VDL Futura FHD2 E6, Workshop Manual

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Futura FHD2/FMD2 E6
REPAIR GUIDELINES
Components
2 - 2
3
DD1020_01
2.2 PLASTIC LINES
Removing nipples or banjo unions from polyamide lines
1. Heat the line to remove the nipple or banjo union. Never
remove the nipple or banjo union by making an incision
along the length of the line, because this could easily
damage the line adaptor. Even minor damage to the
hose adaptor will cause a leak.
Fitting nipples or banjo unions to polyamide lines
1. Do not fit nipples or banjo unions to the same end of a
line more than once, because this could result in a poor
seal.
2. Cut off the bit of the line that has been used before. If
shortening the line means that it now makes a sharp
curve or it becomes too short, a new line must be fitted.
3. Always use a special pair of pliers (VDL Bus & Coach no.
40694829) to fit nipples and banjo unions in polyamide
lines.
4. Clamp the plastic line in the special tool (1).
5. Use a plastic mallet to tap the nipple or banjo union into the
line.
Leaking lines
To avoid dangerous situations, a leaking fuel or air line must
be repaired as soon as possible.
A leaking fuel line may constitute a fire hazard, while a leak-
ing air line may affect the vehicle’s braking performance.
In the event of a leak from a line coupling, it is not permitted
to continue tightening the cap nut or the banjo bolt.
• First check whether the leak is at the connection between
the line and coupling or at the connection between the cou-
pling and the component housing.
• Tighten banjo bolts to the specified torque.
• A cap nut may only be tightened a further half turn (180°)
once. Tightening a cap nut further than this is possible, but
may cause excessive deformation of the thrust washer and
the line, which will seriously weaken the line.
• If the leak has not stopped after the cap nut has been tight-
ened, it will be necessary to take the coupling apart.
• Check the parts for contamination and/or damage. One
scratch along the length of the line adaptor for a nipple or
a banjo union may be sufficient to cause a leak.
• In the case of a banjo bolt connection, check the sealing
surfaces. Reconnect using new sealing rings. Tighten the
banjo bolts to the specified torque.
ILAk0023
Never heat a plastic line when fitting
nipples or banjo unions.