Astra HD 9 Service Manual

Page 1
EURO 3
chassis 6x6
66.38 / 66.42 / 66.44 / 66.48 / 66.54
236
29.8° 417
1525 X 1450 S
K1
DIMENSIONS (mm) short cab (Tyres 13R22,5 156/150G)
X K1 M max (*) S
3500 7675 5350 1200
3800 7975 5650 1200
4100 8275 5950 1200/1500/1900
4500 8675 6350 1200/1900/2500
(*) M max.: indicative value to be confirmed by bodybuilder.
300
18,3°
3391
H
RHD VERSION (opt. code 962)
LONG CAB VERSION (opt. code 200; opt. code 272)
unloaded
1252 1189
305353
2061
ON REQUEST
wheelbase > 3800 mm
H
loaded
3474
TURNING
DIAMETER
(wall to wall)
17400
18300
19300
20600
Chassis 6x6
WEIGHT (kg)
Distribution net weight (*)
X
1staxle 2
3500 5365 4938 10303 3800 5409 4929 10338 4100 5447 4919 10366 4500 5503 4921 10424
(*)Weight including oil, fuel, spare wheel, driver Kg.75 (1) With tyres 1st axle 385/65R22,5160J or 365/85R20166G. Other tyres available, subject to the Astra technical office approval. (2) HD9 66.48 and HD9 66.54 only at max speed 50 km/h. Michelin/Pirelli tyres. Higher speeds are allowed with load reductions
subject to the Astra Technical office approval. (3) 10,000 kg optional: see description on the following pages 10 t.
Technical data and general specifications - validity to be checked according to each individual country.
nd+3rd
axle
Net
weight
st
1
axle
8000 8500(1) 9000(2)
10000(3)
Max. technical weight
nd+3rd
axle
2
32000
Gross Vehicle weight
Gross Combination
40000
(2)
weight
104000
ENGLISH
12-2011
ENGLISH
Page 2
ENGINES
CURSOR 13 turbo intercooler euro 3 diesel injection/cycle with electronic unit injection pumps. Single block head, four valves per cylinder, light alloy pistons. Total displacement: 12.882 cm Viscostatic cooling fan. Dry air filter with safety cartridge. Vertical muffler
66.38
Model IVECO F3B
Max. power (EEC) 280 kW ( 380 HP) Corresponding rpm Max. torque (EEC) 1.800 Nm (183 kgm) Corresponding rpm
Turbine WG Waste Gate
*Requires additional engine radiator, for extremely hot climate (>42°C).
66.42
IVECO F3B
309 kW (420 HP)
1.900
1.900 Nm (194 kgm)
3
. Bore for stroke: 135 x 150 mm. 6 in-line cylinders. Water cooling.
66.54*
IVECO F3B
397 kW (540 HP)
2.350 Nm (240 kgm)
1.000-1.690
324 kW (440 HP)
2.100 Nm (214 kgm)
1.000-1.440
66.44
IVECO F3B
1.900
66.48
IVECO F3B
353 kW (480 HP)
2.200 Nm (224 kgm)
VGT variable geometry
GEARBOX
Manual ZF Ecosplit 4 technology gearbox with servoshift, 16 synchronised forward speeds + 2 reverse:
ZF16S2220TO: HD9 66.38/HD9 66.42 / HD9 66.44 ZF16S2520TO: HD9 66.48/HD9 66.54 On request: ZF16S2320TD: HD9 66.38/HD9 66.42/ HD9 66.44/ HD9 66.48 ZF ASTRONIC 16AS2601OD: HD9 66.44/ HD9 66.48/ HD9 66.54 ALLISON HD4700: HD9 66.44/ HD9 66.48/ HD9 66.54 (wheelbase>4100mm)
Speed [kph] calculated at maximum power rpm
Gears
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 RM RM
Gear ratios
16.41 13.80 11.28 9.49 7.76 6.53 5.43 4.57 3.59 3.02 2.47 2.08 1.70 1.43 1.19 1.00 15.36 12.92
3.793 7.5 8.9 10.9 13.0 15.8 18.9 22.5 27.0 34.1 40.7 49.5 59.2 72.0* 85.9* 103*
4.229 6.7 8.0 9.7 11.7 14.2 16.9 20.2 24.2 30.6 36.5 44.4 53.1 64.6 77.0* 92.4*
5.009 5.7 6.8 8.2 9.8 11.9 14.3 17.1 20.4 25.8 30.8 37.5 44.8 54.6 65.0 78.0* 92.9* 6.0 7.2
5.558 5.1 6.1 7.4 8.9 10.8 12.9 15.4 18.4 23.3 27.8 33.8 40.4 49.2 58.6 70.3* 83.7* 5.4 6.5
6.095 4.6 5.6 6.8 8.1 9.8 11.7 14.0 16.8 21.2 25.3 30.8 36.8 44.8 53.4 64.1 76.3* 5.0 5.9
Rear axle ratio
with transfer 1:1.0
6.588 4.3 5.1 6.3 7.5 9.1 10.9 13.0 15.5 19.6 23.4 28.5 34.1 41.5 49.4 59.3 70.6* 4.6 5.5
Gear ratios
3.793 4.7 5.6 6.8 8.1 9.9 11.8 14.1 16.9 21.3 25.5 31.0 37.0 45.0 53.7 64.4 76.7 5.0 6.0
4.229 4.2 5.0 6.1 7.3 8.8 10.6 12.6 15.1 19.1 22.8 27.8 33.2 40.4 48.1 57.8 6 8.8 4 5 5.3
5.009 3.5 4.2 5.1 6.1 7.5 8.9 10.7 12.8 16.1 19.3 23.4 28.0 34.1 40.6 48.8 58.0 3.8 4.5
ZF 16S2220TO - ZF 16S2520TO
(*) Max speed 90 km/h. Other speeds available, subject to the Astra technical office approval.
5.558 3.2 3.8 4.6 5.5 6.7 8.0 9.6 11.5 14.6 17.4 21.1 25.3 30.7 36.6 43.9 52.3 3.4 4.1
6.095 2.9 3.5 4.2 5.1 6.1 7.3 8.8 10.5 13.3 15.8 19.3 23.0 28.0 33.4 40.1 47.7 3.1 3.7
Rear axle ratio
with transfer 1:1.6
6.588 2.7 3.2 3.9 4.7 5.7 6.8 8.1 9.7 12.3 14.7 17.8 21.3 25.9 30.9 37.1 44.1 2.9 3.4
16.41 13.80 11.28 9.49 7.76 6.53 5.43 4.57 3.59 3.02 2.47 2.08 1.70 1.43 1.19 1.00 15.36 12.92
122.7*
110.0*
8.0 9.5
7.2 8.6
P.T.O.
On request:
Gearbox
P.T.O.
ZF NH/1b ZF NH/1c
ZF NH/4c
ZFN221/10bpl+
ZF NMV 221 Power take-off (ratio 1,55:1) max available torque 1300 Nm for concrete pumps (only for 380, 420 and 440 HP and wheelbase >3800mm). ZF NMV 221 Power take-off (ratio 0,98:1) max available torque 2000 Nm for concrete pumps (only for 380, 420 and 440 HP and wheelbase >3800mm). Power take off at flywheel (ratio 1,29:1) max available torque 900 Nm for concrete mixers (only for 380, 420 and 440 HP and wheelbase >3800mm). PTO Chelsea for Allison gearbox HD4700.
N353/1c
ZF16S2220TO ZF16S2520TO
Ratio
0,91/1,09:1 0,91/1,09:1
1,17/1,40:1
1,75/2,09:1+0,91/1,09:1
Max. torque
Nm.
1000 1000 430
560+600
Application
For tipping unit pumps, pumps for cranes, ecc.. For tipping unit pumps, unit pumps for concrete, pumps for cranes, ecc.. For tipping unit pumps, ecc.. double PTO for concrete pumps
Technical data and general specifications - validity to be checked according to each individual country.
Page 3
CLUTCH
Single dry plate, diameter 17”. Pull type engagement with diaphragm spring. Hydro-pneumatic power steering engagement control, with driven disc wear recovery slave cylinder.
On request: Ceramic clutch 17”
TRANSFER
Mechanical with two ratios. It consists of a series of helical spur gears, mounted on three propeller shafts, engaged with each other. Differential can be locked by pneumatic control. Transmission ratio: 1:1 - 1:1,6 Front/rear torque distribution ratio: 1:4,0
AXLES
FRONT:
Steering cast iron type; with double reduction, central with bevel pinion-crown, lateral by means of epicyclical assembly in wheel hubs.
On request:
Front axle simplex or duplex wedge type Kessler. Kessler front axle
Version Weight on Available Pneus 1
HD9 K 8 t @90 Km/h 5,01; 5,384; 13 R22.5; 5,866; 6,28 12.00 R20;
14.00 R20
REAR:
Two drive axles in tandem with double reduction, central by bevelled pair and final by epicyclical group in wheel hubs. The intermediate axle is fitted with distributor that distributes torque between the two axles Lockable differential with pneumatic control from driver seat. The tandem is anchored to the chassis by silent block mounted torque arms.
On request:
Rear-axle ratio 1:3.793 Rear-axle ratio 1:4.229 Rear-axle ratio 1:5.009 Rear axle ratio 1:5.558 Rear-axle ratio 1:6.095 Rear-axle ratio 1:6.588
10t
On request: Front axle simplex or duplex wedge type Kessler
and Gross Weight 10,000 Kg. Parabolic springs 5 leaves 24x90 mm. Hydraulic power steering ZF 8099 with variable ratio 1:22.2/ 1:26.2. Tyres combination subject to approval of Astra Technical Office. Axle ratio 1:6.33. Maximum speed 70 Km/h.
FRONT AXLE G.V.W. 10t
:
st
axle axle ratio
SUSPENSIONS
FRONT
Parabolic leaf springs with bushings, 4 leaves 24x90 mm, with shock absorbers and standard stabiliser.
On request:
Reinforced conventional springs. 10 leaves 15x90 mm. Reinforced parabolic springs, n° 5 leaves 24x90 mm.
REAR
Parabolic springs, swivelling on central pin: 4 leaves 40x100 mm, supplemented by torque bars and stiffening brackets.
On request:
Stabiliser bar on 2 Stabiliser bar on 3rd axle. Extra-reinforced conventional springs, 10 leaves 25x100 mm.
nd
axle.
TYRES
FRONT: 13R22,5 156/150 G Single tubeless REAR: 13R22,5 156/150 G Twin tubeless
Spare wheel on the chassis.
Other Possible combinations:
TYRES
13 R 22,5 156/150G
12 00 R 20 156/150G
315/80 R 22,5 156/150G
365/85 R 20 164G
13 R 22,5 156/150G
12 00 R 20 156/150G
365/80 R 20 160K
385/65 R 22,5 158K
315/80 R 22,5 156/150G
395/85 R 20 168G
525/65 R 20,5 173F
16 00 R 20 173G
16 00 R 20 163G
24 R 20,5 176F
S single D double
Other tyres available, subject to the Astra technical office approval.
ASSEMBLY
FRONT REAR
S D
S
D
S
D
S
S
S S
S
S
PNEUMATIC SYSTEM
Two-cylinder 630 cc compressor , APU (Air Processing Unit) that includes: regulation valve set at 10.3 bar, drier, 4-way safety valve, pressure reduction valve for parking circuit and services. 3 air tanks, capacity 30 litres + 2 with 20 litres. ABS system and EBL (Electronic Brake Limiter)
CHASSIS
Special steel with high elasticity limit, two flat and parallel side members width 820 mm., C section 320x90x10mm, cross members riveted to the frame. Steel front bumpers with headlamp protection grids, front manoeuvring hook, rear underrun bar, steel fuel tank capacity 300 litres.
On request:
Extra long underrun bar for concrete mixer. Front bumper climbing step. Rapid attachment for compressed air for tyres’inflation. Rear underrun bar in set back position. Rear manoeuvring hook. Rear automatic towing hook. Rubber mudguards on 2 Side windlass for spare wheel
nd
and 3rd axle.
STEERING
Hydraulic power steering ZF 8098 with variable ratio 1:22.2/1:26.2. Steering linkage with self lubricating floating joints. Height and inclination mechanical adjustable steering wheel.
6x6
Chassis
ENGLISH
Technical data and general specifications - validity to be checked according to each individual country.
ENGLISH 6X6
Page 4
ELECTRICAL SYSTEM
Voltage: 24 V Alternator generator 90 A - 28 V (2520 W). Accumulators: 2 in series, 160 Ah. Starter motor 24 V 5,5 kW. Mechanically controlled electrical circuit breaker. 1 electrical joint 7-pole(ISO 7638) for trailer ABS(if applicable). 1 electrical joints 15-pole(ISO 12089-4091) for trailer lighting (if applicable). Electrical provision for bodybuilders. Provision for diagnostics. Provision for radio/cb (without speakers) Glow plug for cold start.
On request:
170 Ah accumulators; 160 Ah tropicalised accumulators; 170 Ah tropicalised accumulators; Reverse alarm;
CAB
White cab built in galvanized pressed steel with hydraulic tilting up to 60°. Cab suspension with 4 helicoidal springs with coaxial shock absorbers and integrated dampers, anti-roll bar and end-of-stroke pads. Tinted electric door windows. Mechanical rear view mirrors, wide angle mirrors and front view mirror. Internal panels completely washable and fireproof. Compressed air quick coupling for cab cleaning. 4-speed ventilation and heating system with air recirculation system. Air suspended 3-way adjustable driver seat with seat belts. Mechanical passenger seat with seat belts.
On request:
Air conditioning with anti-pollen filter Cab rear window. Car radio RDS, CD. Car radio RDS, CD, MP3 Bluetooth technology. External sun visor. Extra colour cab: to be specified in the order. Heated and electric powered rear view mirrors. Long cab for wheelbase >3800mm with interior equipment (seats and beds) on request. Remote controlled and centralized closing of doors. Roof hatch. Rotating lights on top of the cab. White engine hood with central mask in IC575 colour
SERVICE DATA(l)
Engine oil sump and filters ........................................ 28
Gearbox oil: ZF 16S2220TO/ZF 16S2520TO ................ 13
Power steering oil ........................................................ 8,5
Cab tipping oil ................................................................ 1
Clutch circuit oil ........................................................ 0,5
Integral PTO oil ........................................................ 3
Intermediate axle with final red. oil ................................ 27
Rear axle with final red. oil ........................................ 16
Cooling system water ................................................ 33
Diesel ........................................................................ 300
INSTRUMENTATION
Dashboard and ergonomic instrument board contain the function buttons and the identification comm ands. Indicator lights: engine oil low pressure, alternator charging low, main beam lights, side lights, engine warm-up, rear fog light, hazard lights, tractor turn indicators, trailer turn indicators (if applicable), rotating lights,cab lifted, axles differential locked, differential lock, front brakes air pressure low, rear brakes air pressure low, trailer brakes air pressure low (if applicable), parking brake engaged, splitter (reduction on), slow speeds (1-4/9-12),power take-off on (if applicable) air filters clogged, power steering oil level low, rear view mirrors heated (if applicable), ABS, trailer ABS (if applicable), main steering circuit failure, steering auxiliary circuit failure.
ASTRA Veicoli Industriali
Via Caorsana, 79 29122 Piacenza (Italy) Tel. ++39-523/5431 Fax ++39-523/59.17.73 www.astraspa.com
Characteristics and equipment are subject to changes without prior notice.
Technical data and general specifications - validity to be checked according to each individual country.
DEALER
12-2011 A3502172
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