Iveco Stralis AT/AD. Manual

Figure 47

Figure 48

77471

72558

12. Change front, middle or rear axle wheel

hub oil (where applicable)

For the wheel hubs with the cover illustrated in the figure,
proceed as follows:
- turn the wheel hub so as to bring the plug (1) downward;

unscrew the plug and drain off the oil into an appropriate
container;

- then turn the hub and take the hole closed by the plug

(1) back upward and replenish with fresh oil; for the
quantity, see CHARACTERISTICS AND DATA in the
“AXLES” section;

- screw the plug down to the prescribed torque.

Figure 49

Use no chlorothene based solvents to clean the
cover.

For the wheel hub with the cover illustrated in the figure,
proceed as follows:
- remove the plug (1) and draw up the oil with a suitable

string;

- fill the wheel hub with new oil (for the quantity and type

of oil, see CHARACTERISTICS AND DATA in the
“AXLES” section.

The oil level is checked through the window in the plug (1)
with max. and min. on the cover in a horizontal position.

11. Check steering box fixing and mounting

Check that the fastenings of the steering box and
mounting are tightened to the required torque.

10. Check headlight adjustment

72585

- Set the vehicle unladen with its tyres at the required

pressure on level ground facing a light wall.

- Mark two crosses on the wall corresponding to the

centres of the two headlights.

- Turn the switch onto 0.
- Set the vehicle at 10 metres and turn on the low beam.

The distance between the crosses and the points P,
which correspond to the angle of the headlights, has to
be 12.5 cm.

Light beam adjustment screw in horizontal direction.

Light beam adjustment screw in vertical direction.

•

General chassis greasing

•

Manoeuvring

•

Road test

SCHEDULED MAINTENANCE

TRALIS

AT/AD

Base - January 2003

The M2 service includes M1 operations without 1-3.
“Check control belt conditions”. Add also the
following operations.

Figure 50

Figure 51

52758

17. Change gearbox oil

(ZF 16 S 181/221 gearbox)

- With the gearbox warm, take off the plug(s) (1) and

drain the oil into a specific container.

- The oil should be drained off taking care not to soil the

cross member beneath as it is near the outlet on some
types of gearbox.

- It is therefore wise to use a tool to convey the oil away.

- Pour in fresh oil through the hole closed by the plug (2)

(for the quantity, see under the FLUIDS heading of the
GENERAL section).

- Tighten the plugs to the required torque.

(ZF 12 AS 2301 / 16 AS 2601 gearbox)

72579

- With the gearbox warm, take off the plug(s) (1) and

drain the oil into a specific container.

- The oil should be drained off taking care not to soil the

cross member beneath as it is near the outlet on some
types of gearbox.

Figure 52

- With the gearbox warm, take off the plugs (1) and drain

the oil into a specific container.

72570

17. Change oil and filter of ZF 16 S 181/221

gearbox + Intarder

Figure 53

52571

Remove the oil filter as follows:

- unscrew the screw (5) fixing the filter;
- take off the cover and filter (1);
- remove the cover from the filter and replace it. Take care

not to lose the magnetic pad (4) on the outer edge of
the filter, as it has to be repositioned on the new filter;

- check the state of the o-ring (2) and replace it, if

necessary;

- grease the o-ring (3) inserted in the assembly opening of

the new filter;

- couple the new filter with its cover and insert it into its

seat as far as it will go. Secure the screw (5).

SCHEDULED MAINTENANCE

TRALIS

AT/AD

M2 SERVICE

Figure 54

Figure 55

72572

- Screw the plugs back on and tighten them to the

required torque.

- Pour in fresh oil through the hole closed by the plug (7)

until oil comes out of the hole of plug (6) and screw the
plugs back on to the required torque.
(The filling quantity is given under the FLUIDS heading
of the GENERAL section.)

- Clean the gearbox oil vapour breather.

Change oil and filter of ZF Eurotronic

Automated gearbox with Intarder

72573

- With the gearbox warm, take off the plugs (1) and drain

the oil into a specific container.

- Remove the Intarder filter following the procedure

described in the above paragraph.

- Screw the plugs (1) back on and tighten them to the

required torque. Pour in fresh oil through the hole of
plug (3) until oil comes out of the hole of plug (2).
(See the FLUIDS table in the GENERAL section.)

- Screw the plugs back on to the required torque.
- Clean the gearbox oil vapour breather.

Have a short test run on the roads (at least one
minute at least 10 km/h), briefly operating the
Intarder just once (level 6) and then disengage it
(level 0). At the end of the test, stop the vehicle
without operating the Intarder. Stop the engine,
check the level again (plug 2) and top up, if necessary.

Figure 56

21. Change variable geometry turbocharger

(VGT) valve air filter

72577

Using a suitable tool, unscrew the filter (1) and replace it.
Before fitting the new cartridge, moisten the seal with diesel
or engine oil. Screw it on by hand until it is in contact with
the mounting and then tighten by 3/4 of a turn to the
required tightening torque.

1.3. Change miscellaneous drive belts

Figure 57

72586

ASSEMBLY DIAGRAM OF BELTS FOR FAN — WATER

PUMP — ALTERNATOR AND AIR-CONDITIONER

COMPRESSOR

1. Alternator — 2. Fan — 3. Water pump — 4. Crankshaft

5. Air-conditioner compressor automatic tensioner

6. Air-conditioner compressor — 7. Compressor drive belt

8. Drive belt automatic tensioner — 9. Drive belt

To remove and refit the belts (7-9) you need to apply suitable
tools to the tensioners (5-8) in the direction shown by the
arrows.

The tensioners are automatic, so there should be no
further adjustment after assembly.

SCHEDULED MAINTENANCE

TRALIS

AT/AD

Base - January 2003

Figure 58

EXTRA PLAN MAINTENANCE

EP1 SERVICE

Figure 59

23. Change fuel filter

72561

Remove the fuel filter (1) with tool 99360314.
Before refitting the new cartridge, moisten the seal with
diesel or engine oil.
Screw the new one on by hand, taking care to check that the
rubber seal and the mating surface are clean and in a perfect
state of repair. Screw the cartridge on by hand until it is in
contact with the mounting and then tighten by 3/4 of a turn
to the required tightening torque.

Bleed the air from the supply system as described in the
following paragraph.

Bleeding air from the fuel circuit

72562

- Open the bleed screws, connecting them with tubes to

run off the bled fluid into suitable containers to prevent
dirtiness:
1 = located on the pre-filter mount (on the chassis

frame);

3 = located on the filter mount (on the engine);
4 = located on the front of the cylinder head.

Figure 60

- Work the hand pump (2) on the pre-filter till you see fuel

with no air in it coming out of the bleed screw (1)
(retighten the screw when the operation is over).
Keep on pumping until you see fuel with no air in it come
out of the bleed screw (3) on the filter as well (then
retighten the screw) and from the screw (4) on the front
of the cylinder head (retighten the screw when the
operation is over) and tighten them to the required
torque.

The circuit has now been bled. Start up the engine and run
it for a few minutes at idling speed to get rid of all remaining
air.

Never let the fuel soil the drive belt: alternator,
pump, water, etc.

EP2 SERVICE

22.

Check valve clearance and adjust if
necessary

To carry out these operations correctly, refer to the
procedures described in the relative chapter of the
“ENGINE” section.

EP3 SERVICE

15. Change rear axle oil

40657

The lubricating oil has to be drained with the oil warm.
Place a container under the plug (1), remove the plug and
drain off the oil.

Fit the plug (1) back on, remove the plug (2) and pour the
required grade and quantity of lubricating oil in through the
hole. Remove the oil vapour bleed and clean it thoroughly.

SCHEDULED MAINTENANCE

TRALIS

AT/AD

Content .. 280 281 282 283 ..

Iveco Stralis AT/AD. Manual - part 282