Astra HD8Ec, repair e-manual
Only original manuals
Available immediately after payment
Full compliance with the paper edition
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Publisher: © "Motorist"
ISBN: 978-036-000-329-3
Number of pages: 760
Format: file PDF
About the manual
Engine type: F3B WG (380 CV) / F3B VG (420 CV)
In the manual you will find
- Step-by-step guide to repair various components and assemblies
- Self-care and maintenance instructions
- Car design and prevention information
- Information for a trip to the service station, if self-repair is not possible
Publisher:
Motorist
Only original manuals
Available immediately after payment
Full compliance with the paper edition
100% protection of your payments
Publisher: © "Motorist"
ISBN: 978-036-000-329-3
Number of pages: 760
Format: file PDF
About the manual
Engine type: F3B WG (380 CV) / F3B VG (420 CV)
In the manual you will find
- Step-by-step guide to repair various components and assemblies
- Self-care and maintenance instructions
- Car design and prevention information
- Information for a trip to the service station, if self-repair is not possible
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
Customers reviews
from Анатолий Валентинович on 09/06/2021
Трудно было найти инструкцию по ремонту на самосвал. Спасибо. Хорошо что наткнулся на ваш сайт.
