I

USE AND MAINTENANCE HANDBOOK

GB
The company ASTRA VEICOLI INDUSTRIALI reserves the right to make any modifications to vehicles for technical or commercial rea-
sons at any time; the information, descriptions and illustrations contained in this publication are therefore correct at the time going to
press.
This Use and Maintenance Handbook deals with optional equipment which cannot be present on your vehicle, and alternative equipment
as well (e.g. mechanical and automatic gearbox).
Moreover, the regulations in force in certain countries affect the standard equipment of the vehicle.
This publication could therefore contain information and illustrations not corresponding to the vehicle version provided on a particular
market.

ASTRA Veicoli Industriali

Product Logistics
Via Caorsana, 79 --- 29100 PIACENZA (Italy)
Tel. 0523/5431 --- Fax 0523/543459

Print cat. A3500936

First edition --- APRIL 2006
Prepared by SIPAL S.p.A.--- Torino (Italy)

Reproduction, whether total or partial, of the text and illustrations is strictly forbidden.
ASTRA HD8Ec I

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

AFTER SALES SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . IV Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV Hatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
After---sales service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV Drivers seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV Warning light panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Heating and ventilation . . . . . . . . . . . . . . . . . . . . . . . . 1-57
Air conditioned version controls . . . . . . . . . . . . . . . . . 1-58
Position of vehicle identification data plates . . . . . . . . . 1-3 Use of the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
Position of assembly identification data plates . . . . . . . 1-5
Vehicle compositions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . 1-13 Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-66
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 Starting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-67
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Driving the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Stopping the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Engine brake selector . . . . . . . . . . . . . . . . . . . . . . . . . 1-73
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Speed programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-74
Vehicle outfitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Vehicle parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77
Semi-trailer hooking . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78
Trailer hooking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-79
INSTRUCTIONS FOR USE . . . . . . . . . . . . . . 1-19 Towing instructions for trailer/semi---trailer . . . . . . . . 1-79
Hitching---up trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80
General instructions for correct use of the vehicle . . 1-21 Semi---trailer hooking . . . . . . . . . . . . . . . . . . . . . . . . . . 1-81
Cab --- External . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Towing the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-82
External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-85
External rear view mirrors . . . . . . . . . . . . . . . . . . . . . . 1-28 Engine diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-89
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 Diagnostic --- vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90
II ASTRA HD8Ec

MAINTENANCE INSTRUCTIONS . . . . . . . 1-93 Tyres and wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-145

Cabin tipping system . . . . . . . . . . . . . . . . . . . . . . . . . 1-146
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-95 Towing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-147
Opening the cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-97 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-148
Tilting the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98 Bodywork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-150
Daily operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-100 Lighting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-152
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-102 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-158
Fuel feed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-107 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-164
Intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110 Remote switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-166
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-113
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115
Multipower PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-117 TABLE AND DIAGRAMS . . . . . . . . . . . . . . . . 1-169
ZF NWM 221 power take off . . . . . . . . . . . . . . . . . . . 1-118
ZF 16S 1620 TD / 16S 2320 TD transmission . . . . . 1-119 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-171
Distributor---transfer (transfer) . . . . . . . . . . . . . . . . . . 1-121 Lubricants, oils, hydraulic fluids and filter
Transmission shafts . . . . . . . . . . . . . . . . . . . . . . . . . . 1-122 refilling/replacement diagram . . . . . . . . . . . . . . . . . . 1-172
AXLES: 2 axle vehicles . . . . . . . . . . . . . . . . . . . . . . . 1-123 2-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-172
AXLES: 3 axle vehicles . . . . . . . . . . . . . . . . . . . . . . . 1-126 Lubricants, oils, hydraulic fluids and filter
AXLES: 4 axle vehicles . . . . . . . . . . . . . . . . . . . . . . . 1-130 refilling/replacement diagram . . . . . . . . . . . . . . . . . . 1-174
Front and rear suspension . . . . . . . . . . . . . . . . . . . . 1-134 3-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-174
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-135 Lubricants, oils, hydraulic fluids and filter
Changing the hydraulic oil 2 and 3 axle vehicles . 1-136 refilling/replacement diagram . . . . . . . . . . . . . . . . . . 1-176
Changing the hydraulic oil for 4 axle vehicles . . . . 1-137 4-axle vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-176
Compressed air system . . . . . . . . . . . . . . . . . . . . . . . 1-142 Service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-178
Braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-144 Lubricant and hydraulic fluid table . . . . . . . . . . . . . . 1-182
ASTRA HD8Ec III

INTRODUCTION
The handbook contains use and maintenance instructions for all systems foreseen on the vehicle by the Manufacturer.
Some systems described in the handbook may not be present on Your vehicle, according to the chosen version and
market the vehicle is destined for.

This Use and Maintenance Handbook is divided into 4 parts, each of which systematically subdivided according to subject, for quick and
easy consulting.
1) Technical specifications
This contains all the characteristic data which should be read through at least once to acquire a working knowledge of the vehicle.
2) Use of the vehicle and practical hints
This contains information relevant to the main controls and instruments, and the main rules to be followed especially for new vehicles.
3) Maintenance instructions
This section contains the functional instructions for checking and maintaining the vehicle which must be implemented to ensure satisfy-
ing operation, cost---effective running and long life of the vehicle.
4) Tables and diagrams
Contains vehicle scheduled maintenance tables and diagrams.

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
environmental damages.
IV ASTRA HD8Ec

AFTER SALES SERVICE

Warranty
To comply to the warranty conditions, all the instructions for correct use and maintenance described in this manual are to be followed.

After---sales service
For any type of servicing the ASTRA V.I. Dealership is at the complete disposal of the Customer. Equipment and skilled staff are available
for maintenance or repair jobs. The ASTRA V.I. Dealership is always willing to offer you hints and advice to ensure you get best performance
from your vehicle.

Spare parts
Any spare parts used for replacements are to be ”GENUINE ASTRA SPARES” which can be obtained from the dealer warehouses and autho-
rised workshops. Remember that a correct order for spare parts must always include the following details:
--- type of vehicle;
--- chassis number;
--- reference and category numbers, to be found in the Spare Parts Catalogue.
If the items are parts of a main group (engine, cab, axles, power steering, gearbox etc.) indicate also the group version and serial number.
ASTRA HD8Ec 1 --- 1

Technical data
1 --- 2 ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec 1 --- 3

1 POSITION OF VEHICLE IDENTIFICATION DATA PLATES

Model identification plate
Located on the side walls of the cab (Fig. 1, see arrow).

Imprinting of the vehicle chassis

Punch marked at the front end of the right---hand side member (Fig. 2, see arrow).
(see following page).
228DTR21

Vehicle identification plate

2 On bonnet left side in cabin for vehicle identification as per EU standards (Fig. 3, see arrow).
(see following page).

228DTR22
1 --- 4 ASTRA HD8Ec

b Chassis punching
a. right side member
b. front axle

Vehicle registration number

1) World–wide identification of manufacturers (Astra Veicoli Industriali S.p.A.)
2) Type of vehicle
3) Vehicle features
4) Year of construction: (Y=2000; 1=2001; 2=2002; 3=2003; g 9=2009; A=2919; ecc.)
5) Production facility (P=Piacenza)
6) Chassis number

Vehicle identification plate

1) Type approval number markings
2) Vehicle chassis punch markings
3) Overall vehicle weight
4) Overall tractor + trailer/semitrailer weight
5) Maximum admissible weight 1st axle
6) Maximum admissible weight 2nd axle
7) Maximum admissible weight 3rd axle
8) Maximum admissible weight 4th axle
9) Maximum admissible weight on fifth wheel (tractor versions only)
10) Vehicle commercial denomination
11) Axle spacing
12) Engine type
13) Engine power
14) Number of axles
15) Grade of smoke
ASTRA HD8Ec 1---5

A1 POSITION OF ASSEMBLY IDENTIFICATION DATA PLATES

Main assemblies mounted on vehicle are identified by a serial number which can be found
on the concerned assembly in the positions shown on drawings.
Assembly identification data must always be indicated when ordering spare
parts.

Engine
Engine type and serial number are shown on engine plate.
D engine F3B WG (A1);
Power take off
D MULTIPOWER (B1);
B1 D ZF NWM 221 (B2).

B2

228DTR09
1---6 ASTRA HD8Ec

A1 Gear shift
D Gearbox 16 S 1620 TD (A1);
D Gearbox 16 S 2320 TD (A2);
Distributor---reducer (transfer) (B)

A2

B
ASTRA HD8Ec 1---7

A1 Front and rear drive axles

Axle type and serial number are shown on axle casing.
D axle (A1);
D front axle (A2);
D single rear axle (A3);
D tandem rear axles (A4).

A2

A3 A4
1---8 ASTRA HD8Ec

A1 Power steering boxes

D 2---axle and 3---axle vehicles (A1);
D 4---axle vehicles (A2).

A2
ASTRA HD8Ec 1---9
VEHICLE COMPOSITIONS

4x4 MODELS

44.38 F3B WG ZF 16 S 1620 TD R 8284 IVECO 5985 IVECO 32180 IVECO

44.42 F3B WG ZF 16 S 2320 TD R 8284 IVECO 5985 IVECO 32180 IVECO

1---10 ASTRA HD8Ec

6x4 MODELS

64.38 F3B WG ZF 16 S 1620 TD 453291 IVECO TANDEM 9820 ASTRA

64.42 F3B WG ZF 16 S 2320 TD 453291 IVECO TANDEM 9820 ASTRA

6x6 MODELS

66.38 F3B WG ZF 16 S 1620 TD 453291 IVECO 5985 IVECO 32180 IVECO

TANDEM
66.42 F3B WG ZF 16 S 2320 TD 453291 IVECO 5985 IVECO 32220 IVECO
TANDEM
ASTRA HD8Ec 1---11

8x4 MODELS

84.38 F3B WG ZF 16 S 1620 TD 453291 IVECO 9820 ASTRA 9820 ASTRA

TANDEM
84.42 F3B WG ZF 16 S 2320 TD 453291 IVECO 9820 ASTRA 9820 ASTRA
TANDEM
1---12 ASTRA HD8Ec
ENGINE
6 CYLINDERS ENGINES
Engine: F3B WG F3B WG
HP 380 420
Main characteristics:
No. cylinders 6 6
Bore mm 135 135
Stroke mm 150 150
Displacement cm3 12882 12882
Cycle: Diesel direct injection
Performance:
Maximum power output kW (HP) 284 (380) 313 (420)
At speed of approx. rev/min 1900 1900
(rpm)
Maximum torque Nm 1800 (184) 1900 (194)
(kgm)
At speed of approx. rev/min 900-1480 900-1500
(rpm)
Injection system
Ignition order 1-4-2-6-3-5 1-5-3-6-2-4
Adjustments:
Cold tappet clearance
adjustment
Intake valve mm 0.35 ÷ 0.45 0.35 ÷ 0.45
Exhaust valve mm 0.35 ÷ 0.65 0.35 ÷ 0.65
ASTRA HD8Ec 1---13

MECHANICAL TRANSMISSION
Clutch
Single plate, dry, with asbestos---free friction facings. 17” diameter.
Hydraulic control
Gearbox
ZF 16 S 1620 TD
ZF 16 S 2320 TD
Mechanical synchronised gearbox with 8 forward gears divided into one low range group
(1st to 4th) and one high range group (5th to 8th), plus reverse gear, all of which are normal
and stepped down.
The gearbox is equipped with a neutral switch to avoid engine ignition when the gear is
engaged.
Gear ratios
Direct Drive
Normal Stepped down
1st 13.80 16.41
2nd 9.49 11.28
3rd 6.53 7.76
4th 4.57 5.43
5th 3.02 3.59
6a 2.08 2.47
7a 1.43 1.70
8a 1.00 1.19
R.G. 12.92 15.36
R.G. = Reverse Gear
Distributor---reducer (transfer)
On road gear ratio: 1.0
Off---road gear ratio: 1.6
1---14 ASTRA HD8Ec

AXLES
Front driving axle
High resistance pressed steel, not driving axle type.
Front drive axle
With double reduction, central and final. Drive shafts controlling front wheels equipped with
cardan joints.
Single rear drive axle
With double reduction, central by pinion set and final in wheel hubs with epycicloid gear.
Differential between wheels can be locked by pneumatic control in the driver’s cab.
Tandem rear driving axles
Two tandem driving axles with double reduction, central by pinion set and final in wheel hubs
with epycicloid gear.
Tandem is fitted with splitter between the axles and differential between the wheels, which
can be locked by pneumatic control in the driver’s cab.
Tandem is anchored to the chassis by reaction rods fitted with silent block.
Reduction ratio: 1:3.793
1:4.229
1:5.009
1:5.558
1:6.095
1:6.588
ASTRA HD8Ec 1---15

CHASSIS
Constructed of rectilinear side members in special pressed steel with C---shaped cross sec-
tion, connected by bolted or screwed cross members.
Fuel tank
Steel, capacity 300 litres with fuel level and reserve gauge.

STEERING
ZF---Servocom recirculating ball power steering.
2---axle and 3---axle vehicles
Type: 8098
Variable reduction ratio: from 1:22 to 1:26.2
Oil pump controlled by engine.
Steering system on front wheels with articulated quadrilateral kinematic motion.
Left---hand drive with articulated steering column.
4---axle vehicles
Type: 8099
Reduction ratios: 1:18.3
Oil pump controlled by engine.
Emergency pump controlled by transmission.
Steering system on front wheels with articulated quadrilateral kinematic motion.
Left---hand drive with articulated steering column.
1---16 ASTRA HD8Ec

SUSPENSION
Front: with semi---elliptical springs with simple flexibility arranged longitudinally. Double act-
ing telescopic hydraulic shock absorbers and torsion bar.

Rear:
2---axle vehicles
With semi---elliptical springs with simple flexibility arranged longitudinally.
Double acting telescopic hydraulic shock absorbers and torsion bar.
3---axle and 4---axle vehicles
With longitudinal leaf springs with single flexibility, jointly operating on the two flexible axles
with rocker arm system.
The reaction rods between axles and central support counter the axial thrust during accelera-
tion and braking.

BRAKES
The braking system is of the wedge type with double acting braking elements on all the axles.
Adjustment of the brakes is automatic and no interventions are required before the brake lin-
ings are completely worn.
Service brake: pneumatically operated with two independent circuits for non---towing ve-
hicles, and with three independent circuits for towing vehicles.
Emergency brakes and parking brake: mechanical drum type, operating on four rear
wheels by means of pneumatically operated spring brake cylinder.
Retarder brake: installed on the engine, pneumatically actuated by a control pedal in the
driver’s cab.
ASTRA HD8Ec 1---17

TYRES
Front: single
Rear: double or single for single track versions
VEHICLE
TYRES
4x4 6x4 6x6 8x4
12 00 R 20 X X X X
14 00 R 20 X X
16 00 R 20 X X
365/85 R 20 X X X X
395/85 R 20 X X
525/65 R 20 X X
24 R 20,5 X X
13R22,5 X X X X
315/80 R 22.5 X X X X
385/65R22.5 X X X X
1---18 ASTRA HD8Ec

ELECTRICAL SYSTEM
Voltage: 24V
Alternator: 28 V 90 A
Batteries: 2, in series: 12 V 140 Ah

VEHICLE OUTFITTING
Each vehicle is equipped with a set of tools and wrenches so that the Customer can carry
out the normal maintenance operations.
--- Tool box located under the driver’s seat
--- Lifting jack in cab under passenger’s seat in twoseater cab, behind driver’s seat in single
seater cab
--- Cab tilting jack/rod and wheel wrench located under cab grid
--- n˚ 2 chocks
--- Instructions for USE AND MAINTENANCE HANDBOOK
--- Log---book holder
Keys
Each vehicle is supplied with:
--- Ignition/door/fuel filler cap keys (3).
ASTRA HD8Ec 1---19

Instructions for use

1---20 ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec 1---21
GENERAL INSTRUCTIONS FOR CORRECT USE OF THE VEHICLE
Before driving
Adjust the seat, steering wheel and rear---view mirrors to obtain a correct driving position.
Check that there are no obstructions to pedal excursion, in particular the brake pedal.
Check that the horn works correctly.
Check that all external lights function correctly, and if necessary clean the lighting groups.
Check, especially when travelling by night, that headlights are correctly aligned.
Check that no oil or fluids are leaking from under the vehicle.
Check that any cargo is correctly stowed.
Check that the handbrake is on and that no dashboard warning light indicates a fault.
To prevent accidental vehicle movements, disengage the handbrake with the brake pedal pressed.

When driving
Long journeys should only be undertaken in ideal physical conditions.
Light, easily digestible meals help in keeping reflexes ready as well as maintaining the concentration required for safe driving.
Never drive for too many consecutive hours, but make frequent stops, taking the opportunity to stretch and generally refresh.
Make use of the wide range of adjustments offered by the heating, ventilation or air---conditioning system to maintain constant cabin air
change.
The abuse of alcohol, drugs and or certain medicines is extremely dangerous. Never undertake a journey under the influence of alcohol,
pharmaceuticals or drugs.
Careful driving also means being in a condition to foresee the mistakes or carelessness of other drivers.
Always observe speed limits and always drive in the slow lane on motorways.
Always use indicators when changing direction or lane.
Keep a safe distance from the vehicle in front. This distance varies according to speed, weather, traffic and road conditions.
Never drive with the gearbox in neutral.
Never freewheel downhill: With the engine off there is no engine braking, requiring greater force on the brake pedal.
Use engine braking by engaging a low gear to avoid overheating the brakes.
In case of breakdown, park the vehicle off the carriageway, switch on the hazard warning lights and set up the red reflecting triangle sign
to warn other drivers. Always follow the Highway Code.
Do not apply transfers or stickers to the windscreen: these could distract or impair vision.
1---22 ASTRA HD8Ec

Night driving
Take special care, reducing speed if necessary, especially on unlit roads.
Keep a greater safety distance than when driving by day: in effect it is more difficult to estimate the speed of an approaching vehicle when
only its lights are visible.
Stop and rest as soon as you feel tired. To continue would only be a hazard to yourself and others.
Use high beams only outside built---up areas an only when you are sure they do not other drivers.
Always dip headlights with oncoming traffic.

Driving in rain, fog and snow

If the road is wet the grip between the tyres and the road surface is significantly reduced, so braking distance is greater and grip when turning
is reduced. Reduce speed and keep a greater distance from the vehicles in front.
Heavy rain and fog reduce visibility. In compliance with the Highway Code, switch on dipped headlights even by day to render your vehicle
more visible.
Do not drive through puddles or flooded sections of road at high speed. Aquaplaning may cause loss of control. Use engine braking and
in all cases avoid braking sharply.
Set ventilation controls to ensure efficient windscreen demisting.
Before starting out, check the condition of windscreen wipers. If temperature is below 0˚, or if it is snowing, check that the wiper blades and
not frozen against the windscreen---
Proceed with extreme caution in case of fog. Moderate speed and avoid overtaking if possible.
Check that windscreen/headlight washer fluid contains antifreeze and anti---scale products.
In winter, even apparently dry roads may have icy patches, especially sections in the shade or lined by trees or rocks.

Parking
Switch off the engine.
Engage the parking brake.
Engage 1st gear if the vehicle is parked on a slope or reverse gear if the vehicle is facing downwards (manual gearshift vehicles only).
Never leave the key turned to MAR with the engine off to avoid flattening the batteries.
ASTRA HD8Ec 1---23

Tyres
Always reduce speed before taking on a tight bend, even if vehicle performance permits.
Avoid sharp acceleration of heavy braking.
Do not drive at constant high speeds for long periods, especially on uneven road surfaces.
Make certain that wheels are correctly balanced and adjusted.
Avoid violent impacts to tyre walls (for example when parking).
Never tamper with tyre inflation valves.
Do not insert any kind of tool between tyre and wheel rim.
If the rim is damaged, replace it.
If a tyre loses pressure for no apparent reason, replace the wheel and check the faulty tyre.
Tyre pressures, including the spare, must always be as specified.
Tyres that are old (over 6 years) or used should only be used in case of emergency and with due caution.
Do not leave the vehicle parked for long periods on the edge of the kerb or similar irregularities on the road surface.
Regularly check tyre tread depth, changing tyres when depth is less than the legal minimum.
The vehicle mounts ’tubeless’ tyres, meaning without inner tube. Inner tubes must not be fitted to tubeless tyres.
Certain types of tyres are fitted with wear indicators. They must be changed as soon as the indicators become visible on the tread.
Aquaplaning is more likely with worn tyre treads.
Regularly check that tyres are not unevenly worn. If so, check the vehicle in general.

Snow chains
The use of snow chains is governed by local law in each country.
Chains should only be fitted to drive wheels.
To prevent tyre damage, do not drive on clear roads with chains fitted. In extreme cases (tunnels, etc....) proceed at low speed and in any
case remove the chains as soon as conditions permit.
Maintain moderate speed with chains mounted, avoiding potholes and driving onto the kerb.
Certain tyres of snow chain require tension adjustment after travelling a short distance.
1---24 ASTRA HD8Ec

Economic, ecological driving

Road conditions and driving style have a direct influence on fuel consumption and environmental impact.
Carry out the maintenance operations described below at regular intervals and with care.
Do not demand maximum power from the vehicle with the engine cold.
Do not rev the engine when parked.
Always avoid sharp acceleration and repeated braking/acceleration. Engage a higher gear as soon as conditions permit.
If possible, avoid driving with side windows lowered. Use the air---conditioner/ventilation system to obtain the desired conditions in the cab.
Engage a high gear whenever traffic and road conditions permit.
Limit the use of high power absorption utilities (air---conditioner on full, for example) when driving in city traffic or behind slow moving vehi-
cles.
Revving the engine between gears or before stopping the engine serves absolutely no purpose.
Avoid accelerating on full throttle. Fuel consumption will be significantly lower with gradual acceleration.

1 The best ”consumption/performance ratio is achieved with engine revs inside the green sec-
tor on the rev counter.
a. Green sector (economy): 1000 --- 1400
b. Yellow sector (maximum engine braking efficiency). 1900 --- 2400
c. Red sector (over---revving): 2400 --- 2800; never use this sector.
ASTRA HD8Ec 1---25

1 CAB--- EXTERNAL
Glass---fibre with steel frame (Fig. 1).
The cab is hinged at the front and suspended on the chassis to the rear:
D to the front by two longitudinal arms with springs, shock absorbers and buffers.
D to the rear by two control arms with springs, shock absorbers and buffers.
The cabin can be tipped forward by means of a manually controlled hydraulic cylinder.
Always use the grips and steps (Fig. 2, see arrow) specifically designed to permit easy ac-
cessibility to get on and off the vehicle.
Always keep handles and foot---boards clean to avoid slipping.
228NU202

228NU203
1---26 ASTRA HD8Ec

EXTERNAL LIGHTING
1 Front lights (Fig. 1)
1. High beam
2. Parking light and headlight
3. Front direction indicator
4. Side direction indicator
5. Front clearance light
6. Rotary warning lights (if fitted)

Lighting is disposed symmet-

rically on both sides.

228NU204
ASTRA HD8Ec 1---27

Rear lights (Fig. 1)

1 1. Direction indicator
2. Stop light
3. Side light
4. Fog warning light
5. Reversing light
6. Licnse plate light (one side only)
7. Clearance light

Lighting is disposed symmet-

rically on both sides.

228NU205
1---28 ASTRA HD8Ec

1 EXTERNAL REAR VIEW MIRRORS

The vehicle is fitted with the following external rear view mirrors (Fig. 1, Fig. 2):
1. Main left side mirror
2. Main right side mirror
3. Right side wide---angle mirror
4. Right pull---in mirror

238NU206

238NU207
ASTRA HD8Ec 1---29

1 DOORS
The vehicle has two doors symetrically placed at each side.
The external door handle (fig. 1, see arrow) can be locked from the outside with a key.
To open the door pull down the external handle.
When the door is opened the cabin interior light comes on automatically, along with the cabin
step lights.
The inner side of the door has the following controls (Fig. 2):
1. Door opening handle
2. Electric window control
238NU208 3. Door closing handle
4. Knob for locking doors from the inside
2

228NU209
1---30 ASTRA HD8Ec

1 SEATS
This seat provides the following adjustments:
Fore and aft adjustment
Lift lever (Fig. 1) to have the seat free to move backwards or forward. Release the lever and
ensure the mechanism is fully engaged after adjustment.
Seat suspension adjustment
Lift lever (Fig. 2) to lower and lock the seat;
lower the lever to raise the seat
(set beforehand with lever 4).
Cushion angle adjustment
The cushion angle may be adjusted by lifting lever (Fig. 3) and pulling and pushing the back-
rest (12˚ max.). Release the lever after adjustment.
Height adjustment
Lift lever (Fig. 4) to raise the seat; release the lever after adjustment. Seat height is memorised
automatically.
Lower lever (4) to lower the seat (100 mm max.)
178NU07 Backrest angle adjustment
Lift lever (Fig. 5) and set the backrest to the desired angle with your back. Release the lever
to block the backrest.
Springing system adjustment
Springing system adjustment is obtained by lifting or lowering lever (Fig. 6):
Lever up = Maximum springing adjustment.
Lever down = Minimum springing adjustment.
This device provides excellent adjustment of seat springing according to road conditions
and driver’s weight.
Vertical springing system is to be adjusted stiffly to avoid the seat striking the limit stop when
driving on bumpy roads and damaging the springing system.
Headrest
Headrest can be adjusted for height and angle.
These operations must only be carried out when the vehicle is stationary.
ASTRA HD8Ec 1---31

1 SEAT BELTS
The vehicle is equipped with three---point seat belts and automatic reel (Fig. 1).
D To fasten the belt grip the tab and insert it into the buckle until it clicks (Fig. 2).
D To release the belt, press the button on the top of the buckle (Fig. 3).
Do not adjust the mirrors while driving.

178NU08 The belt does not need to be adjusted by hand: the webbing adjusts itself automatically to
the length most suited to the driver allowing him freedom of movement provided that his
movements are not abrupt.
2 The belt mechanism is affected by changes in vehicle attitude and as a consequence the belt
may lock in the following cases:
D sudden braking or acceleration;
D vehicle driving on a slope;
D when cornering.

To fasten the seat belt, take the tab and insert it in the buckle until it clicks (Fig. 2).
To release the seat belt, press the specific button on the upper side of the buckle (Fig. 3).
178NU09 The belt must not twist and must adhere to the hips, not the abdomen, to pre-
vent the risk of slipping forwards.
3 Occasionally check that the anchor bolts are fully tightened and that the belt
itself is not cut or frayed.
In case of accident of a certain gravity, replace the belt involved, even if it
does not appear damaged.
Do not make alterations likely to reduce seat belt efficiency.

178NU10
1---32 ASTRA HD8Ec

1 HATCH
To open the hatch turn the handle (Fig. 1, ref. 1) anti---clockwise.
To close the trap door proceed as follows:
D Turn the handle clockwise to close the trap door
D Bring the handle back to its starting position (Fig. 2)
D Turn the handle further for at most a quarter of a turn, to reach the stop (Fig. 3, arrow)
D Bring the handle back to the closing position and lock it, tipping over the knob
178NU02
To escape from the cabin in an emergency turn the full release handles down-
2 ward (Fig. 1, ref. 2) and push the hatch outwards.

3
ASTRA HD8Ec 1---33

DRIVERS SEAT
1 Main controls (Fig. 1)
1. Engine brake pedal
2. Clutch pedal
3. Main brake pedal
4. Accelerator pedal
5. Combi switch release
6. Instrument and control panel
7. Intarder control
8. Steering wheel
9. Air---conditioning control
10. Side control panel
11. Gear shift
12. Spot/ceiling light switch
13. Ashtray
14. 12V socket
15. Cigar lighter
16. Parking brake
17. Ignition switch
18. Distributor --- transfer control
19. Differential lock control
20. Power take off control

228NU210
1---34 ASTRA HD8Ec

1 Instrument panel (Fig. 1)

1. Tachograph / Spedometer
2. Instrument lights dimmer
3. Rev counter
4. Engine oil pressure gauge with
low pressure warning light
5. Fuel gauge with reserve warning
light
6. Engine coolant temperature
gauge with overtemperature warn-
ing light
7. Front and rear brake air pressure
gauge
8. Warning light panel (A, B, C)
9. Not used

185NU02
ASTRA HD8Ec 1---35

A 1 2 3 4 5
WARNING LIGHT PANEL
A detail
1. Primary power steering circuit failure
Red Indicates that hydraulic pressure in the power steering circuit is too low to guaran-
tee power steering.
2. Secondary power steering circuit failure
Red Indicates that hydraulic pressure in the power steering circuit is too low to guaran-
tee power steering.
6 7 8 9 10 3. Central differential lock on
Yellow. This indicates that the central differential is engaged.
4. PTO on
Yellow. Indicates that power take off is on.
5. Box not secured
Yellow. Indicates that the tipper box is not fully lowered.
6. Speed limiter
Yellow. Indicates that the vehicle has reached the speed limit.
7. Low power steering fluid
Red Indicates that the oil level in the reservoir is lower than minimum.
8. Axle differential lock on
Yellow. Indicates that the axle differential lock is engaged.
9. Supplementary parking brake engaged
Red This indicates that the auxiliary parking brake is applied.
10. Low trailer brake air pressure
Red This indicates that the trailer brake air pressure is low.
1---36 ASTRA HD8Ec

B 1 2 3 4 5 WARNING LIGHT PANEL

B detail
1. Parking brake applied
Red This indicates that the parking brake is applied.
2. Low range gear engaged
Yellow. Indicates low range gearbox selected.
3. Splitter on
Yellow. Indicates splitter selected.
6 7 8 9 10 4. Transfer on
Yellow. This indicates that the central differential is on
5. Engine brake applied
Yellow. This indicates that the engine brake is on
6. Tractor brake air pressure low
Red This indicates that the vehicle brake air pressure is low.
7. Not used
8. Not used
9. Water in fuel filter
Yellow. This indicates the presence of water in the fuel pre---filter.
10. Diagnostics / EDC
Red This indicates that the EDC engine control unit has detected a fault in the system.
ASTRA HD8Ec 1---37

C 1 2 3 4 5
WARNING LIGHT PANEL
C detail
1. Rear differential lock on
Yellow. This indicates that the rear differential is engaged.
2. Preheating on
Yellow. This indicates that the engine preheating system is on.
3. Air filter blocked
Yellow. This indicates that the main air filter must be cleaned or changed.
6 7 8 9 10 4. Cabin released
Red Indicates that the cabin is not correctly fastened to the rear fittings.
5. Low generator charge
Red Indicates that the generator is not supplying current or that the current supplied is
not sufficient to charge the batteries.
6. High beam on
Blue. This indicates that the high beams are on.
7. External lights on
Green Indicates that the parking lights (and headlights) are on.
8. Trailer direction indicator on
Green Indicates that the trailer direction indicators are on.
9. Tractor direction indicators on
Green Indicates that the tractor direction indicators are on.
10. Hazard lights on
Red Indicates that the hazard lights are on.
1---38 ASTRA HD8Ec
Warning light bulb test procedure
Proceed as follows:
D Turn the ignition switch to position 1;
D press the warning light bulb test button (see following page);
D check that the indicated warning lights come on (Fig. 1);
D if not, repair the lights not working.
Lights (1), (2), (3), (4) and (5) come on with ignition switch in position 1.
According to version, not all the warning lights are used.
Warning lights concerning systems managed by electronic control units (engine, etc.) cannot be tested.

2 1 3 2 5

5 4

228NUR25
ASTRA HD8Ec 1---39
TACHOGRAPH (Fig. 1)
1. Lock with key
2. Tachometer dial with clock
3. Tachometer pointer
4. Speed scale
5. Total odometer
6. Tracer operation fault warning light
7. Recording time selector knob (work or rest)
8. Speed limit warning light
If the vehicle has to remain stationary for a long period, disable the tacho-
graph to avoid flattening the battery.
For instructions, refer to the chapter on the Electrical System.

178NU41
1---40 ASTRA HD8Ec

1 CONTROLS
Dashboard controls (Fig. 1)
4 5 6 1. Spotlight control
2. Heated rear view mirror control
3. Front/rear brake wear warning light
4. Rotary warning light control
5. Rear fog warning light control
6. Warning light bulb test control

1 2 3
272NUR26
ASTRA HD8Ec 1---41

1 Side panel controls (Fig. 1)

1. Power take off control
2. Engine brake switch
3. Not used
4. Air---conditioner control
5. Headlight alignment control
6. Power take off/converter oil tem-
perature warning light
7. Automatic transmission diagnosis
warning light
8. Hour meter
9. Converter oil temperature
10. External light switch
11. Hazard warning lights control
12. Cabin heater control

228NUR27
1---42 ASTRA HD8Ec

1 Position light and headlight control (Fig. 1)

The control has three positions:
D Position 0: off;
D Position 1: position lights on;
D Position 2: headlights on.

Headlights control (Fig. 2)

The control has two positions:
D Position 0: dipped---beam headlights;
D Position 1: main---beam headlights.
178NU132B
Press the button on the control lever (arrow) to flash the headlights during daytime.
2 Turn indicator lights and horn control (Fig. 3)
The control has three positions:
D Position 0: off;
D Position 1 (up): right direction indicators;
D Position 2 (down): left direction indicators.
Press the button on the control lever (arrow) to operate the horn.

228NUR28

228NUR29
ASTRA HD8Ec 1---43

1 Headlights height adjustment (Fig. 1)

Headlight height adjustment is performed by turning the panel from position zero (arrow) to
an intermediate position according to vehicle load.

Windscreen wiper/washer control (Fig. 2)

The control has four positions:
D position 0 = off;
D position 1 = flick wipe;
D position 2 = slow wipe;
178NU26A D position 3 = fast wipe;

2 Press the button (arrow) on the control lever to operate the windscreen washer.

Hazard lights control (Fig. 3)

Press the button to switch the hazard lights on.
Press again to switch the hazard lights off.

178NU27

178NU21B
1---44 ASTRA HD8Ec

1 Rear fog warning light switch

The rear fog lamp only comes on with dipped headlights (headlight switch
in second position).
Press the button (Fig. 1, ref. 1) to switch on the rear fog lamp.
Press the button (Fig. 1, ref. 2) to switch on the rear fog lamp.

Rotary warning light switch

228NUR30 Press the button (Fig. 2, ref. 1) to switch on the rotary warning lights on.
Press the button (Fig. 2, ref. 2) to switch on the rotary warning lights on.
2

228NUR31
ASTRA HD8Ec 1---45

1 Heated rear view mirror control (Fig. 1)

Press the button (Fig. 1, ref. 1) to switch on the heater.
Return button to rest (Fig. 1, ref. 2) to switch the heater off.
Motorised rear view mirror control
Main mirror control (Fig. 2, ref. 1);
Right wide---angle mirror control (Fig. 2, ref. 2)

Turn the knob (Fig. 3) to select the mirror to adjust:

228NUR32 D right (Fig. 3, ref. 1: right wide---angle mirror only);
D left (Fig. 3, ref. 2).
2 Turn the knob up/down left/right as per arrows to adjust as required:
D horizontal arrow: the mirror moves left/right;
D vrtical arrow: the mirror tilts up/down.

228NUR33

228NUR34
1---46 ASTRA HD8Ec

1 Ignition switch (Fig. 1)

The ignition switch has three positions:
D position 0: all off, key can be extracted;
D position 1: preparation for cranking and running, electrical systems powered, key can-
not be extracted;
D position 2: cranking.

Engine brake selector control (Fig. 2)

178NU28A
The control has three positions:

2 D position 0: the engine brake engages if the floor pedal is pressed;

D position 1: engine brake enabled on releasing accelerator pedal;
D position 2: engine brake enabled on pressing brake pedal;

228NUR35
ASTRA HD8Ec 1---47

Cruise control
1 The vehicle is equipped with an engine speed/vehicle speed regulator.
Memory control (Fig. 1).
Key (1) RESUME: pressing the button memorises the displayed regulator setting / re-
calls memorised setting;
Key (2) OFF pressing the button disables the function.

178NU39 Setting the speed (Fig. 2)

ON (+) button: pressing the button increases engine speed / vehicle speed value;
2 ON (---) button: pressing the button decreases engine speed / vehicle speed value.

178NU40
1---48 ASTRA HD8Ec

1 Steering wheel position control

Proceed as follows:
D pull upward to release the lever (Fig. 1, see arrow);
D adjust steering wheel height and inclination;
D push down to lock the lever.

Do not adjust the steering wheel while driving.

228NU211 Electric window control

Left door (Fig. 2)
2 1. Left side window control
2. Right side window control

Right door (Fig. 3)

1. Right side window control.

Press the button to lower the window

Pull the button to raise the window.
228NUR36

228NUR37
ASTRA HD8Ec 1---49

Accelerator
1 The accelerator is controlled by means of a pedal on the floor to be operated by the driver’s
right foot (Fig. 1, ref. 1).
Press the pedal to increase the torque output by the engine proportionally to the position of
the pedal.

Service brake
The service brake is controlled by means of a pedal on the floor to be operated by the driver’s
right foot (Fig. 1, ref. 2).
Press the pedal to obtain a braking effect in proportion to the exerted pressure.
178NU133
Clutch
The clutch is controlled by a pedal to be operated with the driver’s left foot (Fig. 1, ref. 3).
Press the pedal to release the clutch.

Engine brake control

The engine brake is controlled by a floor button for the left foot (Fig. 1, ref. 4).
Pressing the button engages the engine braking system.
1---50 ASTRA HD8Ec

1 1 Manual servo assisted gear shift

Gear shift is controlled by a lever used by the right hand (Fig. 1, ref. 1).
Move the lever to engage the various gears.
The lever also has a splitter selector lever (Fig. 1, ref. 2). This lever engages low range gears,
2 engaging with the clutch pedal.

228NU212
ASTRA HD8Ec 1---51

Distributor---reducer (transfer)
1
Position knob (Fig. 1 and Fig. 2, see arrow):
D Position 0 = travelling on road (normal ratios)
D Position 1, “tortoise” symbol = off---road use (step---up ratios)
Shift from one range to the other must take place with the vehicle stopped and
gearbox in neutral.
To shift from normal to reduced:
178NU75
D turn knob (Fig. 1) to position 1.

2 To pass from the step ---up ratio to the normal ratio:

D turn knob (Fig. 1) to position 0.

228NU213
1---52 ASTRA HD8Ec

1 Locking the differential 2---axle vehicles

Position knob (Fig. 1):
4x4 vehicles:
D Position 0 = locking disengaged;
D Position 1 = longitudinal locking engaged (transfer);
D Position 2 = longitudinal and transversal locking engaged.
The differential must be locked when the vehicle is stationary and the wheels
are aligned in the forward position.
4x4 178NU77
Engaging locking function:
D turn knob (Fig. 2, see arrow) to the desired position.
2 Disengaging the locking function:
D turn knob to position 0 keeping vehicle speed constant;
D momentarily ease up on the accelerator and then once again gain speed.
When the locking function is engaged proceed with caution. Do not use the
locking function on roads which do not warrant its use.
If the locking function does not disengage immediately, vary the direction of
travel in order to eliminate any tension present.
228NU214 Ensure that the locking devices are disengaged when they are no longer re-
quired by checking the warning lights on the instrument panel, and checking
the position of the control knob.
In the presence of mud or slippery road surfaces, do not free wheel when the
differential is not locked as this would cause serious damage to the gears (a
few seconds would suffice).
Do not engage the differential locking device while one wheel is free---wheel-
ing; this would cause serious damage to the gears.
ASTRA HD8Ec 1---53

1 178NU78 Locking the differential 3---axle and 4---axle vehicles

Position knob (Fig. 1):
D Position 0 = locking disengaged;
D Position 1 = longitudinal locking engaged (transfer and differential between axles);
D Position 2 = longitudinal and transversal locking engaged.
The differential must be locked when the vehicle is stationary and the wheels
are aligned in the forward position.
6x4 8x4 6x6 8x6 8x8 Engaging locking function:
D turn knob (Fig. 2, see arrow) en la posición deseada.
2 Disengaging the locking function:
D turn knob to position 0 keeping vehicle speed constant;
D momentarily ease up on the accelerator and then once again gain speed.
When the locking function is engaged proceed with caution. Do not use the
locking function on roads which do not warrant its use.
If the locking function does not disengage immediately, vary the direction of
travel in order to eliminate any tension present.
228NU214 Ensure that the locking devices are disengaged when they are no longer re-
quired by checking the warning lights on the instrument panel, and checking
the position of the control knob.
In the presence of mud or slippery road surfaces, do not free wheel when the
differential is not locked as this would cause serious damage to the gears (a
few seconds would suffice).
Do not engage the differential locking device while one wheel is free---wheel-
ing; this would cause serious damage to the gears.
1---54 ASTRA HD8Ec

1 Gearbox power take---off control

Position knob (Fig. 1):
D Position 0 = power take---off disengaged;
D Position 1 = power take---off engaged.
The power take---off must be engaged when the vehicle is stationary, with the
engine running and gearbox in neutral.
To engage the power take---off:
D press the clutch pedal fully and wait a few seconds until the gears of the gearbox come
178NU79 to a halt;
D turn knob (Fig. 2, see arrow) to position 1;
D release the clutch pedal.
2 To disengage the power take---off:
D fully depress the clutch pedal;
D turn knob to position 0;
D release the clutch pedal.

228NU215
ASTRA HD8Ec 1---55

1 ZF NMV 221 power take off control

Control knob position (Fig. 1):
D Position 0 = power take---off disengaged;
D Position 1 = power take---off engaged.

The power take---off may be engaged with the vehicle stopped, or running.

To engage the power take---off:

178NU79 D turn the knob (Fig. 2, see arrow) to position 1.

2 To disengage the power take---off:

D turn knob to position 0.

228NUR40
1---56 ASTRA HD8Ec

1 MULTIPOWER power take---off control

Position knob (Fig. 1):
D Position 0 = power take---off disengaged;
D Position 1 = power take---off engaged.
The power take---off must be engaged when the vehicle is stationary and with
the engine switched off.
To engage the power take---off:
D turn knob (Fig. 2, see arrow) to position 1.
178NU81 To disengage the power take---off:
D turn knob to position 0.
2

228NU215
ASTRA HD8Ec 1---57

HEATING AND VENTILATION

Air---conditioned air flow direction control (Fig. 1)
1. Windscreen air vents/deflectors
2. Side air vents
3. Lower air vents
4. Central air vents

Conditioned air flows from all vents.

j cold air
J warm air

228NUR41
1---58 ASTRA HD8Ec

AIR CONDITIONED VERSION CONTROLS

1 (Fig. 1)
1. Four---speed electric fan control lever.
2. Air temperature adjuster knob:
clockwise: warm air,
anticlockwise: ambient temperature air.
3. Air distribution control knob (see symbols)
clockwise: feet---vents---windscreen,
anticlockwise: windscreen---vents---feet.
4. Internal recirculation control lever
178NU152 towards the left: external air inlet,
towards the right: internal recirculation.

The use of the recirculation function

may affect the quality of the air in the cab
and cause the windows to fog.
To prevent this, move the lever (4) occa-
Simbología sionally to the left.
External air Air flow at feet 5. Air---conditioner control with built---in warning
light (only clima---version).
Recirculation Air flow at feet/vents

Air flow at vents

Windscreen and side deflector demisting

ASTRA HD8Ec 1---59

Proceed as follows (diagram on previous page):

For all versions:
D start the engine;
D move the control lever (Fig. 1, ref. 1) to the right to set the desired level of ventilation;
D turn the knob (Fig. 1, ref. 2) to set the desired cab air temperature;
D turn the knob (Fig. 1, ref. 3) to the desired position according to conditioning requirements (feet---vents---windscreen, see following page
also).

Clima---versions only:
D if necessary, press button (Fig. 1, ref. 5) to switch on air conditioner: air conditioner compressor function is indicated by the built---in warning
light;
D to disable air conditioner press button (Fig. 1, ref. 5).

With the lever (Fig. 1, ref. 1) in position 0 (off), air conditioner control is disabled.

Advice for use

D Do not keep air conditioner on and lever (Fig. 1, ref. 1) (fan) at minimum for long periods to prevent ice forming on the evaporator.
D With overheated cab (vehicle exposed to sunlight), turn knob (Fig. 1, ref. 2) anti---clockwise, switch on the conditioner and ventilate the
cabin with the windows open for a few minutes.
D In case of high humidity, switch on the air conditioner and turn knob (Fig. 1, ref. 3) fully clockwise; if necessary adjust the temperature
with knob (Fig. 1, ref. 2), making the air---conditioner function as a dehumidifier.
D Run the system for a few minutes to ensure full efficiency at least once a week, regardless of the temperature.

Any water dripping from under the vehicle with the air---conditioner on is due to normal condensation discharge.
1---60 ASTRA HD8Ec

Most common control settings:

1. Normal position
j open
J close

228NUR42
2. Defrost/demist position

228NUR45
To obtain quick air temperature increase, set the recirculation lever to the left: however, do not maintain this setting for
too long a time.

3. Maximum heating

228NUR47
4. Maximum ventilation

228NUR49
ASTRA HD8Ec 1---61
USE OF THE VEHICLE
1 Precautions for the initial period of use
When the vehicle is new a brief running---in period of at least 150/200 hours
is required: Observe the following precautions during this time:
D do not demand maximum engine power;
1 D after starting, warm the engine slowly; avoid driving at high revs too soon;
D frequently check the oil level;
206NU23 D check the tightening of the wheel bolts.

REFUELLING
Put out naked flames while refuelling. Do not smoke.

Proceed as follows:
D clean the filler area, open the filler cap (Fig. 1, ref. 1) with the ignition key and refuel with
the specified fuel type;
D close the filler cap carefully.
Keep the fuel tank as full as possible.
Use fuels of the specified types supplied by petroleum companies.
Do not use other than specified fuels. Use of other than specified fuels can
cause severe engine damage.
1---62 ASTRA HD8Ec

1 STARTING THE ENGINE

Exhaust gases are toxic.
before starting the engine in a confined space, make sure there is sufficient
ventilation.
Always engage the handbrake before starting the engine.
Checks before starting
Make sure the general power switch (Fig. 1) is on.
A: power on
178NM81 B: power off
Carry out the required daily checks (for details, see MAINTENANCE chapter).
2 Especially check:
D engine oil level;
D coolant fluid level;
D tyre condition;
D the condition of the tow hook or articulated fifth wheel.

Turn the vehicle electrical system on by turning the switch (Fig. 2) to position 1 and check:
178NU00A D fuel level;
D correct function of lights, warning lights, indicators, horn and windscreen wipers;
D correct function of all warning lights, pressing the warning light test button (TEST).

The engine can only be started with gearbox in neutral or position N for auto-
matic gearbox versions.
ASTRA HD8Ec 1---63

1 Starting from the driver’s cab

Proceed as follows:
D turn the ignition switch (1) to position 1).
The vehicle is equipped with an electronic device for pre---heating intake air for low tempera-
ture starting.
If the engine water temperature is higher than the value set for cut---in (around 10˚C, warning
light (Fig. 2) comes on for 1---2 seconds then goes off.
If instead the pre---heating system cuts---in, warning light (Fig. 2) stays on for the time neces-
sary for pre---heating.
178NU00A The engine can be started when warning light (Fig. 2) begins to flash.

2 If the vehicle is not started within a few seconds of the light beginning to flash
(Fig. 2), the pre---heating system is disabled to avoid depleting the battery.
In this case to start the vehicle the above procedure has to be repeated.
In addition to the normal warning lights, the EDC light (Fig. 3) comes on.
With the ignition switch (Fig. 1) turned to 1, the EDC light goes off the first
time the brake pedal is pressed.
If the engine control unit detects a malfunction, the EDC warning light (Fig.
3) stays on or flashes if the engine is running.
238NU21
Proceed as follows:
D check that the gearbox is in neutral /position N for automatic gearboxes, and that the par-
3 king brake is engaged.
D turn the ignition switch (Fig. 1) to position 2 and release it as soon as the engine fires.
D with the engine running check that the warning light is off).

If the engine does not fire immediately, do not insist with the starter motor for
more than 15 seconds at a time.

206NU50
1---64 ASTRA HD8Ec

1 178NU44 When the engine is running use the pressure gauge (Fig. 1) to check that the oil pressure
is within the specified values (3.5/4 bar).
The engine should not be kept idling for long periods either when cold or hot.
To allow the engine to warm up, after starting the engine, drive the vehicle away proceeding
slowly for a certain time, keeping to low---medium engine revs.
Starting from the engine bay
The engine can be started with the cab tilted. Proceed as follows:
D turn the ignition switch (Fig. 2) to position 1;
D tip the cab and press the starter button (Fig. 3, see arrow).

2 The engine can only be started if:

D the gearbox is in neutral or position N for automatic versions;
D the hand brake is engaged.

Tow start
Proceed as follows:
D turn the ignition switch (Fig. 2) to position 1;
D engage a mid---low range gear according to conditions.
178NU00A

178NU47
ASTRA HD8Ec 1---65

1 4 Emergency electrical power

When the batteries are discharged, connect the vehicle to external batteries to restart it.
The vehicle is equipped with a 24 volt electrical system with negative and
earth.
Only use 24 volt batteries to jump start the engine
Proceed as follows (1):
3 2 1 a. lay the cables on the ground ensuring that the terminals do not touch metal parts or each
other; connect one end of the red cable (A) to the POSITIVE terminal (Fig. 1, ref. 1) of
the flat battery;
b. connect the other end of the red cable (A) to the POSITIVE terminal (Fig. 1, ref. 2) of the
external battery;
c. connect one end of the black cable (B) to the NEGATIVE terminal (Fig. 1, ref. 3) of the
238NU44 external battery;
d. connect the other end of the black terminal (B) to any point of the chassis of the vehicle
(Fig. 1, ref. 4) to be started which is certainly connected to earth.

Select a connection point as distant as possible from the vehicle batteries.

Make sure that the two vehicles do not come into contact.
Respect the sequence of the operation.
Do not reverse the polarity when making the connection.
Use cables with a suitable cross---section area.
After starting the engine, disconnect the cables by reversing the connection sequence.
The vehicle electrical system must work in presence of battery, even if flat.

In any case verify the causes of the batteries discharge.

1---66 ASTRA HD8Ec

1 STOPPING THE ENGINE

Stopping from the driver’s cab
To stop the engine proceed as follows:
D idle the engine for a few minutes to balance the temperature and lubricate the turbo com-
pressor;
D turn the ignition switch key (Fig. 1) to position O and remove it.
Vehicles with robotic transmission: if the gearbox is not in neutral when the
178NU00A engine is stopped, the system automatically sets this position when the key
is removed from the switch.
In this condition there is no mechanical connection between engine and whe-
2 els, and the vehicle may roll forward if the parking brake is not applied.

Stopping from the engine bay

To stop the engine proceed as follows:
D press the engine shut---off device (Fig. 2, see arrow) until the engine stops;
Always disconnect batteries by means of the cut---of provided after stopping
the engine
178NU45
ASTRA HD8Ec 1---67

1 STARTING THE VEHICLE

Before starting the vehicle, make sure that the tractor front brake low pressure warning lights
(Fig. 1, ref. 1) and trailer brake low pressure warning lights (if fitted ) (Fig. 1, ref. 2) are off, and
that brake air pressure has reached 6 bar. If necessary wait a few minutes for the compressor
to charge the air tanks.
To start the vehicle proceed as follows:
D press the clutch pedal (Fig. 2, ref. 3);
206NU51 Press the pedal full down to fully disengage the clutch to prevent premature
wear to synchronisers.
2
D engage a low gear (1st to 3rd according to gradient);
D release the parking brake, then release the clutch while pressing the accelerator pedal
(Fig. 2, ref. 1).
The vehicle must be started in the right gear, especially if loaded and/or on
a hill to prevent premature clutch wear.

Proceed to engage the next gear pressing the clutch down before selecting the gear.
1---68 ASTRA HD8Ec

DRIVING THE VEHICLE

In normal driving conditions the red warning lights (red) must be off. If one or more warning lights come on, stop the vehicle and ascertain
the cause.
Do not exceed maximum engine speed, especially on downhill stretches.
Never run downhill in neutral or with clutch disengaged.
Use auxiliary brakes for long downhill stretches (engine brake) to prevent service brakes from overheating.
Do not for any reason use the parking brake when travelling (except in emergency).

1 When driving, check that:

D the generator light (Fig. 1, ref. 1) is off;
D fuel level (Fig. 1, ref. 2) is not at minimum;
Never totally empty the fuel tank to pre-
vent any deposits or condensation water
from the tank reaching the injectors.
D engine coolant temperature light (Fig. 1, ref. 3) re-
mains at around 90 ˚C;
D engine oil pressure (Fig. 1, ref. 4) is correct (between
4 and 6 bar); the warning light must go off when the
engine starts;
D brake air pressure (Fig. 1, ref. 5) is correct (max. 10.3
bar, min. 6 bar); the warning lights come on with pres-
sure lower than 5 bar.

228NUR52
ASTRA HD8Ec 1---69

1 GEARBOX
The operations to control the gearbox are the same as those on traditional type synchronised
gearboxes, i.e. without requiring doubling of the clutch when changing up and without inter-
mediate acceleration when changing down.
The individual gears can be engaged only when the parts to be mated reach the same speed.
It is therefore important to press the gear lever evenly until the gear is engaged.
Gearbox control (Fig. 1)
When the low range group is selected (“tortoise” warning light on) (Fig. 2) and the gearbox
178NU52 is in neutral, the gear lever is positioned between 3rd and 4th gear whereas when the high
range group is selected (“tortoise” warning light off) and the gearbox is in neutral, the lever
is positioned between 5th and 6th.
2 To engage 1st and 2nd and 7th and 8th, the gear lever must be moved towards the left or
right to overcome the slight resistance of the positioning springs.
The selections 3rd/4th and 5th/6th are separated by a harder spring click.

178NU53
1---70 ASTRA HD8Ec

1 When engaging a different speed range do not grip the lever as when normally changing
gear but hit the lever smartly with the palm of the hand so that it overcomes the reaction of
the spring. The lever will position itself automatically for the desired selection of 3rd/4th and
5th/6th (Fig. 1).
When engaging a different speed range selection the relative warning light on the dashboard
will come on or go out as appropriate (Fig. 2).
To protect the clutch, the engine and the gearbox against run---away speed rates, SPECIAL
CARE MUST BE TAKEN TO AVOID ERRONEOUS OPERATIONS when a lower gear is en-
gaged.
178NU52 A lower gear must be engaged only when the speed of the vehicle corresponds to the maxi-
mum speed of the gear immediately below.
The passage from 5th and 6th to 3rd and 4th with the gearbox in neutral must not be made
2 if the speed of the vehicle does not correspond to the maximum speed of 4 gear. th

Any passage from the high range to the low range other than the passage 5th and 4th used
for normal driving conditions must be avoided. The lever should not be used to set the low
range even when the vehicle is momentarily in neutral.
To avoid damaging the toothing of the gear, reverse should only be engaged
when the vehicle is stationary.

Operating the clutch

178NU53
The clutch pedal (Fig. 3, ref. 1) must be fully depressed each time a gear is changed. If the
clutch is not completely disengaged or if its state is not perfect (it does not engage or disen-
3 gage completely), there will be some difficulty in changing gear.
This also causes wearing of the synchronisers and toothing of the gear.

178NU133A
ASTRA HD8Ec 1---71

Splitter control
1 The splitter control which makes it possible to divide each of the eight gears (and reverse)
occurs via the pre---selection valve located in the control lever and operated by the pre---
selection lever (Fig. 1):
D lever upwards (position A) = > normal gears
D lever downwards (position B) = > step---up gears
To control the splitter the lever should be worked and the clutch pedal fully depressed.
A valve activated by the clutch pedal commands the splitter control cylinder, so that switching
is obtained. To obtain correct splitter operation, engagement and disengagement move-
ments must not be abrupt.
To avoid that the splitter is involuntarily engaged, activate the pre---selection lever before the
command movements.
The use of the splitter is particularly useful in certain cases, for example:
D to exploit the maximum power of the engine when difficulty is experienced when driving
off, overtaking or travelling uphill;
D when travelling in urban areas or when travelling in a queue when you wish to maintain the
engine at an economical rpm.

178NU53
1---72 ASTRA HD8Ec

1 STOPPING THE VEHICLE

To stop the vehicle proceed as follows:
D release the accelerator pedal (Fig. 1, ref. 1) and gradually press the brake pedal (Fig. 1,
ref. 2);
D when the vehicle is drawing to a halt, depress the clutch pedal (Fig. 1, ref. 3) and move the
gear lever to neutral;
D when the vehicle has come to a halt, engage the parking brake.
228NUR51 The lower the position selected (3, 2 or 1) the greater the engine braking ef-
fect, as higher ratios are progressively excluded.
ASTRA HD8Ec 1---73

1 Engine brake selector

There are three engine braking modes settable by means of the selector (Fig. 1) on the da-
shboard, for use in various situations:
position 0: button on cab floor (always enabled);
for intermittent use on hilly roads and on ice or snow;
position 1: coupled with the accelerator, engaging when the pedal is released;
use in long descents with constant gradient.
To get best performance from the engine brake it is advisable to select a gear
that keeps engine revs between 1900 and 2400 rpm.
178NU38

2 position 2: coupled with service brake, with activation over first segment of brake appli-
cation and maintained;
use essentially to reduce service brake wear on routes with frequent brake
application (e.g. in towns).
If only engine braking is required, use the cab floor button.
The warning light (Fig. 2) on the panel comes on each time the engine brake engages.

Engine brake application coupled with accelerator pedal (position 1) disa-

178NU135 bles all settings associated with the speed programmer.
1---74 ASTRA HD8Ec

SPEED PROGRAMMER
1 The speed programmer is a device that acts on the engine fuel supply, controlling engine
speed both with the vehicle at a standstill and in motion, provided that certain conditions are
met.
Engine idling speed regulation/setting
Press the pedal brake throughout the operation.

178NU39 Conditions:
D vehicle stopped and brake pedal pressed for the entire operation;
2 D engine idling;
D engine running at steady operating temperature (temperature above 30 ˚C).

Proceed as follows:
D press button OFF (Fig. 1, ref. 1) for about 2---3 seconds and wait for engine to reach steady
speed;
D adjust engine speed pressing ON (+) to increase and ON (---) to decrease;

178NU40 Each pressure on button (ON) corresponds to an increase or decrease in en-

gine speed of around 20 rpm.
Engine idle speed must be between the following values:
D minimum value: 550 rpm
D maximum value: 800 rpm
Adjust idle speed according to needs (noise, resonance, etc.).
D once the required speed is found, press RESUME button (Fig. 1, ref. 2) for about 5 se-
conds.
The new speed is thus memorised even stopping the engine, and remains valid for subse-
quent start---ups.
The previously memorised setting is retained if the procedure is not followed
correctly and/or if some error occurs during it.
ASTRA HD8Ec 1---75

1 Vehicle speed adjustment/memory (cruise control)

This system controls and maintains vehicle speed:
D increasing fuel flow in case the vehicle slows (hill climbing);
If the set speed cannot e reached, the device automatically cuts---out.

D reducing fuel flow in case the vehicle accelerates (descent): if this is insufficient, the engine
brake automatically cuts---in as well.
178NU38
Conditions:
2 D vehicle travelling at over 30 kph and gear engaged;
D engine running at steady operating temperature (temperature above 30 ˚C);
D brake pedal not pressed;
D clutch pedal not pressed (if present);
D engine brake pedal not pressed;
D engine brake selector (Fig. 1) in position 0 or 2.

178NU40 Activation: proceed as follows:

The function can only be activated if the brake pedal has been pressed at
3 least once after starting the vehicle.
D bring the vehicle to the speed to be maintained with the accelerator pedal;
D press button ON (+) (Fig. 2) just once: the speed value is automatically memorised;
D release the accelerator pedal.
Pressing button RESUME (Fig. 3, ref. 2) before activating the function recalls
the last memorised speed, providing vehicle conditions permit.
178NU39
1---76 ASTRA HD8Ec

1 Changing setting: proceed as follows:

D after activating the function, press button ON (+) (Fig. 1) to increase vehicle speed;
or
D after activating the function bress button ON (---) (Fig. 1) to decrease vehicle speed.

Deactivation: proceed as follows:

D press the brake pedal, clutch pedal (if present) or engine brake button;
or
178NU40 D press OFF button (Fig. 2, ref. 1);
or
2 D press the accelerator (to accelerate) for over 3 seconds.
If the accelerator is pressed for less than 3 seconds the system returns to the
set speed, providing vehicle conditions permit.
After disabling the system, it is possible to return to the previous setting by
pressing button RESUME (Fig. 1, ref. 2).
If the set speed can not be reached the device cuts---out automatically.

178NU39
ASTRA HD8Ec 1---77

1 VEHICLE PARKING
Parking brake (Fig. 1)
The parking brake has two positions:
D position A = on, the vehicle is braked;
D position B = off, vehicle free to roll.
To engage the parking brake, move lever to position A.
To disengage the parking brake lift the collar and lower the lever to position B.
228NU216 The parking brake must be engaged in the following situations:
D temporary or prolonged parking of the vehicle;
D when loaading/unloading the vehicle;
2 D when connecting trailer/semi---trailer to the vehicle.
Additional parking brake
The additional parking brake (Fig. 2, see arrow) has two positions:
D position 0 = off;
D position 1 = on.
To engage the additional parking brake, turn the knob to position 1 and wait for 5 to 6 sec-
onds; when the additional parking brake is engaged, the corresponding warning light on the
228NU217 instrument panel comes on.
The additional parking brake is of the non---proportional type and can be en-
gaged only after engaging the parking brake.
Since it is pneumatically operated, it must be used only with running engine
and for short periods of time.
1---78 ASTRA HD8Ec

1 SEMI---TRAILER HOOKING
The fifth wheel (Fig. 1, see arrow) is the organ for attaching trailers and so
has to meet the most stringent safety requirements.
Hooking up
The fifth wheel is ready for attachment when the operating handle (Fig. 2, ref. 1) protrudes
178NU84 approximately 35 cm from the fifth wheel plate.
If the locking mechanism is closed, proceed as follows:
2 D remove the spring clip (Fig. 2, ref. 2);
2 D move the operating handle forward to free the first gate;
D pull the operating handle to the end up to the second gate;
1 D immobilise the semi---trailer;
The semi---trailer skid plate should be approx. 5 cm lower than the top of the
fifth wheel.
Proceed as follows:
D immobilise the semi---trailer;
178NU85 D reverse the tractor so that it is in line with the semi---trailer, the locking mechanism functions
automatically;
3 D drive the tractor forwards to check that the semi---trailer is hooked---up correctly;
D attach the spring clip.
1 Positioning the cleat serves to permit visually check correct fastening of the
2 articulation pin in the fifth wheel.
Unhooking
Proceed as follows:
D remove the spring clip (Fig. 3, ref. 1);
D move the operating handle (Fig. 3, ref. 2) forwards to release the first gate;
178NU86 D pull the operating hand to the end up to the second gate: when the king pin is released
the locking mechanism will automatically adopt a position ready for hooking up.
ASTRA HD8Ec 1---79

1 TRAILER HOOKING
Proceed as follows:
D ensure that the chocks are positioned under the rear wheels;
D the front axle can still be moved;
D adjust the height of the trailer draw bar to that of the pintle hook;
D lift lever (Fig. 1, ref. 2);
D hook the trailer to hook (Fig. 1, ref. 1).
178NU87

TOWING INSTRUCTIONS FOR TRAILER/SEMI---TRAILER

Before hooking---up
Before reversing with the tractor, make sure no people are standing in the immediate area.

After hooking---up
Engage the parking brake.
Check that the coupling has been made correctly.
Couple the pneumatic hoses and electrical cables.
Check the efficiency of the braking system and lighting system.
Check the safety of the pintle hook and associated crossbar before starting the vehicle.

When travelling
Proceed with special care when towing a trailer/semi---trailer; do not exceed the maximum permitted weight.
When stopping on a slope, ensure that the hand brake is working correctly; this must be able to hold the vehicle stationary.
1---80 ASTRA HD8Ec

14 3
HITCHING---UP TRAILER
Pneumatic connection (Fig. 1)
1. Automatic (red)
2. Adjustable (yellow)
Electrical connection (Fig. 1)
3. 15 pole connector (ISO 12098)
4. not used
2 1
228NUR60
ASTRA HD8Ec 1---81

1 SEMI---TRAILER HOOKING
Pneumatic connection (Fig. 1)
1. Automatic (red)
2. Adjustable (yellow)
Electrical connection (Fig. 1)
3. 15 pole connector (ISO 12098)
4. not used

LADDER
2 To have access to the electrical and pneumatic connections of the tractor use the specific
ladder (Fig.2, ref 1).
Always keep the steps clean to avoid slipping.
1---82 ASTRA HD8Ec

1 TOWING THE VEHICLE

The vehicle must only be towed by the tow---hooks provided for that purpose.
Proceed as follows:
D open the front license holder plate (Fig. 1, see arrow);
D insert the end of the towbar into the seat;
D insert the locking pin and fasten it with the cotter pin.
Always use a suitably anchored rigid bar.
228NUR72
Do not use cables or chains.
Insert the key into the ignition switch to release the steering lock.
ASTRA HD8Ec 1---83

1 The towing vehicle (Fig. 1):

D must be of a similar weight to the one being towed;
D must have sufficient engine power to tow the vehicle up any gradients present on the route;
D must have sufficient braking power to slow the vehicle down any gradients present on the
route.

2 and 3 axle vehicles

D disconnect the transmission shaft between gearbox and axle from the axle (4x2 and 6x4
vehicles;
228NUR61
D disconnect the transmission shaft between transfer box and axle from the transfer box (4x4
and 6x6 vehicles).
If hydraulic servo power to steering is absent, remember that although the
connection between the steering wheel and the wheels themselves always
functions, the amount of effort necessary to steer the vehicle increases great-
ly.
A towing speed limit is not necessary.
4 axle vehicles
The vehicle is fitted with an emergency steering pump driven by the transmission.
Without the hydraulic steering servo (engine off), although the mechanical connection be-
tween steering wheel and wheels still functions, steering is practically impossible.
For this reason, in this case the transmission shaft must not be detached in order to allow the
gearbox to drive the emergency steering pump to provide a certain degree of servo power
to the steering.
To prevent damage to the gearbox, towing speed must be limited.
Maximum towing speed in this condition is 40 kph.
Check that the gear shift lever is in high range (5th --- 8th gear).
1---84 ASTRA HD8Ec

1 Spring cylinder emergency braking device

In the event that compressed air does not reach the parking brake circuit, the vehicle is auto-
matically braked by the spring cylinders.
To enable the vehicle to be towed, the brake must be released with the mechanical release
device.
Mechanical disengagement
To do this, proceed as follows OPERATING ON BOTH CYLINDERS:
D place chocks under the wheels;
D engage the hand brake;
D turn the central screw located on the rear part of the cylinder (Fig. 1) anticlockwise from
position 1 to position 2.

After intervention of the emergency release device, the vehicle must only be
towed and must under no circumstances circulate autonomously.
Before using the vehicle normally again, return both the spring cylinders to
position 1.
238NU56
Compressed air discharged
2 If the vehicle has not been used for a long period and the comprssed air system is dischar-
ged, it can be re---charged from an external source through the connector (Fig. 2, see arrow).
This operation also releases the spring cylinders.

228NUR62
ASTRA HD8Ec 1---85

1 WHEEL CHANGE
Jacking up the vehicle
To use the jack:
D remove the jack (Fig. 1, ref. 1) from its mounting behind the passenger seat by unscrewing
the locking screw (Fig. 1, ref. 2) from the bracket;
D use the bar provided (Fig. 2, see arrow), located under the front radiator;
D check, that the hydraulic valve (Fig. 3, ref. 1) of the jack is rotated clockwise (hydraulic cir-
cuit under pressure);
228NUR63
D position the jack at the raising points specified in the following page;
2 D insert the rod into the bush (Fig. 3, ref. 2) and work the pump until lifting the wheel;
D after changing the wheel, turn the jack hydraulic valve anti---clockwise;
D remove the jack and press the top part of jack cylinder with your foot to fit it back into seat.
Strictly comply with instructions indicated on the label attached to the jack
to use it correctly.
The wheels should be changed when the vehicle is on level ground and un-
loaded with the hand brake engaged and chocks placed against the wheels
which remain on the ground.
228NUR64

178NU91
1---86 ASTRA HD8Ec

1 Changing a wheel
To change a wheel:
D use the wheel brace provided to loosen the wheel bolts on the wheel to be changed;
D raise the vehicle until the wheel is off the ground and set the jack at the following points
(Fig. 1 and Fig. 2, see arrows):
A: axle, B: front axle,
(Fig. 2, see arrow):
C: intermediate axle, D: rear axle;
178NU93 A B D remove the nuts than remove the wheel taking care not to damage the wheel nut threads;
D clean the threads of the bolts and nuts and the mating surfaces between rim and hub;
2 D mount the spare wheel (or repaired wheel);
D slightly tighten the wheel nuts until the wheel is correctly mounted on the hub;
D tighten the bolts in the order shown on drawing (Fig. 3);
D lower the vehicle and complete tightening to a torque of 60 ~ daNm.
Apply body weight (circa 70 daN) to the end of the lever provided to obtain
tightening torque of approximately the specified value.
C D 178NU94
Check wheel nut tightening torque after 20---40 km, then check again after
100 km DO NOT apply oil to the nut/wheel rim contact surface.
3 Excessive tightening may be dangerous: do not use pipes or extensions that
are not provided with the vehicle.
Do not use wheels with wheel bolts which differ from those supplied originally
with the vehicle.

178NU95
ASTRA HD8Ec 1---87
Handling the spare wheel
1
Replacing a front or rear wheel with a spare does not create problems even if the profile of
the thread is different.
A tyre with the same profile should however be reintegrated as soon as possible.
To remove the wheel proceed as follows:
D unscrew the nuts (Fig. 1, ref. 1) fastening the wheel to the support bracket;
D free the handle (Fig. 1, ref. 2) and take it in job position;
178NU96 D turn the crank until sufficiently lowered to remove the wheel.
To replace the wheel, reverse the above procedure.
1---88 ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec 1---89

1 ENGINE DIAGNOSTICS
Normal function
With the ignition switch in position 1 (MAR) the EDC warning light (Fig. 1) goes out when the
brake pedal is first pressed.
If the light does not come on, proceed as follows:
D open the relay housing hatch, press the check key (Fig. 2, ref. 1);
D if the light (Fig. 2, ref. 2) (EDC warning in parallel) odes not come on check the fuse (Fig.
2, ref. 3).
206NU50 Function with fault
If the EDC warning light comes on during normal vehicle operation, a fault has been de-
2 tected. There may be two situations.
D Warning LIGHT ON
System function degraded. Proceed with caution and contact the Dealer as soon as pos-
sible.
D Warning LIGHT BLINKING
System function degraded and loss of one or more safety functions, possible engine stop.
Stop the vehicle and contact the Dealer as soon as possible.
Information on the type of fault, memorised by the EDC is given in the form of a sequence
178NU141 of long and short flashes (blink code). Proceed as follows:
D stop the vehicle and switch off the engine;
D turn the ignition switch to postion 1 (MAR);
D open the relay housing hatch, press the check key (Fig. 2, ref. 1) and check warning light
behaviour (Fig. 2, ref. 2):
D one blink: no fault memorised;
D one blink followed shortly by a sequence of long and short blinks: one or more faults
memorised.
For further information contact your Dealer.
1---90 ASTRA HD8Ec

DIAGNOSTICS --- VEHICLE

Quick guide to the most common problem (excluding 4 axles steering system)
Light on Problem Remedy
WARNING: braking efficiency reduced or absent.
Braking system malfunction Stop the vehicle and contact your Dealer as soon as
possible

Low oil pressure (with engine hot) Stop the vehicle and contact you Dealer as soon as
possible

Low battery Proceed with caution and contact your Dealer as soon
as possible

Water in fuel pre---filter Purge water from pre---filter or replace pre---filter pro-
ceeding as described in the MAINTENANCE chapter

Clogged air cleaner Replace the air filter proceeding as described in the
MAINTENANCE chapter

WARNING: power steering efficiency degraded or

Steering system fault absent.
Stop the vehicle and contact the Dealer as soon as
possible.
ASTRA HD8Ec 1---91

Quick guide to the most common problems --- steering system 4 axle vehicles
(a) engine off, ignition on

Beeper Meaning / behaviour

on on off Normal

off on on WARNING: power steering efficiency degraded or absent.

Stop the vehicle and contact the Dealer as soon as possible.

(b) engine running

Meaning / behaviour
Beeper

Stopped vehicle Running vehicle Normal

off on off off Normal
WARNING: power steering efficiency degra-
on on off off ded or absent.
Stop the vehicle and contact the Dealer as
soon as possible.
Power steering normal, but secondary circuit
off on on off no longer available in case of primary circuit
failure.
1---92 ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec 1---93

Maintenance Instructions
1---94 ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec 1---95
INTRODUCTION
Properly dispose of replaced material (brake pads, filters, etc.) and materials resulting from maintenance operations and
repairs (material soaked in fuel, oil, powder, etc.) according to the laws in force, diversified from normal waste.
Collect and dispose of used lubricants and fluids, according to the laws in force.
Collect and dispose of used batteries according to the laws in force.
Drain and recharge the air conditioning system using the specific devices, according to the laws in force.
Technical information on maintenance (intervals, type and number) is given in TABLES AND DIAGRAMS.

All level checks must be carried out with vehicle parked on flat and handbrake engaged.
Wait a few minutes for the level to stabilise before checking.
Observe scrupulous cleanness of oil and fluid containers when refilling.
Before injecting grease, or checking levels, carefully clean the pressure fittings and the areas around the level and filling caps.
Use oil and fluid of the same type used before in the various assemblies when topping up.
Never tamper with valves, regulators or other devices, unless specified in the handbook, to prevent damage to vehicle components and
consequent hazards for persons.
1---96 ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec 1---97

1 OPENING THE COWL

To open the cowl, lift it (Fig. 1, see arrow): two air springs hold the cowl in the open position.
To close, lower the cowl onto its stop.

228NU219
1---98 ASTRA HD8Ec

1 TILTING THE CAB

The vehicle’s cab can be tilted forward via a hydraulic cylinder driven by the oil pressure sup-
plied by a manually operated pump.
Always apply the parking brake and set the shift lever to neutral before star-
ting any job.

Before tipping open the front grill to prevent damage.

228NUR64
Lifting the cab
2 1
Proceed as follows:
D take the lever provided (Fig. 1, see arrow);
D using the lever (Fig. 2, ref. 1) turn the pawl (Fig. 2, ref. 2) to the circuit pressure position (to
right);
D insert the lever into the seat provided (Fig. 2, ref. 1) and pump until the cabin is fully tipped.
Never leave the cab in a partially tilted position.
Never work under a partially tilted cab.
2 178NU99
Do not stand in front or behind the cab when it is being tilted.

Keep the front grill fully open throughout the operations.

If there is an anomaly affecting the hydraulic system, the cab can be tilted
with mechanical means (e.g. with a crane).
ASTRA HD8Ec 1---99

Lowering the cab

1 1
Proceed as follows:
D using lever (Fig. 1, ref. 1) turn the pawl (Fig. 1, ref. 2) to the circuit decompression position
(to the left);
D insert the lever provided into the appropriate seating and down until the cab has been
tilted;
D check that the cab is fully lowered and secured and that the warning light (Fig. 2) is out;
if the warning light stays on the engine cannot be started.
2 178NU100
Tipping can be interrupted by turning the pawl (Fig. 1 ref. 2).
Leave the pawl (Fig. 1, ref. 2) in decompression position until the next tipping
2 operation.

129NU11
1---100 ASTRA HD8Ec
DAILY OPERATIONS
1 Engine oil level check
Proceed as follows:
D open the grill;
D with the engine cold, remove the oil dipstick (Fig. 1, see arrow) and check that the level is
included between the references on the dipstick. Reposition the dipstick;
If the engine is warm, stop the engine and wait for ten minutes for the oil to
178NM01 drain into the sump;
Do not use the vehicle if the oil level is either under or over the limits.
Lack of lubricant or excessive lubricant can damage the engine.
2
D If required, top up using oil of the same type contained in the oil sump.

Checking engine coolant level

Proceed as follows:
D open the radiator grill;
D on a cold engine, check that the fluid level (Fig. 2, see arrow) is at the specified distance:
distance from cap: 5---6 [cm]
228NM220
D if necessary, top---up level with the same type of coolant already in the circuit.
ASTRA HD8Ec 1---101
Fuel tank water drain
1 Proceed as follows:
D with the engine stopped, loosen the ring (Fig. 1, see arrow) and drain the fuel;
D tighten the ring nut without excessive torque when water---free fuel flows out.
This operation must be carried out if the fuel filter water warning light comes
on (Fig. 2).

Windscreen washer fluid level check

178NM115
Proceed as follows:
D open the grill;
2 D check whether the fluid level in the reservoir is adequate (Fig. 3, see arrow);
D top up, if required.

Perform the following checks before using the vehicle:

D fuel level in tank;
D tyre conditions;
D operation of lights, warning lights on dashboard and windscreen wiper;
D service and parking brake operation;
Visually inspect the vehicle, checking working conditions and for
178NM116 damage/problems which may cause damage to the vehicle or injury to
operators.
3

178NM07
1---102 ASTRA HD8Ec
ENGINE
1
Changing engine oil
Proceed as follows:
D stop the warm engine and wait for the coolant temperature to drop to 60 ˚C;
D tilt the cab;
D arrange a suitable sized container and remove the dipstick;
D clean the cap area, loosen the drain cap (Fig. 1) and drain all the oil for the time required;
178NM10 D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
D clean the filler area and pour in the specific amount of lubricant through the filler (Fig. 2,
2 see arrow);
D close the filler and arrange the dipstick in the housing;
D start the engine and warm it up. Stop the engine and wait for a few minutes;
D remove the oil dipstick and check that the level is included between references on the dip-
stick (Fig. 3);
D top---up the level if necessary.

178NM11 Do not use the vehicle if the oil level is either under or over the limits.
Lack of lubricant or excessive lubricant can damage the engine.
3 The first engine lubricant replacement is to be made at 800 hours.
The following replacements depend on the type of lubricant used.

156NM11
ASTRA HD8Ec 1---103
Replacing engine oil filter
1
Replace the oil filter at the frequency shown. If the filter is clogged up, the
bypass valve will permit lubrication of the engine, but the circulating
lubricant will not be filtered.

Motor F3B: The engine has two identical cartridges.

178NM12

2 Proceed as follows:
D stop the warm engine and wait for the coolant temperature to drop to 60 ˚C;
D loosen the filtering cartridge (Fig. 1, see arrow) using the specific tool and accurately clean
the housing;
D fasten the cartridge by hand until the seal comes into contact with the housing, then turn
by another 3/4 of a turn (Fig. 2).
Do not fasten the cartridge excessively. This could damage the seal. Observe
the specifications provided by the supplier.
178NM13
D start the engine for a few minutes and check for leakage of lubricant;
D check engine oil level and top up, if required.
1---104 ASTRA HD8Ec
Engine oil vapour filter change
1 Proceed as follows:
D loosen the screws of the cover (Fig. 1) and remove it;
D remove the filter (Fig. 2, ref. 1);
When refitting, position the filter with the support brackets (Fig. 2, see arrow)
pointing toward the cover.
D replace the cover;
228NM221
D check that the breather pipe (Fig. 3, see arrow) is not kinked or bent.
2 1

228NM222

228NM223
ASTRA HD8Ec 1---105
Accessory drive belts check
1 The engine has two accessory drive belts (Fig. 1):
1. alternator/fan/water pump drive belt
2. climate control compressor drive belt (only clima---version).
Each belt has an automatic take---up device and does not require adjustment.
Proceed as follows:
D tilt the cab;
D when the engine is cold, check that the belt (Fig. 2) is not frayed or cracked (small cros-
swise cracks are allowed);
D otherwise replace the belt following the instructions below (for further information contact
the Dealership);
D press with the hand on the longer branch to check the take---up device is functioning pro-
178NM14 perly.

Accessory drive belts replacement

2
This operation must be carried out by adequately trained personnel. For fur-
ther information contact your Dealer.

The belts can be removed --- after removing the fan --- by setting each tensioner to zero load.
Remove the air---conditioner compressor drive belt first and then the alternator/fan/water
pump drive belt.
Proceed in reverse order to refit.
178NM05
1---106 ASTRA HD8Ec
Intake---exhaust valve play adjustment (Fig. 1)
1
This operation must be carried out by adequately trained personnel. For fur-
ther information contact your Dealer.
Play is adjusted by means of the screw with lock nut, at the head of each rocker.
Injector---pump pre---load adjustment (Fig. 2)
This operation must be carried out by adequately trained personnel. For fur-
ther information contact your Dealer.
178NM18
Adjust the pre---load by means of the screw with lock nut on the head of each rocker arm
2 (contact the dealership for further information).

178NM19
ASTRA HD8Ec 1---107
FUEL FEED SYSTEM
1
Bleed fuel tank condensation water
Proceed as follows:
D Loosen the drain cap (Fig. 1, see arrow) and let a little fuel out to drain the residues and
condense which normally is formed in the tank.
Keep the fuel tank as full as possible. Use fuels of the specified types
supplied by petroleum companies. Do not use other than specified fuels. Use
206NM01 of other than specified fuels can cause severe engine damage.
1---108 ASTRA HD8Ec
Replacing fuel filters
1 The vehicle has two groups of fuel filtration:
(1) fuel prefilter (on chassis; Fig. 1, see arrow);
(2) fuel filter (on engine; Fig. 2, see arrow).
Proceed as follows:
D with a cold engine, loosen the filtering cartridge using the specific tool and actuately clean
housing and engine;

206NM07 Do not fill the new filter with fuel to prevent foreign matter entering the
injection system.
2 D hand---tighten the cartridge until the washer comes into contact with the support, then tigh-
ten it by ¾ of a turn;
Do not fasten the cartridge excessively. This could damage the seal. Observe
the specifications provided by the supplier.

D start the engine for a few minutes and check for leakage of lubricant.

206NM08
ASTRA HD8Ec 1---109
Fuel circuit bleeding
1 Proceed as follows:
D tip the cabin;
D fit suitable pipes to the bleed nipples and lead them to a container;
D loosen the bleed nipples by a few turns.

Prefilter
D Pump the priming pump (Fig. 1, see arrow) until fuel flows out from the nipple (Fig. 1, ref.
206NM04 1) without air bubbles, then tighten the nipple.

2 Filter
D Repeat the operation for this nipple (Fig. 2, ref. 1);

Cylinder head bleed nipple

D Remove the soundproofed cover;
D Repeat the operation for this nipple (Fig. 3, ref. 1).
206NM03 Absolutely avoid smearing fuel on the accessory drive belts to prevent dama-
ge.
3 Use suitable receptacles to prevent fuel leakage into the environment.

1
178NM119
1---110 ASTRA HD8Ec
INTAKE SYSTEM
1
Intake system seal check
Proceed as follows:
D tip the cabin;
D check the intake system seals and connectors (Fig. 1, see arrow);
D correct any leakage in the section between the intake pipe and turbocompressor, to pre-
vent intake of any foreign matter into the turbo and engine;
D correct any leakage in the section between turbocompressor and engine, to avoid loss of
engine efficiency.

Turbocompressor lubrication check

Proceed as follows:
D tip the cabin;
D inspect the delivery pipes (Fig. 2, ref. 1) and return pipes (Fig. 2, ref. 2) to check absence
of leaks or faults that could cause decreased oil flow to the turbo.

269NM191 Given the high turbocompressor operating speed, any reduction in oil supply
will result in damage.
2
Intercooler external cleaning
1 Clean the radiator using compressed air to remove accumulated debris (leaves, insects).
To remove hardened debris, brush the radiator with a water/detergent solution then use
steam to remove any residue.
2

269NM193
ASTRA HD8Ec 1---111
Main filter element cleaning/change
1
Do not clean the filter daily or at different intervals to those specified.
Clean the main filter element at most 6 times, after which it must be changed.
Proceed as follows:
D release the retainer springs (Fig. 1, see arrow) and remove and thoroughly clean the cover;
D extract the primary cartridge (Fig. 2, see arrow);
D dust removal using compressed air at maximum 3 bar pressure, blowing air from inside
174NM26 filtr element outwards (Fig. 3).
Keep the air jet at a few centimetres from the filter pack to prevent damage.
2 Never clean the filter by beating on a hard surface.

174NM27A

156NM52
1---112 ASTRA HD8Ec

1 Carry out the following checks before refitting the filtering element:
D check conditions of O---rings and plastic tabs. Replace the filtering element, if required;
D check integrity of filtering element by placing a source of light inside (Fig. 1); light will filter
from even the smallest cracks, indicating that the filter must be replaced.

Make sure the temperature does not exceed 60˚C if a light source outputting
heat (e.g. a lamp bulb) is used.
D Clean the rubber drain valve, check integrity and replace it if required.
156NM53 Safety secondary filter element replacement
Proceed as follows:
2 D remove the main filter;
D remove the element (Fig. 2, see arrow).
The secondary element cannot be cleaned. It can only be replaced.

174NM29A
ASTRA HD8Ec 1---113
COOLING SYSTEM
1 Never remove the cap (Fig. 1, ref. 1) when coolant is hot to avoid:
D scalding;
D damage to the engine, in that the system comes under pressure only with
coolant heating from engine cold.
Always top up the system with engine off and cold.

Replacing engine coolant

The system pressure regulator valve (Fig. 1, ref. 2) is sealed and must not be
228NM224 removed for any reason.

2 Proceed as follows:
D turn the cab heater to maximum heat;
D position a container with adequate capacity then remove the cap (Fig. 1, ref. 1) on the
expansion chamber (Fig. 1, ref. 2);
D disconnect the radiator hose (Fig. 2, see arrow), then wait for coolant to fully drain off;
D refit the hose;
D pour the coolant very slowly into the expansion tank until full;
D start the engine and run it slightly faster than idle speed for about 5 minutes;
D stop the engine and top---up expansion chamber coolant level;
D start the engine, warm it up and allow it to run until the coolant in the chamber does not
produce air bubbles;
D check that the system pressure regulator valve opens at the specified pressure value:
otherwise replace it.

228NMR01
1---114 ASTRA HD8Ec
Checking antifreeze concentration
1 A 50---50 mixture of water and specific antifreeze is required to protect the system from cor-
rosion.
The minimum concentration of antifreeze depends on the temperature where the vehicle is
in use (Fig. 1).
antifreeze
water
Check the concentration of antifreeze in the engine coolant.
156NM61
Always respect the supplier’s mixing specifications if particular additives are
used.
ASTRA HD8Ec 1---115
CLUTCH
1
Check clutch disengagement
Proceed as follows:
D run the engine at idle and depress the clutch;
D after approx. 10/12 seconds, slowly engage reverse gear. If the toothing ”grates” (grating
noise of engagement of front teeth) the clutch must be checked and/or bled.

272NM002X Oil level check

Proceed as follows:
D open the radiator grill;
D visually check that oil level (Fig. 1, see arrow) is not below the minimum level;
D if necessary, top---up the level as shown in the following paragraph.
The fluid is corrosive: always wear protective gloves.

Use only the specified type of fluid for topping up.

The fluid will corrode any paintwork it comes into contact with.
1---116 ASTRA HD8Ec
Manual transmission vehicles --- I˚ type
1
Changing the hydraulic fluid
Proceed as follows:
D prepare a suitable container, unscrew tank cap (Fig. 1, see arrow) and unscrew drain pipe
(Fig. 2, ref. A), draining off oil completely;
D seal drain pipe and fill tank with oil to the max. level;
D bleed out air from the system.
272NM003X
Air bleeding
2 Proceed as follows:
D check whether reservoir is full;
D use a transparent tubing and insert one end into the drain valve union (Fig. 2, ref. B) and
the other end into a clean container;
D press clutch pedal and keep it in position;
D open the drain valve a little to allow oil and air bubbles to come out and close it after a few
seconds;
D release clutch pedal completely;
272NM004X D repeat operation until oil without air bubbles comes out of the drain valve;
ASTRA HD8Ec 1---117
MULTIPOWER PTO
1
Oil level check
Proceed as follows:
D with the engine off remove the dipstick (Fig. 1, ref. 1) and check that oil level is between
the notches on the dipstick, then replace it;
D if necessary, top---up the level as shown in the following paragraph.

Oil change
228NM225
Proceed as follows:
2 D place a suitable container, clean the area around the level plug (Fig. 1, ref. 2) and remove
it (Fig. 1, ref. 2);
D remove the drain plug (Fig. 2, ref. 1) fully drain off the oil;
D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
D fill with the required quantity of fluid as shown on the cap (Fig. 1, ref. 2);
D clean the filler cap, check that the thread is in good condition, replace the O---ring and close
it;
228NM226
D test drive then check level again, removing the screw (Fig. 2, ref. 2) waiting for oil to stop
draining then replacing the screw;
D top---up the level if necessary.
Clean the filter on the intake pipe after the first 25 hours of use, proceeding
as follows:
D remove the filter unscrewing the retaining cap (Fig. 2, ref. 3), clean it with
diesel oil and dry with compressed air. If exhausted, replace it;
D check gaskets and replace them if necessary.
1---118 ASTRA HD8Ec
ZF NWM 221 POWER TAKE OFF
1
Oil level check/change
The power take off uses the same oil as the gearbox.
For oil level check/oil change operations refer to the instructions for the
gearbox.
The quantity of oil required in addition to that of the gearbox is circa 2 litres.

228NMR32 Oil filter change (Fig. 1)

2 Change the filter only after having drained off oil.
Oil may leak during these operations.

Proceed as follows:
D position a suitable container then remove the cover (Fig. 2, ref. 1);
D remove the filter (Fig. 2, ref. 2) and recover the seal (Fig. 2, ref. 3);
D refit the filter following above instructions in reverse order.
228NMR02
ASTRA HD8Ec 1---119
ZF 16 S 1620 TD / 2320 TD TRANSMISSION
1
Oil level check
Proceed as follows:
D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the
hole;
D if necessary, top---up the level as shown in the following paragraph;
D close the level plug.
228NM227 Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning.

2 Oil change
Proceed as follows:
D place a suitable container, clean the area around the level plug and remove it (Fig. 1, ref.
1);
D remove the drain plug (Fig. 2, ref. 1) fully drain off the oil;
D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
228NM228 D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1);
D clean the level plug, check that the thread is in good condition, replace the O---ring and
close it;
D carry out a test drive then re---check level at plug (Fig. 1, ref. 1);
D if necessary, top---up with specified oil until it flows from the hole, repeat the test drive and
check the level again.
1---120 ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec 1---121

1 DISTRIBUTOR---TRANSFER (TRANSFER)
Oil level check
Proceed as follows:
D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the
hole;
D if necessary, top---up the level as shown in the following paragraph;
D close the level plug.
238NM10
Oil change
2 Proceed as follows:
D place a suitably sized container, clean the area around the plugs then remove the level plug
(Fig. 1, ref. 1); and filler cap (Fig. 1, ref. 2);
D unscrew the plugs (Fig. 2, ref. 1) and fully drain off the oil;
D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
D prepare 6.5 litres of fresh oil;
D fill through the filler cap (Fig. 1, ref. 2) until oil flows from the level plug (Fig. 1, ref. 1);
238NM11 D clean the filler cap and level plug, check that the thread is in good condition, replace the
O---rings and close them;
D drive the vehicle for a few minutes to allow oil to reach all transfer components, then stop
and wait ten minutes for the oil to settle;
D remove the level plug (Fig. 1, ref. 1): oil should flow from the hole. If not, top up level exclusi-
vely through the cap (Fig. 1, ref. 2) until oil flows from the level plug (Fig. 1, ref. 1);
D close both the level plug and filler cap.
1---122 ASTRA HD8Ec

1 TRANSMISSION SHAFTS
Greasing
Proceed as follows:
D clean the joint concerned;
D Inject grease into the universal joint grease nipples (Fig. 1, see arrow) each transmission
shaft has two or three greasing points.

178NM46
Inject grease until it seeps from the grease nipples to ensure efficient lubrica-
tion
A hand pump must be used for greasing, and never a high pressure grease
gun.
ASTRA HD8Ec 1---123

1 AXLES: 2 axle vehicles

Front axle
Check differential oil level
Proceed as follows:
D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the
hole;
D if necessary, top---up the level as shown in the following paragraph;
228NM230 D close the level plug.

Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning.

Differential oil change

Proceed as follows:
D place a suitable container, clean the area around the level plug (Fig. 1, ref. 1) and remove
it; (Fig. 1, ref. 1);
D remove the drain plug (Fig. 1, ref. 2) fully drain off the oil;
D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1);
D clean the level plug, check that the thread is in good condition, replace the O---ring and
close it;
D carry out a test drive then re---check level at plug (Fig. 1, ref. 1);
D if necessary, top---up with specified oil until it flows from the hole, repeat the test drive and
check the level again.
1---124 ASTRA HD8Ec
Hub oil level check
1 This must be checked separately on both hubs.

Proceed as follows:
D turn the plug (Fig. 1, ref. 1) such that the reference mark is horizontal;
D clean the plug zone and open the plug (Fig. 1, ref. 1): oil should drip from the hole;
D if necessary, top---up the level as shown in the following paragraph;
178NM50 D close the level plug.

Hub oil change

This must be checked separately on both hubs.

Proceed as follows:
D turn any of the screws (Fig. 1, ref. 2) in the lowest position, until the cap is situated aloft;
D clean the area around the cap, then open it (Fig. 1, ref. 1);
D place a suitably sized container, clean the area around the level plug (Fig. 1, ref. 2) and
remove it fully draining off the oil;
D tighten the screw;
D position cap hole (Fig. 1, ref. 1) in horizontal position;
D fill up with new oil until it overflows from hole (Fig. 1, ref. 1);
D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
D repeat operation for the other hub;
D carry out a test drive, then re---check the level at plug (Fig. 1, ref. 1);
D if necessary, top---up with specified oil until it flows from the hole, repeat the test drive and
check the level again.
ASTRA HD8Ec 1---125

1 Rear axle
Oil level check
Proceed as follows:
D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the
hole;
D if necessary, top---up the level as shown in the following paragraph;
D close the level plug.
228NMR09 Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning.

2 Oil change
Proceed as follows:
D on either of the hubs, turn any of the screws (Fig. 2, ref. 1) in the lowest position;
D place a suitably sized container, clean the area around the plugs then remove the level plug
(Fig. 1, ref. 1);
D remove the drain plug (Fig. 1, ref. 2) and both the screws (Fig. 2, ref. 1) and fully drain off
the oil;
D re---fasten the screws;
178NM51 D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1);
Fill gradually to give time for the oil to reach the hub transfer cases. The ope-
ration is finished when the level does not drop for at least five minutes.
D clean the level plug, check that the thread is in good condition, replace the O---ring and
close it;
D carry out a test drive then re---check level at plug (Fig. 1, ref. 1);
D if necessary, top---up with specified oil until it flows from the hole, repeat the test drive and
check the level again.
1---126 ASTRA HD8Ec

1 AXLES: 3 axle vehicles

Front axle
Check differential oil level
Proceed as follows:
D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the
hole;
D if necessary, top---up the level as shown in the following paragraph;
228NM230 D close the level plug.

Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning.

Differential oil change

Proceed as follows:
D place a suitable container, clean the area around the level plug (Fig. 1, ref. 1) and remove
it; (Fig. 1, ref. 1);
D remove the drain plug (Fig. 1, ref. 2) fully drain off the oil;
D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1);
D clean the level plug, check that the thread is in good condition, replace the O---ring and
close it;
D carry out a test drive then re---check level at plug (Fig. 1, ref. 1);
D if necessary, top---up with specified oil until it flows from the hole, repeat the test drive and
check the level again.
ASTRA HD8Ec 1---127
Hub oil level check
1 This must be checked separately on both hubs.

Proceed as follows:
D turn the plug (Fig. 1, ref. 1) such that the reference mark is horizontal;
D clean the plug zone and open the plug (Fig. 1, ref. 1): oil should drip from the hole;
D if necessary, top---up the level as shown in the following paragraph;
178NM50 D close the level plug.

Hub oil change

This must be checked separately on both hubs.

Proceed as follows:
D turn any of the screws (Fig. 1, ref. 2) in the lowest position, until the cap is situated aloft;
D clean the area around the cap, then open it (Fig. 1, ref. 1);
D place a suitably sized container, clean the area around the level plug (Fig. 1, ref. 2) and
remove it fully draining off the oil;
D tighten the screw;
D position cap hole (Fig. 1, ref. 1) in horizontal position;
D fill up with new oil until it overflows from hole (Fig. 1, ref. 1);
D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
D repeat operation for the other hub;
D carry out a test drive, then re---check the level at plug (Fig. 1, ref. 1);
D if necessary, top---up with specified oil until it flows from the hole, repeat the test drive and
check the level again.
1---128 ASTRA HD8Ec

1 Rear intermediate axle

Oil level check
Proceed as follows:
D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the
hole;
D if necessary, top---up the level as shown in the following paragraph;
D close the level plug.
228NM232 Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning.

2 Oil change
Proceed as follows:
D on either of the hubs, turn any of the screws (Fig. 2, ref. 1) in the lowest position;
D place a suitably sized container, clean the area around the plugs then remove the level plug
(Fig. 1, ref. 1);
D remove the drain plug (Fig. 1, ref. 2 and Fig. 3, ref. 1) and both the screws (Fig. 2, ref. 1)
and fully drain off the oil;
D re---fasten the screws;
178NM51
D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
3 D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1);
Fill gradually to give time for the oil to reach the hub transfer cases. The ope-
ration is finished when the level does not drop for at least five minutes.
D clean the level plug, check that the thread is in good condition, replace the O---ring and
close it.
D carry out a test drive then re---check level at plug (Fig. 1, ref. 1);
228NM233 1 D if necessary, top---up with specified oil until it flows from the hole, repeat the test drive and
check the level again.
ASTRA HD8Ec 1---129

1 Rear axle
Oil level check
Proceed as follows:
D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the
hole;
D if necessary, top---up the level as shown in the following paragraph;
D close the level plug.

228NM234 Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning.

2 Oil change
Proceed as follows:
D on either of the hubs, turn any of the screws (Fig. 2, ref. 1) in the lowest position;
D place a suitably sized container, clean the area around the plugs then remove the level plug
(Fig. 1, ref. 1);
D remove the drain plug (Fig. 1, ref. 2) and both the screws (Fig. 2, ref. 1) and fully drain off
the oil;
D re---fasten the screws;
178NM51 D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1);
Fill gradually to give time for the oil to reach the hub transfer cases. The ope-
ration is finished when the level does not drop for at least five minutes.
D clean the level plug, check that the thread is in good condition, replace the O---ring and
close it;
D carry out a test drive then re---check level at plug (Fig. 1);
D if necessary, top---up with specified oil until it flows from the hole, repeat the test drive and
check the level again.
1---130 ASTRA HD8Ec

1 AXLES: 4 axle vehicles

Front axle
Check differential oil level
Proceed as follows:
D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the
hole;
D if necessary, top---up the level as shown in the following paragraph;
228NM230 D close the level plug.

Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning.

Differential oil change

Proceed as follows:
D place a suitable container, clean the area around the level plug (Fig. 1, ref. 1) and remove
it; (Fig. 1, ref. 1);
D remove the drain plug (Fig. 1, ref. 2) and fully drain off the oil;
D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1);
D clean the level plug, check that the thread is in good condition, replace the O---ring and
close it;
D carry out a test drive then re---check level at plug (Fig. 1, ref. 1);
D if necessary, top---up with specified oil until it flows from the hole, repeat the test drive and
check the level again.
ASTRA HD8Ec 1---131
Hub oil level check
1 This must be checked separately on both hubs.

Proceed as follows:
D turn the plug (Fig. 1, ref. 1) such that the reference mark is horizontal;
D clean the plug zone and open the plug (Fig. 1, ref. 1): oil should drip from the hole;
D if necessary, top---up the level as shown in the following paragraph;
178NM50 D close the level plug.

Hub oil change

This must be checked separately on both hubs.

Proceed as follows:
D turn any of the screws (Fig. 1, ref. 2) in the lowest position, until the cap is situated aloft;
D clean the area around the cap, then open it (Fig. 1, ref. 1);
D place a suitably sized container, clean the area around the level plug (Fig. 1, ref. 2) and
remove it fully draining off the oil;
D tighten the screw;
D position cap hole (Fig. 1, ref. 1) in horizontal position;
D fill up with new oil until it overflows from hole (Fig. 1, ref. 1);
D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
D repeat operation for the other hub;
D carry out a test drive, then re---check the level at plug (Fig. 1, ref. 1);
D if necessary, top---up with specified oil until it flows from the hole, repeat the test drive and
check the level again.
1---132 ASTRA HD8Ec

1 Rear intermediate axle

Oil level check
Proceed as follows:
D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the
hole;
D if necessary, top---up the level as shown in the following paragraph;
D close the level plug.
228NM232 Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning.

2 Oil change
Proceed as follows:
D on either of the hubs, turn any of the screws (Fig. 2, ref. 1) in the lowest position;
D place a suitably sized container, clean the area around the plugs then remove the level plug
(Fig. 1, ref. 1);
D remove the drain plug (Fig. 1, ref. 2 and Fig. 3, ref. 1) and both the screws (Fig. 2, ref. 1)
and fully drain off the oil;
D re---fasten the screws;
178NM51
D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
3 D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1);
Fill gradually to give time for the oil to reach the hub transfer cases. The ope-
ration is finished when the level does not drop for at least five minutes.
D clean the level plug, check that the thread is in good condition, replace the O---ring and
close it.
D carry out a test drive then re---check level at plug (Fig. 1, ref. 1);
228NM233 1 D if necessary, top---up with specified oil until it flows from the hole, repeat the test drive and
check the level again.
ASTRA HD8Ec 1---133

1 Rear axle
Oil level check
Proceed as follows:
D clean the area around the level plug and remove it (Fig. 1, ref. 1): oil should drip from the
hole;
D if necessary, top---up the level as shown in the following paragraph;
D close the level plug.

228NM234 Check that the breather (Fig. 1, see arrow) is perfectly clean and functioning.

2 Oil change
Proceed as follows:
D on either of the hubs, turn any of the screws (Fig. 2, ref. 1) in the lowest position;
D place a suitably sized container, clean the area around the plugs then remove the level plug
(Fig. 1, ref. 1);
D remove the drain plug (Fig. 1, ref. 2) and both the screws (Fig. 2, ref. 1) and fully drain off
the oil;
D re---fasten the screws;
178NM51 D clean the drain plug, check that the thread is in good condition, replace the O---ring and
close it;
D fill with the specified oil until it flows from the plug hole (Fig. 1, ref. 1);
Fill gradually to give time for the oil to reach the hub transfer cases. The ope-
ration is finished when the level does not drop for at least five minutes.
D clean the level plug, check that the thread is in good condition, replace the O---ring and
close it;
D carry out a test drive then re---check level at plug (Fig. 1);
D if necessary, top---up with specified oil until it flows from the hole, repeat the test drive and
check the level again.
1---134 ASTRA HD8Ec

1 FRONT AND REAR SUSPENSION

1. axle/front axle (all vehicles);
2. rear axle (2---axle vehicles);
3. rear tandem axle (three axle and four axle vehicles).

Greasing
Proceed as follows:
D clean the nipple before injecting grease;
178NM89 D inject the grease in the pressure nipples of the leaf spring articulations and
the rear carriage support (see arrow).
2 Inject grease until it seeps from the grease nipples to ensure
efficient lubrication
A hand pump must be used for greasing, and never a high pres-
sure grease gun.

178NM91
ASTRA HD8Ec 1---135

1 STEERING SYSTEM
Oil level check
This check is optional, since there is an oil level warning light.

1. 2 and 3 axle vehicles

2. 4 axle vehicles
On 4 axle vehicles the system has two tanks connected together.
228NM235

2 Proceed as follows:
D park the vehicle with the engine off and wheels straight;
D clean the area around the plug, then unscrew the plug and check that the reservoir oil level
is between the two notches (Fig. 3) on the dipstick;
D if necessary top---up the level and close the plug.

228NM236

228NM237
1---136 ASTRA HD8Ec

1 CHANGING THE HYDRAULIC OIL 2 and 3 axle vehicles

Proceed as follows:
Dumping
D raise the vehicle until the front wheels are off the ground;
D prepare a suitable container, unscrew delivery (Fig. 1, see arrow) and return pipes from the
power steering casing and remove the oil reservoir cap;
D with engine off, turn the steering wheel from lock to lock until the oil stops flowing out;
D reconnect the hoses.

Filling
D fill completely reservoir with oil;
D with engine off, turn the steering wheel from lock to lock topping up reservoir with oil, at
the same time, until oil level is stabilised;
D start the engine to fill the system with oil: since the level drops rapidly, continue pouring
oil into the tank while PREVENTING AIR BEING DRAWN INTO THE SYSTEM;
228NMR10 D proceed until the level is steady.

Bleeding off air

D with the engine running at idle, turn the steering wheel from lock to lock until the residual
air bubbles are eliminated.
During this operation the oil level should be constantly checked. If the above
indications are followed strictly, oil should not exceed the upper notch on the
dipstick by more than 0.5 cm when the engine is stopped, nor suddenly
emulsify. This phenomenon would denote a remarkable presence of air in the
circuit due to incorrect operations during the filling phase.
ASTRA HD8Ec 1---137

1 CHANGING THE HYDRAULIC OIL for 4 axle vehicles

Proceed as follows:
Dumping
D raise the vehicle until the front wheels are off the ground;
D prepare a suitable container, unscrew delivery (Fig. 1, see arrow) and return pipes from the
power steering casing and remove the oil reservoir cap;
D with engine off, turn the steering wheel from lock to lock until the oil stops flowing out;
228NM238 D close the plug.

Filling
D fill completely reservoir with oil;
D with engine off, turn the steering wheel from lock to lock topping up reservoir with oil, at
the same time, until oil level is stabilised;
D start the engine to fill the system with oil: since the level drops rapidly, continue pouring
oil into the tank while PREVENTING AIR BEING DRAWN INTO THE SYSTEM;
D proceed until the level is steady.

Bleeding off air

D with the engine running at idle, turn the steering wheel from lock to lock until the residual
air bubbles are eliminated.
During this operation the oil level should be constantly checked. If the above
indications are followed strictly, oil should not exceed the upper notch on the
dipstick by more than 0.5 cm when the engine is stopped, nor suddenly
emulsify. This phenomenon would denote a remarkable presence of air in the
circuit due to incorrect operations during the filling phase.
1---138 ASTRA HD8Ec

1 Replacing oil filter

Proceed as follows:
2
D loosen the retaining screws (Fig. 1, rif. 2), where present;
D remove the cover (Fig. 1, rif. 3), gasket (Fig. 1, rif. 4) and the spring (Fig. 1, rif. 5);
D replace the filter cartridge (Fig. 1, rif. 1);
D check the cover seal. If damaged, replace it;
5
D replace the cover.

178NM60
ASTRA HD8Ec 1---139

1 Stub axle greasing

Axle (Fig. 1)
Drive axle (Fig. 2)
Proceed as follows:
D clean the joint concerned;
D inject grease into the axle stub grease nipples (Fig. 1 --- Fig. 2, see arrow).
Inject grease until it seeps from the grease nipples to ensure efficient lubrica-
178NM47 tion.
A hand pump must be used for greasing, and never a high pressure grease
gun.
2
4---axle vehicle steering rods greasing
Proceed as follows:
D clean the joint concerned;
D inject grease into the joint pressure nipples (Fig. 3, see arrow).
Inject grease until it seeps from the grease nipples to ensure efficient lubrica-
tion.
272NM005X
A hand pump must be used for greasing, and never a high pressure grease
gun.
3

228NMR11
1---140 ASTRA HD8Ec

Front wheel toe---in check

A: 4x2 and 6x4 vehicles
B: 4x4 and 6x6 vehicles
C: 8x4 vehicles

A B
228NMR12 228NMR14

C
228NMR13
ASTRA HD8Ec 1---141

This operation must be carried out by adequately trained personnel. For further information contact your Dealer.

Before starting the check, make sure:

D the vehicle is on a level surface and empty
D the tyres are inflated to the correct pressure.
Proceed as follows:
D set the wheels so that they are pointing forwards;
D check that the distances A and B measured along the centreline of the rims at the same height from the ground, correspond to the specified
values.
Fore---carriage Measurement
1st axle B = A --- (1 / 3 mm)
2nd axle B=A

If this is not the case, adjust as follows:

D loosen the bolts securing the ball joints (ref. 1) to the coupling rod (ref. 2);
D remove ball joint from lower steering lever;
D turn the rod right or left just enough to obtain the measurement required;
D riefit the ball joint and tighten the bolts;
D move the vehicle straight forwards or backwards by at least one turn of wheels and check toe---in again.

The entire steering mechanism must be checked if adjustments require more than 5 mm from the indicated measure-
ments. For further information contact your Dealer.
1---142 ASTRA HD8Ec
COMPRESSED AIR SYSTEM
1
Tank visual inspection
Visually inspect tank external condition.
Under no circumstances should any form of heat treatment or welding be
carried out on the outside of the tank.
If the reservoir is dented, have it replaced.
The conditions for use of the compressed air tank (pressure and
178NM66 temperature) are given on the label applied to the tank itself (Fig. 1).
Application should conform to these indications.
During operation the tank must not be subject to stresses in addition to those
deriving from the normal conditions of use and by its weight.
The tank is only designed for use with compressed air systems.
The tank is maintenance---free. The following precautions should however be taken:
D any painting should be preceded by a preparatory coat;
D surface treating of the bolts and screws with passivation;
D clean with products which do not contain alcohol.
ASTRA HD8Ec 1---143
Air drier functionality check
1 Proceed as follows:
D check that the air drier functions correctly by operating the drain valve (Fig. 1, see arrow),
in this case the air should come out of the tank with no traces of condensation.
As soon as a small amount of moisture is noticed, carry out a number of inspections at shorter
intervals to check whether this fact is only due to temporary overloading of the drier (Fig. 2,
ref. 1) or whether its efficiency is permanently impaired.
In the second case it will be necessary to renew the cartridge as the dampness absorption
capacity of the granulate is greatly reduced due to the action of oils, dirt, etc.If a mixture of
178NM67 oil and water comes out of the tanks during this check, this means that the compressor is not
working correctly as it is discharging oil.In this case in addition to replacing the cartridge, the
compressor must also be overhauled.
2
2 Air dryer filter change
Proceed as follows:
1 D with the engine off unscrew the cartridge (Fig. 2, ref. 2) with the correct spanner if neces-
sary, then thoroughly clean the support seat;
D hand---tighten the cartridge until the washer comes into contact with the support, then tigh-
ten it by ¾ of a turn;

178NM68 Do not overtighten the cartridge to avoid damaging the washer. Always follow
the manufacturer’s recommendations.
D run the engine for a few minutes to check for the absence of air leaks.
1---144 ASTRA HD8Ec

BRAKING SYSTEM
1
Shoe---drum play check
This check must be made separately on both the shoes of each wheel.

Front wheels (Fig. 1)

Rear wheels (Fig. 2)

Proceed as follows:
228NMR17 D remove the caps (see arrow) through the inspection slots;
D measure the play between the shoes and drums; this must be between 0.8 and 1.5 mm
2 D if not, remove and overhaul the automatic play take---up device;
D check the condition of the brake linings;
D measure brake lining thickness: if less than 8 mm, replace the linings.
When checks and adjustments are complete, replace the plugs in the
corresponding slots to prevent foreign matter entering the brakes and
drums.
228NMR18
Check pedal distributors
Check that there are no leaks from the drain holes of the two distributors.
A leak in the rest position indicates that the air inlet valve is worn while the
exhaust valve is worn if the leak occurs during braking.
ASTRA HD8Ec 1---145
TYRES AND WHEELS
1 TYRES PRESSURE Checking wheels and tyres
(Type) (bar) Proceed as follows:
12.00 R 20” 8.50 D check the inflation pressure of the tyres is within the specified values (Fig. 1); otherwise
12.00 R 24” 7.50 adjust to correct pressure.
13.00 R 22,5” 8.00 Check pressure and inflate the tyres when cold.
315/80 R 22,5” 8.50
14.00 R 20” 6.50
178NM69 D check the condition of the rims and the wear on the tyres.
D check that bolts are fastened at the specified torque.
2 D check tyres for evident cuts; check whether the tyres touch the vehicle.

If anomalous wear is found on the front tyres, check the front wheel toe---in.
Never exceed the maximum load per axle if the vehicle is fully loaded.

Inflating tyres
Proceed as follows:
D remove the protective cap and connect the inflation device fitting to the valve (Fig. 2, see
178NM70 arrow);
D take to specified pressure;
3 D disconnect the fitting and close the protective cap.

When it is not possible to inflate the tyres with an external device proceed as follows:
D obtain an air hose extension and pressure gauge;
D unscrew the inflation valve cap alongside the battery case (Fig. 3, see arrow) ;
D drain the valve of any condensation;
D unscrew the inflation hose fitting and inflate the tyres.

228NMR19
1---146 ASTRA HD8Ec

CABIN TIPPING SYSTEM

1
Oil level check / fluid change
To check level, check through the filler cap (Fig. 1, see arrow) that the oil level with cabin tilted
is 1 --- 1.5 cm from the cap. Top---up if necessary.
To change the fluid, proceed as follows:
D clean the area around the cap and remove it;
D using a syringe and flexible pipe, draw---out the fluid in the reservoir;
D fill with the required quantity of fluid then close the cap.
206NM13
Greasing
Proceed as follows:
D tip the cabin;
D grease the cabin locking clamp mechanism;
D grease the telescopic manual gear shift lever.
ASTRA HD8Ec 1---147

1 TOWING PARTS
Greasing the fifth wheel
Proceed as follows:
D uncouple the semi---trailer from the tractor;
D clean the surfaces of the skid plate and the fifth wheel plate;
D abundantly grease the fifth wheel plate, the locking mechanism for the fifth wheel, the king-
pin and semi---trailer attachment plate.
178NM74
The locking mechanism and the articulation should be well greased before
the fifth wheel is used.
2 This operation is of great importance for the duration of the fifth wheel and
pin. Less than 100 km without adequate lubrication is in fact sufficient for the
kingpin and fifth wheel mechanism to be irreversibly damaged.
The rubber buffers require no maintenance.
The grease nipple (Fig. 1, see arrow) of the fifth wheel plate is merely to be used for lubrication
between services without uncoupling the semi---trailer.

Greasing the tow hook

178NM75
Proceed as follows:
D clean the nipple before injecting grease;
D inject grease in the nipples of the tow hook (Fig. 2, see arrow).
Inject grease until it seeps from the grease nipples to ensure efficient lubrica-
tion
A hand pump must be used for greasing, and never a high pressure grease
gun.
1---148 ASTRA HD8Ec

1 AIR CONDITIONER
Air---conditioner system maintenance
Proceed as follows:
D open the radiator grill;
D unscrew the chck screw (Fig. 1, see arrow) and change the pollen filter (Fig. 1, see arrow);
D inspect and clean the condenser with compressed air (max 5 bar).
228NM241

228NM242
ASTRA HD8Ec 1---149

1 System charge check

Check system charge once a year or when reduced cooling effect is noticed (Fig. 1).
1. system checking and charging equipment
2. high pressure circuit valve
3. low pressure circuit valve

Checking and charging must be carried out by specialist personnel using

specific equipment.
R134a (tetrafluoroethane) coolant is used. This coolant is classified as an
environmentally---friendly product by law. Do not use this fluid in systems
working with the previous fluid R12 (Freon 12).
For reasons of incompatibility between compressor oil and fluid, do not use
R12 in systems designed to use R134a.

Do not discharge R134a into the atmosphere. Although the product has a
zero ozone depletion potential it has a global warming potential.
Always use type---approved coolant recovery and recharging devices.
Do not mix different coolants in the same device.
228NMR20
1---150 ASTRA HD8Ec
BODYWORK
1
Replacing front windscreen wiper blade (Fig. 1)
Proceed as follows:
D lift the arm and blade;
D push the blade backwards, disengaging it from the stop and removing it;
D fit the correct adapter on the new blade and approach the blade to the clip to fasten it in
the adapter;
228NM244
D pull the blade fastening the adapter clip.

2 Observe the specifications provided by the supplier.

Temperature Product Water
---35 ˚C 1 0 Windscreen washer reservoir
---20 ˚C 1 1
---10 ˚C 1 2 You are advised to use a specific antifreeze product mixed with water as shown in the table
(Fig. 2).
0 ˚C 1 6 Proceed as follows:
summer 1 10 D open the radiator grill;
178NM80
D unscrew the plug (Fig. 3, see arrow) and fill until completely full;
3 D replace the cap and close the grill.
Use the proportion of detergent recommended by the manufacturer.

178NM07
ASTRA HD8Ec 1---151

Bodywork maintenance
Periodically wash the vehicle with neutral detergent and water to remove any corrosive ag-
ents (salt, sand, etc.).
Dry accurately with compressed air to fully eliminate any stagnating water.
Do not use products containing aromatic solvents, methanol or hydrocarbons for cleaning
paintwork.
Do not wash inside the cab with a jet of water or steam.

Cleaning plastic parts

Plastic parts should be cleaned using the same procedure as for normal washing.
For any remaining traces of dirt use specific products, carefully following the manufacturer’s
recommendations.
Do not use products containing aromatic solvents, methanol or hydrocarbons for ceaning
paintwork.

Cleaning upholstery
Upholstery may be cleaned with dry foam and general solvents. Exercise cau-
tion when using these products as they are flammable and give off fumes.
Ventilate the cabin until they are completely dry. Never use chloride solvents
(trichloroethylene, hypochlorite, etc.).
Seat belts may be washed by hand with hot water and neutral soap, then rinsed and left to
dry in the shade. Never use strong detergents, bleach or dyes. Avoid any chemical substan-
ce that may weaken the fibres.
1---152 ASTRA HD8Ec

1 LIGHTING SYSTEM
Headlight/front sidelight bulb replacement
Proceed as follows:
D unhook the guard grill by rotating it toward the outside (Fig. 1, see arrow);
D unscrew the screws (Fig. 2, see arrow) on the inside of the fenders and rotate the complete
headlight group toward the outside;
D remove the corresponding cover (Fig. 3):
228NMR21 1. headlight
2. side light
2 3. high beams
D disconnect the electrical connector;
D release the bulb retaining spring and remove the halogen bulb
or
D remove the sidelight bulb;
Never touch a halogen bulb with fingers, to avoid damage.

228NMR22
D check that bulb is correctly fitted.

3 D for replacement, follow the removal instructions in reverse order.

228NMR23
ASTRA HD8Ec 1---153

1 Headlight alignment
After dismantling the headlights or following crash damage, the headlights have to be reali-
gned.
It is advisable to use specific equipment for this operation.
However, a sufficiently correct alignment can be achieved proceeding as follows:
D park the unladen vehicle, with tyres at correct pressure, on flat ground nearly up against
a light coloured wall;
D mark two crosses on the wall, corresponding to the two headlights (Fig. 1);
178NM103 D back the vehicle up 10 m and shine the headlights (Fig. 1) on the wall. The distance betwe-
en the crosses and reference points P---P must be equal to the percentage of the distance
between the vehicle and the wall indicated on the specific plate (Fig. 2).
2 4x2---4x4 D if necessary, use the adjuster screws (Fig. 3);
1. vertical adjustment
2. horizontal adjustment
6x4---6x6

8x4---8x6 For vehicles fitted with adjustable headlights, turn the adjuster knob to
position 0.
8x8
178NM105

228NMR24
1---154 ASTRA HD8Ec

1 Front direction indicator light bulb replacement

Proceed as follows:
D working from the inside of the fenders, disconnect the connector (Fig. 1, see arrow);
D rotate and extract the fitting with bulb;
D press and turn the bulb anti---clockwise;
D check that bulb is correctly fitted;
D for replacement, follow the removal instructions in reverse order.
228NMR25
Side direction indicator bulb replacement
2 Proceed as follows:
D remove the cover fastening screws (Fig. 2, see arrow) and remove it;
D press and turn the bulb anti---clockwise;
D check that bulb is correctly fitted;
D for replacement, follow the removal instructions in reverse order.

228NMR26
ASTRA HD8Ec 1---155

Rear light bulb replacement

Proceed as follows:
D remove the cover fastening screws (Fig. 1) and remove it;
D press and turn the bulb to replace (Fig. 2) anti---clockwise:
1. position (double)
2. stop
3. direction indicator
4. clearance
5. rear fog lamp
6. reversing light
D check that the replaced bulb is correctly fitted.
D for replacement, follow the removal instructions in reverse order.

1 2

228NMR27 228NMR28
1---156 ASTRA HD8Ec
Front clearance light bulb replacement
1 Proceed as follows:
D remove the fastening screws and remove the complete light (Fig. 1, ref. 1);
D for replacement, follow the removal instructions in reverse order.

Rotary warning light bulb replacement

Proceed as follows:
228NMR29 D remove the screws and the cover (Fig. 2, ref. 1);
D replace the bulb;
2 D for replacement, follow the removal instructions in reverse order.

Ceiling light bulb replacement

Proceed as follows:
D insert a screwdriver between the light fitting and cabin interior lining (Fig. 3, ref. 1); lever
off the fitting and replace the bulb.
D for replacement, follow the removal instructions in reverse order.
228NMR30
Replacing cab step light
3 Proceed as follows:
D press and turn the bulb anti---clockwise (Fig. 3, ref. 2).
D For replacement, follow the removal instructions in reverse order.

228NMR31
ASTRA HD8Ec 1---157

List of bulbs
Use Type Watt
Lights:
--- main beam and dipped beam light Double filament halogen 75/70
--- position Round 4
Front direction indicator Round 21
Side direction indicator Round 21
Rear lights:
--- position/brake (stop) Round double filament 5/21
--- turn Round 21
--- reverse Round 21
--- rear foglight Round 21
Number plate light Round 10
Overall light Round 5
Rotating light Round 21
Rear light Round 21
Cabin ceiling light Round/cylindrical 5/5
Instrument panel/warning lights All glass 1.2
Warning lights All glass 1.2
1---158 ASTRA HD8Ec

1 ELECTRICAL SYSTEM
Precautions
Make absolutely sure that the electrical power is disconnected before working directly or in-
directly on electrical system parts by operating the battery disconnect switch (Fig. 1).
A: power on
B: power off
The vehicle electrical system should work even if the fitted battery is flat.
178NM81
In order to avoid incorrect interventions which may irreversibly damage the electronic control
units installed on board the vehicle the following recommendations should be followed:
D when work on the chassis requires arc welding the connector should be removed from the
control units: when welding is to be carried out near the control units, remove the units;
D after a service operation requiring battery disconnection, make sure that the terminals are
well connected;
D never use a battery charger to start the engine;
D disconnect the batteries to recharge them;
D do not disconnect or connect the connectors to the electronic control unit when the engine
is running or control units are powered;
D do not disconnect the batteries when the engine is running;
D remove the electronic control units in the event of operations at temperatures exceeding
80˚C (oven painting, etc.).
ASTRA HD8Ec 1---159
Battery maintenance (unsealed batteries)
1
Sealed batteries (maintenance free) do not require topping up with water in
normal working conditions and mild climate.
The electrolyte should be checked approximately once a year in tropical
climates.
Proceed as follows:
D open the access cover (Fig. 1):
D carefully clean the batteries, the cables and the case, removing rust and dirt which can
178NM79 cause voltage drops;

2 D check through the caps that the distance between the electrolyte (Fig. 2) and the upper
edge of the plate of each element is as specified:
level---plate distance 10---12 mm (0.4---0.5 in)
D if required, top up with distilled water when the batteries are cold and rested, through
the specific filler holes;
D check the battery charge with a densimeter (Fig. 3).

Always take the following precautions when working:

D devices that require power from the batteries must be used strictly for the time necessary
174NM43 for carrying out the functional checks on the vehicle.

3 D within reasonable limits and in compliance with safety standards, carry out any functio-
nal checks that require power from the battery with the engine running.
Temperature Electrolyte density
(100% of charge) D do not use the batteries installed to power tools during preparation.
˚C ˚F d/dm3 D always disconnect the batteries when carrying out any kind of welding operation.
40 1,265
20 1,285
0 1,300
---20 1,365
178NM84
1---160 ASTRA HD8Ec

1 Recharge with external devices

Recharge should usually be performed with batteries disassembled from vehicle.If this is not
possible, the batteries can also be recharged using an external source (battery charger) con-
nected directly to the battery terminals.
The vehicle is equipped with a 24 volt electrical system with negative and
earth.

Proceed as follows:
D lay the cables on the ground ensuring that the terminals do not touch metal parts or each
other. Connect the red cable (Fig. 1, ref. a) to the POSITIVE terminal of the flat battery;
D connect the black cable (Fig. 1, ref. b) to the NEGATIVE terminal of the flat battery;
D set the recharge time and current. Start recharging.
174NM44
Respect the instructions provided by the battery charger supplier.
Respect the sequence of the operation.
Do not reverse the polarity when making the connection.
ASTRA HD8Ec 1---161
Changing the battery
1
Follow all safety precautions when handling the battery.

D remove the battery compartment cover (Fig. 1):

D disconnect the battery as follows:
--- disconnect the positive terminal;
--- disconnect the negative terminal.
178NM79 D remove the flat batteries;
D thoroughly clean the battery compartment, removing oxides and grime;
D install the new batteries;
D connect the battery leads as follows:
--- connect the negative terminal;
--- connect the positive terminal.
D smear pure Vaseline on the terminals;
D replace the battery compartment cover.
Always follow the battery manufacturer’s instructions.
Observe the sequence of operations.
When connecting, never invert polarity.
1---162 ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec 1---163
Interconnection control unit (fuse and relays)
1
The fuses protecting the electrical system and the relays are located in a compartment inside
the cab (Fig. 1, see arrow).
Seek the cause of the failure in the electrical system if a fuse blows repea-
tedly.

Tachograph disabling
228NM246 If the vehicle has to remain stationary for a long period, disable the tachograph to avoid flatte-
ning the battery.
Proceed as follows:
D open the compartment (Fig. 1, see arrow);
D remove fuse number 20, placing in the plastic bag containing the ignition key.

Replace the fuse before starting the vehicle.

1---164 ASTRA HD8Ec

FUSES 01 02 03

178AP01

04

178AP02
ASTRA HD8Ec 1---165

FUSES (legend)
Pos. Function Amp. Pos. Function Amp.
1 Air---conditioner/heated mirrors or electric 10.0 01 Lights, front headlight, L parking/panel illu- 7.5
mirrors mination
2 Fridge 5.0 02 Lights, front headlight, R parking/headlight 7.5
01 3 washer
4 03 Dipped headlights/high beam control 3.0
5 04 L dipped headlights 7.5
6 05 L high beam 5.0
1 06 R dipped headlight 7.5
2 07 R high beam 5.0
3 Key operated switch 5.0 08
02 09 Rear fog light 5.0
4 EDC 15.0
5 10
6 11 Horns 10.0
1 12 Brake air dryer 5.0
04
2 Heated Diesel fuel prefilter 15.0 13 Battery charger/automatic glowplug warning 3.0
3 light
03 14 Warning light tester 3.0
4
5 15 Windscreen wiper/timer 7.5
6 EDC 20.0 16 Hazard warning lights 10.0
17 L, R indicators 7.5
18 Stop lights 7.5
19 Reversing light 7.5
20 Tachograph 3.0
21 Cigar lighter/interior light 10.0
22 Rotating lights 10.0
23 Window winder/press. aria condotta autom. 20.0
rim.
24 Fan heater 15.0
1---166 ASTRA HD8Ec

REMOTE SWITCHES

Pos. Function Code

E1 Starter relay 25200
E2 Dipped headlights 25013
E3 Remote switch for 15A terminal 25209
E4 Flasher 25004
E5
E6 Stop lights 25006
E7
E8 Diode holder 61000
E9 Windscreen wiper timer 59100
E15 Anti---starting system 25204
E10 High beams 25009
E11
E12 Horns 25805
E13
E14A
E14B
178AP04
ASTRA HD8Ec 1---167

REMOTE SWITCHES

Pos. Function Code

A Prefilter heater remote switch 25817
B D+ remote switch 25874
C
D
E
F EDC remote switch terminal 15 25858
G
H
I Hour meter remote switch 25814
K Neutral starting remote switch 25605
L Rear fog light on remote switch 25034
M Engine EDC off remote switch 25903
N Air conditioning remote switch 25332
O
P
R
S PTO parametr. resistors 61125
T Engine braking button resistor 61122 B
U Engine braking resistor 61122
178AP03 V Interior light diode holder 61002
W
X
Y
Z
1---168 ASTRA HD8Ec

REMOTE SWITCHES

Pos. Function Code

GA Servosteering fluid level electronic inverter 25868
GB 15/50A terminal remote switch 25213 A
GC Engine running anti---starting system 40A 25224
GD 15/50A terminal remote switch 25213 B
GE EDC general remote switch 25924

Pos. Function Code

AA + set adjustment relay switch
AB --- set adjustment relay switch
AC Engine external switch---off remote switch
AD Engine external start remote switch (handbra-
ke)
AE PTO1 parameter setting
AF PTO2 parameter setting

178AP03
ASTRA HD8Ec 1---169

Table and diagrams

1---170 ASTRA HD8Ec

Page left intentionally blank

ASTRA HD8Ec 1---171

INTRODUCTION
Scheduled maintenance intervals refer to normal operating conditions. They may vary according to the type of use, road
and environmental conditions.
If in doubt or faults not possible to correct with normal maintenance, contact the Dealer.

Carry out the first oil change with from new vehicle or group:
D Gearbox oil change after 100 hours operation;
D Transfer box oil change after 200 hours operation;
D Axle change after 200 hours operation;
D Power steering oil change after 200 hours operation;
1---172 ASTRA HD8Ec

LUBRICANTS, OILS, HYDRAULIC FLUIDS AND FILTER REFILLING/REPLACEMENT DIAGRAM

2---axle vehicles

272NM00F
ASTRA HD8Ec 1---173

Key (see diagram on previous page)

1. trailer pintle greaser 18. manual transmission fluid
2. cardan joint greaser 19. not used
3. not used 20. not used
4. leaf spring articulation greaser 21. transfer oil (only 4x4 version)
5. stub axle greaser 22. front axle final reductions oil (only 4x4 version)
6. not used 23. front axle oil (only 4x4 version)
7. not used 24. not used
8. not used 25. not used
9. engine oil vapour filter 26. not used
10. engine oil 27. rear axle and final reductions oil
11. engine oil filters 28. power steeling oil
12. not used 29. power steeling filter
13. clutch control system oil 30. not used
14. fuel filters 31. air conditioning fluid
15. main/secondary air cleaner 32. air cleaner of air conditioning
16. engine coolant 33. compressed air drier filter
17. power take off oil

Service frequency is expressed in:

[h] vehicle working hours
[m] months
1---174 ASTRA HD8Ec

LUBRICANTS, OILS, HYDRAULIC FLUIDS AND FILTER REFILLING/REPLACEMENT DIAGRAM

3---axle vehicles

272NM00E
ASTRA HD8Ec 1---175

Key (see diagram on previous page)

1. trailer pintle greaser 18. manual transmission fluid
2. cardan joint greaser 19. not used
3. rear carriage articulation greaser 20. not used
4. leaf spring articulation greaser 21. transfer oil (only 6x6 version)
5. stub axle greaser 22. front axle final reductions oil (only 6x6 version)
6. not used 23. front axle oil (only 6x6 version)
7. not used 24. not used
8. not used 25. not used
9. engine oil vapour filter 26. intermediate axle and transfer case oil
10. engine oil 27. rear axle and transfer case oil
11. engine oil filters 28. power steeling oil
12. not used 29. power steeling filter
13. clutch control system oil 30. no used
14. fuel filters 31. air conditioning fluid
15. main/secondary air cleaner 32. air cleaner of air conditioning
16. engine coolant 33. compressed air drier filter
17. power take off oil

Service frequency is expressed in:

[h] vehicle working hours
[m] months
1---176 ASTRA HD8Ec

LUBRICANTS, OILS, HYDRAULIC FLUIDS AND FILTER REFILLING/REPLACEMENT DIAGRAM

4---axle vehicles

272NM00D
ASTRA HD8Ec 1---177

Key (see diagram on previous page)

1. trailer pintle greaser 18. manual transmission fluid
2. cardan joint greaser 19. not used
3. rear carriage articulation greaser 20. not used
4. leaf spring articulation greaser 21. not used
5. stub axle greaser 22. not used
6. not used 23. not used
7. not used 24. not used
8. steering linkages greaser 25. not used
9. engine oil vapour filter 26. intermediate axle and transfer case oil
10. engine oil 27. rear axle and final reductions oil
11. engine oil filters 28. power steeling oil
12. not used 29. power steeling filter
13. clutch control system oil 30. not used
14. fuel filters 31. air conditioning fluid (if present)
15. main/secondary air cleaner 32. air cleaner of air conditioning (if present)
16. engine coolant 33. compressed air drier filter
17. power take off oil

Service frequency is expressed in:

[h] vehicle working hours
[m] months
1---178 ASTRA HD8Ec
SERVICE SCHEDULE
Checking, adjusting and cleaning operations
hours
OPERATION day year
400 800 1600
Check engine oil level Xx
Check engine coolant level X
Check service brake and parking brake X
Check external lights, dashboard warning lights and windscreen wiper X
Windscreen washer fluid level check X
Check trailer pintle /semi---trailer fifth wheel condition X
Bleed compressed air tank X
Check tyre pressure / conditions X
Fuel filter check / water drain (1) X
Turbocompressor intake/lubrication system seal check X
Check clutch control oil level X
Check gearbox oil level X
Check transfer oil level X
Check transfer case oil level X
Check axle oil level X
Pedal distributors check X
Check compressed oil dryer function/visual inspection of tanks X
Battery maintenance (unsealed batteries) X
(1) or when respective warning light comes

The table indicates the time interval between two consecutive operations.
ASTRA HD8Ec 1---179

Checking, adjusting and cleaning operations (contd.)

hours
OPERATION day year
400 800 1600
Check cab tilting system oil X
Check accessory belt X
Check conditioner compressor belts X
Bleed fuel tank condensation water X
Check power steering system oil level (^^) X
Intercooler external cleaning (2) X
Front wheel toe---in check (˚) X
Brake shoe---drum play check X
Check EDC engine control system with diagnosis equipment (˚) X
Adjust tappet /injector---pump play (˚) X
Clean conditioner condenser X
Check antifreeze concentration X
Check headlight alignment X
(˚) For further information contact your Dealer
(^^) This check is optional, since there is an oil level warning light.

(2) according to working environment

The table indicates the time interval between two consecutive operations.
1---180 ASTRA HD8Ec

Lubrication and replacement operations --- engine

hours
OPERATION year
100 400 800 1600 2400 3200
Replace engine oil / filter with ACEA E2 or equivalent (*) X
Replace engine oil / filter with ACEA E2 or equivalent (*) X
Engine oil vapour recirculation filter replacement X
Replace fuel pre---filter / filter X
Replace main air cleaner element (1) (*) X
Replace air cleaner main element (2) X
Change engine coolant (**) X
Replace accessory belt X
Replace air conditioner compressor belts X
(˚) for further information contact your Dealer
(*) yearly for shorter periods of use than foreseen
(**) every two years for periods of use less than envisaged interval
(1) or when respective warning light comes on
(2) or after every three main filter replacements

The table indicates the time interval between two consecutive operations.

The first engine lubricant replacement is to be made at 800 hours.

The following replacements depend on the type of lubricant used.
ASTRA HD8Ec 1---181

Lubrication and replacement operations --- vehicle

hours
OPERATION year
100 400 800 1600 2400 4000
Grease lubrication points (*) X
Change clutch control oil X
Change power hitch oil (*) X
Change manual gearbox oil (3) (*) X
Change transfer oil (4) (*) X
Change axle transfer case oil (4) X
Change power steering system oil (4) X
Replace power steering system oil filter (4) X
Replace compressed air dryer filter (*) X
Change oil in cab tilting system (**) X
Recharge conditioner system fluid / replace dehydrator filter X
Replace air conditioner filter X
(˚) for further information contact your Dealer
(*) yearly for shorter periods of use than foreseen
(**) every two years for periods of use less than envisaged interval
(3) first change/replacement when unit is new or overhauled after 100 hours
(4) first change/replacement when unit is new or overhauled after 200 hours
The table indicates the time interval between two consecutive operations.
1---182 ASTRA HD8Ec
LUBRICANT AND HYDRAULIC FLUID TABLE