 1930 T.D.; S 45/S 50 except HR — EuroTronic 12 AS 2330 T.D.; S 56 — EuroTronic 12 AS 2530 T.O.; S 42/S 45/S 50 HR — EuroTronic 12 AS 2330 T.O.
Manual Transmission Versions with Intarder: ZF 16 S 1920 T.D. → ZF 16 S 1921 T.D.; ZF 16 S 2220 T.D. → ZF 16 S 2221 T.D.; ZF 16 S 2220 T.O. → ZF 16 S 2221 T.O.; ZF 16 S 2320 T.D. → ZF 16 S 2321 T.D.; ZF 16 S 2520 T.O. → ZF 16 S 2521 T.O.
Automated Transmission Versions with Intarder: EuroTronic 12 AS 1930 T.D. → EuroTronic 12 AS 1931 T.D.; EuroTronic 12 AS 2330 T.D. → EuroTronic 12 AS 2331 T.D.; EuroTronic 12 AS 2330 T.O. → EuroTronic 12 AS 2331 T.O.; EuroTronic 12 AS 2530 T.O. → EuroTronic 12 AS 2531 T.O.
Model Years: 2006–2013 (2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013)
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Engine Displacement: 10300 cm³ (F3A); 12880 cm³ (F3B)
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Compression Ratio: 16.5:1
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Engine Configuration: 6-cylinder in-line
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Fuel System: Electronic unit injectors (UIN3.1) with overhead camshaft
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Turbocharger: Holset HE 531 V variable geometry (F3A); Holset HE 551 V variable geometry (F3B)
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Maximum Power: 420 CV (F3AE3681D); 450 CV (F3AE3681A); 500 CV (F3BE3681B); 560 CV (F3BE3681A)
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Maximum Torque: 1900 Nm (F3AE3681D); 2100 Nm (F3AE3681A); 2300 Nm (F3BE3681B); 2500 Nm (F3BE3681A)
Iveco Manual Features & Selected Content Preview
| Publication | Pages |
|---|---|
| Iveco Stralis AS Euro 4/5 Mechanical/Electric-Electronic Repair Manual — P/N 603.93.531, 2nd edition, September 2006; AS 190/260/440 configurations | 1,614 |
| Stralis AT/AD/AS Electronically Controlled Braking System EBS 2/ESP/EBL — P/N 603.93.321, 1st edition, May 2004 | 128 |
| Stralis Circuit Diagrams (BC2) — P/N 603.93.746, 1st edition, March 2007; AS and AT/AD electrical configurations | 174 |
The main volume provides mechanical repair and electric/electronic diagnosis. The companion publications add dedicated brake-system material and the revised BC2 electrical architecture, allowing the appropriate drawings to be selected for the installed system.
Coverage limit: Full mechanical repair coverage is for Stralis AS Euro 4/5. AT/AD coverage consists of the braking publication and BC2 electrical material, including instrument panels, VCM circuits, ventilation, cooling, climate control, and an Allison gearbox circuit. This is not a complete AT/AD mechanical repair manual.
PDF Search, Bookmarks, and Diagram Detail
Text search and drawings: All three PDFs contain searchable text, although some wiring labels are not searchable. The main repair manual and braking manual have embedded bookmarks; the BC2 volume does not. Small wiring labels require zooming, and some diagrams are oriented sideways.
The ZIP download contains three printable English PDFs totaling 1,916 pages. That total includes 16 pages of front matter in the main manual and two cover/publication pages in each companion volume.
Engine Overhaul, Chassis Repair, and Electrical Diagnosis
The following is a selection of covered work, rather than a complete contents list. Further topics include cabin-refrigerator repair and driver-seat component replacement.
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Engine repair: Step-by-step removal, bench disassembly, liner and crankshaft inspection, bearing selection, cylinder-head service, camshaft and phonic-wheel timing, and pump-injector setup.
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Clutch and transmission: Clutch removal and adjustment, hydraulic-circuit bleeding, ZF manual and EuroTronic gearbox removal, Intarder service, and rear reduction-gear work.
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Axles and steering: Differential and wheel-end repair, wheel-geometry checks, added-axle hydraulic bleeding, and ZF power-steering removal, bleeding, and pressure testing.
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Brake systems: EBS/ABS/EBL/ASR and ESP diagnosis, pneumatic diagrams, KNORR SN7 caliper service, drum-brake repair, and steering-angle calibration requirements.
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Suspension: Mechanical and pneumatic suspension repair, ECAS fault diagnosis, chassis-height adjustment, and axle-load display calibration.
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Cab and chassis: Cab-tilt hydraulics, windshield and door work, HVAC diagnosis, frame measurement, straightening and welding guidance, and scheduled maintenance.
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Electrical systems: CAN architecture, ECU and connector data, system-specific wiring diagrams, DTC-FMI troubleshooting, and BC2 circuit and block diagrams.
Iveco expressly addresses this material to qualified and specialized personnel equipped with the required workshop, lifting, testing, and diagnostic equipment.
Configuration Matching and Engine Setup
The model-composition tables distinguish AS 440 tractors, AS 190/260 cab-equipped vehicles, and AS 260 tandem-drive tractors. Their codes identify rear- or all-air suspension, liftable or steering added axles, lowered chassis, rough-road, hub-reduction, and high-cube layouts. This matters because gearbox, axle, brake, and suspension procedures are configuration-specific.
The F3AE3681D, F3AE3681A, F3BE3681B, and F3BE3681A chapters provide assembly-clearance data, inspection and wear limits, component-specific torque tables, tightening sequences, and lubrication and cooling capacities. Timing work identifies dedicated tools, including 99360612 for engine TDC positioning and 99360613 for phonic-wheel timing.
Fuel-system material includes filling and bleeding procedures, while cooling-system sections cover refilling and fan-coupling checks. Separate sections address the optional Hydrocar timing-drive PTO and DENOX 2/SCR dosing components.
The VGT repair instructions caution that forcing the turbine housing during assembly can damage the variable-geometry mechanism and cause control faults.
Drivetrain, Axles, and Brake Service
For Intarder-equipped gearboxes, bench procedures cover the rear epicyclic reduction assembly and bearing or stator end-float adjustment. The separate ZF Intarder section includes removal, overhaul, component inspection, and refilling. Propeller-shaft and universal-joint procedures extend coverage beyond the gearbox.
Axle sections address Meritor MS 13-175/D, Iveco 451391, MT 23-155/D tandem assemblies, 5876-series front and steering axles, and 55080/56082/57080 added axles. Hydraulic layouts distinguish central and rear steering added-axle circuits.
The KNORR SN7 instructions warn that over-travel of the caliper threaded tubes can put the adjusters out of synchronization and require caliper replacement.
Cab Systems and Planned Maintenance
HVAC material covers mechanical fault diagnosis, component replacement, and refrigerant recovery, evacuation, and charging with the specified service equipment. Cab-tilt procedures distinguish manual and electrically driven systems.
M1/M2, Extra Plan, and time-based maintenance schedules are accompanied by service procedures and check-point diagrams.
Brake pneumatics, cab-tilt hydraulics, heavy component handling, refrigerant systems, and ECU work require the stated isolation procedures and appropriate shop equipment.
Diagnostic Drawings and Test Support
Drawings include cylinder-head tightening sequences, configuration-specific EBS and ABS-EBL pneumatic schemes, air-suspension diagrams with and without an added-axle lifter, CAN-line assembly drawings, OBD connector views, and BC2 block diagrams.
MODUS, IT 2000, and E.A.SY. are identified alongside cluster diagnosis. DTC/FMI material links fault reactions to checks and repair actions for EDC, EuroTronic, ECAS, braking, SCR, HVAC, and multiplex systems. Cluster access supports initial fault assessment; the manual specifies diagnostic instruments for deeper investigation.
Examples of Timing and Brake Inspection Data
Camshaft-timing checks specify injector-cam lift of 5.30 ± 0.05 mm for F3A engines and 5.33 ± 0.05 mm for F3B engines. These values are measured at the No. 1 injector rocker roller, with the dial-gauge stem perpendicular to the engine axis.
The disc-brake specifications distinguish normal disc thickness of 45 mm from the minimum permissible thickness of 37 mm, separating the original dimension from the service limit.
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