Iveco Stralis AS/AT/AD Euro 4-5 Bodybuilder Instructions Manual 2008

Description

File Details

• Manual type: Bodybuilder Instructions / Conversion Manual
• Brand: Iveco
• Model: Stralis AS / AT / AD
• Emission standards: Euro 4 / Euro 5
• Document number: 603.93.721
• Edition: Base – January 2008
• Language: English
• File format: PDF
• Page count: Approx. 252 pages

Chapters Covered

• Section 1 – General specifications: Aim of bodybuilders instructions, IVECO “no objection” for changes and fittings, liabilities, guarantees, request procedure, technical documents, trademarks and logos, legal provisions, prevention of accidents, ecology and recycling, vehicle delivery, vehicle identification, dimensions and weights, centre of gravity of body and payload, observing permitted weights, correct functioning and maintenance accessibility, quality system, vehicle maintenance, conventions.
• Section 2 – Chassis modifications: General instructions, specific precautions, painting and rust protection, drilling the chassis, screws and nuts, material characteristics, stresses on the chassis, welding the chassis, closing existing holes, modifying the wheelbase, effects on steering and braking, cross members, changes to transmissions, modifying the rear overhang, installing a towing device, traditional towing hooks, tow hooks for mid-axled trailers, lowered rear cross member, reinforcement of standard rear cross member, increasing towable weight, installing a supplementary axle, steering axles, components and suspension, stabilisers, braking system for additional axle, raise device, modifying the suspension, drive line modifications, engine air intake and exhaust, engine cooling system, supplementary heating, air-conditioning, cab modifications, changing tyre size, braking system modifications, brake pipes, electronic braking control, taking air from the system, electrical system modifications, repositioning parts, ADR hazardous goods transport, retarder installation, rear underrun modifications, rear mudguards and wheel boxes, mudflaps, side guards, chocks.
• Section 3 – Building & mounting the structures: Subframes and bodies, material for steel and aluminium subframes, longitudinal section dimensions, elements of the subframe, longitudinal runner profiles, cross members, connections between frame and subframe, choosing the body mounting type, body mounting characteristics, connection with brackets, greater elasticity connection, U-bolt clamps connection, cleat plate shear-resisting connection, mixed connection, fitting box-bodies, fixed bodies, tipper bodies, heavy-duty and light-duty service, containers, tractors for semitrailers, position of the fifth wheel, coupling of tractor and semitrailer, fifth wheel mountings, installation of structures working with chassis, converting a truck into a semitrailer tractor, variable height fifth wheel, transport of indivisible materials, installation of tanks and containers for bulk materials, installing a crane behind the driver’s cab, crane on rear overhang, removable cranes, installation of tail lifts.
• Section 4 – Power take-offs: General specifications, PTO from gearbox, PTO from transfer box, PTO from drive line, PTO from engine, torque power take-off from the front of the engine, power take-off from the rear of the engine, Multipower power take-off on flywheel side, PTO from timing gears at rear of engine, PTO management, definitions, diagram functions, PTO switch, PTO modes, EM-PTO 1-2-3 configurable and programming, RPM mode, configurable RPM modes, custom settings, special function settings, changes to the torque curve, PTO management for no PTO installed, Multipower, manual gearbox with electric engagement, Allison gearbox, FOCSA, engine PTO, Eurotronic 2 transmission, EM (Expansion Module) and connections.
• Section 5 – Special instructions for electronic subsystems: Electronic system, description of ECUs, Instrument Cluster, Body Computer and Cab Module, bulkhead coupling, Front Frame Computer, Rear Frame Computer, Expansion Module, bodybuilder connectors in the cab and on frame, truck/trailer connectors, electrical circuit modifications, wiring harness length, repositioning ECUs, disconnecting ECUs, FMS, electrical system modifications and drawing-off power, electromagnetic compatibility, additional equipment, taking current, general battery switch, additional circuits fuses and conductor cross-section, harness modifications due to wheelbase changes, power draw-off at different voltage, side marker lamps.
• Section 6 – Special instructions for SCR exhaust system: General specifications, nitrogen oxide catalytic reduction principle and AdBlue, on-board instruments, distribution of the ecological additive AdBlue, specifications for installation and removal, positioning the AdBlue tank, operations on AdBlue pipes and heating water, lengthening and shortening AdBlue ducts, altering the supply module position, operations on the dosing module, operations on exhaust pipes, wiring for positioning of SCR system components, OBD 1 – Stage 2.

This Iveco Stralis AS/AT/AD Euro 4-5 Bodybuilder Instructions manual is the reference document that IVECO issues to bodybuilders and chassis converters working on the Stralis range. It sets out exactly how the vehicle chassis, electrical architecture and exhaust after-treatment system may be modified without compromising safety, reliability or homologation. The manual walks through the entire conversion workflow, from the first weight and centre-of-gravity check on the bare chassis cab, through welding, drilling and wheelbase alteration rules, to the specific requirements for mounting a subframe, a tipper body, a crane, a tail lift or a fifth wheel. Electrical content explains how the MUX system is structured, which bodybuilder connectors are available in the cab and on the frame, and how power may be drawn from the vehicle without damaging control units. PTO coverage is unusually thorough and includes engagement conditions, speed modes, torque limits and the programming responsibilities that fall on the converter. The SCR chapter documents AdBlue tank positioning, pipe routing, dosing module orientation and the correct handling of the exhaust system during bodywork changes. Anyone responsible for building or converting a Stralis to Euro 4 or Euro 5 specification will find the manufacturer’s dimensional limits, material grades, tightening values and connection rules collected in one place.

What This Manual Helps You Do

A bodybuilder working from this Iveco Stralis bodybuilder instructions manual can correctly plan and execute the structural and electrical work that turns a standard Stralis chassis cab into a working vocational vehicle. That includes deciding whether a wheelbase change needs IVECO authorisation, choosing the right steel grade for a subframe, calculating how the payload’s centre of gravity sits relative to the permitted axle loads, and selecting shear-resistant plates or elastic mountings depending on the body type. The wiring and connector reference in Section 5 lets an installer integrate PTO controls, tail lift power, side marker lamps and trailer interfaces through the intended factory points instead of splicing into sensitive CAN lines. The SCR instructions in Section 6 are essential when the AdBlue tank or dosing module has to be moved to make room for a body, because getting the pipe lengths, gradients and dosing module angle wrong can trigger derating or damage the system.

Because this is the document IVECO itself expects converters to follow, the procedures and limits inside it are the ones that keep the conversion within warranty and within the law. Without it, a bodybuilder is working from general experience, which is exactly where mistakes with chassis drilling, welding near electrical units, or AdBlue pipe routing tend to happen.

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Instant PDF Delivery

The manual is delivered as a downloadable PDF immediately after purchase. No shipping and no waiting for a physical book. The file opens on any computer, tablet or smartphone and can be printed for use in the workshop, so the relevant page can sit next to the vehicle while the work is being carried out.