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VDL Futura FHD2 E6 Workshop Manual

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WORKSHOP MANUAL
Futura FHD2/FMD2 E6
Main Group 0
1525
DD1020_01

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Summary of Contents for VDL Futura FHD2 E6

  • Page 1 WORKSHOP MANUAL Futura FHD2/FMD2 E6 Main Group 0 1525 DD1020_01...
  • Page 2 Futura FHD2/FMD2 E6 Foreword This workshop manual contains all the relevant information to help when tracing and solving technical problems, when making adjustments and when carrying out repair work. The book contains diagrams, system descriptions, fault finding instructions and work instructions. It also contains safety regulations, which must be strictly observed.

  • Page 3: Table Of Contents

    CONTENTS Futura FHD2/FMD2 E6 General information Repair guidelines General information........1-1 General information ........1-1 Threaded connections ........1-1 Technical documentation.........1-1 Locking compounds and sealants....1-7 Technical information ........1-2 Conversion tables ......... 1-12 Environment ............1-3 Cleanliness instructions ........1-5 High-pressure hose .........1-6 Safety regulations Tools..............1-7 Work on the engine .........1-8...
  • Page 4 CONTENTS Futura FHD2/FMD2 E6 Instructions for 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 ............. 1-11 Unconditional kneeling ........

  • Page 5: Futura Fhd2/Fmd2 E6

    Futura FHD2/FMD2 E6 Disclaimers © 1525 VDL Bus & Coach bv, Valkenswaard, The Netherlands. In the interest of continuous product development VDL Bus & Coach reserves the right to change specifications or products at any time without prior notice. No part of this publication may be reproduced and/or...
  • Page 6 Futura FHD2/FMD2 E6 2 - 4 DD1020_01...

  • Page 7: General Information

    GENERAL INFORMATION Futura FHD2/FMD2 E6 GENERAL INFORMATION DD1020_01...
  • Page 8 GENERAL INFORMATION Futura FHD2/FMD2 E6 DD1020_01...

  • Page 9: General Information

    • A lubricant must also be applied to new bolts taken from the warehouse. The highly variable coefficient of friction means that dry threaded connections are not permitted. The following threaded connections are used on VDL Bus & Coach vehicles: • Connections of strength classes 8.8 and 8.
  • Page 10 GENERAL INFORMATION General information Futura FHD2/FMD2 E6 • Flange nuts and flange bolts of strength classes 10.9 and • Flange nuts and flange bolts of strength classes 12.9 and • Clamping flange nuts and flange bolts of strength classes 12.9 and 12. 1.1.4 THREADED CONNECTION 10.9/10 As standard, a 10.9/10 threaded connection is tightened to a...
  • Page 11 GENERAL INFORMATION Futura FHD2/FMD2 E6 General information Comment Only use engine oil as a lubricant for reused nuts and bolts. As a result of the differences in the coefficients of friction, lubricants other than engine oil or the factory applied grease must not be used under any circum- stances.
  • Page 12 GENERAL INFORMATION General information Futura FHD2/FMD2 E6 1.1.8 TIGHTENING TORQUES FOR DIPPED THREADED CONNECTIONS The tightening torques in the table below are the standard tightening torques and are only applicable to dipped threaded connections. If one of these threaded connections must be tightened to a different tightening torque, then this will be stated in the tech- nical information for the component concerned.
  • Page 13 GENERAL INFORMATION Futura FHD2/FMD2 E6 General information Overview of standard tightening torques for fixings of strength class 8.8/8 Thread indication Tightening torque (Nm) M4 x 0.7 2.8 ± 0.2 M5 x 0.8 5.5 ± 0.4 M6 x 1 9.6 ± 0.7 M8 x 1.25 23 ±...
  • Page 14 GENERAL INFORMATION General information Futura FHD2/FMD2 E6 Overview of the standard tightening torques for clamp- ing flange nuts and bolts of strength class 12.9/12 Thread indication Tightening torque (Nm) M12 x 1.25 178 ± 14 M14 x 1.5 274 ± 22 M16 x 1.5 425 ±...

  • Page 15: Locking Compounds And Sealants

    GENERAL INFORMATION Futura FHD2/FMD2 E6 General information LOCKING COMPOUNDS AND SEALANTS 1.2.1 LOCKING COMPOUNDS Certain cleaning agents have a negative effect on the effectiveness of locking compounds. 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 that the locking compound functions correctly.
  • Page 16 GENERAL INFORMATION General information Futura FHD2/FMD2 E6 Applying locking compounds The following procedure must be followed when applying locking compounds to threaded connections: 1. Clean both the internal and external thread. Remove any grease from the thread using a suitable degreasing agent which leaves no residue that could reduce the effectiveness of the locking compound.
  • Page 17 GENERAL INFORMATION Futura FHD2/FMD2 E6 General information Loctite 542 Seals small pipe thread fit- Specially suitable for seal- 40697166 tings of line systems. ing hydraulic and pneu- matic fittings. Contains nothing that can cause blockages in filters or valves. Maximum play of 0.25 mm. Loctite 572 Seals against low pres- Threaded connections...
  • Page 18 GENERAL INFORMATION General information Futura FHD2/FMD2 E6 1.2.3 OTHER PRODUCTS OVERVIEW OF SEALANTS Product name Properties Article number Contact spray Cleaning product for clean- Cleaning electrical contact 41387608 ing and degreasing elec- points. tronic and electrical connections. Dispels mois- ture and dirt from electrical contacts.
  • Page 19 GENERAL INFORMATION Futura FHD2/FMD2 E6 General information Molykote P37 Lubrication grease pre- For threaded connections 41391619 vents corrosion which is that are subjected to high resistant to temperatures temperatures, such as for up to 1,400° C. exhaust systems. Molykote PG21 Lubrication grease which is For the sealing rings of the 41738904...

  • Page 20: Conversion Tables

    GENERAL INFORMATION General information Futura FHD2/FMD2 E6 CONVERSION TABLES Consumption km / l 1 / 100 km miles/gallon miles/gallon (Imp) (US) 100/n n x 2.2825 n x 2.352 100/n 282.5/n 235.2/n n x 0.354 282.485/n n x 0.83 n x 0.425 235.294/n n x 1.202 Specific use...
  • Page 21 GENERAL INFORMATION Futura FHD2/FMD2 E6 General information Length units inches feet yards mile (stat.) 0.03937 0.003281 0.001094 0.001 0.000001 0.0000006214 25.4 0.08333 0.2777 0.0254 0.0000254 0.00001577 304.8 0.3333 0.3048 0.0003048 0.0001894 914.4 0.9144 0.0009144 0.0005682 1000 39.37 3.281 1.0936 0.001 0.0006214 1000000 39370...
  • Page 22 GENERAL INFORMATION General information Futura FHD2/FMD2 E6 Pressures kg/cm lbs/sq inch (psi) 0.00001 0.0000101 0.000145 0.0000987 100000 1.0197162 14.500364 0.9868813 98066.5 0.980665 14.22 0.9678 6894.76 0.0689476 0.070307 0.068046 101322.3 1.013223 1.0332 14.70 133.32 0.0013332 0.0013595 0.01934 0.0013158 3386.23 0.0338623 0.03453 0.4912 0.3342 9797.82...

  • Page 23: Safety Regulations

    SAFETY REGULATIONS Futura FHD2/FMD2 E6 SAFETY REGULATIONS DD1020_01...
  • Page 24 SAFETY REGULATIONS Futura FHD2/FMD2 E6 DD1020_01...

  • Page 25: General Information

    SAFETY REGULATIONS Futura FHD2/FMD2 E6 General information GENERAL INFORMATION WARNING SYMBOLS This symbol gives useful tips to simplify the work. This symbol indicates a situation which requires extra attention. This symbol indicates a situation which may result in damage to the vehicle. This symbol indicates a situation which may result in personal injury.

  • Page 26: General Safety Regulations

    Do not ignore them. They are there to ensure your health and safety! – Work may only be carried out by the staff of VDL BUS & Coach dealers and workshops who have received suffi- cient training concerning these systems.

  • Page 27: Safety Regulations When Carrying Out Work

    – Always observe the instructions and regulations given in the VDL Bus & Coach workshop documentation. – Remain a safe distance from rotating and/or moving com- ponents. – Make sure there is good ventilation or extraction equip- ment when carrying out work where vapours and/or gases are released.
  • Page 28 SAFETY REGULATIONS General information Futura FHD2/FMD2 E6 – Always use a tyre cage when fitting and inflating tyres. Thoroughly clean tyres prior to balancing. Only use a bal- ancing device which has a protective cover. – Always use the appropriate lifting gear (gearbox jack) or approved hoisting equipment when removing or installing heavy components.
  • Page 29 SAFETY REGULATIONS Futura FHD2/FMD2 E6 General information SCR unit – The SCR unit contains vanadium pentoxide (see DNX (Denox catalyst) “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 the local, regional and national legislation.

  • Page 30: Liquid, Lubricant And Gas Safety Regulations

    Futura FHD2/FMD2 E6 LIQUID, LUBRICANT AND GAS SAFETY REGULATIONS – Always observe the safety information issued by VDL Bus & Coach and the suppliers. – Various types of oil and other lubricants used on the vehi- cle can harm your health.
  • Page 31 SAFETY REGULATIONS Futura FHD2/FMD2 E6 General information – AdBlue corrodes metals, such as copper and alumin- ium. Alloys, such as brass, can also be damaged. – If AdBlue comes into contact with the electrical installation (wiring harnesses and contacts), then the components concerned must be replaced.
  • Page 32 SAFETY REGULATIONS General information Futura FHD2/FMD2 E6 Batteries Always charge batteries in a properly ventilated area and avoid sparks and naked flames. Always switch off the battery charger before disconnecting the cables. A quick-charger should only be used if absolutely necessary. Disconnect the battery cables when quick-charging.

  • Page 33: Safety Regulations When Jump Starting

    SAFETY REGULATIONS Futura FHD2/FMD2 E6 General information SAFETY REGULATIONS WHEN JUMP STARTING Both systems must have the same battery voltage (24 V). Use thick start cables (at least 25 mm with insulated clamps. Jump starting may only be performed with the aid of batteries. An auxiliary starting device may provide a voltage which is too large and this may cause damage to the vehicle's electrical system.
  • Page 34 SAFETY REGULATIONS General information Futura FHD2/FMD2 E6 After starting the 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 vehicle, turn on as many energy consumers on this vehicle as possible before the cables are removed.

  • Page 35: Avoiding The Risk Of Fire

    SAFETY REGULATIONS Futura FHD2/FMD2 E6 General information AVOIDING THE RISK OF FIRE – Make sure that ignition sources cannot come into contact with inflammable or explosive liquids and gases. If possi- ble, keep these substances fully protected. – Check the fuel lines for leaks and repair any leaks immedi- ately.

  • Page 36: Safety Regulations For Welding Work

    SAFETY REGULATIONS FOR WELDING WORK It is not permitted to carry out welding work on the vehicle without special written permission from VDL Bus & Coach, Failure to observe the welding regulations may cause seri- ous damage to the chassis.
  • Page 37 SAFETY REGULATIONS Futura FHD2/FMD2 E6 General information Welding work on the chassis – When performing welding work on the vehicle, disconnect the connectors from all the electronic devices (including the sensors and actuators) if they are located within a dis- tance of 1 metre from the welding point and within a dis- tance of 1 metre from the earth clamp.

  • Page 38: After A Collision

    Therefore, always treat the steering mechanism with care during repair work. – The steering box must be either inspected 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.

  • Page 39: Wiring Harnesses

    SAFETY REGULATIONS Futura FHD2/FMD2 E6 General information WIRING HARNESSES – After a wiring harness has been removed or replaced, it must be refitted and secured in the same position as it was before it was removed. – Make sure the joins are watertight. Never remove sealing washers from connectors.

  • Page 40: 1.10 Calibrating The Tachograph

    SAFETY REGULATIONS General information Futura FHD2/FMD2 E6 1.10 CALIBRATING THE TACHOGRAPH – A roller test stand can be used to calibrate the tachograph (for example, after changing the type of tyres used on the vehicle). – If the vehicle is equipped with ASR, this system will inter- pret the rotating rear wheels and the stationary front wheels as the rear wheels spinning.

  • Page 41: 1.11 Xenon Lighting

    SAFETY REGULATIONS Futura FHD2/FMD2 E6 General information 1.11 XENON LIGHTING • The connection cable between the headlight and the bal- last electronics carries a high voltage current and may not be disconnected. • Disconnect the power supply to the headlights before changing the light bulbs.
  • Page 42 SAFETY REGULATIONS General information Futura FHD2/FMD2 E6 1 - 18 DD1020_01...

  • Page 43: Diagnosis

    DIAGNOSIS Futura FHD2/FMD2 E6 DIAGNOSIS DD1020_01...
  • Page 44 DIAGNOSIS Futura FHD2/FMD2 E6 DD1020_01...

  • Page 45: Vehicle Behaviour And Performance

    DIAGNOSIS Futura FHD2/FMD2 E6 Vehicle behaviour and performance VEHICLE BEHAVIOUR AND PERFORMANCE INTRODUCTION General information The diagnosis information is intended to help you trace prob- lems. Possible causes of symptoms that are not detected by an electronic unit are given in the fault finding tables. Faults that can be detected by an electronic unit can be read as an error code with the aid of diagnosis equipment.

  • Page 46: Starting Behaviour

    DIAGNOSIS Vehicle behaviour and performance Futura FHD2/FMD2 E6 STARTING BEHAVIOUR 1.2.1 THE STARTER MOTOR DOES NOT WORK General information • Is this symptom the result of a technical fault? • External factors or improper use can also lead to this fault. •...
  • Page 47 DIAGNOSIS Futura FHD2/FMD2 E6 Vehicle behaviour and performance 1.2.3 THE ENGINE IS DIFFICULT TO START The starter motor turns the engine over, but it takes a long time before the engine is running correctly. Possible cause Remedy Fault in the electronic system. Check the symptom with the aid of the diagnosis equip- ment.

  • Page 48: Gear Changing Behaviour Of Amanual Gearbox

    DIAGNOSIS Vehicle behaviour and performance Futura FHD2/FMD2 E6 GEAR CHANGING BEHAVIOUR OF A MANUAL GEARBOX 1.3.1 IT IS DIFFICULT TO CHANGE GEAR General information • Is this symptom the result of a technical fault? • External factors or improper use can also lead to this fault. •...
  • Page 49 DIAGNOSIS Futura FHD2/FMD2 E6 Vehicle behaviour and performance 1.3.2 GEARS CANNOT BE SELECTED Possible cause Remedy There is a fault in the mechanical gearbox mechanism. See the fault finding table below: “Gears cannot be selected (1)”. There is a mechanical fault in the gearbox. See the fault finding table below: “Gears cannot be selected (2)”.
  • Page 50 DIAGNOSIS Vehicle behaviour and performance Futura FHD2/FMD2 E6 1.3.3 THE GEARBOX JUMPS OUT OF GEAR Possible cause Remedy There is a fault in the mechanical gearbox mechanism. See the fault finding table: “Gears cannot be selected (1)”. There is a mechanical fault in the gearbox. See the fault finding table: “Gears cannot be selected (2)”.

  • Page 51: Abnormal Tyre Wear

    DIAGNOSIS Futura FHD2/FMD2 E6 Vehicle behaviour and performance ABNORMAL TYRE WEAR 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 fast for a long period of time.
  • Page 52 DIAGNOSIS Vehicle behaviour and performance Futura FHD2/FMD2 E6 1.4.1 WEAR OF THE TREAD Excessive wear of the tread in the middle of the tread Possible cause Remedy The tyre pressure is too high. Check the tyre pressure. Driving too fast for a long period of time. Check the type of tyre and instruct the driver.
  • Page 53 DIAGNOSIS Futura FHD2/FMD2 E6 Vehicle behaviour and performance 1.4.3 WEAR PATTERNS ON THE TREAD The tread profile contains areas with excessive wear (there is a knocking sound when driving and vibrations can be felt). Possible cause Remedy Damaged or worn mounting components. Check the mounting.
  • Page 54 DIAGNOSIS Vehicle behaviour and performance Futura FHD2/FMD2 E6 1.4.4 WEAR ON THE SHOULDER Wear on the inner shoulder The wear only occurs on the inner shoulder. The wear pattern increases the longer the deviation remains present. Possible cause Remedy Too large negative wheel camber. Check the camber.
  • Page 55 DIAGNOSIS Futura FHD2/FMD2 E6 Vehicle behaviour and performance Wear on both shoulders The wear occurs on both the inner and outer shoulder. Possible cause Remedy The tyre pressure is too low. Correct the tyre pressure. Cupping This type of wear almost only ever occurs on non-driven, non-steered axles.
  • Page 56 DIAGNOSIS Vehicle behaviour and performance Futura FHD2/FMD2 E6 1.4.5 WEAR ON THE WALLS Cuts The wall is damaged from the outside to the inside, which may have damaged the tyre body. Possible cause Remedy Cuts due to a sharp object. Change the tyre, because the damaged wall may cause a burst tyre after it has been pumped up.
  • Page 57 DIAGNOSIS Futura FHD2/FMD2 E6 Vehicle behaviour and performance Circular wear on the walls The wear pattern covers the entire circumference of the tyre. Possible cause Remedy The tyre touches other parts of the vehicle whilst driving. Check the play. Incorrect type of tyre. Check the tyre sizes.

  • Page 58: Operation/Warning/Indication Functions

    DIAGNOSIS Vehicle behaviour and performance Futura FHD2/FMD2 E6 OPERATION/WARNING/INDICATION FUNCTIONS 1.5.1 THE CRUISE CONTROL DOES NOT WORK Possible cause Remedy Mechanical fault/steering column’s switch broken. Check the steering column’s switches in all positions. The cut-out condition(s) for the cruise control is/are Check for the presence of the cut-out condition(s).

  • Page 59: Consumption

    DIAGNOSIS Futura FHD2/FMD2 E6 Vehicle behaviour and performance CONSUMPTION 1.6.1 HIGH FUEL CONSUMPTION General information • Is this symptom the result of a technical fault? • External factors or improper use can also lead to this fault. • It is important to get the correct image of the complaint by asking the customer or the driver for as much information as possible.
  • Page 60 DIAGNOSIS Vehicle behaviour and performance Futura FHD2/FMD2 E6 1.6.2 HIGH ADBLUE CONSUMPTION General information • Is this symptom the result of a technical fault? • External factors or improper use can also lead to this fault. • It is important to get the correct image of the complaint by asking the customer or the driver for as much information as possible.
  • Page 61 DIAGNOSIS Futura FHD2/FMD2 E6 Vehicle behaviour and performance 1.6.3 HIGH OIL CONSUMPTION Before checking the following causes, check whether the consumption is higher than the maximum limit or whether it is caused by an excessive oil leak. Possible cause Remedy Faulty oil system.

  • Page 62: Exhaust Smoke

    DIAGNOSIS Vehicle behaviour and performance Futura FHD2/FMD2 E6 EXHAUST SMOKE 1.7.1 THE ENGINE EMITS BLACK SMOKE Possible cause Remedy The air filter element is blocked. Replace the air filter element. Air leak between the turbo compressor and the inlet Check the hoses and pressure-test the intake section. manifold.

  • Page 63: Pulling Force

    DIAGNOSIS Futura FHD2/FMD2 E6 Vehicle behaviour and performance PULLING FORCE 1.8.1 LOSS OF PULLING FORCE General information • Is this symptom the result of a technical fault? • External factors or improper use can also lead to this fault. • It is important to get the correct image of the complaint by asking the customer or the driver for as much information as possible.
  • Page 64 DIAGNOSIS Vehicle behaviour and performance Futura FHD2/FMD2 E6 Discuss the results with the customer or the driver. If the acceleration time is not achieved, check the following possible causes. Possible cause Remedy Incorrect type of components fitted. Check whether the correct components have been fitted. This refers to the turbo compressor, the filters, etc.

  • Page 65: Vibrations And Abnormal Noises

    DIAGNOSIS Futura FHD2/FMD2 E6 Vehicle behaviour and performance VIBRATIONS AND ABNORMAL NOISES 1.9.1 THE ENGINE VIBRATES EXCESSIVELY Possible cause Remedy Unbalanced flywheel. Check the flywheel’s attachment. The flywheel oscillates. Check the flywheel’s attachment and whether the fly- wheel oscillates. 1.9.2 ABNORMAL NOISES FROM THE DRIVEN SHAFT Possible cause Remedy...
  • Page 66 DIAGNOSIS Vehicle behaviour and performance Futura FHD2/FMD2 E6 1.9.6 NOISE 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 wheel play. The distribution gear wheel is loose.
  • Page 67 DIAGNOSIS Futura FHD2/FMD2 E6 Vehicle behaviour and performance 1.9.7 ABNORMAL NOISE FROM THE STEERING MECHANISM Possible cause Remedy The steering pump makes a screeching noise when See the fault finding table: “Steering pump makes a steering screeching noise during steering, Steering mechanism, Noises”...
  • Page 68 DIAGNOSIS Vehicle behaviour and performance Futura FHD2/FMD2 E6 1.9.9 THE STEERING PUMP MAKES AN ABNORMAL NOISE Is this symptom the result of a technical fault? External factors or improper use can also lead to this fault. The steering mechanism always makes a noise. Normal noises: •...

  • Page 69: Systems

    DIAGNOSIS Futura FHD2/FMD2 E6 Systems SYSTEMS INTRODUCTION General information The diagnosis information is intended to help you trace prob- lems. Possible causes of symptoms that are not detected by an electronic unit are given in the fault finding tables. Faults that can be detected by an electronic unit can be read as an error code with the aid of diagnosis equipment.

  • Page 70: Can Network

    DIAGNOSIS Systems Futura FHD2/FMD2 E6 CAN NETWORK 2.2.1 CAN NETWORK ISO 11898 CAN communication is not possible CAN network fault finding table according to ISO 11898 Communication with the electronic systems in the CAN network is no longer possible. Possible cause Remedy CAN-H short circuit to power supply.
  • Page 71 DIAGNOSIS Futura FHD2/FMD2 E6 Systems Communication with the electronic systems in the CAN network is no longer possible. Possible cause Remedy Connection with two terminating resistors is broken. Check the connections to the terminating resistors. The measured signal can be recognized by: Channel A: CAN-H, no message signal, low signal volt- age.
  • Page 72 DIAGNOSIS Systems Futura FHD2/FMD2 E6 Faults in the CAN communication CAN network fault finding table according to ISO 11898 Communication with the electronic systems in the CAN network is still possible, but the faults will have a greater effect. Possible cause Remedy CAN-L short circuit to earth.
  • Page 73 DIAGNOSIS Futura FHD2/FMD2 E6 Systems CAN communication is not possible between some systems CAN network fault finding table according to ISO 11898 Communication with electronic systems that have been separated by the break in the CAN network is no longer possible. Communication between electronic systems that are located on the same side of the break is still possible.
  • Page 74 DIAGNOSIS Systems Futura FHD2/FMD2 E6 2.2.2 CAN NETWORK ISO 11992/1 CAN communication is not possible CAN network fault finding table according to ISO 11992/1 Communication with the electronic systems in the CAN network is not possible. Possible cause Remedy CAN-H and CAN-L interrupted in the same location. Check CAN-H and CAN-L CAN-H short-circuits to CAN-L.

  • Page 75: Clutch

    DIAGNOSIS Futura FHD2/FMD2 E6 Systems CLUTCH 2.3.1 THE COUPLING IS NOT RELEASED Possible cause Remedy The liquid level in the hydraulic system is too low. Check the hydraulic system for leaks. Top up the hydraulic liquid. Bleed the hydraulic system. The pedal is incorrectly set.
  • Page 76 DIAGNOSIS Systems Futura FHD2/FMD2 E6 2.3.4 THE PEDAL FORCE IS TOO GREAT Possible cause Remedy There is no pressure in circuit 4 of the brake system or Check circuit 4 of the brake system. the pressure is too low. The air line is pinched closed. Check the line and, if necessary, replace it.
  • Page 77 DIAGNOSIS Futura FHD2/FMD2 E6 Systems 2.3.7 THE CLUTCH SLIPS Possible cause Remedy The lining is worn. Replace the clutch plate. There is oil on the lining. Replace the clutch plate and check the engine oil seals and the gearbox oil seals. There is grease on the lining.

  • Page 78: Cooling System

    DIAGNOSIS Systems Futura FHD2/FMD2 E6 COOLING SYSTEM 2.4.1 THE ENGINE TEMPERATURE RISES Possible cause Remedy Faulty intake system. Check the intake system. Incorrect poly V-belt tension. Check the poly V-belt tension. If necessary, replace the poly V-belt or the poly V-belt tensioner. The coolant level is too low.
  • Page 79 DIAGNOSIS Futura FHD2/FMD2 E6 Systems 2.4.3 EXTERNAL COOLANT LEAK Possible cause Remedy The radiator. Check the radiator. If necessary, pressure-test it. The coolant pump leaks. Check the coolant pump. If necessary, measure the bearing play. The cooler. Check the oil cooler. If necessary, pressure-test it. The pressure cap.

  • Page 80: Lubrication System

    DIAGNOSIS Systems Futura FHD2/FMD2 E6 LUBRICATION SYSTEM 2.5.1 ENGINE OIL PRESSURE TOO LOW Possible cause Remedy Engine oil level too low. Top up the engine oil to the maximum level. External oil leaks. Visually check the engine for leaks. If necessary, repair the lines.

  • Page 81: Intake And Exhaust Systems

    DIAGNOSIS Futura FHD2/FMD2 E6 Systems INTAKE AND EXHAUST SYSTEMS 2.6.1 LOSS OF PULLING FORCE This general symptom can be explained based on one of these more detailed causes. Possible cause Remedy Reduced power above a certain engine speed See the fault finding table: "Reduced power above a cer- tain engine speed"...
  • Page 82 DIAGNOSIS Systems Futura FHD2/FMD2 E6 2.6.4 REDUCED MAXIMUM ENGINE SPEED Possible cause Remedy The turbo compressor is damaged. Trace the cause of the damage and replace the turbo compressor. 2.6.5 THE EXHAUST GAS BACK PRESSURE IS TOO HIGH Possible cause Remedy Incorrect butterfly valve setting.

  • Page 83: Fuel System

    DIAGNOSIS Futura FHD2/FMD2 E6 Systems FUEL SYSTEM 2.7.1 LOSS OF PULLING FORCE This general symptom can be explained based on one of these more detailed causes. Possible cause Remedy Reduced power above a certain engine speed See the fault finding table: "Reduced power above a cer- tain engine speed"...
  • Page 84 DIAGNOSIS Systems Futura FHD2/FMD2 E6 2.7.4 REDUCED MAXIMUM ENGINE SPEED Possible cause Remedy There is air in the fuel system. Check whether any air is drawn in. Pay particular atten- tion to the suction line and the delivery pump’s oil seal. Bleed the fuel system.
  • Page 85 DIAGNOSIS Futura FHD2/FMD2 E6 Systems 2.7.7 THE ENGINE IS DIFFICULT TO START Possible cause Remedy There is air in the fuel system. Check whether any air is drawn in. Bleed the fuel system. The fuel pressure control valve remains open. Check the gallery pressure.
  • Page 86 DIAGNOSIS Systems Futura FHD2/FMD2 E6 2.7.10 THE ENGINE RUNS ERRATICALLY Possible cause Remedy There is air in the fuel system. Check whether any air is drawn in. Pay particular atten- tion to the suction line and the oil seal for the fuel delivery pump.
  • Page 87 DIAGNOSIS Futura FHD2/FMD2 E6 Systems 2.7.12 REDUCED POWER ABOVE A CERTAIN ENGINE SPEED Possible cause Remedy The fuel fine filter is partially blocked. Replace the fuel filter and clean the system. There is a mechanical fault with the pump unit(s) or it/ Check the operation of the pump unit(s).
  • Page 88 DIAGNOSIS Systems Futura FHD2/FMD2 E6 2.7.15 REDUCED MAXIMUM ENGINE SPEED Possible cause Remedy There is air in the fuel system. Check whether any air is drawn in. Pay particular atten- tion to the suction line and the oil seal for the fuel delivery pump.

  • Page 89: Vehicle Lighting

    DIAGNOSIS Futura FHD2/FMD2 E6 Systems VEHICLE LIGHTING 2.8.1 THE XENON LIGHTING DOES NOT WORK ON ONE SIDE Possible cause Remedy The dipped beam fuse is faulty. Check/replace the fuse. No power supply to the ballast unit on the faulty side. Check the power supply to the ballast unit.

  • Page 90: Disc Brake Construction

    DIAGNOSIS Systems Futura FHD2/FMD2 E6 DISC BRAKE CONSTRUCTION 2.9.1 GENERAL INFORMATION The brakes drag Disc brake construction, general information Is this symptom the result of a technical fault? External factors or improper use can also lead to this fault. Possible cause Remedy Incorrectly set foot valve stop bolt (residual pressure).
  • Page 91 DIAGNOSIS Futura FHD2/FMD2 E6 Systems 2.9.2 DISC BRAKE CONSTRUCTION Irregular brake pad wear Possible cause Remedy Contaminated or corroded guide bushes. Check the guide bushes. Build-up of contamination between the moving parts of Clean the disc brake construction. the disc brake construction. Moisture and dirt on the internal mechanical compo- Check and clean the brake caliper’s seals.

  • Page 92: 2.10 Steering Mechanism

    DIAGNOSIS Systems Futura FHD2/FMD2 E6 2.10 STEERING MECHANISM 2.10.1 STEERING MECHANISM Warning symbol remains active Possible cause Remedy The oil level in the reservoir is too low. Check the oil level. Check for leaks. Faulty level sensor. Check the operation of the steering mechanism. Air in the steering oil circuit.
  • Page 93 DIAGNOSIS Futura FHD2/FMD2 E6 Systems Fault Possible cause Remedy Hindered return. The axle/axle mounting runs heavily. Repair. The steering mechanism, steering column was installed Rectify the stress. in a stressed condition. The steering column runs heavily. Rectify the heavy run- ning.
  • Page 94 DIAGNOSIS Systems Futura FHD2/FMD2 E6 2 - 26 DD1020_01...

  • Page 95: Components

    DIAGNOSIS Futura FHD2/FMD2 E6 Components COMPONENTS INTRODUCTION General information The diagnosis information is intended to help you trace prob- lems. Possible causes of symptoms that are not detected by an electronic unit are given in the fault finding tables. Faults that can be detected by an electronic unit can be read as an error code with the aid of diagnosis equipment.

  • Page 96: Engine

    DIAGNOSIS Components Futura FHD2/FMD2 E6 ENGINE 3.2.1 VIBRATIONS AND NOISES Noise 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 wheel play. The distribution gear wheel is loose.
  • Page 97 DIAGNOSIS Futura FHD2/FMD2 E6 Components Turbo compressor Possible cause Remedy The air filter element is blocked. Replace the air filter element and clean the turbine side of the turbo compressor. The turbo compressor oil return line is blocked. Check the oil line. If necessary, replace it. The compressor side of the turbo compressor is contam- Clean the compressor side.
  • Page 98 DIAGNOSIS Components Futura FHD2/FMD2 E6 3.2.4 CYLINDER HEAD GASKET The cylinder head gasket is damaged Possible cause Remedy The head gaskets have not been fitted correctly and Check the cylinder heads and the cylinder block. have started to leak. The cylinder heads were not tightened according to the Check the cylinder heads and the cylinder block for dam- specified tightening procedure.
  • Page 99 DIAGNOSIS Futura FHD2/FMD2 E6 Components 3.2.5 CYLINDER BLOCK AND DRIVE The cylinder lining is worn No normal cylinder wear. Possible cause Remedy Highly polluted air has been drawn in over a long period Check the air filter and the entire air intake system. of time.
  • Page 100 DIAGNOSIS Components Futura FHD2/FMD2 E6 Bore-polishing Bore-polishing standard: The cylinder walls are honed. This means that the honing pattern consists of high points (A), shallow valleys (B) and deep valleys (C). If the deeper honing grooves (C) still show a regular pattern, then bore-polishing is not the problem.
  • Page 101 DIAGNOSIS Futura FHD2/FMD2 E6 Components The connecting rod is bent There is a layer of liquid above the piston (hydraulic lock) which has caused the connecting rod to bend. Possible cause Remedy There is water in the air filter as a result of: Check whether the head gasket has been knocked.
  • Page 102 DIAGNOSIS Components Futura FHD2/FMD2 E6 The bearing shells are excessively worn Possible cause Remedy The lubrication oil has been diluted by coolant. Check the oil cooler. Check the cylinder block and the cylinder heads for cracks or a knocked head gasket by pressure-testing the cooling system.
  • Page 103 DIAGNOSIS Futura FHD2/FMD2 E6 Components PISTON Valve impressions on the piston base Possible cause Remedy A broken valve spring. Check the valve springs. A number of pistons have a valve mark Possible cause Remedy The valve timing is incorrect. Check the valve timing. A distribution gear wheel is loose.
  • Page 104 DIAGNOSIS Components Futura FHD2/FMD2 E6 The piston rings are worn Check the cylinder lining for signs of wear. Possible cause Remedy Poor lubrication of the cylinder as a result of fuel in the Check the fuel system. lubrication oil. Poor lubrication of the cylinder as a result of coolant in Check the cooling system.
  • Page 105 DIAGNOSIS Futura FHD2/FMD2 E6 Components On the surface of the piston barrel and te grooves stretch out to the area of the piston ring. Possible cause Remedy A lack of lubrication due to a bent oil injector or a too low Check the oil injectors.

  • Page 106: Driven Axles

    DIAGNOSIS Components Futura FHD2/FMD2 E6 DRIVEN AXLES 3.3.1 GENERAL INFORMATION Oil leak Possible cause Remedy The oil level too high Correct the oil level. The oil has the wrong viscosity. Drain the oil and fill with oil that meets the specifications. Oil seal leaks.

  • Page 107: Axle Mounting And Suspension

    DIAGNOSIS Futura FHD2/FMD2 E6 Components AXLE MOUNTING AND SUSPENSION 3.4.1 SHOCK ABSORBER Shock absorber does not work 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. Replace the shock absorber.
  • Page 108 DIAGNOSIS Components Futura FHD2/FMD2 E6 Shock absorber continues hitting Is this symptom the result of a technical fault? External factors or improper use can also lead to this fault. It is important to obtain a proper idea of the problem. Try to gain as much information as possible from the cus- tomer or driver.
  • Page 109 DIAGNOSIS Futura FHD2/FMD2 E6 Components 3.4.2 REAR AXLE ALIGNMENT Axle tilt Is this symptom the result of a technical fault? External factors or improper use can also lead to this fault. It is important to obtain a proper idea of the problem. Try to gain as much information as possible from the cus- tomer or driver.

  • Page 110: Driver's Seat

    DIAGNOSIS Components Futura FHD2/FMD2 E6 DRIVER’S SEAT The seat cannot be raised Possible cause Remedy Insufficient system pressure. Check the supply of air to the chair. The air supply system is blocked. Check the air supply system. The pins for the level control valve do not press against Raise the chair to the highest position.

  • Page 111: Repair Guidelines

    REPAIR GUIDELINES Futura FHD2/FMD2 E6 REPAIR GUIDELINES DD1020_01...
  • Page 112 REPAIR GUIDELINES Futura FHD2/FMD2 E6 DD1020_01...

  • Page 113: General Information

    Content of the technical documentation The content is based on the products that are manufactured by VDL Bus & Coach and is in agreement with the standard conditions and regulations. DD1020_01 1 - 1...

  • Page 114: Technical Information

    REPAIR GUIDELINES General information Futura FHD2/FMD2 E6 TECHNICAL INFORMATION If tightening torques are stated in the “Technical information” with a certain tolerance, such as 700 Nm ± 50 Nm, a torque spanner must be set to the given value without giving atten- tion to the tolerance.

  • Page 115: Environment

    REPAIR GUIDELINES Futura FHD2/FMD2 E6 General information ENVIRONMENT Carrying out work, such as maintenance work, regularly, on time and with the necessary skill helps to reduce pollution of the environment. This can be achieved by noticing and repairing any leaks in time and by keeping the engine in an optimal condition (adjusting the valves, replacing the air filter element, etc.), so that there is a smaller emission of harmful gases.
  • Page 116 REPAIR GUIDELINES General information Futura FHD2/FMD2 E6 1.3.1 RECYCLING • Drain environmentally harmful liquids, such as oil, hydrau- lic oil and coolant. • Empty the air conditioning system. • Separate the components that are considered to be chem- ical waste. 1.3.2 DISPOSAL OF COMPONENTS Pay attention to the following when disposing of components:...

  • Page 117: Cleanliness Instructions

    REPAIR GUIDELINES Futura FHD2/FMD2 E6 General information CLEANLINESS INSTRUCTIONS Not observing the cleaning instructions may result in serious damage to the systems and/or components. Always observe the warnings and the safety regulations. Cleanliness Make sure the work area and the tools are clean. Waste, components and tools may cause uncleanliness.

  • Page 118: High-Pressure Hose

    REPAIR GUIDELINES General information Futura FHD2/FMD2 E6 HIGH-PRESSURE HOSE It is advisable to clean a vehicle with a high-pressure hose before starting work on a vehicle. A clean vehicle makes the mechanic's work easier and enables him to notice any faults at an early stage.

  • Page 119: Tools

    REPAIR GUIDELINES Futura FHD2/FMD2 E6 General information • To avoid damage to the engine encapsulation when spray- ing it, maintain a minimum distance of 50 cm between the engine encapsulation and the sprayer nozzle. • Do not aim the jet directly at electrical connections, such as connectors, lighting feed-through connections, etc.

  • Page 120: Work On The Engine

    REPAIR GUIDELINES General information Futura FHD2/FMD2 E6 WORK ON THE ENGINE • The earth cable must always be removed from the battery when carrying out work that does not require the vehicle to have an electrical power source. • Dirt may enter the system when opening the engine or parts of the engine.

  • Page 121: Guidelines For A Test Drive And Visual Inspection

    REPAIR GUIDELINES Futura FHD2/FMD2 E6 General information GUIDELINES FOR A TEST DRIVE AND VISUAL INSPECTION A test drive is required after a safety-critical component has been repaired and a visual inspection is insufficient to deter- mine the vehicle's correct driving behaviour. Check the warn- ings and the vehicle’s driving behaviour during a test drive.
  • Page 122 REPAIR GUIDELINES General information Futura FHD2/FMD2 E6 1 - 10 DD1020_01...

  • Page 123: Components

    VDL Bus & Coach quality. Logically, this quality can best be maintained by using origi- nal VDL Bus & Coach parts and components when parts and components need to be replaced. From a maintenance point of view, this applies to compo- nents such as the windscreen wiper blades, air dryer ele- ment, gaskets, V-belts and filters.

  • Page 124: Plastic Lines

    3. Always use a special pair of pliers (VDL Bus & Coach no. 40694829) to fit nipples and banjo unions in polyamide lines.
  • Page 125 REPAIR GUIDELINES Futura FHD2/FMD2 E6 Components Fitting clamping ring connections For air connections where a clamping ring connection is used, the clamping ring connection must be fitted in such a way that the clamping ring (2) is slid as far as possible over the air line and is cut into (clamped on to) the polyamide line at least 2 mm from the end of the air line.
  • Page 126 REPAIR GUIDELINES Components Futura FHD2/FMD2 E6 are available 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 retightening it in a slightly different position.

  • Page 127: Gaskets

    REPAIR GUIDELINES Futura FHD2/FMD2 E6 Components GASKETS 2.3.1 PAPER AND KLINGERIT GASKETS (RUBBER- ARAMIDE FIBRE) The workshop instruction manual gives information about which type of gasket is to be used in which situation. Replacing gaskets 1. Remove the old gasket before fitting a new one. 2.

  • Page 128: Oil Seals

    REMOVING AND 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.
  • Page 129 REPAIR GUIDELINES Futura FHD2/FMD2 E6 Components Installing an oil seal 1. Check the chamber in which the oil seal is to be fitted for damage. Repair any possible damage. 2. Look for any marks on the outside of the oil seal which have been added to indicate the shaft’s direction of rota- tion.

  • Page 130: Bearings

    REPAIR GUIDELINES Components Futura FHD2/FMD2 E6 BEARINGS 2.5.1 GENERAL INFORMATION • A bearing must be replaced if it is worn, if it has become pit- ted (small dents in the running surface) and/or if the bear- ing has been exposed to excessive heat (blue spots). •...

  • Page 131: Liquid And Lubricant Guidelines

    LIQUID AND LUBRICANT GUIDELINES Futura FHD2/FMD2 E6 LIQUID AND LUBRICANT GUIDELINES DD1020_01...
  • Page 132 LIQUID AND LUBRICANT GUIDELINES Futura FHD2/FMD2 E6 DD1020_01...

  • Page 133: General Guidelines

    LIQUID AND LUBRICANT GUIDELINES Futura FHD2/FMD2 E6 General guidelines GENERAL GUIDELINES GENERAL INFORMATION See DW050335XX for an overview of all the permitted liquids and the lubricant specifications. 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- tant reasons why alternative fuels are developed.

  • Page 134: Biodiesel

    LIQUID AND LUBRICANT GUIDELINES General guidelines Futura FHD2/FMD2 E6 BIODIESEL All MX11 and MX-13 Euro 6 engines: Only diesel which has been officially manufactured or mix- tures with an alternative fuel containing no more than 7% biodiesel, in accordance with EN590, are permitted. Biodiesel (FAME) is a fuel that is produced with the aid of agricultural products, such as rape oil, soyabean oil, sugar beet, sunflower oil and palm oil.
  • Page 135 LIQUID AND LUBRICANT GUIDELINES Futura FHD2/FMD2 E6 General guidelines and durability objectives for which they have been designed. • Biodiesel is unstable and degrades at higher temperatures. The maximum storage time must, therefore, be limited to a maximum of: – 4 weeks in fuel tanks of vehicles that are temporarily not in use.

  • Page 136: Pure Plant Oil (Ppo)

    LIQUID AND LUBRICANT GUIDELINES General guidelines Futura FHD2/FMD2 E6 PURE PLANT OIL (PPO) SVO (Straight Vegetable Oil) or Pure Plant Oil is a fuel that can be extracted from a number of agricultural products, of which rape seed is the most commonly used. In contrast to biodiesel, PPO fuels do not undergo esterification.

  • Page 137: Adblue

    LIQUID AND LUBRICANT GUIDELINES Futura FHD2/FMD2 E6 General guidelines ADBLUE AdBlue is a non-inflammable, non-poisonous, colourless, odourless and water soluble liquid. AdBlue is a liquid that consists of 32.5% urea and 67.5% water. Special additives are not permitted. If AdBlue comes into contact with painted or aluminium surfaces when refuelling, rinse the area con- cerned immediately with plenty of water.
  • Page 138 LIQUID AND LUBRICANT GUIDELINES General guidelines Futura FHD2/FMD2 E6 Purity To prevent faults to the exhaust gas after-treatment system, it is extremely important that the AdBlue is pure. If AdBlue is pumped from a tank for repair purposes, the tank must not be refilled with the liquid that has been pumped out, because the purity is then no longer guaranteed.

  • Page 139: Cleaning Instructions

    CLEANING INSTRUCTIONS Futura FHD2/FMD2 E6 CLEANING INSTRUCTIONS DD1020_01...
  • Page 140 CLEANING INSTRUCTIONS Futura FHD2/FMD2 E6 DD1020_01...

  • Page 141: General Information

    CLEANING INSTRUCTIONS Futura FHD2/FMD2 E6 General information GENERAL INFORMATION The paint used on our vehicles offers excellent protection against ageing during the vehicle's lifespan. In order to main- tain this protection, it is important for the vehicle to be regu- larly cleaned.

  • Page 142: Cleaning The Vehicle

    CLEANING INSTRUCTIONS General information Futura FHD2/FMD2 E6 CLEANING THE VEHICLE Cleaning the vehicle with a high-pressure hose If the vehicle is cleaned with a high-pressure hose, then attention must be given to the following: 1. Make sure the doors, windows and roof hatches are securely closed when cleaning the vehicle.
  • Page 143 CLEANING INSTRUCTIONS Futura FHD2/FMD2 E6 General information 2. The maximum permitted water temperature is 50 °C. 3. The maximum permitted water pressure is 80 bar. 4. The minimum distance to the chassis/bodywork is 30 cm. 5. It is not permitted to use additives. 6.

  • Page 144: Cleaning The Engine

    CLEANING INSTRUCTIONS General information Futura FHD2/FMD2 E6 CLEANING THE ENGINE Cleaning the engine with a high-pressure hose The engine and engine compartment can be cleaned with a high-pressure hose. If the engine is cleaned with a high-pres- sure hose, then attention must be given to the following: 1.

  • Page 145: Cleaning The Gearbox

    • Make sure no water that contains cleaning product is left on the gearbox. Avoiding damage to the paintwork The ZF gearboxes used by VDL Bus & Coach have a paint layer applied to them during manufacture. This layer of paint is intended to prevent corrosion of the gearbox housing.

  • Page 146: Cleaning The Interior Of The Vehicle

    1. Remove the excess dirt using a vacuum cleaner. 2. Clean the dashboard and/or plastic components with a damp cloth. For stubborn dirt, use a VDL Bus & Coach all-purpose cleaner. Read the instructions for the VDL Bus & Coach all-purpose cleaner before use.

  • Page 147: Cleaning Parts Of The Vehicle Contaminated By Liquids

    1.5.1 CONTAMINATED WITH COOLANT Cleaning upholstery contaminated with coolant 1. Remove the coolant stains with the aid of a VDL Bus & Coach upholstery cleaner. 2. Try to remove the contamination as quickly as possible. Older stains are more difficult to remove.
  • Page 148 1.5.3 CONTAMINATED WITH ADBLUE Cleaning upholstery contaminated with AdBlue 1. Remove the AdBlue stains with the aid of a VDL Bus & Coach upholstery cleaner. 2. Try to remove the contamination as quickly as possible. Older stains are more difficult to remove.

  • Page 149: Storage And Preservation

    STORAGE AND PRESERVATION Futura FHD2/FMD2 E6 STORAGE AND PRESERVATION DD1020_01...
  • Page 150 STORAGE AND PRESERVATION Futura FHD2/FMD2 E6 DD1020_01...

  • Page 151: Points Of Attention

    • During storage, connect the batteries to a trickle charger, so that the batteries remain continuously charged. Contact VDL Bus & Coach for the measures to be taken if the vehicle is to be stored for a very long time.
  • Page 152 STORAGE AND PRESERVATION Points of attention Futura FHD2/FMD2 E6 1.1.5 EXTERIOR Storage period of less than 3 months: • Clean the vehicle (if wax has been applied). • Repair paint damage. • Preferably store vehicles indoors or under cover. • The area where vehicles are parked must be dry and free of overgrowth.

  • Page 153: Preparing For Use

    Replace the backup battery according to the procedure. Not doing so will result in irreparable damage. • Test all the functions. Contact VDL Bus & Coach for the measures to be taken if the vehicle is to be stored for a very long time. 1.2.4 TECHNOLOGY •...
  • Page 154 STORAGE AND PRESERVATION Points of attention Futura FHD2/FMD2 E6 1.2.5 EXTERIOR For a storage period of less than 3 months: • Clean the entire vehicle. • Clean all the rubbers. This applies to: • Door rubbers • Window rubbers. • Windscreen wipers •...
  • Page 155 PAINT TREATMENT Futura FHD2/FMD2 E6 PAINT TREATMENT DD1020_01...
  • Page 156 PAINT TREATMENT Futura FHD2/FMD2 E6 DD1020_01...

  • Page 157: Paint Treatment

    This section gives instructions for respraying and repairing VDL Bus & Coach paint systems which have been applied to various base materials. The products to be used are supplied by a number of manu- facturers.
  • Page 158 PAINT TREATMENT Paint treatment Futura FHD2/FMD2 E6 – 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 the area where the rust has been removed from. 1 - 2 DD1020_01...

  • Page 159: Respraying/Repairing Conventional Paint

    PAINT TREATMENT Futura FHD2/FMD2 E6 Paint treatment RESPRAYING/REPAIRING CONVENTIONAL PAINT SYSTEMS General information – This section gives guidelines concerning respraying and repairing conventional paint systems. – Only use the products stated in the guidelines, because only then can the paint system be properly repaired. –...
  • Page 160 PAINT TREATMENT Paint treatment Futura FHD2/FMD2 E6 Applying the topcoat Topcoat to be used: Percotex ® Steinslagschutz halbmatt RAL 7024 graphitgrau by Spies Hecker. Hardener to be used: Priomat ® Härter 3840. 1. Sand the primed areas with sandpaper. Use P320 - P500 sandpaper for dry sanding and P600 - P800 sandpaper for wet sanding.

  • Page 161: Repairing The Layer Of Zinc

    PAINT TREATMENT Futura FHD2/FMD2 E6 Paint treatment REPAIRING THE LAYER OF ZINC Repair • Only use the products stated in the guidelines, because only then can the paint system be properly repaired. • Carefully follow the paint manufacturer’s instructions when applying paint.
  • Page 162 PAINT TREATMENT Paint treatment Futura FHD2/FMD2 E6 1 - 6 DD1020_01...

  • Page 163: Anticorrosion/Antichip Coating

    PAINT TREATMENT Futura FHD2/FMD2 E6 Anticorrosion/antichip coating ANTICORROSION/ANTICHIP COATING ANTICORROSION COATING Hollow cavities and the inside of beams should be demon- strably checked every year for faults. 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.

  • Page 164: Antichip Coating

    PAINT TREATMENT Anticorrosion/antichip coating Futura FHD2/FMD2 E6 ANTICHIP COATING The underside of the vehicle is treated with an antichip coat- ing during manufacture. This coating should be demonstrably checked for damage every year. This coating must be replaced no later than every three years.
  • Page 165 Connectors Electronic units Distribution box or fuse box Cables Gearbox cables, if present. Fuel tanks All the fuel tanks provided by VDL Bus & Coach, with the exception of the top Absorption materials All. Insulation materials All. Absorption and insulation material must...

  • Page 166: Sealant Seams

    PAINT TREATMENT Anticorrosion/antichip coating Futura FHD2/FMD2 E6 SEALANT SEAMS 2.3.1 GENERAL INFORMATION The seams between panels are sealed with an elastic seal- ant to prevent the penetration of dirt and moisture. The seal- ant may be burnt in the event of repair work close to the sealant seams.
  • Page 167 PAINT TREATMENT Futura FHD2/FMD2 E6 Anticorrosion/antichip coating 2.3.2 REPAIRS TO SEALANT SEAMS Follow the procedure given below to repair sealant seams: Always read the manufacturer's instructions before use. Preparing the surface 1. Remove the old sealant. 2. Repair the damaged layer of paint: •...
  • Page 168 PAINT TREATMENT Anticorrosion/antichip coating Futura FHD2/FMD2 E6 2 - 6 DD1020_01...

  • Page 169: Instructions For Jacking Up And Supporting The Vehicle

    INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Futura FHD2/FMD2 E6 INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE DD1020_01...
  • Page 170 INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Futura FHD2/FMD2 E6 DD1020_01...

  • Page 171: Lifting, Jacking Up And Supporting

    Following these instructions does not relieve the user of his responsibility to carry out his duties safely. VDL Bus & Coach cannot be held responsible for any consequential damage caused as a result of lifting and/or supporting the vehicle, regardless of whether this is carried out in accordance with these instructions or not.
  • Page 172 INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Lifting, jacking up and supporting Futura FHD2/FMD2 E6 Read the instructions provided with the lifting equipment to see whether the lifting equipment can be placed under the vehicle without the use of axle supports. Equipment The following equipment can be used: –...
  • Page 173 INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Futura FHD2/FMD2 E6 Lifting, jacking up and supporting 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 –...

  • Page 174: Wheel Lifts

    INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Lifting, jacking up and supporting Futura FHD2/FMD2 E6 WHEEL LIFTS Always read the supplier’s instruction manual and instructions before using the wheel jacks and any auxiliary tools. ILHz0042 Wheel lifts Lifting instructions using wheel lifts 1.
  • Page 175 INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Futura FHD2/FMD2 E6 Lifting, jacking up and supporting 6. "Unconditionally kneel" the vehicle (see 1.6 Unconditional kneeling (1 - 13)). Warn people in the immediate vicinity before raising or lowering the vehicle and stand in a safe location where you can observe the situation.

  • Page 176: Central Lifting Columns

    INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Lifting, jacking up and supporting Futura FHD2/FMD2 E6 CENTRAL LIFTING COLUMNS It is not permitted to use two lifting columns to lift a 3-axle vehicle, because the vehicle components are then subjected to an excessive load.
  • Page 177 INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Futura FHD2/FMD2 E6 Lifting, jacking up and supporting 7. Operate the central lifting columns simultaneously and raise the vehicle to the desired height. Warn people in the immediate vicinity before raising or lowering the vehicle and stand in a safe location where you can observe the situation.

  • Page 178: Placing Axle Supports Under The Frame

    INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Lifting, jacking up and supporting Futura FHD2/FMD2 E6 PLACING AXLE SUPPORTS UNDER THE FRAME First, read the instructions concerning 8 - 1.2 Wheel lifts (1 - 4) 8 - 1.3 Central lifting columns (1 - Read the instructions provided with the lifting equipment to see whether the lifting equipment can be placed under the vehicle without the use of axle...
  • Page 179 INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Futura FHD2/FMD2 E6 Lifting, jacking up and supporting 4. Make sure the axle supports under support points (A) support the vehicle first if the vehicle is lowered horizon- tally. Next, rotate the spindles of the two rear axle sup- ports until the supports touch the support points.
  • Page 180 INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Lifting, jacking up and supporting Futura FHD2/FMD2 E6 Supporting order for a 3-axle vehicle 1. Raise the vehicle to a height that is higher than the axle supports. 2. At the front of the vehicle, place the axle supports under the support points (A).

  • Page 181: Jacking Up

    INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Futura FHD2/FMD2 E6 Lifting, jacking up and supporting JACKING UP The contact switch must be turned off. When the contact switch is turned on, the height control system produces too much movement, causing the vehicle to become unbalanced.
  • Page 182 INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Lifting, jacking up and supporting Futura FHD2/FMD2 E6 1.5.2 JACK POINTS FOR THE 2 AXLE OF A 3-AXLE VEHICLE Read the accompanying documentation before using the jack. To jack up the driven rear axle, place the jack under the indi- cated locations.

  • Page 183: Unconditional Kneeling

    INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Futura FHD2/FMD2 E6 Lifting, jacking up and supporting UNCONDITIONAL KNEELING The vehicle has a switch, which is only intended for the unconditional kneeling function. Always apply the handbrake before turning off the ECAS system. If work must be carried out on a vehicle, the ECAS system can be temporarily turned off to prevent the system from making adjustments whilst the work is carried out.

  • Page 184: Auxiliary Tools For Lifting The Vehicle

    INSTRUCTIONS FOR JACKING UP AND SUPPORTING THE VEHICLE Lifting, jacking up and supporting Futura FHD2/FMD2 E6 AUXILIARY TOOLS FOR LIFTING THE VEHICLE 1.7.1 AUXILIARY TOOLS FOR THE WHEEL LIFTS Place a wheel adaptor on each wheel lift so that if there is a puncture, the wheel rim cannot get between the support bracket.

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