Issuu

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The trade magazine for servicing and repair professionals

COMMERCIAL

VEHICLE WORKSHOP APRIL 2020

TECHNICAL SUPPLEMENT Specialist advice from the biggest aftermarket suppliers tailored exclusively for workshops

Also in this issue… The importance of preventing diesel spills ■ Debunking the most common DVSA myths ■ Why proper and regular handwashing is key ■

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CONTENTS

Volume 17

Issue 4

REGULARS 5

Viewpoint

71 What’s New?

News

73 MECHANEX Monthly

13 Tech Tips 14 Business & Training

SPECIAL REPORT 17 Highways England guidance on preventing diesel spills

CV SHOW PREVIEW 19-33 Your guide to the UK’s largest road transport and commercial vehicle exhibition

LIGHT COMMERCIAL VEHICLES 35 What is brake judder and how can it be avoided? 36 Correcting an emission fault on a Mercedes Sprinter 39 How to upgrade outdated halogen bulbs 40 Trakm8’s telematics solution for LCV fleets

COMPLIANCE 43 One company reveals the results of switching to TruTac 44 DVSA debunks roadside enforcement myths

46 Four questions to help you find the right tachograph download system 48 Guidance on the changes to Regulation 48

TECHNICAL SUPPLEMENT 51 Simplifying commonly-occurring clutch faults 55 What to do when the whole caliper needs replacement 56 Breathe new life into your workshop battery processes 59 How to efficiently treat a Ford Transit turbo 60 Tips to help diagnose Knorr-Bremse’s trailer EBS 63 Why batteries need support during vehicle diagnostic work 64 The process of diagnosing a misfire fault on a Scania R480 66 Common myths associated with filters

69 When to replace the receiver dryer

COMPETITIONS 70 Giveaways APRIL 2020 CVW 3

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VIEWPOINT

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UNPRECEDENTED TIMES

Editor CIAN BRITTLE Editorial Assistant LAURA GUALDI Consulting Editor SHARON CLANCY

Digital Manager KELLY NEWSTEAD Account Manager ALEX DILLEIGH Group Manager ROBERT GILHAM Graphic Designer GEMMA WATSON Group Production Manager CAROL PADGETT Publisher BRYAN SHANNON Subscriptions Commercial Vehicle Workshop is a business magazine for companies and individuals involved in all aspects of commercial vehicle servicing. It is published 11 times a year and is available on free subscription to qualified readers. Subscription rates: UK £30 To be removed from this magazine’s circulation, please call 01923 237799 or email circulation@hamerville.co.uk. Printed by Walstead Peterborough Published by HAMERVILLE MEDIA GROUP Regal House, Regal Way, Watford, Herts WD24 4YF Tel: (01923) 237799 Website: www.hamerville.co.uk Copyright © 2020

hen I first sat down to write this month’s Viewpoint, I considered avoiding the matter of Covid-19 entirely. Cases are increasing exponentially across the country, to the point that anything I write could be outdated by tomorrow, let alone when this magazine is published in a few weeks’ time. It’s 13th March 2020 at the time of writing, and the Government has given some loose guidance to the public, but we are still waiting for concrete advice to follow in order to mitigate the effects of this virus. It’s easy to look back to the Swine Flu of 2009, but there is little else in the way of comparison for the European population: these are unprecedented times. We don’t know what the full ramifications of the Coronavirus will be, but there’s little use in speculating potential outcomes. All we can do is follow the facts as they are presented to us. As employers, you have a duty of care towards your employees in the face of this virus. Emergency legislation has been put in place that requires statutory sick pay (SSP) to be paid to anyone self-isolating in order to prevent the infection or spread of the virus. It has also been announced that employers will be able to recover SSP payments for Coronavirus from the Government – however, this will only apply to employers with fewer than 250 employees and only for a maximum of 14 days’ worth of SSP payments. Self-isolating is crucial to prevent this virus spiralling out of control. If you are suffering with symptoms, there is an online Coronavirus service at 111.nhs.uk that you can contact. Self-isolating is solely for the benefit of those that are most vulnerable in our society, and the 14-day period allows a full recovery without putting anyone else at risk. It’s important not to panic, however, as you need only look at China to see how this should play out if we follow professional advice. As of the beginning of March, cases are finally decreasing in the country due to the containment measures enforced across the country. China’s leader, Xi Jinping, even paid a visit to Wuhan, the city where it all started. It will be an arduous process, but there is a light at the end of this tunnel. On a CVW-specific note, Coronavirus has caused plenty of uncertainty around the CV Show. As you will have seen from the Contents page, we have a dedicated preview for the show – pages 19-33 – running this month. At the time of signing off this month’s issue, there have been no communications from the organisers of the CV Show to suggest any cancellation or postponement. Whilst this may have changed by the time the magazine is available, we will have up-to-date information on the CVW website – www.cvwmagazine.co.uk – to keep you abreast of the latest news.

Cian B rittle Editor

10,066 From 1 July 2018 to 30 June 2019

Associate member

The publishers and editor do not necessarily agree with the views expressed by contributors, nor do they accept responsibility for any errors of translation in the subject matter in this publication

APRIL 2020 CVW 5

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NEWS Volkswagen Commercial Vehicles rolls out AR headsets

©OceanProd/AdobeStock

DfT holding back carbon benefit of longer semi-trailers, says FTA The government should make use of longer semi-trailers (LSTs) a permanent fixture on the UK’s roads following the successful outcome of its trial, according to FTA. The Department for Transport (DfT) funded study demonstrates that use of these vehicles continues to have a significant impact on the reduction of carbon emissions and road congestion across the UK; they have also been found to be safe for both the driver and other road users. DfT has been running a trial of the operation of LSTs on roads for the past seven years. Over this period, use of LSTs resulted in 365,000 fewer journeys taking place. This reduction in mileage has led to the saving of 37,000 tonnes of CO2 and 187 tonnes of NOx. Additionally, LSTs had 55% fewer collisions compared to the HGV average.

Phil Lloyd, Head of Engineering & Vehicle Standards Policy at FTA, comments: “Failure to make LSTs permanent is holding back an opportunity to significantly reduce carbon emissions. After all, the benefits LSTs provide to both the environment and the economy have been made evident in the Government’s study. “The UK’s roads are congested and carbon emissions from road transport remain too high; with LSTs able to carry more goods per journey than traditional HGVs, they present an efficient and environmentally-prudent method of freight transportation. “The quantity of freight that needs to be moved is relatively fixed – if we can move the same amount with fewer journeys, the better for the environment, the economy, and other road users.”

UK new van market declines in February The UK new light commercial vehicle (LCV) market fell -2.0% in the second month of the year, after two successive months of growth, according to the latest figures released by the Society of Motor Manufacturers and Traders (SMMT). February, typically one of the year’s smallest months as many operators wait for the new March number plate, saw 14,103 new units registered. Pickups and small vans weighing less than two tonnes experienced double-digit declines, with registrations down -10.1% and -11.1% respectively. Mid-size vans weighing between two and two-and-a-half tonnes, however, bucked the trend, with demand growing 9.3%. Larger vans

©ellisia/AdobeStock

weighing more than two-and-a-half tonnes made up the bulk of registrations, but were down -2.8%, with 9,082 units registered. Year-to-date, however, the overall market remains ahead by 2.8% on the same period in 2019, bolstered by a strong January when almost 24,000 new models hit UK roads.

Volkswagen Commercial Vehicles is rolling out augmented reality (AR) headsets for technicians across its Van Centre network to help speed up complex repair work with the potential to save customers five years of downtime – equal to £1million. The innovative system allows experts based at the Technical Support Centre (TSC) to send precise visual instructions remotely to technicians at Van Centres and Mobile Service Clinics to ensure any maintenance issues can be fixed as quickly and efficiently as possible, minimising the time a van spends off the road.

“It saved customers a year of downtime, equal to almost £250,000, with repair efficiency up by 93%.” The nationwide rollout follows a successful trial that saved customers a year of downtime, equal to almost £250,000, with repair efficiency up by 93%. Not having to physically travel also meant a reduction of over 2.5 tonnes of CO2 for the TSC. Each of the 67 Van Centres and 30 Authorised Repairers across the UK will have access to a pair of the RealWear glasses, which includes microphone, head camera, display screen, and voice activation.

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NEWS ATIEL changes quality process in response to VLS investigation

Scania introduces side detection functionality Scania has introduced side detection functionality via two systems. Together, they help avoid scenarios where trucks may come into contact with other road users. The two systems work in parallel, and to some extent overlap each other, despite having different focuses. Pedestrians and cyclists are amongst those who will benefit the most from the extra ‘eyes’ that Scania gives its trucks with the help of radar, radar sensors, and camera. Advanced driver assistant systems (ADAS) support truck drivers by constantly monitoring blind spots beside the vehicle. In the UK, the most common incident is when a truck turns left at a junction whilst a cyclist tries to pass the truck on the left side. With side detection functionality, if a cyclist (or a pedestrian) enters a risk zone near the truck, the system will alert the truck driver by visual and audible warnings in the cab. Whilst the Blind Spot Warning (BSW) system is mainly designed to warn truck drivers of ‘hidden’ cars when at higher speeds switching lanes, it can also warn for bikes and pedestrians. And whilst the main focus of Vulnerable Road User Collision Warning (VRUCW) is detecting cyclists and motorbikes, it can also spot pedestrians.

“Advanced driver assistant systems (ADAS) support truck drivers by constantly monitoring blind spots.” 8 CVW APRIL 2020

ATIEL, the representative body for manufacturers and marketers in the European lubricants industry, has changed its quality management policy to ensure that ATIEL member products are now included in compliance programmes for the first time. The change comes in response to a Verification of Lubricants Standards (VLS) investigation, which was referred to ATIEL in 2019. Case 160 involved a 5W-30 Fully Synthetic SN/CF Oil, which was making technically conflicting claims concerning the ACEA engine oil sequences and OEM specifications which were not technically feasible. After months of investigation and dialogue, the named party failed to provide the Candidate Data Pack, putting them in breach of the ATIEL Code of Practice. VLS reported the company to ATIEL for breaching its undertakings under the ATIEL Code of Practice. Previously, ATIEL members only had to sign a letter of compliance, saying that their products conformed to the correct standards. Their products were not subject to compliance testing – only non-member products were. However, the investigation into case 160 highlighted that this process may not be stringent enough to uphold industry standards. At a meeting of the ATIEL Quality Management Committee, it was decided that the policy would be changed to that all

products would be subject to sampling and testing, including member products, to ensure that industry standards are maintained and products really can deliver what they claim. Andrew Goddard, Chairman of VLS, said: “The case demonstrates that, as an independent trade body, VLS will strongly pursue cases, including referring them to other European industry bodies, to ensure that lubricant products are fit for purpose. This announcement sends a strong message to the industry that no one is exempt from testing. Product quality and motorist safety must come first.”

TMD Friction CV wins IFA supplier of the year award TMD Friction CV has won CV supplier of the year at the Independent Motor Trade Factors Associated (IMTFA) annual gala dinner dance and awards ceremony at the K Club in Country Kildare, Ireland. The award marked the end of a very successful year for TMD Friction CV, with the introduction of new braking solutions, expansion of its online catalogue system Brakebook, and success on the racing track through its sponsorship of Newell & Wright Truck Racing. More than 180 IFA members and suppliers attended the event in December,

which lasted the entire weekend and included a host of networking opportunities and activities such as a trip to Dublin city, a wine tasting afternoon, clay pigeon shooting, and the IFA golf tournament held on the famous Ryder cup course.

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Comline launches ‘stay protected’ campaign Comline has announced the launch of a campaign focusing on the importance of cabin and activated carbon filters. The company wants to communicate exactly why a regular change of cabin filter is essential for the driver and vehicle occupants to ‘stay protected’. The core of the campaign is a dynamic new video and an infographic poster, both of which communicate the benefits of cabin and carbon filters in engaging style. Focusing on the potential health issues that the cabin filter aims to negate, both video and poster quickly build a clear understanding as to why it’s

essential for any motorist to change their cabin filter in-line with their regular service intervals. Group Marketing & Communications Manager Leigh Davies commented: “It continues to surprise me how many motorists don’t see the importance of changing the cabin filter because it’s not mechanically essential for the vehicle. Ultimately, a cabin filter protects what’s most important in a vehicle – the driver and vehicle occupants! “With our latest ‘stay protected’ campaign, Comline is aiming to deliver simple, educational tools that depict exactly why the cabin filter is so important.”

Trailermaster launches new mobile app Trailermaster, the connected trailer solution from Axscend, has launched a new iOS compatible mobile app. The new solution will give users complete visibility of their entire trailer fleet from any computer, tablet, or smartphone, without any feature losses on smaller devices. Axscend National Sales Manager Glenn Young explained: “Traditionally, trailer telematics has been little more than a GPS tracking device, and cost justification has always been a challenge. The Trailermaster solution is proven to dramatically enhance the efficiency, productivity, and utilisation of trailer fleets, resulting in tangible cost savings.” Young continued: “The Trailermaster system monitors much more than just

location, alerting fleet managers to faults with lighting, tyre pressures, EBS, braking performance, and more. We’re delighted to be launching this new app which will extend all the benefits of the platform to users on-the-go.” Using both desktop and mobile versions of the platform, Trailermaster connects and integrates the many pieces of equipment commonly fitted to trailers to provide complete connectivity and control over a trailer fleet via a single integrated dashboard. Features of the platform include maintenance monitoring, tyre pressure monitoring (TPMS), and the Axscend’s patented Electronic Brake Performance Monitoring System (EBPMS).”

LEVC set to launch new electric van Production of the VN5 from LEVC is set to commence in Q4 of this year with volume expected to take up 70% of the annual 20,000-unit production capacity. The VN5 cargo capacity can easily accommodate two Euro-sized pallets with a gross payload of over 800kg. It has been built with a large side-loading door and a 60/40 split door at the rear to make loading and unloading easier for the driver. Based on a real world 47-mile delivery route into central London, VN5 can make approximately twice the amount of journeys and deliveries as its segment competitors by having the flexibility to operate emission (and penalty) free in the city’s restricted ULEZ environment. The van offers 25,000-mile service intervals, Plug-In Vehicle Grant eligibility, zero ULEZ charge, and significant fuel savings. A full charge with a 50kW charger takes 30 minutes. VN5 will offer an electric powertrain with a pure EV range of 63 miles and a total flexible range of 301 miles.

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NEWS

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Leaders demand government backing to tackle air pollution

Mirka joins European sustainability-focused initiative Mirka is joining the new European programme focused on sustainability called SEAM (Sustainable European Abrasive Manufacturers). The initiative is designed to drive forward the industry’s pledge to implement new sustainability measures for the long term. The objective of the SEAM programme is to support and assist abrasive manufacturers in their aim towards sustainable growth and sustainability improvements, mostly in production and distribution. Stefan Sjöberg, CEO of Mirka, commented: “Long-term sustainable development has always been an important and natural part of our business. Being sustainable is an integral part of our vision: to be the most responsible company in our industry. “For us, it has always been clear not to waste financial or material resources – of our own or those of our customers. These initiatives and achievements are compiled under ‘Our Clean Commitments’, where we describe the development of our corporate sustainability programme transparently with various KPIs. This goes hand-inhand with the new SEAM programme.”

“The objective of the SEAM programme is to support and assist abrasive manufacturers in their aim towards sustainable growth and sustainability improvements.”

10 CVW APRIL 2020

Greater Manchester authorities are calling for clarity to help businesses in the region upgrade their fleets before the proposed introduction of a Clean Air Zone next year. In 2019, the Greater Manchester Combined Authority (GMCA) submitted its Clean Air Plan outline business case to government. The proposals include a significant funding package for businesses to upgrade their fleets to cleaner vehicles, the largest proposed Clean Air Zone in the UK, and a bid to treble the size of the region’s electric vehicle public charging network. However, nearly a year later, the Government still has not confirmed the financial support that will be available to help businesses upgrade their vehicles. The only government funding committed so far has been £36m to take forward proposals for a charging Clean Air Zone, under which the most polluting commercial vehicles would pay a daily charge to travel on local roads in Greater Manchester. Until Greater Manchester receives confirmation on the clean vehicles funding available from government to support Greater Manchester businesses, it is unable to complete the Clean Air Plan proposals

and won’t be in a position to submit the full business case to government. It’s currently anticipated that the ten Greater Manchester councils will receive a report in the coming months on proposed timings for a major public consultation on the Clean Air Plan. Chris Fletcher, Marketing & Campaigns Director at Greater Manchester Chamber of Commerce, said: “Poor air quality is an issue that affects everyone, especially businesses, as an unhealthy workforce means more sick leave and lower productivity. “The Clean Air Plan proposals for Greater Manchester are ambitious, but businesses need clarity on the support they will receive from government to help them upgrade their fleets, as the cost can be considerable. We need this now.” The proposed Clean Air Zone would be implemented from 2021 and would initially mean that buses, coaches, HGVs, taxis, and private hire vehicles that do not meet emission standards would be required to pay a daily penalty to drive in Greater Manchester. Non-compliant vans would be included from 2023.

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TECH TIPS

ADVANTAGES OF ADHESIVE THREADLOCKING

very day we use products which contain numerous threaded fasteners. Screwed joints are amongst the most common form of a detachable yet secure fixing between two parts. Although they come in various shapes and sizes, all threaded fasteners have the same purpose: to ensure a durable assembly. However, the self-loosening of threaded fasteners is a leading cause of catastrophic failure in vehicle engine, transmission, and suspension components. Adhesive threadlocking is proven to be an excellent method of keeping fasteners firmly in place and there is a wide range available to choose from. There are various threadlocking methods: mechanical devices (e.g. tab washers), friction devices (e.g. nylon ring), locking devices (e.g. saw-tooth flanged bolts and wedge-type locking washers), and material integration–threadlocking adhesives. A transverse shock test shows the performance of some different threadlocking methods.

Considering the dangers surrounding the self-loosening of threaded fasteners, Henkel explains one method of ensuring fasteners remain firmly in place. HOW TO APPLY THREADLOCKING ADHESIVE PREPARATION To achieve optimum results, all parts need to be clean and free of oil/grease. A product such as Loctite SF 7063 is ideal for degreasing and cleaning surfaces prior to applying the adhesive.

APPLICATION (LIQUID) Apply liquid threadlocker to the engagement area. There are different application methods: 1. Through-hole – Assemble bolt first and then apply threadlocker. Fit nut and tighten to correct torque.

Standard bolt with Loctite® threadlocking system

Nut with polymide ring

Bolt with DIN 127 A spring washer

Bolt with saw-toothed flange

Bolt with DIN 6797 A Tooth lock washer

Unsecured standard bolt

Reasons for failure of the different methods are: ■ Relaxation – caused by a change in bolt tension leading to a reduced clamping force ■ Self-loosening – caused by dynamic loading, vibration, or changes in temperature ■ Differential thermal expansion – dissimilar metals have different thermal expansion coefficients which may result in a loss of bolt tension and a reduction in clamp force ■ Corrosion – water ingress can create corrosion in the threads

2. Blind hole – Apply appropriate amount of threadlocker into lower third of the blind hole. 3. Post assembly – Assemble the nut and bolt then dispense product at the edge of nut and bolt.

FOR MORE INFORMATION,

APPLICATION (STICK) Twist the threadlocker stick to the amount required, then apply sufficient product around the thread of the bolt.

ASSEMBLY Assemble and tighten. If several bolts are being assembled, torque them down to the correct value within the fixture time of the product or use a slow curing product.

DISASSEMBLY A choice of adhesive strengths are available to allow dismantling if required. If a high strength product is chosen which cannot be dismantled with standard hand tools, the application of localised heat at approximately 250°C will allow easy disassembly (whilst hot).

WWW.RDR.LINK/VP010

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BUSINESS & TRAINING

A HELPING HAND

ith colder and wetter weather, the risks to hands are heightened, as is the prevalence of work-related skin issues – a common problem for those who work with vehicles. In fact, they are one of the most common health issues for this group; work-related skin disorders, such as dermatitis, have been quoted by the European Agency for Safety and Health at Work as the second most common work-related health problem in Europe. Furthermore, according to the HSE, they are thought to affect one in ten workers. These skin issues can have a serious impact on an individual; dry, cracked, and sore hands are often amongst the first symptoms. Skin disorders can come in many forms and, after repeated contact with contaminants (a daily sight for technicians), it is also possible to develop an allergic reaction to a specific substance.

14 CVW APRIL 2020

Although the days are gradually becoming lighter and longer, many in the trade will still be feeling the chill of the winter months as the cold refuses to abate. Swarfega explores the best ways of keeping your skin in check. In addition to this, the impact on an individual’s wellbeing cannot be underestimated; many workers have spoken out to say that skin problems can be demoralising. They can affect personal and mental wellbeing, hindering various tasks from simply making a cup of tea to preventing an individual carrying out their work properly. For technicians, the hands are the most important tools for the job, so looking after them is vital. Good skin care should be one of the core aspects of health and safety, and so proper and regular handwashing is key. The top layer of the skin is merely between 0.03m-0.25mm thick, and it forms the main barrier against contaminants. Easily damaged, the skin can take up to six weeks to be repaired; even something such as overwashing or using a cleanser that is too harsh for the level of soiling can take its toll. To help understand the issues surrounding skin care in the trades, Swarfega carried out extensive research to find out what modern workers were looking for in terms of skin care. The challenges that the employees faced were as predicted – stubborn dirt, lack of training,

intermittent glove use, and over-washing of hands were all cited as issues. In terms of product, common complaints included unclear labelling and ineffective results – further to this, inappropriate hand cleaners were also being used. Before grabbing the nearest hand cleaner to the sink, consider what kind of soiling you’re tackling. You may be using a cleaner that is too weak or strong – both of which can land your skin in poor condition. Aim for the mildest cleaner that will still do the job, as this will help avoid loss of the skin’s natural oils. Protection and restoration creams should also be used as part of a three-step approach to skin care. An at-work dispenser system is the best way to keep on top of this, with protective creams helping reinforce the hands against soiling, and moisturising creams helping to restore the skin’s essential oils.

TO WATCH AN INFORMATIVE VIDEO EXPLAINING SWARFEGA’S SKIN CARE SOLUTIONS, WWW.RDR.LINK/VP011

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SPECIAL REPORT

THE IMPORTANCE OF PREVENTING DIESEL SPILLS Diesel spillages affect us all – they cost money to clear up, delay traffic, and affect the environment. Highways England talks through its guidance for commercial vehicle drivers and operators to help stop them happening.

ighways England recorded 314 HGV diesel spillages in 2018. Diesel left on the road surface for as little as two hours leads to structural damage, resulting in the need for resurfacing. It can cost around £540,000 for a four-hour delay on a busy route. From a study of these types of incidents, it found:

There are additional safety measures available to them to prevent spillages such as: ■ Fitting fuel caps with anti-syphon

devices and self-sealing tanks ■ Installing guard rails to the sides and

extended cat walks on the top of the fuel tank for protection ■ Carrying spill kits (comprising booms, mats, sealant putty, and portable containers).

■ 41% of incidents were estimated to be

two hours or less ■ 14% of incidents were between two to

The impact and cost of a diesel spillage

five hours ■ 22% of incidents were over five hours

Best practice guide The diesel spillage best practice guide aims to help HGV drivers and operators reduce the number of incidents, as well as explain the impact they have. Highways England encourages operators and drivers to be proactive in taking steps to prevent diesel spills. A survey of over 200 fleet operators found 42% don’t equip their vehicles with spill kits. This would result in a spillage not being treated until a response unit arrived. The best practice guide provides advice on dealing with and reporting spills, as well as actions to take to prevent them. It’s split into two parts covering driver and operator responsibilities.

Drivers can prevent spillages Drivers can improve safety and understanding by:

Highways England has also produced a leaflet entitled ‘What is the impact and cost of a diesel spillage’ to highlight the impact and cost of diesel spillages. This illustrates real-life case studies of spillage incidents and features costs incurred by stakeholders involved in the clean-up and repair. To see it for yourself, WWW.RDR.LINK/VP012

Conclusion ■ Carrying out daily walk-around checks

of their vehicle to prevent spillages ■ Ensuring they’re aware of environmental risks associated with diesel spillages ■ Improving their awareness of penalty notices and fines ■ Having an understanding of their diesel spill response plan and, where fitted, using a spill kit

The focus of these documents is to improve road user knowledge and attitude, promote best practice, and improve responses to diesel spillages. Highways England aims to achieve: ■ A reduction in the number and severity

of incidents ■ Less risk of diesel entering the water

course and causing environmental damage

Operator responsibilities

■ Less costs from resurfacing and repairs

The guide also advises operators on what they can do to prevent diesel spillages which will help the operator by:

■ A reduction in the number and cost of

to roads claims for Highways England to pursue and reclaim

■ Avoiding DVSA prohibitions (vehicle

immobilisations) and other potential penalties ■ Not increasing insurance premiums ■ Reducing loss of vehicle, fuel, and driver time

17 CVW APRIL 2020

TO READ HIGHWAYS ENGLAND’S BEST PRACTICE GUIDE ON DIESEL SPILLAGES, WWW.RDR.LINK/VP013

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THE CV W GUIDE TO

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CV SHOW PREVIEW

RUNNING THE SHOW CVW speaks to Murray Ellis, Show Organiser, to discover more about this year’s CV Show. DISCLAIMER At the time of going to print, the organisers of the CV Show had not made any announcements for the postponement or cancellation of the show due to the spread of Covid-19. We will have up-to-date news on the CVW website as and when further information is released.

he Commercial Vehicle Show is claimed to be the largest, most comprehensive, and best-attended commercial vehicle event in the UK. Held at the NEC Birmingham, the event will be celebrating UK premieres from several van and truck manufacturers, as well as the latest innovations from more than 400 exhibitors spanning the whole road transport, distribution, and logistics sectors. New for this year will be a series of live theatre discussions, where sector leaders, innovators, and commentators will talk about key industry issues throughout the three days of the show. CVW will be running a series of seminars over the course of the show, and the timetable can be found within this guide. For now, Murray Ellis provides more detail on the upcoming event:

So, Murray, what’s new at this year’s CV Show? Murray Ellis (ME): This year, the show is pleased to announce several companies making their first appearances at the show, such as the London Electric Vehicle Company, Daltec, and Midlands Truck and Van. Renault Vans and Nissan are returning to the show for 2020, and we will also be hosting regular exhibitors like Ford, Volkswagen, Fiat Professional, Vauxhall, and MAN. New on the agenda for 2020 will be three

WHAT YOU NEED TO KNOW OPENING HOURS

VENUE

Tuesday & Wednesday: 08:30 to 17:00 Thursday: 08:30 to 16:30

Halls 3a, 4, and 5, NEC Birmingham, Pendigo Way, Marston Green, Birmingham, West Midlands, B40 1NT

HOW TO GET THERE

By road

By rail Birmingham International Railway Station is located within the NEC complex. Connections can be made from all major UK cities.

live theatres where sector leaders, innovators, and commentators will talk about key industry issues throughout the three days of the show. Designed to educate and provide insight from within the industry, the full timetable and guest speakers for the Theatres are currently live on the CV Show website.

From the M6: Exit at Junction 4 or 4a and head for the NEC via Junction 6 of the M42. Paying for parking at the NEC on the day for a full day costs £16.

most comprehensive product range, thousands of visitors have already preregistered and over 400 exhibitors confirmed. The scene is set for a great show.

Why should workshops and fleet operators attend?

ME: The CV Show aims to offer visitors a

What are you hoping to achieve with the show this year?

ME: As the largest, most comprehensive, and best-attended commercial vehicle event in the UK, the three-day show provides truck and van operators with a far greater choice than can be found anywhere else. The 2020 CV Show will see every segment of the road transport industry represented. With exhibitors spanning the whole road transport, distribution and logistics supply business, the event provides everything fleet operators and sole traders need to help them purchase and maintain the safest and most efficient vehicles. The biggest of its kind, unrivalled in size and visitor attendance, and offering the

ENTRY TO THE SHOW IS FREE, SIMPLY 20 CVW APRIL 2020

From the M42: Exit at Junction 6 and follow the signs to the NEC.

complete package of the commercial vehicle industry. It is the industry’s largest and most established trade show with new vehicles, emerging technologies, and the opportunity to connect with key decision makers and other individuals who are as passionate about the sector as we are.

What benefit will they get out of the Workshop Theatre?

ME: The Theatre is designed to educate and provide insight and will see a line-up of experts and commentators present talks on a variety of topics covering Earned Recognition, the latest development in fleet and workshop compliance to practical tips on brakes and electrical diagnostics.

WWW.RDR.LINK/VP014 TO REGISTER

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CV SHOW PREVIEW

WORKSHOP THEATRE TIMETABLE Taking place on Stand 4D95, make sure you come along to hear essential technical and business advice from technical experts in the commercial vehicle industry, courtesy of CVW. SESSION

TUESDAY 28TH APRIL

WEDNESDAY 29TH APRIL

THURSDAY 30TH APRIL

10:30

EARNED RECOGNITION DVSA

TWO SCHEMES, ONE OBJECTIVE: WORKSHOP BEST PRACTICE IRTE

BRAKES CLINIC 2 Jonathan Jackson, MEI Brakes

11:30

MIND YOUR BATTERIES Ken Clark, Rotronics

BRAKES CLINIC 1 Jonathan Jackson, MEI Brakes

PANEL DISCUSSION: PROFESSIONAL REGISTRATION IRTE

13:30

COMPLIANCE GOES DIGITAL Paul Clarke, Truckfile

THE ENFORCERS DVSA

PARTS FOR THE 21st CENTURY Robert Molloy, EMS-FP&S

15:00

TACKLING THE SKILLS SHORTAGE Dani Rathke, irtec

PARTS FOR THE 21st CENTURY Robert Molloy, EMS-FP&S

TUESDAY 28TH APRIL

WEDNESDAY 29TH APRIL

THURSDAY 30TH APRIL

EARNED RECOGNITION How to enrol in the DVSA’s flagship compliance scheme and what data will be required

TWO SCHEMES, ONE OBJECTIVE: WORKSHOP BEST PRACTICE Two key schemes that promote workshop best practice, plus the growing importance of skills development for electric vehicles

BRAKES CLINIC 2 Real-life examples of early disc brake component failure resulting from failure to carry out basic inspections

MIND YOUR BATTERIES How a proactive battery testing and charging strategy can deliver cost savings and improved operational reliability COMPLIANCE GOES DIGITAL Find out how switching to digital systems can save time and money whilst improving compliance TACKLING THE SKILLS SHORTAGE Top tips on polices that are effective in attracting the next generation of technicians and engineers

BRAKES CLINIC 1 Real-life examples of early disc brake component failure resulting from failure to carry out basic inspections

PANEL DISCUSSION: PROFESSIONAL REGISTRATION The importance and benefits of demonstrating your professional competence both as a technician and as a workshop

THE ENFORCERS DVSA’s enforcement team focuses on serially non-compliant operators. Find out how and why all operators benefit and hear some top tips on staying compliant

PARTS FOR THE 21ST CENTURY The CV parts sector is in transition. Will online parts buying become the norm? What impact will Brexit have? Will 3Dprinted parts happen?

APRIL 2019 CVW 23

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CV SHOW PREVIEW

쑿 ACTIA STAND 4A64 With 25 years’ experience in the bus and coach industry, Actia is at the forefront of vehicle electronics, from next generation multiplexing and instrumentation, to telematics, CCTV, multimedia, parts direct and across-the-fleet workshop diagnostics. Actia will be displaying its latest solutions, with a focus on its diagnostic tools – Multi-MUX and Multi-DIAG – that provide complete solutions to meet the many needs and requirements of multi-make workshops. Actia will be also displaying Multi-SCAN, its new diagnostic tool that enables ‘first aid’ diagnostics of the vehicle driveline ECUs (e.g. engine, transmission, ABS, retarder). Fully integrated into Multi-MUX with the same familiar user interface, the Multi-SCAN tool allows new access to real-time sensor data and diagnostic trouble codes. From a single click all reported faults on all detected ECUs are reported, enabling the potential problem area to be identified quickly.

씱 BG PRODUCTS STAND 3C07 The company is proving itself an important business partner to organisations in improving the environmental performance of engines of all shapes and sizes, from Transit vans and lorry fleets to diesel-fuelled power stations. Maintenance regimes continue to demonstrate significant reductions in harmful emissions, and by allowing expensive equipment to stay on the road much longer, preventative maintenance becomes self-funding. A council fleet featuring Transits, bin lorries, and other municipal vehicles continues to see MPG improvements of 7% compared to pre-BG Products regime and complete elimination of DPF issues.

쑿 ATLAS COPCO STAND 4H30 Atlas Copco will showcase the latest developments in breathing air purifiers and on-site nitrogen generation, together with the company’s professional range of compact air compressors. Atlas Copco’s new BAP(+) breathing air purifier units combine the functions of water separation, contaminant filtration, and desiccant drying. Breathing air purifiers play an essential role by ensuring that workplace air is free from fumes, oils, vapours, gases, solid particles, and microorganisms. Its new addition to its family of nitrogen generators, the NGMs 1-3 membrane technology units, can be seen on the company’s stand. For repair shops, tyre bays, bodyshops, and service garages in need of a small, reliable, and affordable compressor, Atlas Copco offers the ‘Professional’ range of compressors. This includes the robust piston compressors and small rotary screw compressors, such as the company’s GX2-7 EP and G7-15 ranges.

BOWMONK TAPLEY 씰 STAND 4C71 Bowmonk Tapley will be demonstrating BrakeCheck – the DVSA-approved portable brake tester for recording and printing brake test results. BrakeCheck is fully approved for interim safety inspection brake tests and for the three-monthly voluntary brake test. Other diagnostic products on display will include SensorCheck, for quickly diagnosing ABS-related faults without having to remove the road wheel, and TrailerCheck, which allows single-man testing of trailer lighting, ABS circuitry, and CAN activity. Visitors to Bowmonk’s stand will be able to see a live demo of the company’s on-board weighing system – now for all suspension types – including a Bluetooth link to a nearby smartphone for single-man loading or electronic recording of weight data. Also on display will be its range of lightweight landing legs which afford increased payload capacity. Bowmonk’s In-Car PC division will be showing a range of 4G Wi-Fi routers, which can utilise high-gain external antennas to offer a reliable source of internet connectivity, especially in more remote locations.

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CV SHOW PREVIEW

BRIGADE ELECTRONICS STAND 3A09 Brigade Electronics returns to the CV Show this year to dispel the myths surrounding the new Direct Vision Standard (DVS) and to advise customers on how they can comply with legislation. Brigade has partnered with Vision Systems to offer main mirror replacement systems for class two and four areas. The system out-performs conventional mirrors thanks to the antiglare glass used on the monitors, low luminosity functionality, and improved visibility in wet conditions, making it a much safer option. Also on display will be Brigade’s range of high definition camera monitors and a HD Backeye 360 system. Brigade will be introducing three Internet Protocol (IP) cameras which prevent image quality degradation for applications that use extended cable length. To complement these, Brigade’s power over network (PON) switches, which can increase the number of channels available for mobile digital (MDR-5XXX) recording systems, will be displayed. This enables the eight-channel system to cater for up to sixteen cameras.

BRIDGESTONE & WEBFLEET SOLUTIONS STAND 5B70 Bridgestone, at its joint stand with Webfleet Solutions, will showcase how advanced technologies can help truck and van operators drive efficiencies, realise cost savings, reduce their carbon footprint, and raise the bar in service delivery. Webfleet Solutions will demonstrate how business and processes can be streamlined with seamlessly connected, end-to-end systems, including integrations with applications ranging from transport management systems and on-board cameras, to mileage, route optimisation, and HGV-specific navigation. Meanwhile, Bridgestone will be onhand to talk about the latest additions to its tyre ranges, including the Ecopia H002, engineered to improve companies’ fuel economy and reduce CO2 emissions, the Duravis R002, designed to help fleets lower their operational costs by reducing cost per kilometre, and the COACH-AP 001, a costefficient option developed specifically for coach fleet managers.

26 CVW APRIL 2020

COMMERCIAL VEHICLE WORKSHOP STAND 4D96 CVW will once again be taking a stand at the show, providing an excellent opportunity for the magazine to connect with its readers about the issues that are currently affecting business and the industry in general. This gives us the chance to find out how to evolve in a way that suits our target audience. There will also be an opportunity to sign up to CVW’s online newsletter, so that you receive all the latest news and industry information direct to your inbox each week. Don’t forget, the Workshop Theatre will be running throughout the course of the show, with a seminar programme created especially by the team at CVW.

DPF RECOVERY STAND 4H60 DPF Recovery is launching an advanced new process at the Commercial Vehicle Show, aimed at helping fleet operators and engineers save time and money from costly DPF and Euro VI replacements. DPF Recovery believes its process is one of only a few similar in operation across the country and has calculated that the savings for operators could be up to 60% vs replacing the DPF, DOC, or SCR unit. For example, on a large commercial truck, it has estimated that a new Euro VI DOC/SCR unit would cost in the region of £6,000 to 8,000, yet the cost of refurbishing the same unit using their new process would be around £2,000. On a fleet of 50 vehicles, that could be a saving of around £100,000 for the operator. Visitors can see the evidence for themselves as DPF Recovery will be showcasing commercial vehicle DPFs, DOCs, and SCRs it has remanufactured, with examples showing before and after the process. The team will be happy to chat with fleet engineers, operators, and transport managers about how the company’s new technology can help save time and money and drive efficiency.

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ì”± GEMCO STAND 4E60 Gemco is showcasing a wide range of commercial vehicle equipment, including Mobile Columns, Two Post Vehicle Lifts, Roller Brake Testers, Workshop Pits, and more. Its skilled technicians will be on the stand all week providing live demonstrations, and the dedicated Gemco Sales Managers will be available throughout the week to provide visitors with product information, and even book site visits, so make sure you donâ€™t miss out!

ì‘¼ GRP SOLUTIONS & SABA

ì‘¿ ECLIPSE DIAGNOSTICS STAND 4F95 Eclipse will display its Jaltest and EDIS diagnostics products at this yearâ€™s Commercial Vehicle Show. There are more than 2,500 Eclipse Jaltest units now being used by workshops and fleet users of all sizes. The software is continually being improved to both expand the number of brands/models covered as well as extending the functionality that is available. The software is updated three times a year with the many improvements available for all users who have subscribed to download new versions. Jaltest now covers Trucks, Trailers, Bus and Coach, Light Commercials, Off Highway, Agricultural, and Marine vehicles and engines, covering more brands in more sectors than other products. At the show, visitors will be able to hear why workshops of all sizes are adopting these Eclipse diagnostic products as their de facto standard and also see the up-to-date innovations, together with bench-test demonstrations.

STAND 4H01

ì‘¿ EMINOX STAND 5B42 Showcasing its retrofit solutions designed to help operators meet the requirements of Londonâ€™s Ultra Low Emissions Zone, various other clean air zones, and Scotlandâ€™s low emission zones, Eminox will also reveal a new approach to retrofitting specialist trucks. Eminox retrofit systems offer a low-cost alternative to buying new vehicles. The greatest cost benefit is for high-value vehicles such as buses, coaches, and specialist trucks. With over 40 years of experience, Eminox provides solutions for bus, coach, specialist truck, and refuse collection vehicles, all approved by the Clean Vehicle Retrofit Accreditation Scheme (CVRAS). Visit the stand to learn more about the companyâ€™s ongoing retrofit development programme and to see which new models are being added to the portfolio.

SABA is teaming up with its UK & Irish distributor GRP Solutions for this yearâ€™s Commercial Vehicle Show. SABA has 86 yearsâ€™ experience in the transport industry, and the companyâ€™s Sabatack range contains no solvents or isocyanates, so is consequently both user-friendly and environment-friendly. SABA product specialists will be on hand to discuss the Sabatack MS Polymer range, designed with unique properties for the transport industry, including process security, sustainability, simple processing, and reliability.

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CV SHOW PREVIEW

쑼 HOPE TECHNICAL DEVELOPMENTS STAND 5F62

쑿 HANKOOK STAND 5B50 This year, Hankook is unveiling new truck tyres from its second brand Laufenn, as well as a comprehensive range of Hankook truck and bus tyres, including new steer (SmartWork AM11), drive (SmartWork DM11), and trailer (SmartWork TM11) tyres from the recently expanded SmartWork series, for regional on/off road. The new all-season Vantra ST AS2 (RA30) multiperformance van tyre for reliable driving in all weather conditions can also be seen in the UK for the first time. Paul Emery, Sales Director for Hankook Tyre UK, states: “As Hankook is viewed as the leader in the UK truck tyre replacement market and the Commercial Vehicle Show is the largest road transport and commercial vehicle event in the UK, it is the ideal opportunity to present our new tyre brand alongside our existing innovative tyre solutions.”

Exhibiting its full range of LCV rear protection equipment – Safe-T-Bar, Safe-TStep, Sensor Connect Relocation System & Accessories – Hope Technical Developments will also be unveiling a newly re-modelled van-mounted HOPE Scrutineer, for mobile diagnostic servicing. This new model, manufactured in aluminium, provides all the benefits of the original Work shop model but is 60% lighter. Hope Technical is inviting visitors onto its stand to discuss opportunities as well as showcase its in-house manufacturing capabilities, enabling it to provide ‘added value’ engineering support and fast solutions for bespoke or challenging customer requirements. The manufacturers’ new vehicle exhibits are also of huge significance to our business in understanding the latest and evolving vehicle specifications and technologies.

쑿 JAAMA STAND 4G100 Fleet and asset management software provider Jaama will be highlighting its Key2 Commercial Vehicle Management system. It ensures that fleets have a central hub through which all fleet and driver data is managed and stored. Furthermore, Key2 Contract Hire and Leasing is an intelligent, configurable business system that helps businesses to compete in a competitive marketplace by controlling costs, providing tools to make predictive forecasts, and add value and satisfaction for customers. The entire Key2 product suite will be at the show and can be experienced by visiting vehicle operators via five touchscreen demonstration areas with a team of five from Jaama. Visitors to its stand will also be able to test their darts skills, with a prize available to the highest scorer.

쑿 HJS STAND 3C26 A cost-effective retrofit SCR exhaust system will be on display at HJS’ stand. It provides operators of Euro V light commercial vehicles with an upgrade solution, enabling them to comply with Euro VI emission standards. The retrofit SCR system offers ULEZ/LEZ and CAZ compliance for a range of Euro V Light Commercial chassis applications, including the Ford Transit, Mercedes Sprinter, Volkswagen T5/Crafter, Vauxhall Movano, and Renault Master, plus many others. Mark Cooper, HJS UK, said: “HJS systems are already contributing to air quality improvements across the UK through the completion of thousands of bus retrofits. The cost of replacing any fleet is a huge expense and the HJS SCR system enables operators to upgrade vehicles at the fraction of the cost of buying a replacement vehicle.” In addition, HJS will now be developing solutions for the HGV market and inviting operators of all commercial vehicles to visit its stand to discuss their options further.

28 CVW APRIL 2020

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CV SHOW PREVIEW

쑼 MERRIDALE STAND 4H10 Celebrating 20 years at the Commercial Vehicle Show, Merridale’s range of products includes storage tanks, tank management and pump systems, and a range of software. One such product, FuelWorks, is a web-based software that allows users to monitor fuel usage, efficiency and stock, predict restocking requirements, and evaluate environmental impacts, therefore enabling fleet owners to adhere to FORS reporting standards. The CV Show has played an important role in how Merridale has adapted and improved its products by offering a platform for discussion between developers and fleet operators.

쑿 MAHA STAND 5B50 Maha is displaying its extensive range of workshop equipment for the HGV market, including mobile column lifts, brake testers (both in and above floor), play detectors, headlamp testers, and tachograph solutions. Maha offers cable-free columns with an adjustable carriage, from 550mm up to 1500mm, and with a lifting height of 1750mm. The UK-specific roller brake tester – MBT7250 – is used extensively by many ATF lanes and independent workshops for pre-testing and maintenance records.

씱 PREMIER PITS STAND 4C90

씰 ORBCOMM STAND 4D50 Recent innovations will be on display at Orbcomm’s stand, including its new Working Hours Analysis workspace within its cloud-based fleet management platform, the availability of its in-cab mobile solution on Samsung’s ruggedised Galaxy Tab Active2 and Galaxy Tab A 8.0 tables, the new EBS trailer weight monitoring in its trailer tracking solution, and the integration of Orbcomm telematics data into third-party camera systems, including Fastview 360 and Cameramatics.

An example of a Premier Pit will be on display to show how a prefabricated steel pit has many benefits compared to traditional brick and concrete methods, offering a safe, well lit, and watertight working environment for vehicle technicians. A Premier Washdown Ramp will also be on display with information available on the complete range of Premier Pits Under-Chassis Washdown solutions. Also on the stand will be BrakeMate, the revolutionary elevated platform designed to improve the safety and efficiency of replacing brake disc assemblies. Premier Pits are the UK distributor of BrakeMate; it significantly reduces manual lifting during the brake disc maintenance process and reduces service time. Traditionally a twoperson job, disc replacement can now be achieved with one mechanic whilst also reducing downtime by up to 50%.

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CV SHOW PREVIEW

씰 R2C ONLINE STAND 4H10 The company will be showcasing its connected fleet and workshop platform, including its newly-launched stock management module. r2c customers can now utilise stock and workshop loading modules, alongside digital inspection sheets, fleet maintenance planner, driver walk-around checks, defect reporting, workload management, invoicing, and automatic maintenance authorisation all via one system. r2c Online has also recently processed it’s 15,000,000th digital job sheet. Today, nearly 30,000 fleets and over 1,200 workshops use the platform, with the company projecting a runrate of 5,000,000 job sheets per year.

쑼 TOTALKARE STAND 4E80 Commercial vehicle operators and workshops will soon have access to ‘mobile’ products for three critical tests thanks to Totalkare. The increased product range will be showcased at the Commercial Vehicle Show, with Totalkare’s new smoke meters and headlamp testers on display. Experts will also be on hand to explain the additional flexibility and unrivalled performance these products will deliver for firms looking to achieve compliance on their HGV or van fleets. The new additions will be displayed alongside Totalkare’s core portfolio, including its T8DC mobile column lifts, heavy-duty two post lifts, light commercial four post lift, and the G8AC wash bay column lift – all of which can be lease purchased over a period of time to suit workshop requirements.

쑿 THE TOOL CONNECTION STAND 4C72 This will be the first time that The Tool Connection has exhibited at the Commercial Vehicle Show, and it will be displaying its Laser Tools and Connect Workshop Consumables brands. The Laser Tools brand has a broad range, and on display will be examples from its HGV/PSV specialist tools range, plus hand tools suitable for HGV/PSV service and repair. You will also see its expanding range of hybrid/EV safety equipment, PPE, and specialist tools for service and repair of hybrid/electric HGVs, PSVs, and LCVs. Additionally, Laser Tools will be showing examples from its extensive range of torque wrenches, both for general service work and wheel nut torque, including the new range of lightweight aluminium torque wrenches. Connect Workshop Consumables is another Tool Connection brand that is generating traction, and on display at the show will be a large range of consumables, including many that are HGV specific.

쑿 TOTAL LUBRICANTS STAND 4F36 Total Lubricants is displaying its packaging design for its OEM-approved range of Total Rubia engine oils. The update, which features ergonomic packaging, improved product naming classification, and a dashboard-inspired artwork redesign, aims to highlight the modernity, innovation, and premium quality that underpins the Total Rubia brand. The product range has also been segmented with platinum-gold, silver, and bronze packaging to denote top tier, midtier, and entry level product ranges, making it easier to select the right lubricant for a vehicle. For fleets looking to improve efficiency, Total will demonstrate how its fleet management system based on oil analysis, Total Anac (Analysis Compared), can anticipate planned maintenance operations, increase equipment lifespan, improve the reliability and performance of equipment, and optimise oil change frequencies via the early detection and identification of engine health issues.

32 CVW APRIL 2020

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씰 TRAKM8 STAND 5E80 Visitors to the Trakm8 stand will have the opportunity to learn more about the business’ technology solutions, which are adaptable for fleets of all sizes, providing insights that can improve fleet efficiency and ultimately reduce risk across fleet operations. Amongst the innovations Trakm8 will be showcasing include its optimisation software which is proven to cut fleet fuel spend by 20%, and bolster productivity by upwards of 33%, and its RH600 Dashboard Camera solution, which combines an in-cab camera system with the same technologies found in Trakm8’s most sophisticated telematics devices. Visitors to the stand will also be given the chance to learn more about Trakm8’s Connectedcare package, which provides enhanced vehicle status and health data insight to vehicle and plant OEMs, alongside leasing or hire companies.

쑿 TRUTAC STAND 4C01 TruTac is launching its new fleet system at the CV Show to plan and manage all vehicle maintenance and compliance. Aptly named TruFleet, the easy-to-use software enables transport managers to plan, organise, and control all aspects of day-to-day fleet and O’Licence management. Features include vehicle history, maintenance records, safety inspections, defect reporting, rectifications, and audit checks. TruFleet provides real-time updates on maintenance schedules, online storage for compliance documents, interactive dashboards, and alerts. The system fully integrates with TruTac’s comprehensive suite of compliance control products. TruFleet is fully compatible with TruTac’s modular suite of TruControl software and enables managers to switch seamlessly between tacho analysis, daily checks, and maintenance calendars, giving instant visibility and control over every vehicle and driver. A full demonstration of TruFleet and the full TruControl suite will be on the company’s stand.

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LIGHT COMMERCIAL VEHICLES

CAUSES OF

BRAKE JUDDER Brake judder can be divided into two types: hot and cold brake judder. Juratek explains how it can be avoided. Hot brake judder

What causes excessive heat?

Whenever you bring two surfaces into contact and at least one of them is moving at high speed, the result will be friction. This friction then creates heat which is transmitted to other parts of a vehicleâ€™s braking system. Whenever you bring two surfaces into contact and at least one of them is moving at high speed, the result will be friction. This friction then creates heat which is transmitted to other parts of a vehicleâ€™s braking system. Brake discs are usually made of cast iron, and when this material gets hot, it naturally expands and distorts, before returning to its original shape when cool. This natural reaction to heat is consistent and brake discs are designed to handle this and can operate in temperatures up to around 500Â°C. If the brake discs exceed the normal operating temperature, â€œhotâ€? brake judder can sometimes be the consequence. Fig. 1 & 2a show an exaggerated view of the effects of temperature on a brake disc.

The most common cause is abuse. Brakes are designed to withstand high temperatures, and they cool down quickly. But, if the driver applies them hard several times in quick succession, this can cause a phenomenon known as â€˜brake fadeâ€™, which is when the brakes get so hot that they fail to work effectively. Repeated heavy use of front brakes might also cause the discs to turn blue. Once these marks appear, it means the disc has been permanently damaged and will need to be replaced. Another potential reason is that the brake caliper could cease to function properly, which causes the brake pad to remain in contact with the disc even when not braking. Heat will steadily increase and can eventually get so hot that the brake disc may crack if rapidly cooled.

í˘ą

í˘˛

í˘ľ

This is almost always a direct result of a fitting problem between brake disc and hub. Brake discs and hubs are manufactured to strict tolerances, therefore, any rust or other debris that can cause fitting issues (Fig. 3) needs to be removed prior to installation.

Fig. 2b shows a disc that displays several signs of disc thermal distortion and excessive heat. Firstly, the oxidisation (orange colouring); secondly, the blue tint to the braking surface; thirdly, the dark spots on the disc surface (high spots); and finally, the large radial crack where excessive heat has caused permanent damage. All these factors are indicative of distortion caused by excessive temperature.

í˘ą Clean the hub of rust or debris í˘˛ Check the hub for run-out using a dial gauge í˘ł Install the new disc and then check using a dial gauge mounted close to the outer radius of the disc (Fig. 5). The installed value of radial run-out should not be greater than 100 microns, and in an ideal situation, not more than 70 microns.

Cold brake judder

í˘ł í˘˛

As mileage increases, this results in a progressively larger localised variation in the thickness of the disc, known as Disc Thickness Variation (DTV). This means that, when the brakes are applied, a pulsation can be felt through the brake pedal and steering wheel. To ensure this does not occur, follow these steps:

If the disc is installed with too high levels of radial run-out, the consequence is very light, continuous contact between the pad and disc at diametrically opposite points on the disc face in the â€˜brakes offâ€™ condition (Fig. 4).

í˘´

Poorly manufactured brake discs can also cause brake judder. This will be detected immediately on fitting, but Juratek is now manufacturing to the strict regulations imposed by UN ECE R90:02, which covers the way a disc is manufactured and the composition of the material used. The issue of brake judder, which is often blamed on a warped disc, is almost never a fault of the product and, in most cases, is caused by either excessive heat or poor preparation and fitting.

FOR MORE INFORMATION WWW.RDR.LINK/VP015

APRIL 2020 CVW 35

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LIGHT COMMERCIAL VEHICLES

EMISSION FAULT DIAGNOSIS

Brett Edkins, Technical Manager at Eclipse Diagnostics, explains how to identify and correct an emission fault on a Mercedes Sprinter.

dentifying faults on many modern LCVs is increasingly difficult given the rising levels of technology employed by manufacturers. This analysis of the emission fault on a Mercedes Sprinter (907) model shows how the Eclipse Jaltest package is becoming the go-to diagnostic solution for the LCV sector.

The problem The Mercedes Sprinter (907) had recently been into a workshop when, after diagnosis, it was suggested that the Diesel Particulate Filter (DPF) needed replacing because it was blocked. As the vehicle was less than a year old, the owner had brought it for a second opinion to another garage that uses the Eclipse Jaltest package. With many possible causes of the DPF fault, the technician first needed to interrogate the electronic diesel, common rail ECU (CDID3 S2) using Jaltest Diagnostics before replacing any components.

Initial assessment The Technician made an initial diagnosis of the electronic diesel, common rail ECU (CDID3 S2) to check whether there were any logged faults in the diagnosis memory, present or historic, which would assist in the possible cause of the DPF problem. One active fault was detected by the electronic diesel, common rail ECU (CDID3 S2): P300137 Particulate filter restriction â€“ Ash Accumulation. The technician was unsure if this code meant that the DPF required replacing, so he called the Eclipse vehicle support helpdesk for some expert advice from one of the trained technicians.

36 CVW APRIL 2020

Jaltest analysis

Carrying out the DPF regeneration

Using the Eclipse Assist (remote support), the customer was guided by the Eclipse Vehicle Support Technician to the system display screen where they could look at all the live data for the DPF. This would enable the technician to analyse all the sensor readings and determine if the fault was with the filter itself or one of the sensors that was giving an inaccurate reading. As can be seen from the reading that they obtained, the DPF reading is high but not outside the range limits to carry out the regeneration.

With the help of the Eclipse Vehicle Support Technician, the regeneration function was easily found within the software and the process was fully explained to the customer technician, ensuring that his knowledge of the Jaltest software would benefit. The regeneration process, likewise with all other Jaltest functions, guides the user through the procedure from any initial setup conditions through to the conclusion. The customer can always be confident that the Eclipse support service is on hand to help with any diagnostic problems.

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Clearing down the fault Once the regeneration has successfully been completed, the technician will then be able to clear the fault code from the vehicle and clear the warning light off the dash.

With the use of all the features available within the Jaltest software, and a support team on-hand to assist, the technician is easily able to identify both the fault and possible cause of the fault leading to the rapid rectification of the problem.

Looking after the customer Eclipse has developed its business around the core philosophy of customer support from when the system is first purchased and throughout its life. That support begins with the software, which is updated three times a year to reflect new models and more information as it becomes available, and continues with the Eclipse support services. A range of features and services are available including a comprehensive training package, which also includes full training programmes held at the Eclipse Training Centre, as well as cover from the Technical Support Service. This cover includes Vehicle Technical Support, which is a telephone-based service manned by trained and experienced professionals and available to all users to answer questions and solve vehicle problems. Eclipse is the largest supplier of multi-brand diagnostic products in the commercial vehicle aftermarket, with its Eclipse Testpad ExtremeÂŽ+ running Jaltest software helping many businesses to improve vehicle and machinery performance. There are more than 2,500 Eclipse Jaltest packages in use covering a wide range of commercial vehicles, including all LCVs.

FOR MORE SOLUTIONS FROM ECLIPSE DIAGNOSTICS, WWW.RDR.LINK/VP016

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LIGHT COMMERCIAL VEHICLES

LED BY EXAMPLE Ensuring good visibility in all conditions is of paramount importance for commercial vehicles, so Hella talks through its LED Luminator solution.

he demand on commercial vehicle lighting is high, especially when it comes to road safety and ensuring the best visibility in every situation. Hella’s LED Luminator enables halogen bulbs to be upgraded to LED, maximising lighting output. Depending on the vehicle, changing bulbs can be a lengthy process for technicians; however, with the arrival of the LED Luminator, its halogen predecessors can be easily converted to incorporate LED technology thanks to a suitable insert. It takes between 15-20 minutes to fit, and the process itself is simple: 1. Loosen the four screws from the lensretaining rim and remove the rim

2. Remove the halogen insert from the housing and loosen the cable plug connections 3. Connect the cabling from the new LED insert with the existing wiring using the enclosed crimp connectors (in accordance with the included mounting instructions) 4. Place the LED insert in the housing and replace the lens-retaining rim 5. Finally, tighten the four securing screws Along with fitting, technicians are now expected to offer advice to customers about the best solution for their vehicle. Therefore, it’s advised that technicians understand as much about the products they fit as possible. The LED Luminator is available in black or silver, and it features EdgeLight technology, giving the LED position light a more striking appearance. The quality of the illumination provided by its LED light source provides huge advantages, as it is similar to daylight, therefore contributing to creating safer operating conditions and fatigue-free driving. Furthermore, the instantaneous high-beam light signal enables drivers to flash their lights clearly and effectively.

To ensure the unit is vibration resistant even under extreme conditions, the LED Luminator’s housing and fixing bracket are manufactured using a zinc diecasting process, which is proven to enhance day-to-day durability. In order to guarantee that the light’s LEDs function at an optimum operating temperature, a horizontal cooling strip with an area of 230cm² has been integrated into the design. It has been tested according to ECE regulations (ECE R112 high beam, ECE R7 position light, ECE R10 EMC). Moreover, thanks to its multi-voltage function, this auxiliary headlamp is suitable for both 12 and 24-volt rated voltage. Senior Head of Marketing and Communications Helen Goldingay comments: “We launched the LED Luminator at the end of 2019 and it has been a tremendous success, with fleet managers particularly commenting on the reliability of the product.”

FOR MORE INFORMATION ON THE HELLA RANGE, WWW.RDR.LINK/VP017

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LIGHT COMMERCIAL VEHICLES

LIGHTS, CAMERA, ACTION Chris Horobwyj, Channel Sales Director at Trakm8, looks at the latest technology innovations helping LCV operators get the most out of their fleet.

he main priorities for any commercial vehicle operator are, amongst others, ensuring the safety of their drivers and maximising return on investment for their assets. After all, it’s impossible to run an effective CV offering without drivers or vehicles. But, in the face of dispersed fleets and workforce, how can CV operators make sure their vehicles are running smoothly and being driven safely – and efficiently? Trakm8’s RH600 solution features two ultra-high-definition cameras. The detachable camera heads service to monitor the road ahead, providing concrete proof in the face of false claims or collisions, enabling commercial vehicle operators to quickly determine responsibility.

In addition to this, the secondary camera can be used to monitor the driver’s behaviour in-cab. Again, this can be an invaluable tool in the result of a collision, but also enables operators to identify – and rectify – dangerous driving behaviours, such as mobile phone use and microsleeping (a particular concern amongst long distance CV drivers). This rich bank of data is easily accessible, and can be live streamed or downloaded from Trakm8’s portal. It can also be used alongside the host of actionable data collected by Trakm8 technology, including driver behaviour scoring, GPS, and vehicle health. The RH600 has been designed to work in close partnership with Trakm8’s wider

software offering, including the scheduling and route optimisation technologies. Trakm8’s telematics web portal takes a holistic view of a fleet, analysing available vehicles, drivers, and even individual unit capacity, to plan the most fuel-efficient route – ultimately helping commercial vehicle operators save money. Furthermore, the system calculates these routes in just minutes, saving hours that would previously have been devoted to manual planning. The utilisation of the RH600 solution can have a significant impact on business operations. For example, since installing the telematics cameras across its fleet of light commercial vehicles, a utility contractor has witnessed a 39% drop in accidents involving its vehicles, as well as a 35% decrease in speeding instances.

FOR MORE INFORMATION, WWW.RDR.LINK/VP018

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COMPLIANCE

CASE STUDY: A.I.M. COMMERCIAL SERVICES A.I.M. Commercial Services reveals the results of switching to the TruTac range of tachograph analysis and fleet management software.

.I.M. Commercial Services claims to have significantly raised the compliance standards for its customers throughout the UK in using TruTac’s range of products. Currently supplying over 1,000 operators with services including specialist vehicle and driver training, compliance Allison Kemp auditing, and tachograph analysis, A.I.M. says the TruTac platform offers more options, greater transparency, and improved functionality compared with previous experiences. Managing Director Allison Kemp comments: “Since moving to TruTac, over 300 of our ‘live’ tachograph customers have switched to TruTac, and over 90% of those who have seen the system are instantly convinced.” Allison, who has over 30 years’ professional experience, continues to say that the TruTac solution is not only more comprehensive in the checks and controls provided via each software module, but also seamlessly integrates, making system usability far easier.

“A.I.M. Commercial Services is focused on keeping vehicle operators compliant through our industry knowledge and the bespoke services and products we supply,” continues Allison. “Accordingly, we moved to TruTac because its knowledge and interactive approach to compliance control perfectly complements our way of doing things.” Particular reference is made to the TruTac modules which help to monitor and improve driver performance. A combination of TruChecks and TruLicence, says Allison, enables drivers to quickly and easily check and report on the condition of their vehicles before each journey and, thereafter, to focus on their daily driving history and to review reasons for infringements as they occur. “Roadside checks are a part of everyday life,” adds Allison. “But, with a full and clear reporting system, instantly accessible and retrievable from any portal, our customers can easily satisfy DVSA compliance regulations on the one hand, whilst encouraging drivers to improve on the other.”

About A.I.M. Commercial Services With 14 personnel in the team, the company comprises three key divisions: On-site training, including DGSA/ADR, Transport and Driver CPC, TFL/FORS approved SUD and OLAT courses, and also NOCN Cash in Transit courses; Audit and Transport Compliance; Tachograph Analysis Services. In addition, the Ripley-based company supports operators of various profiles, including vans, HGVs, mini-buses, coaches and buses, to achieve FORS accreditation. TruCheck is available on android and iOS.

TO SEE THE TRUCHECK DATA SHEET, WWW.RDR.LINK/VP019

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COMPLIANCE

Driver and Vehicle Standards Agency (DVSA) Enforcement Policy Specialist Mark Horton debunks the top myths surrounding the agencyâ€™s roadside enforcement role.

ROADSIDE ENFORCEMENT MYTHS

VSA carried out almost 200,000 roadside checks and vehicle inspections last year. Yet, many HGV drivers and operators have misunderstandings about what the organisation does. Mark Horton comments: â€œI heard all the myths connected to our roadside enforcement work when I was a frontline officer. Now, Iâ€™m in a management role, and I often hear the same untruths at seminars and conferences.â€? So, here are the most common myths surrounding DVSA enforcement work and the reality behind them:

í˘ą â€˜DVSA roadside checks include carsâ€™ This is a common confusion, but the truth is DVSAâ€™s enforcement focus is on commercial vehicles as set out by law. The Police are responsible for roadside enforcement of cars. The reason for this is clear. Commercial vehicles â€“ whether theyâ€™re lorries, vans, or large passenger vehicles â€“ pose a higher risk to road users. Often, their sheer size means the impact of something going wrong is huge and is potentially even worse when youâ€™re talking about a coach with 70 passengers on board.

Unlike the average car driver with a short daily commute, commercial drivers are on the road for long hours, so the risks are much higher. DVSAâ€™s role is to make sure commercial drivers are taking breaks and not driving for too long to keep us all safe. DVSA has dealt with over 21,000 serious driversâ€™ hours offences since last April. The Government also requires DVSA to check other road users, such as vehicles towing trailers and caravans, as part of wider road safety initiatives. However, DVSA works with the Police in joint-enforcement operations targeting all vehicles, and DVSA covers cars with its statutory work on MOTs.

í˘˛ â€˜DVSA pulls over all lorriesâ€™ The enforcement is focused on the seriously non-compliant operators to improve safety and traffic flows. DVSA is very unlikely to stop vehicles run by the safest operators â€“ belonging to DVSAâ€™s Earned Recognition (ER) scheme â€“ unless there is an obvious visual problem. This is an extra incentive to encourage operators to keep their vehicles in good order and follow the rules. The organisationâ€™s enforcement officers check how compliant an operator is at the touch of a button. Their compliance ratings are based on previous roadside checks along with other intelligence, such as annual test results of their vehicles.

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What are the benefits of joining the ER scheme?

â€œDVSAâ€™s role is to make sure commercial drivers are taking breaks and not driving for too long to keep us all safe. DVSA has dealt with over 21,000 serious driversâ€™ hours offences since last April.â€? í˘ł â€˜DVSA keeps the money from its roadside finesâ€™

í˘ľ â€˜DVSA gives out huge fines on any defect or offenceâ€™

All of the money from the fixed penalty fines goes to the Government to fund vital public services. The only exception is the ÂŁ80 fee DVSA charge to free up an immobilised vehicle once a serious defect or offence has been resolved, which partially covers the cost of the action. A large part of its enforcement funding comes from other DVSA income, such as lorry and large passenger vehicle testing fees. Above all, DVSA fines aim to deter commercial drivers and operators from breaking the rules and not maintaining their vehicles. Other deterrents include prosecutions and referring more serious offences to the Traffic Commissioner.

It is all about the level of risk, so the fine or other punishment is in line with the severity of the defect or offence. Just like a car MOT, DVSA gives out advisory notices on minor defects which need looking at but arenâ€™t serious safety risks, and these do not involve a fine. Whilst some drivers feel a faulty indicator bulb is not a major issue, DVSA ensures the bulb is replaced before allowing the vehicle to move on to prevent an accident. DVSA only hands out a fine if the driver was aware of the defect and carried on with the journey. Itâ€™s estimated 85% of defects can be spotted by the commercial driver during their required walkaround check before each journey.

í˘´ â€˜Human error causes most accidents, why bother with vehicle defects?â€™ It is true that defective vehicles account for around 2% of all road accidents, and the UK has some of the safest roads in the world. However, this is partly testament to DVSAâ€™s enforcement role dealing with vehicle defects along with car MOTs and annual tests for larger vehicles. This myth also ignores DVSAâ€™s work on distractions, such as mobile phone use and driversâ€™ hours, which help to reduce accidents caused by human error.

í˘ś â€˜DVSA maintains Britainâ€™s roadsâ€™ The clue is in the title â€“ our role covers drivers and vehicles, not the roads themselves. Councils are responsible for maintaining local roads, whilst Highways England and Traffic Scotland cover the maintenance of motorways and major trunk roads in England and Scotland. However, DVSA is part of the bigger road condition â€˜pictureâ€™ as it tackles overloaded lorries and insecure loads, which can cause significant damage to the network.

DVSA set up ER so it knew which operators could be left alone to run their business, allowing it to focus on the seriously and serially non-compliant. The scheme is free to join, with no fees payable to DVSA. One operator has seen savings of ÂŁ13,480 since joining the scheme. However, ER has many other benefits for operators, including: â– Recognition by Government as an

â– â– â– â– â–

â–

exemplary operator â€“ an advantage when bidding for contracts The ability to use the ER marque and be published on GOV.UK Efficiency savings by using a digital monitoring system Dedicated contacts in DVSAâ€™s ER team Free DVSA workshops and support Future discounts on products that DVSA is in the process of negotiating for ER members which will be useful to your business Optional additional commercial and business modules, which are being developed

Phil Breen, DVSAâ€™s National Account Manager for its ER scheme, will be on Stand 4G115 at the CV Show to answer any further questions you may have.

TO FIND OUT MORE ON BECOMING AN ER OPERATOR AND HOW IT WORKS, WWW.RDR.LINK/VP020

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COMPLIANCE

ANSWERING YOUR TACHOGRAPH QUERIES

he obligation to save digital tachograph driver and vehicle data applies equally to all companies, whether they are small, medium, or large transport companies. That seems clear enough but itâ€™s up to each individual business to decide just how itâ€™s going to fulfil this obligation. The various product offerings, from simple download keys to hardware for automatic downloading, raise many questions for those concerned and hardly anyone has the time or inclination to create a detailed analysis and weigh up the pros and cons in the stressful everyday life of a transport company. This creates frustration and means that companies fail to use their potential to improve their efficiency. Continental-VDO has sold more than 500,000 of its VDO download keys, 200,000 of which are of the latest generation. The company goes about finding the right choice for a specific fleet by asking four simple questions.

í˘ą How much can be budgeted? For fleets with small budgets, download keys are the right choice. However, if a fleet requires a higher quantity of download keys and has many vehicles to download, it pays to consider a different option. For example, an upload terminal can transfer some of the data from the tachograph to the archive automatically.

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Tachograph data can provide a great overview of vehicles and drivers, but which download system is best for your fleet? The answers to four questions will help you make the right choice, says Diego Santos-Burgoa, Head of Aftermarket Sales at Continentalâ€™s Commercial Vehicle Fleet Services business. A VDO SmartTerminal can be set up in the companyâ€™s premises and drivers can manually transfer their tachograph data to it. From here the data is fed by Wi-Fi into the company network. â€œThe important thing is to keep the total costs in mind,â€? says Santos-Burgoa.

í˘˛ Can tachograph data be downloaded manually or should it be sent automatically? At present, many transport companies have an employee who goes to the depot when many vehicles are present and walks from vehicle to vehicle with the download key, reading out the data manually. Sometimes, even the owner performs this task. Companies that want to cut back on this activity and save time should invest in automatic solutions. An upload terminal like the VDO SmartTerminal relieves this work because drivers submit the data themselves. With automatic wireless downloading via SIM card, companies can cross this job off their

to-do lists. Downloading is performed automatically at pre-set times. There is more time to deal with important matters, for example, the evaluation of their tachograph data by means of automatically generated reports.

í˘ł Will the solution ensure compliance with legal requirements? Thereâ€™s no reason to worry. By downloading their data and backing it up, transport companies fulfil their legal obligations. Backup copies can be saved on a hard disc, a server, or an SD memory card that can be inserted into a download key. However, when vehicles do not return to a depot regularly, an automatic solution like DLD Wide Range II with remote data transmission is almost imperative. Otherwise, there is a risk of not meeting deadlines. By law, driver card data must be read and archived at intervals of no more than 28 days. For vehicle data, the maximum interval is 90 days.

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í˘´

Tachograph data is easily transferred via Wi-Fi from a VDO SmartTerminal to the companyâ€™s network

What about evaluation of tachograph data? Many companies are not yet making full use of the information contained in their tachograph data. That is because they often think that the path from downloading to creation of a finished report is long and complicated. This simply isnâ€™t true. Solutions exist that can fully or partially automate this process. The data can flow directly to the archiving software or, in the case of driver data, with a single click. Many of these programs can also evaluate the data immediately. Fleet managers can obtain an overview of the fleet and drivers and increase their efficiency. An example is VDO TIS-Web from Continental, which generates reports from the data. This software was developed in conjunction with the digital tachograph and the download tools. It also displays violations that were registered by the tachograph, so fleet managers can act quickly and avoid fines.

FOR MORE INFORMATION,

WWW.RDR.LINK/VP021

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COMPLIANCE

REGULATION 48: WHAT’S CHANGING Regulation changes can be a confusing topic for many companies due to the technical details and specifications involved. With the Issue 6 amendments for Regulation 48 (REG 48) approaching, Truck-Lite gives some guidance.

EG 48 is in relation to flashing sidemarkers on all new trailers across the UK and Europe. The Issue 6 amendment requires either of the following options. All new vehicles of categories N2, N3, 03, and 04 must have either:

■ A maximum of three Category 5 (CAT 5)

indicator sidemarker lamps per side and evenly spaced, or ■ At least three amber sidemakers flashing in phase and simultaneously with the direction indicator (using a flasher unit) per side. Examples of the options in place are illustrated on the right: This Issue has been part of a gradual change across the industry over the past few years, seeing all newly-built trailers adopt the safety requirement. The aim of the regulation is to improve road safety and visibility surrounding the vehicle when changing lanes. With indicators covering the length of the vehicle, other road users – such as cyclists and passenger cars – will be less likely to misinterpret a manoeuvring signal. Truck-Lite’s dedicated trailer support team are on hand to provide advice and guidance on industry regulations, as well as recommendations on the most suitable trailer kits for the vehicle’s needs.

48 CVW APRIL 2020

CAT 5 option

Flashing sidemarker option

Part of safety is also reliability, and Truck-Lite is proud to offer a unique selection of trailer light kits including a lifetime and a five-year warranty kit which includes parts and labour. Best practice training, guidance, and tips are also provided to fleets free of charge and are aimed at prolonging the life of trailer kits.

The Truck-Lite trailer support team regularly visits customers to provide training and certification to employees fitting its lighting kits to vehicles. The unique training sessions will cover various aspects of trailer kit fitment and regulations. Some of the sections include trailer kit connections, junction plates, correct fitting

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procedures, and repair processes. The training will be accompanied by Truck-Lite’s pocket-size best practice booklets and certificates following each visit. Truck-Lite’s Model 900 multifunction LED rear lamp boasts a number of features, such as homogenous lighting, progressive direction indicating, integrated intelligence, LED failure detection, and additional takeoffs eliminating the need for a junction box. An optional proximity sensing stalk is also available to enhance driver awareness and assist trailer docking.

The Model 900 also caters for the REG 48 requirements with the ability to flash sidemarkers directly from the lamp itself. With other rear lamps, an additional flasher unit is needed alongside a junction box, but the Model 900 eliminates the need for both of

About Truck-Lite Truck-Lite Europe is a global leader in the design and manufacturing of vision systems servicing the automotive and commercial vehicle industry. Under the brand names of Truck-Lite, Rubbolite, Rigid, and Signal-Stat, the company has become a forerunner in LED and incandescent lighting technology, mirror manufacturing, and trailer assemblies. Servicing the truck, trailer, off-road, and military sectors, as well as the independent aftermarket, it has an extensive portfolio of OEM customers and over 95 years of experience in an ever-changing and evolving marketplace.

these items with an in-built flasher unit and additional take-offs for extra connectivity. Truck-Lite models 876 and 877 provide CAT 5 indicators which flash without the need for an external unit. These LED lamps have a combined function that provides additional directional indicators down the side of the vehicle. These can be fitted in sequence with the 870/871 LED marker to meet the new regulations. Alternatively, you can fit the marker lamps with the company’s model 828 flasher.

TO SEE AN OVERVIEW OF THE REG 48 AMENDMENTS, WWW.RDR.LINK/VP022

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TECHNICAL SUPPLEMENT

CLUTCHES

COMMONLY OCCURRING CLUTCH FAULTS The following faults, causes, and associated solutions are divided into possible complaints to help simplify the troubleshooting process. CLUTCH DOES NOT DISENGAGE This is not necessarily a clutch fault, but often relates to the release system. It is vital to a successful installation that vehicle manufacturer specifications and instructions are strictly adhered to.

SYMPTOM

CAUSE

SOLUTION

Tangential leaf springs are bent

Clutch pressure plate dropped Tip-in back-out clunk

Replace clutch pressure plate Check powertrain

Cover is bent

Centring pin not utilised Incorrect installation/mishandling/ damaged in transit

Replace pressure plate

Excessive clutch disc lateral runout

Mishandling/damaged in transit Lateral runout not checked (max 0.5mm)

Align or replace disc

Lining seized with rust

Vehicle left unused for extended time in high humidity

Remove rust on seized parts (including lining surface)

Linings sticking

Linings contaminated with oil/grease

Replace clutch disc & seal area around clutch

Clutch disc sticking on transmission shaft

Deformed hub profile Hub is seized with rust Incorrect grease applied Worn hub profile/transmission shaft

Rework hub profile Check lubrication (using correct grease) Replace clutch disc, transmission shaft or both

Clutch disc dimensions not aligned

Incorrect disc installed

Install correct parts

Torsional damper fouling other components

Clutch disc installed incorrectly Incorrect clutch disc

Install correct disc in line with vehicle specifications

Worn guide sleeve

Incorrect release bearing installed Incorrect pairing of components Incorrect lubrication (metal to metal)

Replace guide sleeve Use correct parts Use correct lubrication

Worn/defective pilot bearing

Worn bearing Engine and transmission misaligned

Replace pilot bearing

Release travel too short

Air in the system Defective/worn master or slave cylinder

Bleed system Replace defective/worn components

CLUTCH GRAB A worn bearing or engine setup can prevent smooth clutch engagement. Installing incorrect parts is also a regular cause.

SYMPTOM

CAUSE

SOLUTION

Pressure plate lifts at an angle

Bent/buckled tangential leaf springs

Replace clutch pressure plate Check powertrain

Contaminated clutch linings

Leaking rotary shaft seal Excessive lubrication Release bearing grease loss (due to overheating)

Replace clutch

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TECHNICAL SUPPLEMENT

CLUTCHES

CLUTCH GRAB Continued...

SYMPTOM

CAUSE

Incorrect clutch disc

SOLUTION Install correct parts

Stiff operation

Worn release bearing Worn guide sleeve Worn/defective master or slave cylinder

Replace worn/defective components

Air in the clutch hydraulic system

Leaking/defective hydraulic system

Bleed system Replace defective/worn components

Worn guide sleeve

Insufficient/incorrect guide sleeve lubrication

Replace guide sleeve Use correct lubrication

Worn/defective pilot bearing

Engine and transmission misaligned

Replace pilot bearing Check engine/transmission alignment

New clutch grabs

Clutch not configured correctly during installation Clutch booster tappet not set correctly

Configure clutch according to VM specifications/instructions Adjust clutch booster tappet

NOISY CLUTCH A whistling clutch is often caused by irregular contact of the release lever, a worn pilot bearing, or an eccentric transmission input shaft. Incorrect part installation is also an issue, whilst clutch discs with first stage dampers can cause 'clicking noises' when the load changes (without impairing functionality).

SYMPTOM

CAUSE

SOLUTION

Vibrations when engine running

Bent/buckled tangential leaf springs

Replace clutch pressure plate Check powertrain

Incorrect clutch disc

Torsional damping not to vehicle specification

Install correct clutch disc

Torsional damper broken

Incorrect clutch disc installed Excessive play in powertrain (universal shafts) Poor driving behaviour (e.g. speed does not match gear)

Replace clutch

Worn/defective release bearing

Grease loss from overheating Faulty release system

Replace release bearing Repair release system

Worn/defective pilot bearing

Worn/missing pilot bearing

Replace pilot bearing

Diaphragm spring fingers have run in

Incorrect release bearing preload

Replace slave cylinder Replace clutch

STIFF CLUTCH The most commonly occurring cause of stiff clutch operation is the release system or related components.

SYMPTOM

CAUSE

SOLUTION

Incorrect clutch pressure plate

Release load too high

Install correct pressure plate

Worn guide sleeve

Worn release bearing Insufficient/incorrect lubrication

Replace guide sleeve Use correct lubrication

Worn release shaft bearing

Worn bushes Bearings not lubricated

Replace release shaft bearing Lubricate correctly

FOR MORE INFORMATION ABOUT THE CLUTCH COMPONENTS AVAILABLE FROM SCHAEFFLERâ€™S LUK BRAND, GO TO WWW.RDR.LINK/VP023

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TECHNICAL SUPPLEMENT

BRAKES

BRAKE CALIPER REPL ACEMENT Sometimes, a situation arises where the whole caliper needs to be replaced. If this is the case, MEI Brakes urges technicians to consider a number of detailed points.

irst of all, it is important to be clear on the reason why a caliper needs changing. Failure to recognise the root cause can result in a new caliper having problems soon after instalment, for example, water ingress through the air chamber. Identifying which replacement caliper you need is also a key issue. If the original part number is still visible, then cross referencing is quite easy, but if not, it may be necessary to make some visual checks. When changing a caliper, the whole brake assembly is normally removed. On some vehicles â€“ typically trailer applications where access to guide sleeve bolts is not restricted â€“ it may be possible to leave the carrier in place. If the whole caliper assembly has to be removed, it is important to remember that when loosening (and tightening) the guide sleeve bolts, the carrier must be held securely at the same end as the bolt you are releasing (as shown in Fig 1 & 2):

í˘ą

í˘˛

Failure to hold the carrier can result in a bent or even broken carrier, due to the forces needed to release (and tighten) the bolts. If you have sufficient access to do this on the vehicle, the brake mounting bolts do a good job of protecting the carrier. With the caliper removed, the carrier can now be inspected. The pads can make indentations in the carrier abutments and corrosion can also take hold. This can result in sticking pads which can cause dragging or taper wear. Clean the abutments as shown in Fig 3 & 4 (use file or similar) and, if indentations remain, it may be necessary to replace the carrier. The carrier below had

í˘ł

í˘´

sticking pads but cleaned up well. Ensure the guide sleeve counter bores and threads are also clean and free from corrosion/damage. New calipers come with a complete fitting kit: the correct grease is important as alternatives can affect sliding, or may not have the correct thermal properties. The same applies to bolts. Use the new ones supplied and ensure they are tightened to 180Nm, plus 90Â°. This high torque ensures the bolts stay tight in all conditions. New bolts are needed as it is not recommended to tighten more than once to this level. Ensure the seal is correctly located in the groove on the guide sleeve, as shown in Fig 5:

í˘ľ

Ensure the white plastic ring is fitted correctly. This keeps the seal in the groove, as shown in Fig 6: Secure the carrier in the vice and tighten the guide sleeve bolts to 180Nm, plus 90Â°. The guide sleeve seal must be compressed prior to cap fitment, which happens naturally if held as shown in Fig 7 & 8. If it is not

í˘ś

í˘ˇ

í˘¸

compressed, the seal can balloon when the caliper is pushed back for pad fitment and become trapped. The end cap must go in exactly square â€“ using the MEI tool kit makes this job a lot easier â€“ if not there is a chance of damaging the cap, or even water ingress. Ensure that the long bolt (with lock patch) is used for the long guide sleeve on all calipers. Before refitting the caliper, check the pads and rotor for damage. Now is the time to change them if there is any doubt. After refitting the caliper, check it is sliding smoothly on the guide sleeves before pad fitment. If the old caliper had seized due to water ingress, there is a good chance that the water came from damaged air chamber seals. Therefore, it is important to check for telltale signs of water ingress. If it all checks out, then tighten the air chamber nuts to a snug torque, fully tightening to 180-210Nm. Set the running clearance (0.6-1.2mm) as follows: turn the adjuster shaft clockwise until the pads touch the disc and resistance is felt (do not exceed 25Nm torque). Next, turn the adjuster shaft anti-clockwise by three clicks (note that each click corresponds to 0.6mm of running clearance and three clicks gives 1.8mm clearance, which is more than required but allows the adjuster to settle to its natural position). Pump the brake pedal >5 times and the adjuster shaft will be seen to index clockwise, and will bring the clearance into specified limits. Finally, check for free running of the disc, fit the adjuster cap and the job is done.

FOR COMPREHENSIVE FITTING INSTRUCTIONS, WWW.RDR.LINK/VP024

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TECHNICAL SUPPLEMENT

BATTERIES

TOP BATTERY TESTER TIPS Health check The first key activity for workshop technicians is to make sure that a battery health check is completed for every vehicle that comes in. What you need to confirm, via the battery tester, is that the batteries are in balance and in a good state of charge. If they are out of balance and need a charge, double check the test results and ensure that they are getting charged correctly. It is important to really understand what the test results are telling you – do you understand the results that you are getting? If not, examine the test report, and take action to charge or replace those batteries that have been identified as requiring attention. Printing off a test report and attaching it to a ‘job sheet’ does not cure flat batteries or prevent vehicles from breaking down.

Ken Clark, Managing Director at Rotronics, provides some top tips on how to breathe new life into your workshop and get battery processes in optimal order.

Time to charge What charging time are you making available in the workshop processes? It’s not time consuming, you just need to follow the simple key steps. We have discovered that it is common practice for workshop staff to simply perform a battery test without either checking the electrical system, or remedying the test result, particularly when it comes to the ‘battery requires charging’ outcome. A battery test is a simple process, which technicians can perform quickly; however, this is only part of the process. We also find that ad hoc testing is being done, and processes can be inconsistent and numerous vehicles can go through without being checked. Rotronics has now introduced ROBIS, the wireless web-based dashboard and reporting system that helps workshops collect and analyse battery data from their regional and national workshops, quickly and easily.

We can now identify where testing and charging is not being completed consistently. Our customers, with national commercial vehicle workshops, have a clear action pathway to validate that all vehicles are being tested and charged in the correct way. This leads to improved fleet battery health and performance, and fewer costly roadside defects.

Take the extra step If a battery needs to be replaced or require further charging, how are you making sure that this happens? The old saying goes: “What gets measured gets actioned.” If a battery is suspect and the technician charges it up, it may show that it is charged. But, just

“You can’t recover a battery by simply charging it; you need to expand the process to include a battery test first to understand whether the battery itself is recoverable.” 56 CVW APRIL 2020

hooking the battery up to a charger does not necessarily mean that it is recoverable. You can’t recover a battery by simply charging it; you need to expand the process to include a battery test first to understand whether the battery itself is recoverable. If any battery requires ‘deep’ charging before it can be tested (often seen as a ‘charge and test’ result), then it should be treated with some caution. This is likely to be unrecoverable if it has been discharged for a prolonged period. Modern intelligent battery chargers may indicate the battery is fully charged, however, this can also mean the ‘charge acceptance’ of the battery is very low. This gives the impression the battery has fully recovered, when, in fact, to prevent excessive gassing, the charger has ceased charging the battery to prevent thermal runaway. In such cases, you may need to consider testing the battery after charging to ensure it has either recovered or requires replacing to prevent further defects.

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Stay up-to-date Many commercial vehicles are now fitted with enhanced flooded batteries (EFBs). Does your workshop have the technology that can accurately test these batteries? It’s crucial to ensure your workshop has the upto-date technology. There are many EFBs that can only be tested with specificallydesigned algorithms within Midtronics’ dedicated EFB testing platform.

Battery performance If you are not happy with your batteries, or the perceived performance they are giving you, should you change supplier? After all, this is often the time of year when workshops look to renew or change battery supplier contracts. We know from our research with Rotronics that, if batteries are not fully looked after, they will fail, so simply changing your battery supplier will not make any notable difference. Before making this step, consider this as an

opportunity to look at your battery-related workshop practices as a starting point, and introduce a battery management programme to fully understand the root cause for your concerns, then proceed armed with the facts.

Midtronics and Professional CTEK charging platforms, the PRO Series, 25A and above. Rotronics often visits workshops to discover unused, but still essential, equipment that is doing nothing more than gathering dust. The technicians are delighted to know that it can be repaired. If your tester or charger is showing any sign of fault or malfunction, don’t throw it away. We can help to provide a full repair with warranty if the product is still in the warranty period. One key area to check is the software on your battery testers. It is vital to ensure you can support modern day batteries, stop/start applications, and EFBs. Left unchecked, and without the latest update, your testers will misdiagnose, and this can lead to lost revenue streams and dissatisfied customers.

Don’t throw it away Dirty clamps and worn cables can frequently leave some testing and charging technology out of action. Rotronics has an expert service and repair team, offering a comprehensive service supporting all

FOR MORE INFORMATION ON ROTRONICS’ RANGE OF BATTERY TESTING SOLUTIONS, WWW.RDR.LINK/VP025

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TECHNICAL SUPPLEMENT

ENGINES

TREATING TRANSIT TURBOS Turbocharger distributor BTN Turbo offers advice on how best to replace a faulty turbo in a Ford Transit.

ord Transits are workhorses that are often pushed hard day after day. So, when a customer’s Transit comes into your workshop for a turbo replacement, you know they’ll want it back on the road as soon as possible. They certainly won’t want the replacement turbo to fail soon afterwards. That’s why BTN Turbo has issued a critical instruction specifically for this job. With over 40 years in the turbocharger business, BTN Turbo has collected masses of useful information from vehicle technicians, factors, and turbo manufacturers, and the company freely shares essential fitting advice via critical instructions.

Reducing the risk The turbo used on the Ford Transit 2.2, 2.4 and 2.5LD is a robust unit, but, like all turbochargers, it relies on a constant supply of oil. If that supply fails, the turbo bearings will quickly suffer irreparable damage and the turbo will fail. The manufacturer advises that, when replacing the turbo on these Transit engines, best practice is to replace the oil strainer and oil feed pipe. Remove the sump and clean it, and fit a new oil strainer and oil feed pipe.

Then, after 100 miles, change the oil and filter again to deal with any carbon buildup in the lubrication system. The reason for this preventative action is that most failures of this turbocharger are caused by abrasives in the oil system or restricted oil feed. Replacing the old oil feed pipe and strainer with new parts helps ensure that the turbo receives the quantity and quality of oil it needs to protect it and maintain performance.

Not just Transits It’s worth remembering that an estimated 95% of all turbo failures are caused by oil related problems. Oil starvation due to a restricted or completely blocked flow and contamination from foreign bodies, such as carbon in the oil or using the wrong grade of oil, are the main offenders. The Transit turbos covered in BTN Turbo’s critical instruction are just some of several units that are particularly prone to blockages in the turbo oil feed pipe. That’s why the company now offers a range of oil feed pipes that should be fitted when replacing a turbo on those vulnerable applications. The range includes feed pipes for the Transits affected. When you need to replace a turbo, BTN Turbo will help get it to you fast, with over 2,500 part numbers available and more than 18,000 turbos in stock ready for next day delivery. BTN Turbo is a leading UK distributor for all the major manufacturers, including Honeywell Garrett which is the original factory fit on Ford Transits.

FOR MORE INFORMATION, WWW.RDR.LINK/VP026

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TECHNICAL SUPPLEMENT

TRAILERS

TEBS

DIAGNOSIS Darren Stevens, Technical Sales Engineer for Knorr-Bremse, provides some helpful tips for diagnosing the company’s trailer electronic brake systems.

norr-Bremse introduced its first generation of Trailer Electronic Braking Systems (TEBS) in 2001. Known as TEBS 4 ECU, it became a mainstay for trailer manufacturers for the following seven years. After this, the second generation (TEBS G2) was introduced in 2008, followed by the release of TEBS G2.1 and TEBS G2.2 over the next five years. Here are some useful tips for fleet workshops running Knorr-Bremse TEBS trailer systems:

What happens if your trailer warning lamp is active? Have you tried another tractor unit? We often find trailer faults caused by bad power supplies. Trying another tractor unit/towing vehicle is an easy way to diagnose simple power issues.

Does your trailer have a TIM (Trailer Information Module) fitted? Usually mounted on the left-hand rear corner of the trailer chassis, the TIM module gives you direct access to the active and stored fault messages in our TEBS ECU. If your trailer is still covered by the manufacturer’s warranty scheme, the trailer manufacturer should be contacted in the first instance. For older trailers, one of our 80 UK-approved Knorr-Bremse Service Centres can help, details of these can be sourced from our Knorr-Bremse Technical Team. We can also supply further advise/information on our trailer systems, by phone: 0117 9846222, or via email: technical@knorr-bremse.com

Knorr-Bremse ECUtalk (PC-based) trailer diagnostics For further diagnosis of our trailer systems, a special diagnostic software is necessary – Knorr-Bremse ‘ECUtalk for TEBS4 or TEBSG2’, this can be used in conjunction with our Trailer Diagnostic Connection Kit (part number KB915). Trailer diagnosis can be carried out via a suitable laptop. PIN numbers are needed to work on the TEBS systems and to enable the replacement of an ECU with full traceability and safety. These PINs can be purchased via the Knorr-Bremse website. One number is required for TEBS4 and one pin number for TEBSG2. Purchasing the pins entitles the owner to on-site training. Knorr Bremse ‘ECUtalk’ software downloads and software PIN number applications can be carried out via our website, www.knorr-bremseCVS.com

Diagnostic developments As part of its improvements to vehicle safety and productivity, we have launched three systems for use on all types of trailer. These devices are designed to offer significant operational benefits to fleets both in terms of practicality and reducing costs. The products are: 1. iTAP (Trailer Access Point) 2. iLVL (Trailer Suspension control) 3. TPMS (Tyre Pressure monitoring) For more information on any of these products contact Knorr-Bremse technical services on 0117 9846222, or via email: technical@knorr-bremse.com

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Info screen

iTAP (Trailer Access Point) Trailer Access Point (iTAP) equips the trailer with a secure Wi-Fi connection. This means that, from the comfort of the vehicle cab, the driver can access any number of trailer functions to interrogate them for information and also to interact directly with them. This eliminates the need for bespoke wiring between truck and trailer, and also reduces the need for the driver to climb out of the cab to operate buttons and levers etc. Clearly, this has major health and safety benefits. Using a tablet or smartphone the driver can control lift axles, suspension height (iLVL), steering axles, tyre pressures and temperatures, bogie weight, air pressures and fault information. The iTAP is powered directly by and communicates with the trailer EBS. Future developments for the iTAP will include a wireless reversing camera.

iLVL screen

TPMS screen

“If your trailer is still covered by the manufacturer’s warranty scheme, the trailer manufacturer should be contacted in the first instance.”

Reverse screen

The system replaces standard level valves and raise/lower valves with a level sensor and control buttons. These allow the system to monitor and control trailer height, as well as allowing manual control. Such control allows the trailer to be set with several selectable ride and dock heights, as well as a high speed ride height or improved aerodynamics and stability. The driver can interact with the system via the buttons (multiple sets are possible), TIM (Trailer Information Module) or iTAP.

iLVL (Trailer Suspension Control) We often receive requests from our customers for suspension controls, which are outside of the normal set up. In addition to manually raising and lowering, we are asked for alternate ride heights, dock heights and other ways for the driver to control the system. To this end, KnorrBremse offers the iLVL suspension control system.

TPMS (Tyre Pressure Monitoring System) How much do tyre failures cost your operation? Keep in mind that it’s not just the tyre failure, but also damage to the trailer, late delivery and, of course, the serious Health and Safety implications of a failure on the highway. Knorr-Bremse TPMS uses sensors mounted inside the tyre to measure the pressure to ensure correct inflation of the tyre. The internal temperature is also monitored, which can warn of not only potential tyre failure, but also dragging brakes, bearing failures or other possible causes of trailer fires. This data is then collected and transmitted via – iTAP, TIM, Vehicle dash (if compatible), or a warning light.

FOR MORE INFORMATION ON KNORR-BREMSE, WWW.RDR.LINK/VP027

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TECHNICAL SUPPLEMENT

DIAGNOSTICS

Protec ting your

BATTERIES

CTEK explains exactly why batteries need support during vehicle diagnostic work.

f we take a look at modern vehicles, it could be argued that the most expensive computers that a commercial vehicle business owns aren’t sat in the office, but out on the road. And whether the vehicle is in use or in the workshop, the battery is being placed under great strain – we therefore cannot ignore the demands that complex vehicle technologies are placing on commercial workshops. CTEK’s research has identified that as many as one in four commercial vehicles arriving in the workshop has a battery problem, a threat that could cause you problems when carrying out work on the vehicle. So, whether you are repairing a vehicle, testing electrical circuits, carrying out diagnostic procedures, or flash programming ECUs, battery support is a vital activity often not fully appreciated for its ability to save the technician time and hassle. It will also guard against programming failures and prevent possible costly damage to the ECU. The reprogramming of ECU modules and fault code diagnostics requires the ignition to be switched on without the engine running. This means that, during programming, the vehicle's systems are operated solely from the power of the battery. Maintaining battery charge is critical to avoid unnecessary down time, lost vehicle data, or even damage to sensitive electronics. ‘Battery support’ (as

PROTECT AGAINST DE-RATING Battery support units deliver high levels of power over a relatively long period of time, and as a consequence they can generate a lot of heat. As a safety precaution, many units are set to derate. This is a process whereby the unit will reduce charge levels, and at really high temperatures reduce current output. De-rating is becoming a huge challenge to many workshops, risking disruption to the diagnostic or reprogramming procedure. distinct from charging) is vital for the supply of ‘clean’ constant voltage for vehicle programming. It will also protect against loss of battery charge, and against the battery from discharge when the work is complete and the vehicle is back out on the road. Should battery voltage alter significantly during reprogramming, the program can fail – meaning a time consuming restart – or worse still, the ECU can be damaged beyond recovery, requiring expensive replacement. Using equipment dedicated to battery support is now a necessity in the modern commercial vehicle workshop. Using a slave battery, standalone battery charger, or booster pack is not appropriate.

Slave batteries and boost packs are unreliable as they depend on a battery themselves, so they can struggle to cope with sudden increases in current demand. ‘Pure’ battery chargers are not recommended either, as they can increase battery voltage beyond operating levels – fine for charging – but can affect reprogramming procedures, as well as possibly damaging sensitive test equipment. The MXTS 40 from CTEK provides a stable voltage and up to 40Amps in 12V mode, and 20Amps in 24V mode, of fully regulated power. This prevents loss of charge and damage to the battery, so it’s ideal for a wide range of commercial vehicles with average power consumption. If even more power is required, the MXTS 70 provides up to a 70amps of battery support (35Amps) in 24V. This unit gives the flexibility to cover all vehicles, including high specification vehicles with large flash programming demands. Using a CTEK battery charger in ‘Supply’ mode maintains an ideal battery voltage throughout the period of repair or reprogramming, at the ideal voltage.

FOR MORE INFORMATION ON CTEK’S RANGE, WWW.RDR.LINK/AP028

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TECHNICAL SUPPLEMENT

DIAGNOSTICS

Scania R480 â€“ Poor idle, misfire and smoke Ben Martins, Automotive Application Specialist at Pico, talks us through the process of diagnosing a misfire fault.

was recently asked to take a look at a 12.3 litre HGV. I was lucky to have assistance on the day, with access to the relevant technical information. A slight misfire had started at idle and worsened over time. A heavy diesel knock was present when started up from cold. There were no warning lights, but a strong fuel smell with smoke. It all improved as the engine warmed up, but with the engine at idle and the crane in use, over time the symptoms returned. The way this engine injects fuel is very different from typical systems. It has individual cylinder heads for each of the 6 bores and the injectors are mechanically operated by a pushrod. The system alters how much fuel is injected and how long the injector is open with four solenoids attached to a fuel gallery, linking the front and rear bank. Instead of using electrically â€“ controlled injectors, the diesel pressure act hydraulically on the injector to determine how much fuel is injected when the mechanical rocker depresses the upper plunger. It has a set of six injectors, three at the front and three at the back of the engine. It would be really easy to look at all this information and check the controlling solenoids, measure fuel pressure, or look for a leak of pressure. However, in this particular case, I chose to check DTCs first.

í˘ą Despite there being no warning lights, there could be stored fault codes which could steer us in the right direction. A quick scan of the ECM found a crankshaft sensor rotation code. Referring back to the technical information and wiring diagram, there were two inductive crankshaft sensors. There is no camshaft sensor as itâ€™s a fixed gear. Timing is done by fuel. Apart from a rail pressure sensor, there isnâ€™t really anything to monitor the injection.

I decided that a potential issue with a crankshaft sensor needed to be checked out first. Something must have happened to trigger the code. The scan tool didnâ€™t say was which sensor to look at, so we used the wiring diagram to find the connectors. As this test would only utilise two channels, I used the other two to look at the current draw from the timing solenoids, providing a rough trigger point for each cylinder. 1. Âą50 V due to inductive sensor 2. AC coupled for inductive sensor 3. Ch. A LH crankshaft sensor 4. Ch. B RH crankshaft sensor 5. LH Timing Solenoid 6. RH Timing Solenoid

í˘˛ 64 CVW APRIL 2020

Channel B has a good waveform pattern, with the typical AC signal and the gap for crankshaft position reference. This is not the case for Channel A, which has no gap, but two smaller pick-up points with an odd reverse effect on the lower half of the signal. I had the chance to capture a known good waveform from one of the other R480

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engines on site to use for comparison, where Channel A was massively different compared to our faulty vehicle. This was enough evidence to remove the sensor for inspection. The fault code didnâ€™t give enough detail as to which sensor was faulty and, without the scope, we could have wasted time removing and replacing the wrong parts. We also decided to remove the inspection plate between the crankshaft sensors, which revealed more than expected. There were drilled holes used as teeth for the flywheel and the missing teeth, a non-drilled section of the flywheel. We also saw damage to the ring gear. This could be down to a number of reasons which would have been nice to explore, but the company needed the truck back on the road.

í˘ł Once the sensor was removed it was quite clear there was damage. We fitted a new sensor and re-tested.

í˘´ 1. Same settings as before. 2. Ch. A LH Crankshaft sensor. 3. Ch. B RH Crankshaft sensor. The trace is a lot cleaner and the misfire improved. The smoke and smell of unburnt fuel and the sound of diesel knock were also gone. There was still a slight judder in the mid-RPM range but the technician I was with said he wouldnâ€™t replace more parts until he had done a top-end adjustment. He believed a lot of the leftover judder could be eradicated with this procedure. After clearing the codes and doing a re-check, the crankshaft code didnâ€™t reappear and the truck went to work.

FOR MORE INFORMATION, WWW.RDR.LINK/VP029

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TECHNICAL SUPPLEMENT

FILTERS

MYTH BUSTERS Mann-Filter lifts the lid on the most common myths associated with filters. MYTH í˘ą â€œThe same paper is often used in both cheap and expensive filters â€“ at the end of the day, there are only a handful of filter paper manufacturers worldwide.â€?

Standardised production processes and production technology lead to high product quality and help keep production costs competitive.

MYTH í˘˛

MYTH í˘ł

Wrong! Consider the facts: The number of filter material manufacturers is indeed small, but the origin of the paper tells you nothing about its quality â€“ and nothing about the efficiency of the filter. There are many other factors that have a significant effect on the quality of the filter media, such as: â– impregnation of the filter media â– improvement through the use of

activated carbon or nano-fibres â– type and quantity of the synthetic fibre

added to the paper pulp

â– optimum level of automation

Whatever the application, Mann-Filter selects the right medium for the job from the wide range available, as well as developing special, high performance filter media, which combine all the necessary properties.

â€œFilters produced by low-cost manufacturers are less expensive and are almost as good as MannFilter filters.â€? Wrong! Consider the facts: Low cost is not good, because expensive raw materials are the main driving force behind the price. Without good material, nobody in the world can make an efficient filter. These are precisely the ways in which Mann-Filter differs from less specialised manufacturers:

â€œMann-Filter filters are produced with the same technology as cheap filters. Cheap filters mainly cost less because they are not so widely advertised.â€? Wrong! Consider the facts: Even if it were assumed that only the paper was pleated and that the other components were thrown together in some way, this statement contains little truth. The key features of an OE-quality Mann-Filter product are:

â– composition of the synthetic raw

materials used in production â– drying time and temperature â– production processing (pleating, curing

using heat)

â– standardised processes â– well-trained specialist staff â– high-quality raw materials and filter

components

â– highest development competence

â– â– â–

â–

through many years of partnership with vehicle manufacturers production technologies certified according to the latest standards high quality materials optimally adapted to the application latest test methods according to OE specification and international test standards continuous quality control throughout the entire production process

Mann-Filter constantly invests in the continuous further development of test standards and production processes. This investment pays off and represents the essential difference compared with cheap products.

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MYTH í˘´ â€œUnlike with oil filters, the quality of air filters is not an issue â€“ they are more or less all the same and are not as important for the running of the car. You can opt for the bottom price range without any problem.â€? Wrong! Consider the facts: Oil filters are usually highlighted and attract the most attention. However, the importance of the air filter has increased enormously in modern vehicles. Reasons why you shouldnâ€™t skimp on this: â– modern engines are becoming

increasingly efficient and are, therefore, placing ever higher demands on air filters â– with the increase in the air volume passing through the filter, both the load on the air filter and its importance have risen â– an efficient air filter is the basis for optimum fuel combustion â– if water enters the air filter housing, the correct function of simple air filters can no longer be guaranteed, which leads to a drop in engine power

â– a flame-retardant impregnation protects

both the engine and the vehicleâ€™s occupants

any attempt to clean an air filter can have detrimental effects: â– mechanical stress during the cleaning

The technologies and materials that are used in internal combustion engine blocks have become much more sensitive. If low efficiency air filters are used, the hard surface coating of the cylinder block will be attacked by particles that have not been removed and an active wear process begins. With modern engines, there is then only one solution â€“ replace the original block with a new one.

MYTH í˘ľ â€œAir filters do not necessarily have to be changed at each vehicle inspection. It is enough to clean them or blow them through with compressed air to restore their function.â€? Wrong! Consider the facts: Permanent temperature loading of 80ËšC and temperature peaks of more than 100ËšC can occur at the filter element during vehicle use. Even materials of the highest quality will, therefore, age and suffer fatigue. Also,

process can lead to rupture of the pleats â€“ which means the end of the filtration effect â– the high cleaning air pressure may destroy the structure of the filter paper, reducing the dust holding capacity. The reduced holding capacity in turn reduces the service life â– dirt particles can enter the engine through broken pleats and damaged structures Mann-Filter air filters use the very latest filter media, which achieve high separation efficiencies, so technicians can be certain that even the most modern engines have the best protection at all times. Through special processing, a long service life can be achieved and service intervals greatly extended, even under harsh environmental conditions.

FOR MORE INFORMATION, WWW.RDR.LINK/VP030

APRIL 2020 CVW 67

When life changes we're life changing.

Life can throw the odd curved ball no matter what stage of life you're at: money worries, illness, mental health issues, social isolation. It can create a downward spiral for you and your family. It's why Ben's here. At these moments our support and care services can be life-changing. Ever since there's been an automotive industry Ben has been helping its people and their loved ones keep life on track. Together we’ll tackle the challenges that get in life’s way and make sure they don’t, for life.

Always here for you www.ben.org.uk Helpline 08081 311 333

Find plenty of advice, online chat and self-help tools on our website, or talk to us on the helpline, free and in complete confidence, Monday-Thursday 8am-8pm, Friday 8am–5pm

Here for the automotive industry

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TECHNICAL SUPPLEMENT

AIR CONDITIONING

WHEN TO REPLACE THE RECEIVER DRYER Nissens takes a look at the receiver dryer and when to replace it. BACKGROUND The receiver dryer is a filtering unit located on the high-pressure side of the AC loop, between the condenser and the expansion valve. The part’s main role is to filter particles and debris flowing in the circuit, as well as to absorb any moisture. The receiver dryer also stores the refrigerant and lubricant.

What can impact the receiver dryer function? Wear Filtering and desiccant layers are normally worn out after a period of time. This will cause the receiver dryer to lose its ability to properly filter the refrigerant and oil.

System opening If the system is opened during service procedures or the system is leaking, the extremely hygroscopic desiccant will attract moisture from the air, thus losing the ability to remove any humidity from the system. Running the system empty due to leakages will also negatively impact the receiver dryer.

Excessive system pollution Particles produced by chemical reactions caused by the wrong use of additives (flushing, leak-stop agents), wrong oil mixtures, particles from compressor seizure, inner corrosion and/or carbonised oil caused by overheating, can quickly soil and clog the receiver dryer.

Too much oil in the system PROBLEM The receiver dryer is crucial for optimal system operation and especially for the longevity and vitality of the compressor. Absorbing moisture in the AC system prevents inner corrosion and ensures proper system/compressor lubrication. In addition, particles, debris, metal chips, and other materials flowing in the loop are filtered and kept away from the system components, preventing them from clogging (condenser, expansion valve, evaporator) or seizure (compressor). If the receiver dryer is worn out, spoiled or not operating, it will eventually lead to circuit clogs, abnormal system pressures and, ultimately, lack of performance. This will seriously affect other system components, where the compressor is particularly at risk. Under normal running conditions, both inlet and outlet lines of the dryer should feel warm and be more or less the same temperature. A cold outlet line or any frost spots on it is an indication that the filter has failed.

Excessive lubricant volumes reduce the dryer’s ability to filter the system properly as the desiccant and filter layers become too oily or saturated. Too much UV agent or flushing agent residue in the system will have the same effect on the receiver dryer.

Contamination of the inlets and outlets will cause the receiver dryer to clog

Worn out desiccant and filtering layers inside the receiver dryer

An overflowing desiccant layer inside the receiver dryer

A worn insert bag dryer – desiccant has been soaked by too much UV agent

RECOMMENDED SOLUTION It is recommended that the receiver dryer is replaced every second year or whenever the circuit has been opened. Always install a new receiver dryer any time the compressor is replaced and always when a serious leakage has been noticed and repaired. During service procedures, such as flushing the system, the part must be bypassed and replaced after the procedure is completed. Follow user manuals and manufacturers’ guidelines whenever applying additives such as UV dye agent, leakstops, and/or flushing agents. Excessive volume or improper use of additives and/or oil will spoil the receiver dryer. Avoid exposing a new dryer to the ambient air by, for example, removing sealing caps or leaving the circuit open without seals.

TO FIND OUT MORE ABOUT THE AC COMPONENTS AVAILABLE FROM NISSENS, WWW.RDR.LINK/VP031

APRIL 2020 CVW 69

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GIVEAWAYS

ARE YOU FEELING LUCK Y? FOR YOUR CHANCE TO WIN THESE GIVEAWAYS, GO TO WWW.RDR.LINK/VP032

10 THREADLOCKING STICKS

10 500-POINT BONUS CARDS

HENKEL

Haldex

Loctite anaerobic threadlockers from Henkel provide a quick and easy way to prevent the loosening of threaded fasteners on engine components and chassis. The adhesive fills all voids, completely sealing space between the threads to prevent galling and corrosion. Loctite 248 sticks are a popular choice for all metal threaded assemblies, and are perfect for applications where a liquid product is too fluid to stay on or is too difficult to apply. This waxlike, semi-solid product offers a medium bond strength for threads up to M50. It secures and seals bolts, nuts, and studs to prevent loosening due to vibration. Suitable for use on all metal surfaces, it is also effective on substrates such as stainless steel and has been proven to tolerate minor contamination by industrial oils such as engine oils.

Valeo is offering 500-point bonus cards for the Valeo Specialist Club. The club is a rewards programme for technicians that offers incentives for loyalty and is available online or via smartphone app. Purchased products simply need to be scanned to earn points, which can then be redeemed against a wide selection of items. The club covers products for both passenger cars and commercial vehicles, and allows garages to sign up using one account or open multiple accounts to reward individual teams. Sign up to the Valeo specialist club at www.valeoservice.co.uk, or via the specialist club app.

ROTRONICSâ€™ EXCLUSIVE CVW GIVEAWAY To help bring your fleet back to life, Rotronics is pleased to offer CVW readers 10% off any calibration or repair, PLUS a free carry case (worth ÂŁ36) with every tester sent in for repair. Get in touch with the Rotronics team by calling 0121 514 1161 and quote CVWSB20. This exclusive offer expires on 31/05/20.

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WHAT’S NEW?

OPTIMAL UK DOLZ WATER PUMPS The Dolz range of water pumps and water pump and timing belt kits now complement the existing range available from Optimal UK. The complete range consists of over 1,200 references for commercial and passenger car applications. Optimal offers over 200 references for truck applications, as well as 70 kit references and over 400 water pump references for light commercial vehicles. All water pumps are of OE quality and come complete with the necessary components needed for a quick and easy installation, including an O ring and paper gasket. WWW.RDR.LINK/VP033

GRANVILLE OIL & CHEMICALS ENGINE OIL Granville Oil & Chemicals has expanded its Hypalube range. Joining the range will be two new grades of engine oil: ■ Hypalube FS 0W/20 – a fully synthetic, low-viscosity engine oil formulated for fuel efficiency. It also provides wear protection under the extreme conditions. ■ Hypalube FS 5W/20 – a synthetic engine oil, formulated to meet the performance demands of the latest intelligent eco-engines. The Hypalube Commercial range, Hypafleet, has also been introduced. This range of commercial lubricants offers products primarily in 20L and 199L sizes, with certain grades being available in a handy 5L bottle. WWW.RDR.LINK/VP034

VISION TECHNIQUES VT STOPSAFE

DELPHI TECHNOLOGIES DPF CLEANER Delphi Technologies has launched the Hartridge DPF200 Master. Using Hartridge’s DPF200 Master, workshops can quickly and safely clean blocked particulate filters. As well as helping to improve the vehicle’s fuel economy and emissions performance by significantly extending the filter’s service life, it avoids the need for a complete filter replacement. This ensures a more cost-effective service and avoids unwanted vehicle downtime in the future. The easy-to-use software built into the machine includes flow testing and ‘failed cell’ detection diagnostic steps so that a faulty filter can be identified prior to cleaning, increasing efficiency of diagnosis and treatment. WWW.RDR.LINK/VP035

West Dunbartonshire has become the first Scottish Council to introduce the VT Stopsafe system that allows its refuse collection vehicles to be brought to a controlled stop in an emergency situation. The emergency braking system allows crew members or other passengers to safely slow down and stop the vehicle if the driver loses control for any reason. When the system is activated, it limits the vehicle engine revs from the accelerator pedal and uses braking pulses to bring the vehicle to a halt in seconds. This method means the vehicle won’t swerve, skid, or lock up, reducing the risk to other road users and pedestrians. Once activated, alarms also sound from the vehicle to alert pedestrians to an approaching hazard. The Vehicle Certification Authority (VCA) approved safety feature was installed in each of the Council’s 21 bin lorries over the past few months, and all waste services staff have received training in operating the system. WWW.RDR.LINK/VP036

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WHAT’S NEW?

SNICKERS LIGHTWEIGHT WORKWEAR LASER TOOLS SPOT REPAIR SANDER & POLISHER KIT The spot repair orbital sander and polisher (part number 7683) from Laser Tools is a compact air tool powered by a workshop’s compressed air supply. The product has a maximum RPM of 13,000 and an average air consumption of 2.6 CFM. The speed of the spot repair sander can be easily adjusted on the instrument. Its well-balanced action and selection of sanding pads is suited to smaller repairs, letting the operator contain the sanding action to just the damaged area. Included in the kit are three different sized sanding pads, and two types of polishing head. Additionally, a selection of abrasive sanding discs is included.

The LITEWork range from Snickers can help you keep cool when working in warm and humid environments. The ergonomic trousers, shirts, shorts, mid-layer Jackets and wind-proofers have the comfort, and functionality of other Snickers Workwear stretch garments whilst giving extra freedom of movement. LITEWork garments are also quick-drying, with ventilation and moisture transport features that keep you feeling cool wherever you are on site in warm weather. WWW.RDR.LINK/VP038

WWW.RDR.LINK/VP037

GYS WELD FUME SOLUTIONS To help keep staff safe from the risks of welding fumes, GYS offers two solutions: ■ The Gysmatic 5/13 Air Truecolour XXL, an air-fed welding helmet ■ A range of fume extraction systems, including the EVO 2.1 RE The helmet features a 100mm x 83mm, XXL Truecolour lens. The three-speed motor supplies purified air into the helmet at a speed of up to 220 litres per minute. The helmet comes equipped with a shoulder harness, battery pack, charger, and spare filters. The EVO 2.1 RE fume extraction unit extracts and purifies air at the rate of 1200 cubic metres per hour. The mobile unit has a three-metre arm, which can be placed over the welding area.

SEALEY SPRING 2020 PROMOTION With over 570 offers and more than 80 new products, Sealey’s Spring Promotion offers discounts of up to 55% off. The promotion is valid until 31st May 2020. It includes a number of product types, including hand tools, lighting, storage, jacking and lifting, welding and cutting, motorcycle tools, pumps & janitorial items. The promotion can be viewed on the company’s website, where you can also search for spare parts and register warranty. Catalogues are also available from your local stockist or can be requested and viewed online. WWW.RDR.LINK/VP039

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PROFESSIONAL MOTOR MECHANIC

MECHANEX

THE REGIONAL TRADESHOW FOR AUTO REPAIR PROFESSIONALS

GETTING READY FOR SANDOWN PARK! The UK’s only regional tradeshow dedicated to garage businesses is gearing up for another year. We look forward to seeing you!

EVERYTHING YOU NEED TO STAY AHEAD OF THE GAME The automotive aftermarket is evolving at an alarming rate, so it’s more important than ever that you stay on top of the latest technology, training, products and information available to your business. Attending this year’s MECHANEX – the only regional show dedicated to the specific needs of garages in the UK – is the perfect way to ensure that you are up to speed. The dates for this year are:

10TH – 11TH NOVEMBER 2020 GET SOCIAL To keep up to date with all things MECHANEX in 2020, be sure to visit WWW.MECHANEX.INFO, like us on Facebook and follow us on Twitter!

MECHANEXShow

@MECHANEXShow

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ADVERTISEMENT INDEX Actia Limited .............................................................. (page 22)

Liftmaster Limited ...................................................... (page 73)

Atlas Copco ASAP Service Centre ............................ (page 33)

Maha UK .................................................................... (page 21)

Ben .............................................................................. (page 68)

Mann & Hummel UK Limited ...................................... (page 12)

Bowmonk Limited ...................................................... (page 21)

Merridale Limited ........................................................ (page 21)

Castrol UK Limited ........................................................ (page 4)

Mirka (UK) Limited ...................................................... (page 37)

Commericial Vehicle Show .......................................... (page 4)

Morris Lubricants ........................................................ (page 38)

Continental Automotive Trading Limited .................... (page 65)

Optimal Distribution UK Limited ................................ (page 70)

CVW Online ................................................................ (page 58)

Premier Diagnostics Limited ...................................... (page 42)

DPF Recovery ............................................................ (page 18)

Premier Pits Limited .................................................... (page 27)

Drakefield .................................................................... (page 50)

RDR.link ...................................................... (inside back cover)

Eclipse Automotive Technology Limited .................... (page 41)

Ring Automotive ........................................................ (page 22)

Energizer Auto UK Limited .......................................... (page 62)

Robert Bosch Limited ................................................ (page 15)

Ferdinand Bilstein UK Limited .................................... (page 54)

Rotronics Battery Management Solutions .................. (page 11)

Garage Equipment Association .................................... (page 9)

Schaeffler (UK) Limited .............................................. (page 57)

Gemco Equipment ...................................................... (page 24)

Stertil UK Limited ........................................................ (page 34)

Hella Ltd ................................................................ (Back cover)

T Cards Direct ........................................................(loose insert)

Hella .................................................................. (Bound outsert)

Totalkare Heavy Duty Workshops .............................. (page 29)

Honda (UK) .................................................................. (page 16)

Truck-Lite Europe ........................................................ (page 47)

Hope Technical Developments Limited ...................... (page 41)

VBG Limited ................................................................ (page 49)

Induction International ................................................ (page 62)

Vision Techniques ...................................................... (page 53)

Jack Sealey Limited .................................................... (page 30)

VLS (UK) Limited ........................................................ (page 29)

Knorr Bremse Truck Service ........................ (inside front cover)

Volvo Group UK Limited (Roadcrew) ..........................(page 38)

KEEP UP TO DATE WITH CVW

LIKE US ON FACEBOOK

VISIT OUR WEBSITE

@CVWMAGAZINE

WWW.CVWMAGAZINE.CO.UK

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WANT TO KNOW MORE? TO HELP YOU FIND OUT MORE ABOUT ANYTHING YOU’VE SEEN IN THIS ISSUE, WE’VE INTRODUCED A NEW DIGITAL INFORMATION SERVICE. RDR.LINK IS DESIGNED TO GET YOU FASTER ACCESS STRAIGHT TO THE EXACT ONLINE PLATFORM THAT HAS THE SPECIFIC INFORMATION YOU WANT. FROM VIDEOS TO TECHNICAL GUIDES, PDF’S TO PODCASTS – RDR.LINK WILL TAKE YOU STRAIGHT THERE.

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