ALIGNMENT

Futura FHD2/FMD2
System manual

1441 DD1265_00
Futura FHD2/FMD2

Foreword
This system book contains safety regulations which must
be strictly observed.
Work which is not described in this system book, such as
revision, is described in the VDL Bus & Coach workshop
instructions or the workshop instructions for the
component concerned.

Experienced mechanics
The technical information and the explanations given in
this system book have been compiled with the utmost
care.

Whilst compiling this system book, 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

DD1265_00
 CONTENTS
Futura FHD2/FMD2

Alignment procedure
Alignment ...................................................... 1-1
0
Introduction ..................................................... 1-1
Safety .............................................................. 1-2
Precautionary measures ................................. 1-3
General alignment instructions ....................... 1-4

DD1265_00
CONTENTS
Futura FHD2/FMD2

Disclaimers

© 1441 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.

DD1265_00
 ALIGNMENT PROCEDURE
Futura FHD2/FMD2

ALIGNMENT PROCEDURE
0

DD1265_00
 ALIGNMENT PROCEDURE
Futura FHD2/FMD2

DD1265_00
 ALIGNMENT PROCEDURE
Futura FHD2/FMD2 Alignment

1. ALIGNMENT
0
1.1 INTRODUCTION

A vehicle must be correctly aligned because the position of

the wheels is largely responsible for road handling and com-
fort. The greater the deviation from the specified values, the
more noticeable it becomes. The position of the wheels is not
only important for road handling and comfort, but also for the
wear of tyres, mounting rubbers and bearings, which wear
extremely quickly and irregularly as a result of incorrect align-
ment. It is important to regularly check the position of the
vehicle's wheels, because the position can change as a
result of wear and the rubbers and bearings settling, or as a
result of unforeseen circumstances, such as hitting a kerb or
driving into a ditch. It may be possible to derive the cause of
excessive tyre wear from:
• The wear pattern of the tyres.
• The vehicle's driving characteristics.

A correctly aligned vehicle also uses less fuel.

DD1265_00 1-1
 ALIGNMENT PROCEDURE
Alignment Futura FHD2/FMD2

1.2 SAFETY
0 Poor alignment has a negative influence on road handling
and may lead to a dangerous situation.

The alignment may only be checked and
corrected by authorized trained mechanics.
Repairs or maintenance work carried out by
unauthorized mechanics may lead to a
dangerous situation and is not covered by
the warranty.

1-2 DD1265_00
 ALIGNMENT PROCEDURE
Futura FHD2/FMD2 Alignment

1.3 PRECAUTIONARY MEASURES

Safety in the workplace

0
The following must be observed to ensure the alignment
work is carried out safely:
1. Only use reliable turning plates.
2. Place the turning plates directly under the wheels.

Do not work under a vehicle while it is
jacked up. Place reliable supports under
a jacked-up vehicle.

DD1265_00 1-3
 ALIGNMENT PROCEDURE
Alignment Futura FHD2/FMD2

1.4 GENERAL ALIGNMENT INSTRUCTIONS

0 1.4.1 GENERAL INFORMATION

1. The floor on which the alignment work takes place must

be level.
2. Drive the vehicle in a straight line to where the alignment
work is to be carried out. If this is not possible, drive the
vehicle back and forth in the location where the align-
ment is to be carried out with the front wheels in the
straight-ahead position so that the wheel mounting
becomes free of tension.
3. During the alignment work, nobody may be in the vehicle
and nobody may carry out work on the vehicle that could
have an influence on the alignment procedure.
4. Check the tyres (the correct dimensions, the weight cat-
egory, the same tyres on one axle, etc.).
5. Check the wear pattern of the tyres.
6. Inflate the tyres to the correct pressure.
7. Turn off the ECAS system using the ECAS switch in the
electrical box.

ECAS

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 being carried out. The
switch is located in the fuse box in the driver's sleeping com-
partment.

Always apply the handbrake before turning off the

ECAS system.

Turn the ECAS system back on after completing the

work on the vehicle.

1-4 DD1265_00
 ALIGNMENT PROCEDURE
Futura FHD2/FMD2 Alignment

1.4.2 INSPECTIONS BEFORE STARTING THE

ALIGNMENT WORK 0
1. Check the axle mounting for play.
2. Check the attachment of the wheels.
3. Check the wheel bearing play of the front wheels.
4. Check the steering mechanism for play.
5. Check the adjustment of the pneumatic suspension.

If an irregularity or fault is observed as a
result of the above inspections, it must
be rectified before starting the alignment
work.

1.4.3 ALIGNMENT

1. Only use reliable alignment equipment.

2. Make sure the alignment equipment has been calibrated
correctly.
3. Fit the alignment equipment.
4. Observe the guidelines applicable to the alignment
equipment. If necessary, see the instruction manual pro-
vided with the alignment equipment.

DD1265_00 1-5
 ALIGNMENT PROCEDURE
Alignment Futura FHD2/FMD2

1.4.4 EXPLANATION OF ALIGNMENT TERMINOLOGY

0
A - + + - B
- +

C D E
- +

M10516

A Toe-in/out
B Camber
C Kingpin inclination (KPI)
D Caster
E Wheel rotation
F Set back
G Tilt angle

Toe-in/out
Toe is the pulling inwards or pushing outwards of the front
wheels. If the wheels point inwards, it is called +toe (or toe-
in). If the wheels point outwards, it is called -toe (or toe-out).
Most vehicles have slight +toe to compensate for the rotation
of the steering mechanism and the mounting when the vehi-
cle starts to roll forwards.

Camber
Camber is the tilting inwards or outwards of the wheel as
viewed from the front of the vehicle. This is a tyre wear angle.
Excessive positive camber causes wear to the outside of the
tyre. Excessive negative camber causes wear to the inside of
the tyre.

1-6 DD1265_00
 ALIGNMENT PROCEDURE
Futura FHD2/FMD2 Alignment

Kingpin inclination (KPI)

Kingpin inclination (KPI) is the angle that is formed by the
axis of rotation of the front wheel mounting in relation to a
0
vertical angle through the centre of the axle stub. This
ensures that the wheels return to the straight-ahead position
after steering. It is not adjustable. If the KPI is not correct, it
requires the replacement of the worn or damaged wheel
mounting components to rectify it.

Caster
The caster is the backwards or forwards tilting of the axle
stub as viewed from the side of the vehicle. Excessive posi-
tive caster results in good stability of the driving direction, but
requires a strong steering force to steer the vehicle away
from the straight-ahead position. Excessive negative caster
makes steering very easy, but results in excessive "search-
ing" of the wheels.

Wheel rotation
Wheel rotation in the maximum rotation to the left and right of
the wheels of the steered axle and must be set so that the
wheels do not touch the mounting.

Set back
Set back is when one of the front wheels is positioned further
backwards than the other wheel. A set back of less than 10
mm is seen as a normal tolerance by some vehicle manufac-
turers. If the set back is greater, something may be bent.

Tilt angle
The tilt angle is the direction in which the rear wheels point in
relation to the vehicle's centre line. If this angle is not "0", the
vehicle pulls and the steering wheel is not in the straight-
ahead position.

DD1265_00 1-7
 ALIGNMENT PROCEDURE
Alignment Futura FHD2/FMD2

1.4.5 WEAR PATTERNS AND POSSIBLE CAUSES

0 Incorrect camber

A B
+ - - + + - - +

M10517

If the camber is too positive (A), the tyre's tread will wear on
the outside. If the camber is too negative (B), the tyre's tread
will wear on the inside. To adjust the camber, shims must be
added to or removed from the correct position (C).

Only the camber of the front axle of the
Futura FHD2/FMD2 can be adjusted. If the
camber of the trailing axle and/or the rear
axle is incorrect, something is worn or
damaged.

Incorrect toe

A C

- + + -

- + + -

M10518

An incorrect toe-in results in both tyres wearing quickly simul-

taneously. This type of tyre wear is called the sawtooth wear
pattern, as shown in the diagram. If the sharp edges of the
tread pattern point towards the middle of the vehicle, there is
too much toe-in (A). If the sharp edges of the tread pattern

1-8 DD1265_00
 ALIGNMENT PROCEDURE
Futura FHD2/FMD2 Alignment

point towards the outside of the vehicle, there is too much

toe-out (B). Adjust the track rod (C) to change the toe. 0

Only the toe of the front axle and the
trailing axle can be adjusted.

Incorrect tilt angle

A B

M10519

An incorrect tilt angle causes tyre wear on the inside of one

tyre and the outside of the other tyre of the rear axle. Add
shims to or remove shims from the torque rod (B) to correct
the tilt angle.

DD1265_00 1-9
 ALIGNMENT PROCEDURE
Alignment Futura FHD2/FMD2

1.4.6 ROAD HANDLING

0

M10520

1. The vehicle pulls to the left or the right.

Cause:
The rear axle is not positioned straight under the vehicle and
the front and the rear wheels are not aligned with each other.

M10521

2. The vehicle pulls to the left or right when pulling away.

Cause:
• The rear axle does not follow the centre line of the vehicle.
• Unequal tyre wear.
• Unequal tyre pressure.
• Punctured front tyre.
• Damaged wheel rim.

1 - 10 DD1265_00
 ALIGNMENT PROCEDURE
Futura FHD2/FMD2 Alignment

1.4.7 ALIGNMENT INFORMATION

0
Axle type Toe-in Camber KPI Caster Inner wheel H mm H mm H mm
mm/m rotation Front axle Rear axle Trailing
axle
(a) (b) (c) (e)
Front axle 0 - 2 mm 10’ - 30’ 7°30’ 2°23’ - 2°53’ 58° 290
Driven axle (d) 0° 290
Trailing axle 0 - 2 mm 0° ± 0.5° 8° ± 40’ 0° ± 0.5° 15°
a: Use shims to adjust the toe of the driven axle (1 mm shim = approx. 1mm/m).
b: Use shims to adjust the camber (1 mm shim = approx. 9’).
c: Use shims to adjust the caster (1 mm shim = approx. 8’).
d: Tilt 1 to 2 mm.m, maximum 5 mm from the middle.
e: Pneumatic suspension adjustment, measure the height between the top and bottom plates of the air
bellows.

1.4.8 ALIGNMENT ORDER

General information
1. Check the rear axle's tilt angle and check whether the
rear axle is in the middle. If necessary, adjust it.
2. Check and, if necessary, adjust the trailing axle's caster.
3. Check and, if necessary, adjust the trailing axle's toe.
4. Check and, if necessary, adjust the front axle's caster.
5. Check and, if necessary, adjust the front axle's camber.
6. Check and, if necessary, adjust the front axle's toe.
7. Adjust the play of the blocking cylinders after the trailing
axle's wheels have been put in the straight-ahead posi-
tion.
8. Check and, if necessary, adjust the trailing axle's maxi-
mum wheel turning angle.

DD1265_00 1 - 11
 ALIGNMENT PROCEDURE
Alignment Futura FHD2/FMD2

Adjusting the rear axle tilt angle

0
A B

M10519

Add shims to or remove shims from the track rod (B) to cor-
rect the tilt angle.

Rear axle middle position

A B

M10522

The rear axle usually automatically gets placed in the correct

position after the tilt angle has been corrected. Add shims to
or remove shims from the track rod (B) to correct the middle
position.

The KPI and caster of the rear axle cannot
be adjusted because the rear axle is rigid.

1 - 12 DD1265_00
 ALIGNMENT PROCEDURE
Futura FHD2/FMD2 Alignment

Trailing axle caster

0

Turn off the main switch and the contact
switch so that the blocking cylinders are
aerated, which causes the wheels to be
pushed into the straight-ahead position.

Place shims between the top torque rod (1) and the axle
beam.

It is important that the same number of
shims are added to the left and the right.

Trailing axle toe

2
1
M10523

Turn off the main switch so that the
blocking cylinders are aerated and the
wheels can rotate freely.

Make sure the blocking cylinders can
move freely. If they cannot move freely,
there is a chance the blocking cylinder's
piston rod is bent.

DD1265_00 1 - 13
 ALIGNMENT PROCEDURE
Alignment Futura FHD2/FMD2

Unscrew the clamping bolt (1) so that the track rod can be
0 adjusted with the bush (2).

Make sure the ball joint’s threaded end is
not screwed too far out of the track rod.
The clamping bracket must always fully
engage the ball joint’s screw thread.

The KPI and caster of the trailing axle
cannot be adjusted because the trailing
axle is rigid.

Front axle caster

- +

B
A
D
C
M10525

Add or remove shims diagonally from each other (A/D or C/

B) to adjust the caster.

Front axle camber

- +

M10526

Add or remove shims to adjust the camber.

1 - 14 DD1265_00
 ALIGNMENT PROCEDURE
Futura FHD2/FMD2 Alignment

Front axle toe

0
A C

- + + -

- + + -

M10518

Adjust the track rod to change the toe.

Blocking cylinder play

A B CDE F G H J

M10509

A Fork
B Hose clip
C Lock nut
D Dust cover
E Hose clip
F Piston rod (pitch = 1.5 mm/rev.)
G Internal stop
H Piston
I Piston rod stop

1. Undo the hose clips (B and E) of the dust covers (D) and
slide the dust covers out of the way for both cylinders.
2. Loosen the lock nuts (C) of the forks (A) and screw the
piston rods (F) as far as possible into the forks (A).
3. Turn off the main switch and the contact switch. The
blocking cylinders will be aerated. As a result, the pistons
(H) are pushed outwards against the internal stop (G)
(blocking position).
DD1265_00 1 - 15
 ALIGNMENT PROCEDURE
Alignment Futura FHD2/FMD2

F
M10527

4. Rotate the left-hand blocking cylinder's piston rod (F) so

that the trailing axle's wheel is parallel to the wheel on the
driven axle.
5. Whilst taking the measurement, push the front (K) of the
left-hand trailing axle wheel until its touches the internal
stop.
The piston rod (F) of the left-hand cylinder will touch the
left-hand piston rod stop (J).
There is play between the piston rod (F) of the right-hand
cylinder and the right-hand piston rod stop (J).

K K

M10528

6. Press the front (K) of the right-hand trailing axle wheel

against the piston rod stop (J).
7. Determine the toe-in (L).

1 - 16 DD1265_00
 ALIGNMENT PROCEDURE
Futura FHD2/FMD2 Alignment

L L 0

F J

M10529

8. Rotate the piston rod (F) of the left-hand blocking cylin-

der so that the toe-in (L) is the same on both sides.
9. Rotate the piston rod of the right-hand blocking cylinder
so that the piston rod touches the stop (J).
10. The wheels must now not have any play.
11. Tighten the lock nuts (C) to the correct torque (100 ± 10
Nm).
12. Refit the dust covers (D).

Trailing axle wheel turning angle

1. Turn off the main switch and the contact switch so that
the blocking cylinders are aerated, which causes the
wheels to be pushed into the straight-ahead position.

2. Turn on the main switch so that the blocking cylinders are

bled and the wheels can rotate freely.
3. Adjust the wheel turning angle by screwing the stop bolt
in or out.
4. After finishing the adjustment, check that the tyres do not
come into contact with other components.
5. Lock the stop bolts.

DD1265_00 1 - 17
 ALIGNMENT PROCEDURE
Alignment Futura FHD2/FMD2

1 - 18 DD1265_00