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ASTRA HD8Ec
PREFACE
Definitions adopted in the current Manual
The Company ASTRA VEICOLI INDUSTRIALI, Via Caorsana, 79 - 29100 PIACENZA (Italy) is hereinafter called Manufacturer.
The current WORKSHOP MANUAL is hereinafter called Manual.
The equipment dealt with in the current Manual is hereinafter called vehicle.
The operator directly or indirectly involved in vehicle repair is hereinafter called operator.
Introduction
The current Manual applies essentially to authorised workshop technical staff.
This Manual provides technical information but cannot replace a thorough professional experience.
This Manual contains all data and information required to perform correct checking and setting up operations as well as repair
and overhaul operations.
Read this Manual right through before performing any operation on the vehicle.
Compliance with the provided information and the use of the recommended tools guarantee correct repair and avoid damages
to operators.
You will frequently see that parts of the text are highlighted as shown below:
Failure to heed and/or correctly carry out procedures, technical information and precautions given may cause injury.
Failure to heed and/or correctly carry out procedures, technical information and precautions given may cause damage
to the vehicle.
Procedures, technical information and precautions which must be highlighted.
Failure to heed and/or correctly carry out procedures, technical information and precautions given may cause environ-
mental damages.
This Manual has been divided into Sections, each of which has a number and its relevant contents are indicated in the Index of
Sections.
Each section features a main Unit (e.g.: engine, gears, etc.)
Where possible, the same sequence of procedures has been followed for easy reference.
Diagram and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with (see
next page) instead of giving descriptions of some operations or procedures.
Example:
Ø 1 = Housing for connecting rod small end bush
Ø 2 = Housing for connecting rod bearings
SECTION I
α
INTRODUCTION
Tighten to torque
Tighten to torque + angular value
3

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Summary of Contents for Astra HD8Ec

  • Page 1 PREFACE Definitions adopted in the current Manual The Company ASTRA VEICOLI INDUSTRIALI, Via Caorsana, 79 - 29100 PIACENZA (Italy) is hereinafter called Manufacturer. The current WORKSHOP MANUAL is hereinafter called Manual. The equipment dealt with in the current Manual is hereinafter called vehicle.
  • Page 2 ASTRA HD8Ec SECTION I INTRODUCTION MEASURES (INTERNATIONAL SYSTEM) Force in N (Newton) Pressure in kPa (kilopascal) Other units in use: Conversion: kg/cm (kilograms per square centimeter) Atm (metric atmosphere) 0,1019 kg psi (pounds per square inch) 1 kg = 9,81 N...
  • Page 3 ASTRA HD8Ec SECTION 3 ENGINE - F3B TIGHTENING ORDER OF GEARBOX TO ENGINE BLOCK FASTENING SCREWS Figure 8 stage 1: pretightening, FRONT SIDE outer screws 30 Nm 60592 stage 2: pretightenig, FRONT SIDE inner screws 120 Nm 60593 stage 3:...
  • Page 4 ASTRA HD8Ec SECTION 3 ENGINE - F3B Injection phases Figure 227 Figure 228 60669 60670 1. Fuel valve 1. Fuel valve 2. Pumping element 2. Pumping element 3. Fuel discharge 3. Fuel discharge 4. Filling and flowing back channel 4. Filling and flowing back channel...
  • Page 5 ASTRA HD8Ec SECTION 6 MANUAL GEARBOX DESCRIPTION The ZF 16S 1620 and ZF 16S 2320 TD version consist of: Lubrication is by means of a gear pump. The double H type gear shift control is equipped with a - a central box containing the primary shaft, drive input shaft, pneumatically powered “servoshift”...
  • Page 6 MANUAL GEARBOX SECTION 6 ASTRA HD8Ec Figure 10...
  • Page 7 ASTRA HD8Ec SECTION 12.1 FRONT DRIVE AXLE Figure 37 39593 CAMBER ANGLE CHECK 1. Support - 2. Goniometer - 3. Cross bar - 4. Centering cones - 5. Spacer...
  • Page 8 ASTRA HD8Ec SECTION 12.4 INTERMEDIATE AXLE IN TANDEM DIAGNOSTIC Main axle faults: 1 - Wheel hubs noisy 2 - Noise 3 - Noise at release 4 - Noise during acceleration 5 - Cornering noise WHEEL HUBS NOISY Insufficient lubrication Check there are no leaks from gaskets or the axle casing and top up oil to correct level.
  • Page 9 ASTRA HD8Ec SECTION 12.5 REAR AXLE IN TANDEM DESCRIPTION The rear axle is a double reduction type: the first reduction is The bevel pinion unit is adjusted through adjusting rings that by means of the pinion - ring bevel gear unit and the second are fitted between the the two taper roller bearings.
  • Page 10 ASTRA HD8Ec SECTION 12.5 REAR AXLE IN TANDEM Figure 9 40430 WHEEL HUB COMPONENTS 1. Brake drum – 2. Adjusting screw and nut – 3. Cover – 4. Gasket – 5. planetary gear pin and rollers – 6. Planetary gear carrier –...
  • Page 11 REAR SUSPENSIONS SECTION 14.2 ASTRA HD8Ec The hydraulic shock absorbers are of the telescopic double act- ing type. Hydraulic shock absorbers These shock absorbers are also defined ”direct acting” since Figure 4 their braking action is directly performed on the suspension el- ements without levers.
  • Page 12 ASTRA HD8Ec SECTION 16 PNEUMATIC SYSTEM - BRAKES BRAKING SYSTEM DIAGRAM 8x4 vehicles without tow hook Air compressor A = Hand brake Air drier B = Rear Tank (30 l) C = Front 3a Tank (20 l) D = Services...
  • Page 13 ELECTRICAL SYSTEM SECTION 17 ASTRA HD8Ec 4 - DIGIT CABLE COLOUR CODES 0300 6-diode self-rectifying alternator 0000 General earth 0001 Radio set insulated earth 0002 Hazard lights earth 0003 Earth of ceiling lamp switch on device (door post switch) 0004...
  • Page 14 SECTION 17 ASTRA HD8Ec...
  • Page 15 ASTRA HD8Ec SECTION 18 CAB AND CHASSIS Protection and painting operations are to be carried out accu- Finding chassis twist rately on all the parts involved, following any instructions, methods, and preventive precautions indicated by the paint Figure 27 manufacturers.