Astra HD8Ec, service e-manual - Скачать книгу бесплатно

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