Maintenance manual Astra HD9 Series (Euro 3) 2008 thru 2013 in electronic form

Content

Introduction

After sales service

Warning

Technical data

• Position of vehicle identification data plates
• Model identification plate
• Imprinting of the vehicle chassis
• Vehicle identification plate
• Chassis punching
• Vehicle registration number
• Engine
• Main specifications
• Manual transmission
• Clutch
• Gear shift
• Ratios
• Transfer distributor
• Axle
• Front steering axle
• Front steering drive axle
• Single rear drive axle
• Tandem rear drive axles
• Brakes
• ABS
• Tyres
• Suspension
• Steering
• Electrical system
• Chassis
• Fuel tank
• Tightening torques
• Vehicle outfitting

Instructions for use

• General instructions for correct use of the vehicle
• Range of use of the engine
• Left hand drive vehicles
• Cab-external
• External lighting
• Doors
• Central locking remote control
• Replacing remote control battery
• Driver’s seat
• Internal lighting device
• Upper dashboard
• External rear view mirrors
• Mirror selection and handling
• Seats
• Fore and aft adjustment
• Cushion angle adjustment
• Seat suspension adjustment
• Springing system adjustment
• Height adjustment
• Backrest angle adjustment
• Seat belts
• Electric window control
• Electric window risers control
• Hatch
• Compartments
• Dashboard
• Upper dashboard
• Door
• Tunnel
• Seat
• Rear wall
• Accessories - devices
• Sun blind tabs
• Grip handle
• Coat hook
• Cigar lighter
• Ashtray
• 12Volt current socket
• Controls
• Module holder dashboard controls
• Steering wheel position control
• Accelerator
• Service brake
• Clutch
• Manual transmission control
• Instruments
• Functions of instrument panel keys
• Warning lights panel
• Warning lights on dashboard
• Control operation
• Position and headlight controls
• Headlight control
• Direction indicator control
• Horn
• Windscreen washer / wiper control
• Ignition switch
• Engine braking control
• Cruise control
• Hazard light control
• Exhaust brake pre-selection
• Courtesy light switch
• Electro-pneumatic horn pre-selection
• Swivelling light control
• Work light
• Rear fog light
• Fog light control
• Electric battery isolator control
• ASR off command
• ABS off command
• Distributor-reducer (transfer)
• Differential lock control (2 axle vehicles)
• Reat longitudinal distributor and transverse differential lock (4x4 vehicles only)
• Rear transverse differential lock (4x2 vehicles only)
• Differential lock control (3-4 axle vehicles)
• Interaxle longitudinal differential lock and rear transverse differential lock
• Longitudinal distributor differenital lock (6x6, 8x6 and 8x8 vehicles only)
• Power take off control
• Multipower PTO on flywheel
• P.T.O. manual transmission
• Tachometric simulator
• Heating and ventilation
• Climate control system air vents
• Climate controls
• Most common control position
• Auxiliary heater (WEBASTO)
• Auxiliary heater control panel
• Operation of the heater with key-off without programming
• Operation of the heater with key-on without programming
• Use of the vehicle
• Precautions for the initial period of use
• General checks
• Refuelling
• Starting engine
• Checks before starting
• Starting from the driver’s cabin
• Starting from engine bay
• Tow starting
• Emergency electrical power
• Cold start
• Starting with heater
• Stopping engine
• Stopping from drivers cabin
• Stopping from engine bay
• Manual transmission vehicles
• Starting the vehicle
• Driving the vehicle
• Gearbox
• Gearbox control
• Operating the clutch
• Splitter control
• Stopping the vehicle
• Speed programmer
• Engine idle speed adjustment / memorising
• Vehicle speed (cruise control) adjustment / memorising
• Enable
• Changing setting
• Tip function
• Ramp Function
• Permanent disable
• Temporary disable
• Engine brake
• Vehicle parking
• Parking brake
• Additional parking brake
• A.B.S. Anti-lock braking system
• Semi-trailer coupling
• Coupling
• Check closure
• Uncoupling
• ABS coupling
• Pivoting fifth wheel
• Trailer hooking
• Norms for towing trailer / semi-trailer
• Trailer coupling
• Semi-trailer coupling
• Ladder
• Towing the vehicle
• Wheel change
• Diagnostics
• Quick guide to the most common problem

Maintenance instructions

• Introduction
• Opening radiator grill
• Tilting the cab
• Lifting the cab
• Lowering the cab
• Main levels check
• Check engine oil level
• Check engine coolant level
• Check windshield washer level
• Engine
• Changing engine oil
• Replacing engine oil filter
• Engine oil vapour filter change
• Accessory drive belts check
• Intake-exhaust valve play adjustment
• Injector-pump pre-load adjustment
• VGT actuator grease application procedure
• Fuel feed system
• Bleed fuel tank condensation water
• Fuel tank water drain
• Purging water from fuel decanter
• Replacing fuel filters
• Replacing fuel decanter filter
• Fuel circuit bleeding
• Intake system
• Intake system seal check
• Turbocompressor lubrication check
• Intercooler external cleaning
• Main filter element cleaning / change
• Safety secondary filter element replacement
• Replacing the VGT piloting hoses filtering element
• Cooling system
• Replacing engine coolant
• Checking antifreeze concentration
• Clutch
• Check clutch disengagement
• Changing the hydraulic fluid
• Air bleeding
• Multipower PTO
• Oil level check
• Oil change
• ZF NMV 221 power take off
• Oil filter change
• Gearbox
• Oil level check
• Oil change
• Distributor-transfer (transfer)
• Transmission shafts
• Greasing
• Axles
• Front axle
• Check differential oil level
• Hub oil level check
• Front axle
• Checking differential oil level
• Checking oil hub level
• Front intermediate axle
• Check differential oil level
• Differential oil change
• Hub oil level check / change
• Rear intermediate axle
• Rear axle
• Suspensions
• Leaf spring pins greasing
• Carriage pin greasing on 3 and 4-axle vehicles
• Steering system
• Bleeding off air
• Stub axle greasing
• Steering linkage grease application
• Front wheel
• Compressed air system
• Tank visual inspection
• Air drier functionality check
• Air dryer filter change
• Braking system
• Shoe-drum play check
• Check pedal distributors
• Tyres and wheels
• Inflating tyres
• Cab tipping system
• Greasing
• Towing systems
• Greasing the fifth wheel
• Tow hook greasing
• Air conditioner
• Air-conditioner system maintenance
• System charge check
• Supplementary heater
• Replacing the supplementary heater fuel filter
• Bodywork
• Replacing front windscreen wiper blade
• Windscreen washer reservoir
• Bodywork maintenance
• Cleaning plastic parts
• Cleaning seat belts
• Lighting system
• Headlight / front sidelight bulb replacement
• Headlight alignment
• Front direction indicator light bulb replacement
• Side direction indicator bulb replacement
• Rear light bulb replacement
• Front clearance light bulb replacement
• Rotary warning light bulb replacement
• Ceiling light bulb replacement
• Replacing cab step light
• List of bulbs
• Electrical system
• Precautions
• Battery maintenance (unsealed batteries)
• Recharge with external devices
• Changing the battery
• Interconnection control unit (fuses and relays
• Fuse replacement
• Fuse / relays holder plate
• Fuses
• Fuse holder
• Relays
• Supplementary relays
• Additional relays board .
• Supplementary flying fuse

Table and diagrams

• Introduction
• Lubricants, oils, hydraulic fluids and filter refilling / replacement diagram
• Axle vehicles
• Location of components
• Engine F3B
• Engine F2B
• Manual transmission
• Multipower / NMV 221 power take off
• Drive line
• Greasing transmission shaft
• Suspension geasing
• Steering linkages, semi-trailer fifth wheel, tow hook greasing
• Systems
• Service schedule
• Lubricant and hydraulic fluid tables

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