VDL Futura FHD2 E6, Workshop Manual

Page 1: ...Futura FHD2 FMD2 E6 1525 DD1020_01 Main Group 0 WORKSHOP MANUAL...

Page 2: ...ics The technical information and the explanations of the repair work stated in this workshop manual have been compiled with the utmost care Whilst compiling this workshop manual it has been assumed t...

Page 3: ...ghting 2 21 Disc brake construction 2 22 Steering mechanism 2 24 Components 3 1 Introduction 3 1 Engine 3 2 Driven axles 3 12 Axle mounting and suspension 3 13 Driver s seat 3 16 Repair guidelines Gen...

Page 4: ...jacking up and supporting the vehicle Lifting jacking up and supporting 1 1 General information 1 1 Wheel lifts 1 4 Central lifting columns 1 6 Placing axle supports under the frame 1 8 Jacking up 1...

Page 5: ...l be governed by and applied in accordance with the laws of the Netherlands Any dispute here under shall be referred to the decision of the District Court of s Hertogenbosch in the Netherlands Next re...

Page 6: ...0 Futura FHD2 FMD2 E6 2 4 DD1020_01...

Page 7: ...0 Futura FHD2 FMD2 E6 GENERAL INFORMATION 0 DD1020_01 GENERAL INFORMATION...

Page 8: ...0 Futura FHD2 FMD2 E6 GENERAL INFORMATION 0 DD1020_01...

Page 9: ...ded connections to be accurately observed Always use a torque spanner to accurately tighten the threaded connections to the correct torque 1 1 3 THREADED CONNECTIONS GENERAL INFORMATION The following...

Page 10: ...are usually only tightened to the stand ard tightening torques See Tightening torques for the standard tightening torques If one of these threaded connections must be tightened to a different tighteni...

Page 11: ...ts do not visibly have lubricant applied to them then lubricant must be applied to them To obtain the correct pretension when using new bolts the following procedure must be followed 1 Apply one drop...

Page 12: ...tening torques for flange bolts and nuts with strength class 10 9 10 Bolt length L is the length of the bolt between the head of the bolt and the nut If a component is secured using more than one bolt...

Page 13: ...M5 x 0 8 5 5 0 4 M6 x 1 9 6 0 7 M8 x 1 25 23 2 M10 x 1 5 46 4 M12 x 1 75 79 6 M12 x 1 25 87 6 M14 x 2 125 9 M14 x 1 5 135 9 M16 x 2 195 14 M16 x 1 5 210 14 M18 x 2 5 213 15 M18 x 1 5 315 20 M20 x 2 5...

Page 14: ...htening torques for banjo bolts Overview of the tightening torques for clamping ring cap nut connections for air lines Thread indication Tightening torque Nm M12 x 1 25 178 14 M14 x 1 5 274 22 M16 x 1...

Page 15: ...average breaking strength Can be unlocked using nor mal tools For locking threaded con nections 40068197 Loctite 262 Locks with a high breaking strength Difficult to unlock For locking threaded con n...

Page 16: ...ffect on the effectiveness of the sealant Therefore the general rule is that after fixings and components have been cleaned with a cleaning agent they must be treated with a cleaning liquid to ensure...

Page 17: ...stant to water coolant and oil For sealing aluminium components 41441339 Loctite 5910 Silicon sealant resistant to oil Withstands temperatures up to 200 C For sealing flush connec tions such as the fr...

Page 18: ...untreated metal components against corro sion Components that have been installed with a close fit such as wheel hub units 41443160 Loctite 401 Comment Drying time of a couple of seconds Hardening ti...

Page 19: ...rication grease which is water resistant and which prevents corrosion For the sealing rings of the MX engine cylinder lining 41738904 Renolit HLT2 Lubrication grease white Disc brake adjustment mechan...

Page 20: ...235 294 n n x 1 202 n cm sec m sec km h feet sec mile h 1 0 01 0 036 0 03281 0 02237 100 1 3 6 3 281 2 237 27 78 0 2778 1 0 9113 0 6214 30 48 0 3048 1 097 1 0 6818 44 70 0 4470 1 609 1 467 1 no Celsi...

Page 21: ...rds m2 1 0 01 0 00155 0 00001076 0 000001196 0 000001 100 1 0 155 0 001076 0 0001196 0 0001 645 2 6 452 1 0 006944 0 0007716 0 0006452 92900 929 144 1 0 1111 0 09290 836100 8361 1296 9 1 0 8361 100000...

Page 22: ...6 10 01 0 9678 6894 76 51 715 2 036 0 7037 0 068046 101322 3 760 29 92 10 337 1 133 32 1 0 03937 0 01361 0 0013158 3386 23 25 40 1 0 3456 0 3342 9797 82 73 49 2 893 1 0 09668 248 89 1 867 0 07349 0 02...

Page 23: ...0 Futura FHD2 FMD2 E6 SAFETY REGULATIONS 1 DD1020_01 SAFETY REGULATIONS...

Page 24: ...0 Futura FHD2 FMD2 E6 SAFETY REGULATIONS 1 DD1020_01...

Page 25: ...may also cause serious damage to the vehicle or may even create a dangerous situation This symbol gives useful tips to simplify the work This symbol indicates a situation which requires extra attentio...

Page 26: ...d if necessary apply pro tective cream to unprotected parts of your body Long hair must be tied back or placed in a hairnet Do not wear jew ellery when carrying out work Use approved ear protection wh...

Page 27: ...trical power source In order to prevent people from starting the engine when work is being carried out on the vehicle always disconnect the battery s earth connection Place a sign that reads DO NOT OP...

Page 28: ...ary use wheel adaptors to prevent damage to the wheel bolts When charging the batteries make sure there is good ven tilation and avoid sparks or a naked flame Only use a quick charger in the event of...

Page 29: ...Safety data sheet See the product s safety data sheet for the properties risks and safety information The SCR unit must be removed and disposed of in accordance with Directive 91 689 EEC 160802 and th...

Page 30: ...gnition sources cannot come into contact with inflammable or explosive liquids and gases If possi ble keep these substances fully protected Diesel Diesel fuel is toxic and may therefore have a damagin...

Page 31: ...stance When adding AdBlue the Webasto and the engine must be turned off and the main switch must be turned to the off position If the AdBlue cap is opened at a high exterior temperature then it is pos...

Page 32: ...k charger should only be used if absolutely necessary Disconnect the battery cables when quick charging Wear protective clothing gloves and a mask when carrying out work where it is possible to come i...

Page 33: ...he vehicle is started using separate batteries approximately 24 V or with the aid of another vehicle with a running engine approximately 28 V then the battery cables must not be disconnected When the...

Page 34: ...he vehicle with the aid of auxiliary batteries turn on as many energy consumers as possible in order to avoid a load dump when the start cables are removed If another vehicle is used to start the vehi...

Page 35: ...ge to the engine encapsulation when spray ing it maintain a minimum distance of 50 cm between the engine encapsulation and the sprayer nozzle Clean the engine compartment and in particular the encapsu...

Page 36: ...ese compo nents is also not permitted Failure to observe these instructions may result in serious damage to bearings springs etc The accessory or contact position of the contact lock con tact switch m...

Page 37: ...n the chassis must also be discon nected Welding work on the bodywork Follow the guidelines given in Welding work on the chas sis Also follow any special welding instructions given for performing weld...

Page 38: ...cted by VDL Bus Coach or replaced if there has been a collision which may have affected the steering box or other parts of the steer ing mechanism This also applies if no external damage can be observ...

Page 39: ...ure the joins are watertight Never remove sealing washers from connectors Fit the connectors in the correct manner Good earth connections are essential There must be no paint or oxidation between the...

Page 40: ...s the rear wheels spinning Since a reduction in acceleration is not applicable in this instance the system will try to neutralize this spinning by braking the rear wheels The result is that the vehicl...

Page 41: ...electronics without a bulb being fitted This will lead to a voltage surge to the fitting Wear safety glasses and safety gloves The light is pressurized risk of breaking Never touch the light bulb s gl...

Page 42: ...0 Futura FHD2 FMD2 E6 SAFETY REGULATIONS General information 1 18 1 DD1020_01...

Page 43: ...0 Futura FHD2 FMD2 E6 DIAGNOSIS 2 DD1020_01 DIAGNOSIS...

Page 44: ...0 Futura FHD2 FMD2 E6 DIAGNOSIS 2 DD1020_01...

Page 45: ...of diagnosis equipment Every possible cause of a complaint by the driver leads you to a solution and the repair work that it involves As shown in the diagram the diagnosis information is divided into...

Page 46: ...engine immediately after an unsuccessful attempt was made to start the engine 4 Can the driver or the customer reproduce the fault Discuss the results with the customer or the driver 1 2 2 THE STARTE...

Page 47: ...symptom with the aid of the diagnosis equip ment There is air in the fuel system Check whether the fuel system draws in air The fuel filter is blocked Replace the fuel filter The fuel pressure in the...

Page 48: ...ism 1 The clutch is not released correctly Check whether the clutch is released There is a mechanical fault in the gearbox See the fault finding table below Faulty mechanical gearbox mechanism 2 There...

Page 49: ...ating and hinged points for excessive play and or sufficient lubrica tion The gearbox mechanism is not configured correctly Check the gearbox mechanism s configuration There is too much play in the si...

Page 50: ...Servoshift unit is faulty Check the shift valve in the Servoshift unit The gearbox jumps out of gear 1 Possible cause Remedy The gearbox mechanism is not configured correctly Check the gearbox mechani...

Page 51: ...Wear of the tread Is this symptom the result of a technical fault External fac tors or improper use can also lead to this fault Wear of the middle of the tread can also be the result of driv ing too f...

Page 52: ...river The edge of the tread is feather like and is worn more on one side than the other The edges of the worn areas can be felt when a hand is rubbed over the tread Possible cause Remedy The toe in is...

Page 53: ...bsorbers Unbalanced tyre wheel combination Check the wheel balance Sudden and heavy braking the wear pattern covers the entire tread Inform and instruct the driver Separation in the tyre as a result o...

Page 54: ...present Possible cause Remedy Too large negative wheel camber Check the camber Too large kingpin inclination Check the kingpin inclination The wear only occurs on the outer shoulder The wear pattern...

Page 55: ...ow Correct the tyre pressure This type of wear almost only ever occurs on non driven non steered axles The wear pattern shows itself as feather like wear on the shoulder of the tyre The wear edges can...

Page 56: ...tyre due to a heavy knock that has resulted in separation of the tyre which has resulted in a lump on the wall Possible cause Remedy A knock against a sharp edge on a stone kerb or hole in the road Ch...

Page 57: ...tyre sizes The tyre often comes into contact with the kerb or guide rails Instruct the driver The tyre has been used for a long period of time whilst the tyre pressure was too low Change the tyre bec...

Page 58: ...the engine manage ment electronic unit Check the engine management software and if neces sary alter the master card Possible cause Remedy Mechanical fault steering column s switch broken Check the st...

Page 59: ...The tachograph discs of journeys 2 Reliable fuel consumption information from journeys Discuss the results with the customer or the driver If the complaint related to high fuel consumption is justifi...

Page 60: ...use of AdBlue Long lasting idling can result in a reduced use or no use of AdBlue Low ambient temperatures can result in a reduced use or no use of AdBlue High ambient temperatures can result in an in...

Page 61: ...fault See the fault finding table High turbo compressor oil consumption 2 3 2 2 High oil consumption 3 2 Air compressor fault Check the air compressor for carbon deposits Mechanical engine fault See...

Page 62: ...bolts and the gaskets Gas leak between the exhaust manifold and the turbo compressor Check the attachment bolts The turbo compressor is damaged Trace the cause and replace the turbo compressor Fault...

Page 63: ...old engine etc Ask for reliable information concerning consumption during journeys Ask for tachograph cards of journeys Can the customer or driver reproduce the problem Has the customer or a third par...

Page 64: ...igned Check the alignment of the vehicle The wrong type of tyre is used Check the type and size of the tyres The brakes drag See the fault finding table Brakes drag Disc brake con struction General in...

Page 65: ...ses 2 3 3 2 Vibrations and noises 3 12 Noises in the rear axle See the fault finding table Noise in the rear axle Driven axles Vibrations and noises 2 3 3 2 Vibrations and noises 3 12 Possible cause R...

Page 66: ...SE IN THE DISTRIBUTION BOX Possible cause Remedy The distribution gear wheel is damaged Check the distribution gear wheel The distribution gear wheel play is not correct Check the distribution gear wh...

Page 67: ...se when steering See the fault finding table Steering pump makes a screeching noise during steering Steering mechanism Noises 2 Fault finding tables 2 24 The steering pump makes an abnormal noise See...

Page 68: ...always makes a noise Normal noises A hissing noise in the steering box when steering The strength of the noise depends on the system pressure A noise that increases in strength when the poppet valve o...

Page 69: ...ause of a complaint by the driver leads you to a solution and the repair work that it involves As shown in the diagram the diagnosis information is divided into three separate sections Besides this se...

Page 70: ...tronic systems in the CAN network is no longer possible Possible cause Remedy CAN H short circuit to power supply Check CAN H CAN L short circuit to power supply Check CAN L CAN H short circuit to ear...

Page 71: ...ignal low signal volt age Channel B CAN L no message signal low signal volt age Comment The signal may vary depending on the electronic unit that is used vehicle configuration CAN H and CAN L have the...

Page 72: ...lts will have a greater effect Possible cause Remedy CAN L short circuit to earth The measured signal can be recognized by Channel A CAN H message signal Channel B CAN L no message signal low signal v...

Page 73: ...inating resistors Possible cause Remedy CAN H interrupted Check CAN H CAN L interrupted Check CAN H Communication with electronic systems that have been separated by the break in the CAN network is no...

Page 74: ...CAN H and CAN L interrupted in the same location Check CAN H and CAN L CAN H short circuits to CAN L Check CAN H and CAN L CAN H and CAN L have been switched over Check CAN H and CAN L Communication w...

Page 75: ...booster Replace the clutch booster The thrust bearing has been fitted incorrectly Check whether the thrust bearing has been fitted cor rectly Fit the thrust bearing correctly The clutch housing has c...

Page 76: ...nd or main cylinder Repair or replace the clutch booster main cylinder Comment If the seal has expanded clean the system and fill with new fluid Possible cause Remedy The bleed opening in the reservoi...

Page 77: ...he clutch release assembly is not released correctly Check the clutch release assembly The splines have corroded Replace the clutch plate and or clean and apply grease to the splines Possible cause Re...

Page 78: ...cap The thermostat opens insufficiently or does not open Check the thermostat and its operation The coolant filter is contaminated Check the coolant filter If necessary replace the filter and clean th...

Page 79: ...ace the expansion plug s Possible cause Remedy The cylinder head gasket s is are faulty Check the cylinder head gasket s The cylinder head s or cylinder block are cracked Check the cylinder heads and...

Page 80: ...cessary repair the lines The oil pump does not work well enough Check the oil pump Worn main bearings and or big end bearings Check the main bearings and the big end bearings Loose piston cooling grea...

Page 81: ...control valve remains open Check the gallery pressure The fuel supply pump s delivery is too small Check the fuel supply pump and the gallery pressure Poor fuel quality Drain the fuel rinse the fuel s...

Page 82: ...tted in the wrong position Check whether the butterfly valve has been fitted cor rectly The butterfly valve is partially operated by a residual pressure in the operating cylinder Check the operating c...

Page 83: ...valve remains open Check the gallery pressure The fuel supply pump s delivery is too small Check the fuel supply pump and the gallery pressure Poor fuel quality Drain the fuel rinse the fuel system re...

Page 84: ...he pump unit s or it they is are blocked Check the operation of the pump unit s Possible cause Remedy There is air in the fuel system Check whether any air is drawn in Pay particular atten tion to the...

Page 85: ...of the pump unit There is a mechanical fault with the injector or it is blocked Check the operation of the injector Possible cause Remedy Incorrectly programmed pump unit s injector s Check the calib...

Page 86: ...e operation of the pump unit s There is a mechanical fault with the injector s Check the operation of the injector s Incorrectly programmed pump unit s injector s Check the calibration codes and if ne...

Page 87: ...Drain the fuel rinse the fuel system replace the fuel fil ters and fill the fuel tank with fuel There is air in the fuel system Check whether any air is drawn in Pay particular atten tion to the suct...

Page 88: ...pump Bleed the fuel system The fuel filter is blocked Replace the fuel filter and clean the system The fuel supply pump s delivery is too small Check the fuel supply pump and the gallery pressure Ther...

Page 89: ...it and the ignition unit is faulty Check the wiring The ballast unit is faulty Replace the ballast unit The ignition unit s connector has not been connected correctly Check whether the connector has b...

Page 90: ...e movement of the brake shoes clean the brakes Different or incorrect brake lining quality Check the brake lining Slack or broken return spring Check the return spring Faulty automatic slack adjuster...

Page 91: ...he trailer brake system The brake pad is stuck in the brake caliper Check the play between the brake pads and the brake caliper Incorrect play between the brake pads and the brake cal iper Check the p...

Page 92: ...ering oil line is bent or pinched Check the steering oil lines The steering pump s delivery is too small Check the steering pump s delivery Fault Possible cause Remedy Noises Air in the oil The oil le...

Page 93: ...teering column runs heavily Rectify the heavy run ning The steering mechanism is faulty Repair Replace It is not possible to drive for wards in a straight line The oil level in the reservoir is too lo...

Page 94: ...0 Futura FHD2 FMD2 E6 DIAGNOSIS Systems 2 26 2 DD1020_01...

Page 95: ...e cause of a complaint by the driver leads you to a solution and the repair work that it involves As shown in the diagram the diagnosis information is divided into three separate sections Besides this...

Page 96: ...ling sys tem Check the oil cooler The oil temperature is too high Check whether the correct oil cooler has been fitted Too high sump pressure as a result of a too high blow by Check the compression pr...

Page 97: ...n the compressor side The turbo compressor is damaged Trace the cause of the damage and replace the turbo compressor Possible cause Remedy The engine distribution is incorrectly configured Check the e...

Page 98: ...ure is too high cooling system The coolant temperature is too high 3 4 Possible cause Remedy Faulty intake system Check the intake system Incorrect poly V belt tension Check the poly V belt tension If...

Page 99: ...long period of time Check the air filter and the entire air intake system Damaged piston s Check the piston s The cylinder lining has become worn due to poor cylinder lubrication Check the lubricatio...

Page 100: ...he problem Bore polishing smooth surfaces without a visible regular honing pattern A B and C have disap peared The cylinder bore must be replaced if there is any degree of bore polishing Possible caus...

Page 101: ...of the injector s Possible cause Remedy If only the exhaust valve tappets have been broken the engine speed is too high Check the engine protection data in the engine manage ment system Instruct the...

Page 102: ...m Too little lubricating oil due to The oil level being poorly checked Too low oil level Not topping up the oil Excessive oil use An external oil leak Air bubbles in the lubrication system due to a lo...

Page 103: ...the camshaft gear wheel are in the wrong position Check the position of the camshaft gear wheel Possible cause Remedy During work a foreign object has got into the combustion chamber via the inlet ex...

Page 104: ...he entire air intake system Damage caused by the piston pin lock spring or springs that has or have been driven out Possible cause Remedy The lock spring for the piston pin is broken or has been fitte...

Page 105: ...n places due to a leaking dripping partially blocked fuel injector Check the operation of the injector The entire surface of the piston barrel Possible cause Remedy Overheating of the cylinder due to...

Page 106: ...s of the differential housing Clean the contact surfaces and apply new sealant Possible cause Remedy Damaged or broken spider with stuck or seized ring gear Caused by long lasting excessive wheel spin...

Page 107: ...ymptom can be the result of overloading the vehicle Possible cause Remedy Internal fault in the shock absorber Replace the shock absorber Too little oil in the shock absorber due to an oil leak Replac...

Page 108: ...ck Not enough shock absorption See the fault finding table Shock absorber damping too soft Axle mounting and suspension Shock absorber Shock absorber damping too soft 3 13 The shock absorber is broken...

Page 109: ...every correction that is made and if necessary correct the alignment Possible cause Remedy Incorrectly adjusted or faulty height control Check the height control Bent torque rod Replace the torque ro...

Page 110: ...urface Raise the chair to the highest position Possible cause Remedy There is a leak in the pneumatic system Check the level control valve the air suspension and the air lines for leaks The cylinder i...

Page 111: ...0 Futura FHD2 FMD2 E6 REPAIR GUIDELINES 3 DD1020_01 REPAIR GUIDELINES...

Page 112: ...0 Futura FHD2 FMD2 E6 REPAIR GUIDELINES 3 DD1020_01...

Page 113: ...ten based on the assumption that the repair and maintenance work will be car ried out by an experienced well trained mechanic This mechanic must be qualified to carry out the work in a respon sible an...

Page 114: ...nce 50 Nm in the example is for the use of the torque spanner These tightening torques deviate from the standard tighten ing torques given in the standard tightening torques over view The threaded con...

Page 115: ...s which pollute the environment Therefore make sure the drained oils greases and liquids as well as the used oil filters and fuel filters are collected in appropriate separate containers When working...

Page 116: ...e components that are considered to be chem ical waste 1 3 2 DISPOSAL OF COMPONENTS Pay attention to the following when disposing of components Non chemical waste Chemical waste Overview of components...

Page 117: ...air because it will result in mechanical damage Place clean disassembled components in a dry location and cover them with a dry suitable cover Plug the areas where components have been removed so that...

Page 118: ...e behind them will be flushed away As a result the spider may get stuck and cause the steering mechanism to jam A bleed valve is fitted to the steering mechanism s power steering reservoir Water may e...

Page 119: ...nnections etc Make sure no water can enter the air intake system via the air inlet or its flexible seals When the vehicle has been cleaned it must be lubricated again with a grease gun or via the cent...

Page 120: ...psulation is dirty A certain quantity of fuel may be released when removing engine components or fuel system components To keep this quantity of fuel to a minimum unscrew the tank cap to allow any exc...

Page 121: ...le s correct driving behaviour Check the warn ings and the vehicle s driving behaviour during a test drive Also check the brake system for leaks if repairs have been carried out on the brake system Th...

Page 122: ...0 Futura FHD2 FMD2 E6 REPAIR GUIDELINES General information 1 10 3 DD1020_01...

Page 123: ...iew this applies to compo nents such as the windscreen wiper blades air dryer ele ment gaskets V belts and filters If for example non original VDL Bus Coach filters are used insufficient protection ma...

Page 124: ...aking fuel or air line must be repaired as soon as possible A leaking fuel line may constitute a fire hazard while a leak ing air line may affect the vehicle s braking performance In the event of a le...

Page 125: ...use a rubber or mallet 4 Push the air line together with the clamping ring con struction into the connection coupling until it touches and tighten the cap nut on to the coupling by hand 5 Tighten the...

Page 126: ...able for lines with a diameter of 6 mm 10 mm and 22 mm The line clamps can be joined together Rubbing through can sometimes be prevented by unscrew ing an elbow piece or a T piece and then retightenin...

Page 127: ...rfaces and is resistant to oil water and heat 5 There are different instructions for cylinder head gaskets 6 Always tighten the attachment bolts evenly 2 3 2 LIQUID GASKETS The instructions give infor...

Page 128: ...INSTALLING OIL SEALS Removing an oil seal 1 If possible use the special tools VDL Bus Coach no 41329458 and VDL Bus Coach no 40694928 or VDL Bus Coach no 40694928 A and VDL Bus Coach no 40484899 B to...

Page 129: ...itted with a liquid gasket and an oil seal with a rubber sleeve is fitted with oil or liquid soap 6 Unless otherwise stated always fit unitized oil seals in a dry condition 7 Always apply a small amou...

Page 130: ...ns specify that the bearing should be heated before it is fitted avoid exceeding the specified tempera ture Also avoid local overheating Raise the temperature of the bearing evenly by heating it in an...

Page 131: ...0 Futura FHD2 FMD2 E6 LIQUID AND LUBRICANT GUIDELINES 4 DD1020_01 LIQUID AND LUBRICANT GUIDELINES...

Page 132: ...0 Futura FHD2 FMD2 E6 LIQUID AND LUBRICANT GUIDELINES 4 DD1020_01...

Page 133: ...1 2 ALTERNATIVE FUELS The worldwide demand for less polluting engine emissions and the increased use of renewable energy sources in order to reduce our dependence on fossil fuels are the most impor ta...

Page 134: ...with normal diesel it practically becomes non biodegradable The disadvantages include Biodiesel is unstable and degrades at higher tempera tures Poor cold starts at low ambient temperatures Lower vap...

Page 135: ...tanks of vehicles that are temporarily not in use 6 months for storage in storage tanks and supply sys tems Comment Biodiesel has solvent properties so that changing from diesel to biodiesel may cause...

Page 136: ...emissions deposits in combustion chambers and a reduction in performance and the useful life of fuel injection equipment The use of PPO is not permitted as a fuel in combustion engines because the as...

Page 137: ...asured using a refractometer Use a soft lint free cloth to clean the prism and the flip lid and apply a few drops of the liquid to be measured on the prism 1 Closing the lid 2 will cause the liquid to...

Page 138: ...the tank must not be refilled with the liquid that has been pumped out because the purity is then no longer guaranteed Avoid bodily contact In the event of skin contact rinse with plenty of water In...

Page 139: ...0 Futura FHD2 FMD2 E6 CLEANING INSTRUCTIONS 5 DD1020_01 CLEANING INSTRUCTIONS...

Page 140: ...0 Futura FHD2 FMD2 E6 CLEANING INSTRUCTIONS 5 DD1020_01...

Page 141: ...n this protection it is important for the vehicle to be regu larly cleaned This should be done at least once a year It is important to do so at the end of the winter Gritting salt has a negative effec...

Page 142: ...e behind them will be flushed away As a result the spider may get stuck and cause the steering mechanism to jam 10 Be careful not to damage the lamellae when cleaning the cooling unit s radiator inter...

Page 143: ...m distance to the chassis bodywork is 30 cm 5 It is not permitted to use additives 6 The pH value must be between 6 and 8 7 Always rinse the vehicle with clean water 8 When the vehicle has been cleane...

Page 144: ...pray directly at the electrical components such as the starter motor and the alternator 3 Do not spray directly at electrical connections such as the motor management system s connectors 4 Make sure n...

Page 145: ...e because this can result in the penetration of moisture Comments Give special attention to the strengthening ribs on the top of the gearbox because water could remain behind them Make sure no water t...

Page 146: ...dashboard and other plastic parts The following must be taken into consideration when the dashboard or other plastic components must be cleaned 1 Remove the excess dirt using a vacuum cleaner 2 Clean...

Page 147: ...ation a steam cleaner may also be used 3 If a steam cleaner is used do not aim the spray too long at the same place because this can result in the pene tration of moisture 1 5 2 CONTAMINATED WITH DIES...

Page 148: ...ossible Older stains are more difficult to remove Cleaning metal or plastic components contaminated with AdBlue 1 In the event of contamination with AdBlue the AdBlue must be removed from the metal or...

Page 149: ...0 Futura FHD2 FMD2 E6 STORAGE AND PRESERVATION 6 DD1020_01 STORAGE AND PRESERVATION...

Page 150: ...0 Futura FHD2 FMD2 E6 STORAGE AND PRESERVATION 6 DD1020_01...

Page 151: ...tteries must be removed Store the batteries in a dry location During storage connect the batteries to a trickle charger so that the batteries remain continuously charged Contact VDL Bus Coach for the...

Page 152: ...t open if the air pressure drops Storage period of more than 3 months For a storage period of more than 3 months the measures given below must be taken into consideration in order to avoid a decline i...

Page 153: ...the tachograph back into operation If the vehicle has been stored for more than a year the tachograph s backup battery must be replaced Test all the functions Contact VDL Bus Coach for the measures t...

Page 154: ...t water hose to a maximum pressure of 100 bar and a maximum temperature of 90 C Never direct the jet too long at the same area because the high pressure and high temperature may damage the paintwork o...

Page 155: ...0 Futura FHD2 FMD2 E6 PAINT TREATMENT 7 DD1020_01 PAINT TREATMENT...

Page 156: ...0 Futura FHD2 FMD2 E6 PAINT TREATMENT 7 DD1020_01...

Page 157: ...e a two component epoxy or polyester based filler Use a two component PUR finishing coat with a gloss level of 70 units for a chassis finishing coat measured at 60 degree geometry Maximum drying tempe...

Page 158: ...treatment 1 2 7 DD1020_01 Leave the rust removal agent to work for the time specified by the manufacturer Rinse the area where rust has been removed at least twice with plenty of clean tap water Dry t...

Page 159: ...and the area to be treated using P80 sandpaper so that it is completely clean and free of rust 5 Remove any dust from the sanded area with a tack rag 6 Remove any grease and dirt from the area to be t...

Page 160: ...for dry sanding and P600 P800 sandpaper for wet sanding Remove any dust from the sanded area with a Tack rag and clean the area with a solvent 2 Apply the topcoat over the primer and the sanded areas...

Page 161: ...per Use a Tack cloth to remove any dust from the area to be treated Degrease the surface to be treated and the surround ing area with a solution of for example paint thinner 2 Applying zinc paint Prim...

Page 162: ...0 Futura FHD2 FMD2 E6 PAINT TREATMENT Paint treatment 1 6 7 DD1020_01...

Page 163: ...ts They should be re treated every three years Hollow cavities and the inside of beams should be treated for corrosion after repair to prevent them from rusting on the inside 2 1 1 PRODUCT Only use Wa...

Page 164: ...Check all the external components for damage and check the attachment of the protective layers such as the antichip coating and the paint 3 Thoroughly check the corners where dirt can collect and if n...

Page 165: ...ith the paint instructions 2 2 4 COMPONENTS NOT TO BE TREATED A coating must not be applied to the following components because this may have an adverse effect on their operation Wheel suspension Air...

Page 166: ...f dirt and moisture The seal ant may be burnt in the event of repair work close to the sealant seams It is very important that the sealant seams are carefully repaired so as to prevent corrosion betwe...

Page 167: ...ealant at a temperature below 5 C or above 40 C The optimal application temperature is between 15 C and 25 C 5 Apply sealant Sikaflex 221 and smooth out the joins using Sika Tooling Agent N as shown i...

Page 168: ...0 Futura FHD2 FMD2 E6 PAINT TREATMENT Anticorrosion antichip coating 2 6 7 DD1020_01...

Page 169: ...0 Futura FHD2 FMD2 E6 INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE 8 DD1020_01 INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE...

Page 170: ...0 Futura FHD2 FMD2 E6 INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE 8 DD1020_01...

Page 171: ...ed In the situations given below the equipment and the instruc tions are linked to individual work tasks 1 1 1 SITUATION I Inspection or work on the underside of the vehicle while the air bellows rema...

Page 172: ...ifting equipment does not provide sufficient safety The following conditions apply The air bellows are emptied 0 5 bar prior to lifting After lifting the vehicle is supported by axle supports People a...

Page 173: ...and supporting 8 DD1020_01 1 1 4 SITUATION IV Removing a wheel from a vehicle The following conditions apply Only one wheel is raised off the ground Nobody is under the vehicle Equipment Jack jack sta...

Page 174: ...le vehicle place the six synchronized wheel lifts under the front axle the 2nd axle and the 3rd axle 5 Lift the vehicle so that all the tyres are a couple of centi metres off the ground Check the posi...

Page 175: ...Stop lowering when the vehicle is a couple of centimetres off the ground 3 Turn off the unconditional kneeling function so that the vehicle returns to the driving height 4 Lower the vehicle to the gr...

Page 176: ...dule where the transverse beam crosses the longitudinal beams and raise the front module so that the tyres come off the ground 6 Unconditionally kneel the vehicle see 1 6 Unconditional kneeling 1 13 I...

Page 177: ...ring when the vehicle is a couple of centimetres off the ground 3 Turn off the unconditional kneeling function so that the vehicle returns to the driving height 4 Lower the vehicle further until the w...

Page 178: ...pports with a spindle First read the instructions concerning 8 1 2 Wheel lifts 1 4 and 8 1 3 Central lifting columns 1 6 Read the instructions provided with the lifting equipment to see whether the li...

Page 179: ...e is lowered horizon tally Next rotate the spindles of the two rear axle sup ports until the supports touch the support points 5 For extra stability an axle support can be placed under support point C...

Page 180: ...e supports at the rear of the vehicle under the support points C Use work shop axle supports with a spindle 5 Make sure the axle supports under support points A support the vehicle first if the vehicl...

Page 181: ...g chassis the jack must never be placed in the area between the two steering stubs When the contact switch is turned on the height control system produces too much movement causing the vehicle to beco...

Page 182: ...up the trailing axle place the jack under the axle beam as indicated Read the accompanying documentation before using the jack ILAz0082 To prevent deformation of the axle beam the jack must not be pl...

Page 183: ...in the fuse box in the driver s sleeping compart ment Manually bleeding the air bellows If the vehicle does not have the function described above the air bellows must be bled manually After doing so...

Page 184: ...heel rim cannot get between the support bracket 1 7 2 AUXILIARY TOOLS FOR CENTRAL LIFTING COLUMNS Use suitable supports with the appropriate separate auxiliary tools for the axles and slide them suffi...