Astra HD8Ec, repair e-manual

Content

Introduction

• Preface
• Definitions adopted in the current manua
• Introduction
• Graphs and symbols
• Measures (international system)
• Conversion values for British units
• Standard tightening torques
• Screws and nuts with metric thread

General specifications

• Composition of the model
• Position of vehicle identification data
• Model identification plate
• Chassis
• Manufacturer’s plate
• Position of assembly identification data
• Engine
• Engine dependent power take-off
• Gearbox 16 S 1620 TD
• Gearbox 16 S 2320 TD
• Distributor-reducer (transfer)
• Front and rear drive axles
• Power steering boxes
• Cab
• Lubricant and hydraulic fluid tables

Engine - F3B

• Views of the engine
• Technical specification
• General characteristics
• Assembly clearance data
• Diagnosis
• Blink code
• Fault checking/identification procedure
• Fault memory cancellation procedure from drivers seat
• MS 6.2 EDC electronic control unit blink code table
• Diagnosis tools
• IT2000
• Upper level diagnosis
• Control unit diagnosis
• Engine diagnosis (engine test)
• Auxiliary functions
• Troubleshooting
• Introduction
• Troubleshooting (blink code)
• Troubleshooting by symptoms
• Tightening torques
• Tightening order of gearbox to engine
• Block fastening screws
• Tools
• Engine removal replacement
• Removal
• Replacement
• Bleeding air from supply system
• Checks and controls
• Dismantling the engine on the bench
• Repair operations
• Holset HX 50W (Turbine wastegate)
• Pressure limiter valve
• Pressure limiter valve control and adjustment
• Fuel feed
• Pump-injector
• Pumping element
• Nozzle
• Solenoid valve
• Replacing pump-injectors
• Injection phases
• Filling phase
• Injection phase
• Pressure reduction phase

Clutch

• Description
• Hydraulic control
• Master cylinder
• Specifications and data
• Diagnostics
• Hydraulic oil change
• Bleeding off air
• Maintenance
• Tightening torques
• Tools
• Removing and refitting
• Removal
• Checks
• Refitting
• Removing-refitting collar bearing
• Replacing the support bearing of the clutch shaft
• Clutch pedal adjustment
• Clutch actuator adjustment
• Vehicles with robotic transmission
• Servoclutch adjustment
• Mounting servoclutch in clutch housing

Power take off

• Description
• Operation
• Power take off disengaged
• Power take off engaged
• Features and data
• Driving torques
• Tools
• Special maintenance
• Oil replacement
• Stripping down refitting integral power take-off
• Stripping down
• Refitting
• Strip down main housing
• Strip down bearing for shaft with toothed crown
• Strip down output shaft
• Strip down oil pump
• Cleaning and checking the parts
• Fitting
• Oil pump
• Fitting the bearings for shaft with toothed crown
• Output shaft unit
• Setting the taper bearings on the output shaft
• Fitting the main housing
• Setting the ball bearings

Manual gearbox

• Description
• Operation
• Slow range
• Fast range
• Reduced gears
• Normal gears
• Servoshift
• Specifications and data
• Diagnostics
• Tightening torques
• Tools
• Gearbox removal-refit
• Removal
• Refit
• Overhauling operations
• Preliminary operations
• Removal gear command box
• Refitting gear command box
• Epicyclic reduction unit (E.R.U.) removal
• Disassembling the epicyclic reduction unit (E.R.U.)
• Assembling the epicyclic reduction unit (E.R.U.)
• Refitting the epicyclic reduction unit (E.R.U.)
• Disassembling the gearbox
• Disassembling the main shaft
• Disassembling the input shaft
• Disassembling the transmission shaft
• Checks
• Gearbox
• Hubs - sliding sleeves - forks
• Bearings
• Shafts - gears
• Synchronisers
• Single cone synchronisers type BK
• Assembling the input shaft
• Assembling the main shaft
• Adjusting the main shaft - version with straight tooth epicyclic reduction unit
• Adjusting the main shaft - version with helical tooth epicyclic reduction unit
• Assembling the gearbox
• Oil pump
• Adjusting the transmission shaft end float
• Input shaft cover
• Adjusting the input shaft end float
• Completion
• Version fitted with intarder
• Description
• General characteristics
• Tightening torques
• tools
• Stripping down-refitting gearbox
• Versions with separate exchanger
• Removal
• Refitting
• Versions with built-in exchanger
• Removal
• Refitting
• Repair operations
• Removing the hydraulic retarder
• Refitting the hydraulic retarder
• Removing the epicyclic reduction unit (E.R.U.)
• Disassembling the epicyclic reduction unit (E.R.U.)
• Epicyclic reduction group components
• Assembling the epicyclic reduction unit (E.R.U.)
• Refitting the epicyclic reduction unit (E.R.U.)

Reduction gear unit TC1800

• Description
• On road 
• Transmission of motion pictorial diagram: on-road Off road 
• Transmission of motion pictorial diagram: off road
• Specifications and data
• Tightening torques
• Tools
• Stripping down-refitting the reduction gear unit
• Stripping down
• Refitting
• Disassembling the reduction gear unit at the bench
• Dis-assembling the input shaft
• Dis-assembling the countershaft
• Dis-assembling the epicyclic reduction gear
• Replacing the seal rings of driving shaft covers
• Clean out and checks
• Fitting in place the input shaft
• Fitting in place the counter shaft
• Fitting in place the epicyclic reduction gear unit
• Assembling the reduction gear unit at the bench
• Adjustments
• Shaft bearings pre-load adjustment
• Indication switch adjustment
• Pulse transmitter adjustment

Reduction gear unit TC2200

• Description
• On road
• Transmission of motion pictorial diagram: on road
• Off road
• Transmission of motion pictorial diagram: off road
• Specifications and data
• Tightening torques
• Tools
• Stripping down refitting the reduction gear unit
• Stripping down
• Re-fitting
• Disassembling the reduction gear unit at the bench
• Disassembling the input shaft
• Disassembling the countershaft
• Disassembling the epicyclic reduction gear
• Replacing the seal rings of driving shaft covers
• Clean out and checks
• Fitting in place the input shaft
• Fitting in place the countershaft
• Fitting in place the epicyclic reduction gear unit
• Assembling the reduction gear unit at the bench
• Adjustment
• Shaft bearings pre-load adjustment
• Indication switch adjustment
• Pulse trasmitter adjustment

Propeller shafts

• Description
• Diagnostic
• Tightening torques
• Tools
• Removing and re-fitting in place the propeller shaft
• Universal joint
• Removing
• Cleaning
• Checks
• Assembling
• Checking the propeller shafts on the vehicle

Axle

• Description
• Characteristics and data
• Diagnostic
• Tightening torques
• Tools
• Removing and re-fitting the axle
• Removal
• Refitting
• Disassembling
• Checking disassembled parts
• Axle body checks and measurements
• Leaf spring contact surfaces check using gauge 99305111
• Kingpin holes camber angle check using gauge 99305111
• Refitting

Front drive axle

• Description
• Specifications and data
• Driving torques
• Tools
• Diagnostics
• Removing - refitting the front drive axle
• Removal
• Refitting
• Repairing the axle and wheel hubs
• Removing the fork support
• Removing the stub axle
• Removing the epicyclic reduction gear
• Clean-out and checks
• Checking the axle casing camber angle and caster angle
• Fitting in place the fork support
• Fitting in place the stub axle
• Fitting in place the epicyclic reduction gear support
• Greasing the stub axle pins
• Epicyclic units lubrication
• Removing the differential (with axle on stand 99322215)
• Axle casing check
• Refitting in place the differential (with axle on stand 99322215)
• Repairing the differential
• Removal

Single rear axle

• Description
• Specifications and data
• Tightening torques
• Tools
• Diagnostic
• Removing - refitting the rear axle
• Removal
• Refitting
• Rear axle assembly overhaul operations
• Removing the epicyclic reduction gear
• Removing the wheel hubs
• Wheel hubs and epicyclic reduction gear components check
• Fitting in place the wheel hubs
• Fitting in place the epicyclic reduction gear
• Removal and re-fitting in place the differential
• Removal
• Re-fitting in place
• Removing the differential housing
• Removing the gear housing
• Removing the bevel pinion support
• Differential components check
• Fitting in place the gear housing
• Fitting in place the bevel pinion support
• Procedure to determine the thickness of the bevel pinion rolling torque adjusting ring
• Fitting in place the differential housing
• Adjusting the rolling torque of the gear housing bearings
• Total rolling torque Nm

Intermediate axle in tandem

• Description
• Specifications and data
• Tightening torques
• Tools
• Diagnostic
• Removing - refitting the intermediate axle
• Removal
• Refitting
• Removing-refitting in place the differential-reduction gear unit (with axle on vehicle)
• Removal
• Refitting
• Intermediate axle assembly repair operations
• Removal
• Removing the epicyclic reduction unit
• Removing the wheel hubs
• Checks on the wheel hubs and epicyclic reduction gear components
• Fitting in place the wheel hubs
• Fitting in place the epicyclic reduction unit
• Removal-refitting in place of the differential-reduction gear unit (with axle on stand 99322215)
• Removal
• Refitting
• Differential-reduction gear unit repair operations
• Removal
• Removing the gear housing
• Removing the differential-reduction gear unit
• Check on differential-reduction gear unit components
• Refitting the differential-reduction gear unit
• Fitting in place the gear housing
• Fitting in place the bevel pinion housing
• Procedure to determine the adjusting ring thickness for the bevel pinion rolling torque
• Fitting in place the differential housing
• Adjusting the rolling torque for the gear housing bearings
• Adjusting the end play between bevel gear pair and pinion
• Driving shaft
• Removal
• Checking components
• Refitting in place

Rear axle in tandem

• Description
• Specifications and data
• Tightening torques
• Tools
• Diagnostics
• Removing - refitting the rear axle
• Removal
• Refitting
• Rear axle assembly repair operations
• Removing the epicyclic reduction unit
• Removing the wheel hubs
• Wheel hubs and epicyclic reduction gear components check
• Fitting in place the wheel hubs
• Fitting in place the epicyclic reduction uni
• Removal and refitting in place the differential
• Removal
• Refitting
• Differential repair operations
• Removing the differential housing
• Removing the gear housing
• Removing the bevel pinion support
• Differential components check
• Fitting in place the gear housing
• Fitting in place the bevel pinion support
• Procedure to determine the thickness of the bevel pinion rolling torque adjusting ring
• Fitting in place the differential housing
• Adjusting the rolling torque of the gear housing bearings
• Adjusting the end play between bevel gear pair and pinion

Brakes

• Description
• Specifications and data
• Diagnostics
• Tightening torques
• Tools
• Front brakes
• Removal
• Drum tuning
• Replacing brake linings
• Fitting in place
• Rear brakes
• Removal
• Fitting in place
• Setting the brake peda
• Floor pedal unit
• Hanging pedal unit

Wheels and tyres

• Description
• Specifications and data
• Tightening torques
• Tools
• Checks and requirements
• Wheel static balancing
• Correcting residual static imbalance
• Tyre pressure
• How tyre behaviour depends on pressure

Front suspensions

• Description
• 1st axle suspension
• 2nd axle suspension
• Hydraulic shock absorbers
• Noise
• Changes in braking effect
• Characteristics and specifications
• Leaf springs
• Shock absorbers
• Diagnostics
• Tightening torques
• Tools
• Leaf spring removal-replacement (axle)
• Removal
• Replacement
• Leaf spring removal replacement (drive axle)
• Removal
• Replacement
• Repair operations
• Removing the rear leaf spring
• Checks
• Fitting in place the leaf spring

Rear suspensions

• Description
• 2-axle vehicle suspension
• 3 and 4-axle vehicle suspension
• Hydraulic shock absorbers
• Noise
• Changes in braking effect
• Specifications and data
• Leaf springs
• Shock absorbers
• Diagnostics
• Tightening torques
• 2-axle vehicles
• Front suspension
• 3 and 4-axle vehicles
• Front suspension
• Tools
• Leaf spring removal-replacement (2-axle vehicles)
• Removal
• Replacement
• Removing-refitting the leaf spring (3-axle and 4-axle vehicles)
• Removal
• Replacement
• Repair operations
• Removing the rear leaf spring
• Checks
• Fitting in place the leaf spring
• Replacing the floating arm pin (3-axle and 4-axle vehicles)
• Removal
• Fitting in place
• Refitting and adjusting the floating support (3-axle and 4-axle vehicles)

Steering system

• Description
• 2-axle and 3-axle vehicles
• 2 and 3-axle vehicle hydraulic servosteering system
• 4-axle vehicles
• 4-axle vehicle hydraulic power steering system
• Scheme
• Power steering - 2 axles and 3 axles vehicles
• Power steering - 4 axles vehicles
• Steering hydraulic limitation
• Automatic steering regulation
• Specifications and data
• 2 and 3 axle vehicles
• Steering angle and toe-in - 2 and 3 axle vehicles
• Hydraulic system - 4 axle vehicles
• Steering angle and toe-in - 4 axle vehicles
• First axle / axle set steering angle
• Second axle / axle set steering angle
• Diagnostics
• Tightening torques
• Power steering box
• Linkage
• Tools
• Steering box removal-replacement
• 2 and 3-axle vehicles
• Removal
• Replacement
• 4-axle vehicles
• Removal

Pneumatic system - brakes

• Description
• Service braking
• Emergency braking
• Slow-down braking
• Parking braking
• Braking system diagrams
• 4x4 vehicles without tow hook
• 4x4 vehicles with tow hook
• 6x4 and 6x6 vehicles without tow hook
• 6x4 and 6x6 vehicles with tow hook
• 6x4T and 6x6T vehicles with tow hook
• 8x4 vehicles without tow hook
• 8x4 vehicles with tow hook
• Pneumatic system diagrams (services)
• 2-axle vehicles
• 3-axle and 4-axle vehicles
• Diagnostics
• Tightening torques
• Tools
• Braking system main components check
• Braking system main components
• Compressor
• Head locking screw torques
• Drier
• Four-way safety valve
• Duplex distributor
• Pressure reducer
• Triple control servo distributor
• Coupling heads
• Check valve
• Parking brakes control hand distributor
• Relay valves
• Engine brake control pedal valve
• Engine brake control operator cylinder
• Diaphragm brake cylinder
• Combined brake cylinder
• Combined cylinder emergency relief device
• Repair operations
• Braking control
• Adjusting the load sensing valve on the vehicle
• Brake anti-lock distributor
• RPM sensors
• Phonic wheels
• Pipes and couplings
• General
• End forming on rigid pipes
• Bending rigid pipes
• Cutting rigid pipes
• Replacing flexible hoses with threaded couplings
• Replacing flexible hoses with quick-connection couplings
• RPM sensor phonic wheel

Electrical system

• Technical data
• International system units (S.I.)
• Main elements - resistivity and temperature coefficient
• Resistor colour codes
• Wires
• Composition and characteristics
• General instructions
• General precautions
• General precautions for electronic components
• The concept of earth and electromagnetic compatibility
• Practical hints
• Cable colour codes
• 4-digit cable colour codes
• 4-digit component codes
• 5-digit component codes
• Fuses
• Remote switches
• Electrical system diagrams

Cab and chassis

• Description
• Cab repair
• Introduction
• Surface repairs
• Structural repairs
• Chassis
• Specifications
• Chassis
• Auxiliary chassis
• Repair operations checks
• Modifying the chassis
• Finding chassis lateral bending
• Finding chassis bending up and down
• Finding chassis displacement
• Axle position
• Finding chassis twist
• Precautions
• Welds on the chassis

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