VDL Futura FHD2 E6 Instruction manual

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

Futura FHD2/FMD2 E6
DD1020_01
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 andwork instructions. Italso contains
safety regulations, which must be strictly observed.
Experienced mechanics
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 that the mechanic has the necessary
experience and has had the required education or
training to be able to carry out the work in a responsible
and safe manner.
Vehicle type.
The information in this manual has been updated until
the time of printing and only concerns the following
vehicle series:
Futura FHD2/FMD2 E6
In this manual, this series of vehicles is referred to as:
"Futura FHD2/FMD2 E6".

Futura FHD2/FMD2 E6 CONTENTS
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General information
General information...................................... 1-1
Threaded connections .................................... 1-1
Locking compounds and sealants................... 1-7
Conversion tables ......................................... 1-12
Safety regulations
General information...................................... 1-1
Warning symbols ............................................ 1-1
General safety regulations.............................. 1-2
Safety regulations when carrying out work..... 1-3
Liquid, lubricant and gas safety regulations.... 1-6
Safety regulations when jump starting............ 1-9
Avoiding the risk of fire.................................. 1-11
Safety regulations for welding work.............. 1-12
After a collision.............................................. 1-14
Wiring harnesses.......................................... 1-15
Calibrating the tachograph............................ 1-16
Xenon lighting............................................... 1-17
Diagnosis
Vehicle behaviour and performance........... 1-1
Introduction..................................................... 1-1
Starting behaviour........................................... 1-2
Gear changing behaviour of a manual gearbox .1-4
Abnormal tyre wear......................................... 1-7
Operation/warning/indication functions......... 1-14
Consumption................................................. 1-15
Exhaust smoke ............................................. 1-18
Pulling force.................................................. 1-19
Vibrations and abnormal noises.................... 1-21
Systems......................................................... 2-1
Introduction..................................................... 2-1
CAN network................................................... 2-2
Clutch.............................................................. 2-7
Cooling system ............................................. 2-10
Lubrication system........................................ 2-12
Intake and exhaust systems ......................... 2-13
Fuel system................................................... 2-15
Vehicle lighting.............................................. 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
General information ......................................1-1
Technical documentation.................................1-1
Technical information ......................................1-2
Environment ....................................................1-3
Cleanliness instructions...................................1-5
High-pressure hose.........................................1-6
Tools................................................................1-7
Work on the engine .........................................1-8
Guidelines for a test drive and visual inspection.1-9
Components...................................................2-1
General information.........................................2-1
Plastic lines......................................................2-2
Gaskets ...........................................................2-5
Oil seals...........................................................2-6
Bearings ..........................................................2-8
Liquid and lubricant guidelines
General guidelines ........................................1-1
General information.........................................1-1
Alternative fuels...............................................1-1
Biodiesel..........................................................1-2
Pure plant oil (PPO).........................................1-4
City diesel........................................................1-4
AdBlue.............................................................1-5
Cleaning instructions
General information ......................................1-1
Cleaning the vehicle........................................1-2
Cleaning the engine.........................................1-4
Cleaning the gearbox ......................................1-5
Cleaning the interior of the vehicle ..................1-6
Cleaning parts of the vehicle contaminated by
liquids ..............................................................1-7
Storage and preservation
Points of attention.........................................1-1
Storage............................................................1-1
Preparing for use.............................................1-3
Paint treatment
Paint treatment ..............................................1-1
General instructions.........................................1-1
Respraying/repairing conventional paint
systems ...........................................................1-3
Repairing the layer of zinc...............................1-5
Anticorrosion/antichip coating ....................2-1
Anticorrosion coating.......................................2-1
Antichip coating ...............................................2-2
Sealant seams.................................................2-4

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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.................................. 1-13
Auxiliary tools for lifting the vehicle............... 1-14

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Futura FHD2/FMD2 E6
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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
published by printing, by photocopying, in digital format
or in any way whatsoever without the prior consent in
writing of VDL Bus & Coach.
This manual shall 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 remark is relevant if the text has been translated for
your convenience from the English original into an other
language.
A translation, however, can have the consequence that
differences of interpretation arise with respect to the
content and meaning of the text.
In all cases, therefore, the English version of this
document will be regarded exclusively as the single and
authentic source to establish the content and the
meaning of the text in case of a dispute.

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Futura FHD2/FMD2 E6 GENERAL INFORMATION
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GENERAL INFORMATION

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1. GENERAL INFORMATION
1.1 THREADED CONNECTIONS
1.1.1 DIPPED THREADED CONNECTIONS
The threaded connections on VDL Bus & Coach vehicles
have been treated with a lubricant (dipped threaded connec-
tions). During manufacture, a wax dip is applied to galva-
nized nuts and bolts.
Black annealed and phosphated nuts and bolts are oil-
dipped. The advantage of using a lubricant is that the friction
created when tightening the threaded connections is
reduced, so that the specified pretension can be more accu-
rately and more easily obtained. The tightening torque can
be reduced for the same pretension.
1.1.2 TORQUE
To achieve a small tolerance range for the pretension, it is
necessary for the tightening torques of the dipped threaded
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 applies to all threaded connections (for both
new and used vehicles):
• Standard connection: apply lubricant when fitting and
tighten/retighten according to the standard for dipped bolts.
• Special connection: apply lubricant when fitting and
tighten/retighten to the torque specified in the instructions.
• 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.
Have torque spanners regularly checked
and calibrated.
Not observing the instructions given
below may result in the bolt connections
coming loose. This can cause damage to
the vehicle and lead to a dangerous
situation.

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• Flange nuts and flange bolts of strength classes 10.9 and
10.
• Flange nuts and flange bolts of strength classes 12.9 and
12.
• 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
specified torque followed by an additional rotation. The addi-
tional rotation depends on the length of the bolt. See “Tight-
ening torques” for the tightening torque and the appropriate
additional rotation.
If one of these 10.9/10 threaded connections must be tight-
ened to a different tightening torque, then this will be stated
in the technical information for the component concerned.
1.1.5 OTHER THREADED CONNECTIONS
The 8.8/8 and 12.9/12 threaded connections and the 12.9/12
clamping flange bolt 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 tightening torque, then this will be stated in the tech-
nical information for the component concerned.
1.1.6 REUSING FIXINGS (NUTS/BOLTS/THREADED
ENDS)
To obtain the correct pretension when reusing a threaded
connection, the following procedure must be followed:
1. Clean the thread (take particular care to remove any
locking compound residue) and the fitting faces.
2. Check the thread for damage.
To do so, screw on a new nut/bolt by hand.
If the new nut/bolt cannot be screwed along the entire
length of the thread that is being checked, then the fixing
may no longer be reused.
3. Apply one drop of engine oil to the firstwinding of the bolt
(threaded end)/bottom winding of the nut andone drop to
the fitting faces.
Not observing the instructions given
below may result in the bolt connections
coming loose. This can cause damage to
the vehicle and lead to a dangerous
situation.

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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.
4. If a locking compound is specified, no oil should be
applied to the thread. See “Locking compounds and seal-
ants” for instructions on how to apply a locking com-
pound.
5. Tighten the connection to the specified torque.
1.1.7 NEW NUTS/BOLTS
If bolts 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 of engine oil to the first winding of the
bolt/bottom winding of the nut and one drop to the fitting
faces.
Comment
Only engine oil may be used as the lubricant to be
applied. 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.
2. If a locking compound is specified, no oil should be
applied to the thread. See “Locking compounds and seal-
ants” for instructions on how to apply a locking com-
pound.
3. Tighten the connection to the specified torque.

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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.
The quality is stamped on the nut or bolt, except on the
clamping flange bolt.
The clamping flange bolt can be recognized by a groove
between the hexagonal bolt head and the flange. Standard
flange bolts do not have this groove.
Overview of the standard tightening 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, all the
bolts must first be tightened to the specified torque and then
tightened further by the additional rotation.
Clamping flange bolt Standard flange bolt
Thread indication Tightening torque (Nm) Additional rotation (approx. 10%) for bolt length L
(mm)
L 40 41-80 81-130 131-180
M8 x 1.25 30 ± 2 30° 60° 90° 120°
M9 x 1.25 35 ± 3 30° 60° 90° 120°
M10 x 1.5 60 ± 4 45° 90° 120° 150°
M12 x 1.75
M12 x 1.25 110 ± 8 110 ± 8 30° 45° 60° 90° 90° 120° 120° 150°
M14 x 2
M14 x 1.25 170 ± 15 170 ± 15 30° 45° 60° 90° 90° 120° 120° 150°
M16 x 2
M16 x 1.5 260 ± 20 260 ± 20 30° 45° 60° 90° 90° 120° 120° 150°
M18 x 2.5
M18 x 1.5 360 ± 30 360 ± 30 30° 45° 60° 90° 90° 120° 120° 150°
M20 x 2.5
M20 x 1.5 520 ± 40 520 ± 40 30° 45° 60° 90° 90° 120° 120° 150°
M22 x 1.5 700 ± 50 45° 90° 120° 150°

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Overview of standard tightening torques for fixings of
strength class 8.8/8
Overview of standard tightening torques for fixings of
strength class 12.9/12
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 ± 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 2.5 298 ± 21
M20 x 1.5 440 ± 30
M22 x 2.5 540 ± 40
M22 x 1.5 590 ± 40
M24 x 3 680 ± 50
M24 x 2 740 ± 50
M27 x 3 1,000 ± 70
M27 x 2 1,100 ± 70
M30 x 3.5 1,350 ± 100
Thread indication Tightening torque (Nm)
M8 32 ± 3
M10 67 ± 5
M12 113 ± 9
M14 178 ± 14
M16 274 ± 22
M18 385 ± 30
M20 550 ± 43
M22 740 ± 60
M24 925 ± 72
M27 1,370 ± 110

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Overview of the standard tightening torques for clamp-
ing flange nuts and bolts of strength class 12.9/12
Overview of the tightening torques for banjo bolts
Overviewof the tighteningtorquesfor clampingring 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 1.5 425 ± 35
M18 x 1.5 550 ± 45
M18 x 2.5 500 ± 45
Thread indication Tightening torque (Nm)
M6 8 ± 0.8
M8 15 ± 1.5
M10 30 ± 3
M12 40 ± 4
M14 50 ± 5
M16 60 ± 6
M18 70 ± 7
Air line diameter Tightening torque (Nm)
8 mm 15
10 mm 25

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1.2 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.
SUMMARY OF LOCKING COMPOUNDS
Product name Properties Use Article number
Loctite 243 Locks with an 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-
nections, such as pinion
nuts.
41279841
Loctite 638 Locks with a high breaking
strength under a dynamic
load.
Difficult to unlock.
For locking cylindrical con-
nections. 40645557
Loctite 648 Locks with an average
breaking strength.
Withstands high tempera-
tures.
For locking threaded con-
nections in warm locations. 41436842
Loctite 2701 Locks with a high breaking
strength.
Restores the fit in bearing
houses.
Seals to prevent leaks.
Difficult to unlock.
For locking threaded con-
nections, gear lever ball
joints and expansion plugs.
41340646

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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.
2. Depending on the diameter, apply one or more drops of
locking compound to the thread. Never dip the bolt or
stud into the locking compound.
3. Apply a drop of oil under the bolt head. Locking com-
pounds also reduce the frictional resistance, so that no
oil has to be applied to the thread.
4. Tighten the connection to the specified torque.
1.2.2 SEALANTS
Certain cleaning agents have a negative
effect 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 withacleaning liquid toensure
that the sealant functions correctly.
OVERVIEW OF SEALANTS
Product name Properties Use Article number
Dirko D Withstands temperatures
up to 180° C.
Resistant to oil and cool-
ant.
For sealing flush connec-
tions. 41345014
Dow Corning 752 Withstands temperatures
of -55° C to 220° C.
Processing time of less
than 15 minutes.
Maximum drying time of 24
hours.
Minimum sealing bead
thickness of 4 mm.
Silicon sealant for sealing
floor panels (feed-through
connectors, etc.).
40693628
Loctite 510 Withstands temperatures
up to 200° C.
Resistant to oil, brake fluid
and coolant.
For sealing flush (flange)
connections that are sub-
jected to high operating
temperatures, such as the
flywheel housing.
40697149
Loctite 518 Withstands temperatures
up to 150° C. For sealing differential and axle beam contact sur-
faces.
41357034

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Loctite 542 Seals small pipe thread fit-
tings of line systems.
Contains nothing that can
cause blockages in filters
or valves.
Maximum play of 0.25 mm.
Specially suitable for seal-
ing hydraulic and pneu-
matic fittings.
40697166
Loctite 572 Seals against low pres-
sures immediately after fit-
ting.
Threaded connections 40292336
Loctite 574 Resistanttohighpressures
(up to 120 bar).
Resistant to oil, brake fluid
and coolant.
For sealing flush connec-
tions against high pres-
sures.
41246867
Loctite 5205 Surface sealant specially
intended for sealing alu-
minium components.
Withstands temperatures
up to 150° C.
Resistant 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 front and
rear covers of gearboxes,
the differential housing,
hub caps, axle shaft
flanges and the oil cooler.
41663011
Loctite Blue Withstands temperatures
of 60° C to 260° C.
Resistant to oil.
For sealing flexible con-
structions, such as (cylin-
der head) covers.
41242895
Loctite From a gasket Hardens on contact with
metalandwhencompletely
sealed.
For locking, securing and
sealing. 41322823
Loctite Ultra Copper Silicon sealant, resistant to
oil.
Withstands temperatures
up to 350° C.
For sealing flush connec-
tions, such as hub caps. 41284122
Loctite Ultra Grey Silicon sealant, resistant to
coolant.
Withstands temperatures
up to 350° C.
For sealing (flush) connec-
tions in the cooling system. 41284123

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1.2.3 OTHER PRODUCTS
OVERVIEW OF SEALANTS
Product name Properties Use Article number
Contact spray Cleaning product for clean-
ing and degreasing elec-
tronic and electrical
connections. Dispels mois-
ture and dirt from electrical
contacts.
Cleaning electrical contact
points. 41387608
Copaslip Copper paste with excel-
lentbondingpropertiesthat
inhibits corrosion and with-
stands temperatures from
35° C to 1,100° C.
Resistant to water, salts
and acids.
Prevents wear, oxidation,
rust, corrosion and the sei-
zure of metal surfaces.
For connections sensitive
to oxidation or corrosion,
such as battery terminals,
exhaust connections, etc.
41284344
Gleitmo 805 Protects 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 time of 12
hours.
Fast-setting glue for gluing
the rubber profile of a fixed
window in a door.
41246863
Loctite 7063 Cleans and degreases.
Highly inflammable.
Non-corrosive.
For cleaning/degreasing
materials that must be fit-
ted with a locking com-
pound.
41322827
Loctite 7200 Gasket remover. For removing gaskets/gas-
ket residue. 41450211
Loctite 7649 Locking glue activator. For installing the wheel
speed sensor bus. 41680227
Molykote Longterm 2
PLUS Lubricating grease, with- stands temperatures from -
30° C to +130° C.
Everywhere where lubrica-
tion grease is suitable and
usual.
Foralmostallballbearings,
roller bearings, friction
bearings, guides, spline-
shaft connections,
threadedspindlesandgear
drives with a low rotational
speed.
41396271

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Molykote P37 Lubrication grease pre-
vents corrosion which is
resistant to temperatures
up to 1,400° C.
For threaded connections
that are subjected to high
temperatures, such as for
exhaust systems.
41391619
Molykote PG21 Lubricationgreasewhichis
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
mechanism. 41448907
Staburags NBU 30 PTM Lubricationgreasewhichis
water resistant and pre-
vents corrosion.
Wheel speed sensors. 41677646
Syntheso GL EP1 Lubrication grease (green). Disc brake rubber guides. 41448908
Tectyl Protects hollow spaces
against corrosion. Can be used to protect metal objects. 41343888

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1.3 CONVERSION TABLES
Consumption
Specific use
Speed
Temperature
Weight units
(1) US + UK
km / l 1 / 100 km miles/gallon
(Imp) miles/gallon (US)
n 100/n n x 2.2825 n x 2.352
100/n n 282.5/n 235.2/n
n x 0.354 282.485/n n n x 0.83
n x 0.425 235.294/n n x 1.202 n
km / l 1 / 100 km miles/gallon
(Imp) miles/gallon (US)
n 100/n n x 2.2825 n x 2.352
100/n n 282.5/n 235.2/n
n x 0.354 282.485/n n n x 0.83
n x 0.425 235.294/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
noCelsius = 9/5 n + 32 oF = 4/5 noR= n + 273.15 K
noFahrenheit = 5/9 (n - 32) oC = 4/9 (n -32)oR= 5/9 (n - 32) + 273.15 K
noRéaumur = 5/4 n oC = 9/4 n + 32 oF = 5/4n + 273.15 K
noKelvin = n - 273.15 °C = 9/5 (n - 273.15) = 32 °F = 4/5 (n - 273.15) °R
kg ounces pounds (lbs) short tons (1) long tons (1) ton (metr.)
1 35.27 2.205 0.001102 0.0009842 0.001
0.02835 1 0.0625 0.00003125 0.0000279 0.00002835
0.4536 16 1 0.0005 0.0004464 0.0004536
907.2 32000 2000 1 0.8929 0.9072
1016 35840 2240 1.12 1 1.016
1000 35274 2205 1.102 0.9842 1