Commercial Vehicle Workshop May 2022

001_CVW_APR22_Layout 1 27/04/2022 14:45 Page 1

The trade magazine for servicing and repair professionals

COMMERCIAL

VEHICLE WORKSHOP M AY 2022

DON'T WASTE TIME! Discover how a waste management specialist has “revolutionised” its workshop and fleet management.

Also in this issue…

■ The CV Show returns ■ We look back at the most read technical articles on our website ■ What role are operators playing to achieve net zero?

■ It all starts with a tidy workshop...

CPN/CVW page grid_Layout 1 20/05/2021 11:21 Page 1

003_CVW_MAY22_Layout 1 27/04/2022 14:49 Page 3

CONTENTS

Volume 19

Issue 5

REGULARS 5

Viewpoint

10 Business & Training

6

News

49 What’s New?

CV SHOW PREVIEW 17 Show director Murray Ellis answers some questions ahead of the CV Show 18 CV Show preview

26

EMISSIONS 23 A look at the role of operators in achieving net zero for commercial vehicles and advice for those looking to cost effectively upgrade fleets 24 HELL A reveals the expansion of NOx sensors range

30

25 CVW speaks to David Wright about the latest developments in emissions standards and their impact on lubricants 26 Ceramex makes a case for the significance of a circular economy

WORKSHOP MANAGEMENT 29 Pro-Align's stance on how Hunter's workshop equipment can help improve efficiency 30 Jack Cockerham from Kärcher UK highlights the importance of having a tidy workshop 32 Collard skips forward with Truckfile workshop and fleet management software

TECHNICAL SUPPLEMENT 36 Schaeffler REPXPERT, Tim Adams, runs through a timing belt installation 38 Why check the flywheel? ZF Aftermarket explains all 40 febi runs the rule over electrical coils 44 The DVSA’s tips on making sure brakes aren’t the reason annual tests are failed 46 Tips on how to correctly apply Teroson MS 9320 SF seam sealant

40

48 In part eight of the series, Bosch examines ESI Truck’s advanced mode

MAY 2022 CVW 3

CPN/CVW page grid_Layout 1 20/04/2022 09:05 Page 1

005_CVW_MAY22_Layout 1 27/04/2022 14:51 Page 5

VIEWPOINT

www.cvwmagazine.co.uk

CVWmagazine

@CVWmagazine

BEGINNING A NEW CHAPTER

Editor TOM HENMAN Editorial Assistant FREYA COLEMAN Group Editor KIERAN NEE Digital Manager KELLY NEWSTEAD Senior Account Manager ALEX DILLEIGH Group Manager ROBERT GILHAM Graphic Designer GEMMA WATSON Group Production Manager CAROL PADGETT 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 © 2022 ©jamesteohart/AdobeStock (pg6) ©Melanie Kocheva/AdobeStock (pg 24)

W

elcome to the May edition of Commercial Vehicle Workshop (CVW)! This is my first issue since taking the reins in early April – and what a time to do it as I become a father for the third time!

It’s been a hectic time, juggling many different things – from editorial schedules to nappies! – but I’m delighted to be able to sign-off this issue and hit the ground running, almost literally to the CV Show, which takes place later this month (24th-26th).

This year, we have the pleasure of collaborating with the show’s organisers to produce the Workshop Theatre. Like 2021, we have approached brands about borrowing their experts for the event, so they can share their knowledge and experience with visitors all looking to polish their skillsets and learn something new as well.

As you’ll read in the CV Show preview (pgs 17-21), more than 200 exhibitors are raring to go and are keen to seize the opportunity of having CV associates all camped under one roof at the NEC. I had a chance to put some questions to CV Show Director, Murray Ellis, and he is bullish about this year’s event, which reverts back to its spring timeslot, and is keen to get going.

I asked him what he would say to CV professionals, sitting on the fence and undecided about whether to attend, in a bid to convince them to sign-up – he replied: “If you’re in the CV industry, then this is the business event that you cannot afford to miss! It is the show for the industry. A place to see major VMs, new products and the latest technology – reflective of the innovation from within the sector.

“Remember, live trade exhibitions are an essential part of doing business. They are unbeatable at providing the very best opportunity to see the new products and services available on the market. Nothing beats being able to examine these vehicles and products, along with learning first-hand about future trends in the industry and the opportunity to engage in that face-to-face interaction.

“Many big brand names will join other well-respected companies and start-up enterprises, as the Commercial Vehicle Show continues to provide a platform as the key event in the sector where business gets done.”

CVW will be hosting its own stand – 4C33 – and I hope many of you will stop by – I'd be delighted to have a chat! I am eager to meet and build relationships with the hard-working people that take time out of their busy schedule to read the magazine, so I hope you’ll introduce yourself!

In the meantime, enjoy the issue and, fingers crossed, I’ll see you at the CV Show in a couple of weeks’ time.

Tom Henman 8,459

Editor

From 1 July 2020 to 30 June 2021

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

MAY 2022 CVW 5

006_CVW_MAY22_Layout 1 27/04/2022 20:55 Page 6

NEWS Rising freight prices New industry index data reveals March’s average haulage and courier price-permile was up 12% year-on-year.

Cutting carbon UK Fuels has launched a new service that is said to offset 100% of the carbon its fuel card customers currently release from the 1 billion litres they use each year.

The average price-per-mile for haulage and courier vehicles increased from 100.6 points to 112.2 points between March 2021 and March 2022, according to the TEG Road Transport Price Index. These year-on-year increases have now continued for 14 months due to Brexit, driver shortages, high fuel prices and various other factors.

High fuel prices is one aspect putting a strain on the road freight industry, along

with the war in Ukraine and subsequent disruption to global fuel supplies further exacerbating the issue. High prices at the pumps have already had significant impacts on both businesses and consumers. Another issue is supply chain concerns; some manufacturers are facing shortages of components produced in Russia, while farmers’ costs are rocketing due to the price of gas, needed for fertiliser and heating greenhouses. At the end of the supply chain, cost of living rises have been well documented, with expenses surging for twothirds of UK adults, according to ONS data.

UK Fuels, the UK’s biggest supplier of fuel cards and carbon offsetting service, has partnered with UK-government endorsed carbon offsetting company Forest Carbon to invest in renewable energy projects. Businesses which take up the new service can reduce their carbon footprint and support their social and environmental responsibilities, while avoiding the risk of wasted investment in ineffective offsetting schemes. This is said to benefit 76,000 fleet businesses and their 500,000 drivers using UK Fuels’ cards.

"Businesses which take up the new service can reduce their carbon footprint and support their social and environmental responsibilites."

As well as UK environmental projects, investment will be made around the world in renewable energy projects including wind, hydro, wasteto-energy and solar power – chosen for their ability to achieve immediate carbon neutrality. The company has also pledged not to take any profits from the new biodegradable Radius Future fuel card. Companies will pay 1 pence on each litre of standard fuel, which will be invested by both Forest Carbon and UK Fuels. Carbon footprints will be calculated using UK government conversion factors that correlate litres of diesel and petrol to the equivalent emissions in tonnes of CO2 .

6 CVW MAY 2022

LC V registration decline New light commercial vehicle (LCV) registrations decreased by 27.6% in March to 40,613 units, according to the SMMT. Following last month’s growth, the medium-sized van segment (>2.0 – 2.5 tonnes) saw a significant decline. Year to date, this segment, which is a good indicator of the robustness of the service sector, is 11.6% below 2021’s levels. Looking at the other segments of the market, pickups fell by 48.4% to 4,457 units; small

vans experienced a significant decline, down by 70.8% to less than 1,000 units, whilst 4x4s fell by 33% although this is the smallest segment in volume terms (446 units). Positively, sales of battery electric vans (BEVs) rose by 17.7% to 1,909 units. In the first quarter of the year, BEVs were up by an impressive 68.9%. Lastly, Ford was the market leader in March with a 41.9% share. It was followed by Vauxhall (10.4%) and Citroën, Peugeot and Volkswagen with an 8.1% market share each.

006_CVW_MAY22_Layout 1 27/04/2022 14:59 Page 7

www.cvwmagazine.co.uk

CVWmagazine

@CVWmagazine

Commercial Vehicle Workshop

Second-hand ease

Van safety priority

Scania UK has announced Scania Go, its used vehicle programme, designed to give customers “ultimate transparency and peace of mind”.

The introduction of the Highway Code Hierarchy and enforcement of the Direct Vision Standard in London has made commercial vehicle (CV) safety a priority for business owners.

Whether a buyer wants a low mileage twoyear-old vehicle, a high-powered V8 or one that’s up to five-years-old and 550,000kms on the clock, there is a vehicle available to suit all budgets. Each handpicked truck, bus and coach will be supported by a set of flexible benefits. They are designed to take away the stress when buying and ensure it meets the company’s standards for used vehicles, while also allowing customers to tailor the support they receive from Scania UK and its 84 nationwide service centres.

Supporting the used programme are a set of core benefits which customers of trucks, buses or coaches can enjoy. There are also two additional features for truck buyers – the Replace Before Failure Guarantee and

Crystal Clear Grading. The former is preventative maintenance carried out by the company ahead of the vehicle being sold, and the latter gives transparency about the truck’s age and mileage. Every used vehicle will be treated to an improved and rigorous 300+ point mechanical and cosmetic inspection, which includes a thorough test drive all carried out by a Scania UK technician.

Tyre choices Volkswagen selects Vredestein Quatrac allseason tyres for new Caddy.

Volkswagen Commercial Vehicles has selected Apollo Tyres’ latest Vredestein Quatrac all-season tyres as original equipment (OE) for the new Caddy. The agreement means that Quatrac tyres in 205/65R15 99H XL specification will be fitted as standard to selected Caddy models at point of manufacture, at Volkswagen’s production

facility in Poznan, Poland.

The tyres chosen for the Caddy meet a range of challenging performance criteria, offering high levels of fuel efficiency (class A), handling in wet, snow and dry conditions, as well as affording impressive comfort and a quieter ride. To support Volkswagen Caddy customers in the long term, the selected tyres will also be available on the European replacement market.

Whether driving a single van around town, managing a substantial fleet of HGVs or operating vehicles across a network of major building sites, the importance of keeping workforces and other road users safe is vital; however, vans don’t fall into the parameters of the DVS regulations, permits and vehicle safety devices are not required.

Emily Hardy, of Brigade Electronics, said: “We have been working closely with Logistics UK and its Van Excellence Standard to highlight the need for safety technology for vans. Since January 2021, changes to the Van Excellence Code have required all new vans entering fleets to be fitted with safety equipment, such as reversing alarms, sensors and cameras, to prevent collisions and protect vulnerable road users. This brings vans in line with larger CVs, particularly in the freight, haulage and construction industries that have been adhering to voluntary schemes, including Truck Excellence, FORS and CLOCS for more than a decade.”

Since these changes were implemented, Logistics UK has reported a rise in van safety standards; more than 100 businesses and local authorities are now choosing to operate their vans to the ‘highest standards of safety, compliance and efficiency’.

006_CVW_MAY22_Layout 1 27/04/2022 15:09 Page 8

NEWS Diagnostic and ADAS services Repairify is introducing a new market initiative to deliver the best value for remote diagnostics, ADAS calibrations, coding, and programming in the collision repair industry.

Truck investments Two-person delivery specialist Panther Logistics has invested in 35 new trucks as part of its continuing growth plans.

Panther, will replace part of its fleet with MAN's TGX model –– as well as 20 new trailers. The vehicles, which are all DVS compliant, are fitted with five cameras for added safety, driver visibility and incident management. The TGX, winner of International Truck of the Year 2021, boasts economical engines, improved aerodynamics, GPS-supported cruise control, and innovations that allow fuel savings of up to 3.7%.

The Repairify Remote Services Pledge has been designed to offer existing and new customers of asTech and RED (EU) the “best value on the market” by simplifying and reducing its pricing by as much as 45% for some of its remote services. The company’s

proposition provides diagnostic scans and resets, and ADAS calibrations, which are supported remotely by IMI certified and ADAS trained technicians. The programme conforms to the UK Insurance Industry Requirements (IIR) for the safe repair of ADAS equipped vehicles.

"As an added benefit, the company warrants the work its technicians undertake."

Operating under the asTech and RED (EU) brands in the UK, services enabled by the pledge empowers repairers to benefit from the new income streams by not outsourcing or hiring subcontractors to do the work, aiming to reduce key-to-key times and saving money. As an added benefit, the company warrants the work its technicians undertake. Given the nature of the work, it is also underwritten by significant insurance to back up its services, leaving repairers safe in the knowledge that they are fully supported.

006_CVW_MAY22_Layout 1 27/04/2022 21:10 Page 9

www.cvwmagazine.co.uk

CVWmagazine

@CVWmagazine

Commercial Vehicle Workshop

Renewable fuelled fleet

Exeter acquisition

Veolia has launched a brand-new fleet of green-fuelled vehicles to collect waste and recycling, including food and garden waste, from residents across the Broadland district.

Renault Trucks distributor, Sparks Commercial Services, is widening its reach across the South West with the acquisition of Renault Truck Commercials Exeter.

In a first for Veolia in the UK, the fleet will be solely powered by renewable Hydrotreated Vegetable Oil, HVO, a biobased liquid fuel made from vegetable oils and animal fats.

Veolia’s new contract for recycling and waste services for Broadland District Council included a commitment to reduce operational emissions and develop low

This latest acquisition takes the number of Sparks Commercial Services sites to five, joining facilities in Southampton, Portsmouth, Poole and Swindon. The company has confirmed that all 12 former employees of the Exeter branch will transfer to Sparks Commercial Services to join its growing workforce of 122.

Sparks Commercials Exeter in Marsh Road, Marsh Barton, sells the full truck range from 2.8 to 44t, both new and used, the latest generation of electric vehicles, as well as trailers and ancillary equipment. It also provides comprehensive aftersales support for Renault Trucks and all-makes customers.

“In a first for Veolia in the UK, the fleet will be solely powered by renewable Hydrotreated Vegetable Oil, HVO, a biobased liquid fuel made from vegetable oils and animal fats.”

carbon solutions, and this supports the council’s aim for continuous environmental improvement.

HVO is a low carbon, low emission, fossil-free and sustainable alternative to conventional fossil diesel, which eliminates up to 90% of net CO2 and reduces nitrogen oxide, particulate matter and carbon monoxide emissions; however, it is fully interchangeable with conventional diesel and can be used pure or blended with fossil diesel, if required, Veolia said.

010_CVW_MAY22_Layout 1 27/04/2022 21:04 Page 10

BUSINESS & TRAINING

PHOENIX TRAINING CENTRE GOES FROM “STRENGTH TO STRENGTH” Alison Fastnedge, Phoenix Training Centre Training and HR Manager, tells us how the company has evolved and made great strides since its CVW debut in May 2019 – despite the COVID-19 pandemic in-between:

B

ased close to Heathrow but also offering off-site training, Phoenix Training Centre is now accredited to provide manager CPC training and refresher courses – Heathrow’s only training centre to offer these courses.

Also available are driver CPC, first aid and mental health awareness, among others. Our trainers can also deliver clients bespoke courses to their employees.

Interestingly, there are rooms also available for outside hire for training or meetings, and these are ideally located close to Heathrow, with excellent accessibility and transport lines. High speed internet connectivity aids the delivery of content and enables smooth, seamless meetings, with various room configurations available.

Continued development Meanwhile, another arm to our business, Phoenix Van Truck and Trailer Maintenance, has prospered in its new premises and has added a dedicated MOT class 4, 5 and 7 test lane, while plans are ongoing for an ATF facility.

The new 22,000sqft four-bay trailer workshop is operating with an inspection pit and rolling road brake testing facility, and it is staffed by a specialist providing this often-overlooked service.

Due to its success, Phoenix Van, Truck and Trailer Maintenance is now open for business from 6am to midnight, five daysa-week and Saturday mornings, much to the delight of our time conscious clients!

FOR MORE INFORMATION ABOUT PHOENIX TRAINING CENTRE, WWW.RDR.LINK/VAN001

10 CVW MAY 2022

CPN/CVW page grid_Layout 1 20/10/2021 08:32 Page 1

CPN/CVW page grid_Layout 1 20/04/2022 09:06 Page 1

013_CVW_MAY22_Layout 1 27/04/2022 15:19 Page 13

BUSINESS & TRAINING

Nissens Automotive has designed a new website for automotive professionals to leverage their technical skills within the thermal management, efficiency and emissions system sectors.

NISSENS AUTOMOTIVE LAUNCHES WEB PORTAL

N

issens reported that its new internet platform is an easy-to-use website and boasts a library of more than 100 assets, which includes technical articles, tips, bulletins and tools – all dedicated to technicians and, as an added benefit, visitors can also download or print the material for future reference.

Whether linked to a specific part or a general system insight, every piece of new Nissens technical content goes straight to the library, whenever a new product is introduced.

Driving value to aftermarket professionals As time progesses, Nissens will continue to expand the portal and add new insights and features to deliver valuable technical content to hungry professionals. Along with the technical literature on the latest

technologies and vehicles, it will also include a selection of practical tools that technicians can use in their daily work.

Nissens Automotive Marketing Manager, Jan Zieleskiewicz, said: “We believe in consistently driving value to aftermarket professionals and strive to make access to our considerable knowledge even easier.

“As a dedicated parts supplier, delivering genuine Nissens quality components across several product groups, our objective is to set technicians up for success by providing the resources they need to do their job well.”

This latest development, alongside other policies that Nissens has implemented, is part of the company’s goal of reducing its environmental footprint. Not only does this make its latest product information more accessible to aftermarket professionals, but it’s also consistent with its plan to phase out paper product literature by the end of 2022.

Accessible tech insights Platform users can navigate the site's library via the top stories or product categories. The top stories section highlights assets recommended by the editorial staff as relevant for the given season or a particular system; whereas in the category section, users can choose from product groups to find the information they are searching for. At any point, the needed library assets can be searched and filtered through relevant text, such as component name or part number.

Drop-down menus containing relevant content, such as video tutorials and best practice guides, are presented in an accessible way that is easy to digest.

Multiple training options “Integrating the company's wellestablished educational platform, the Nissens Training Concept (NTC) to allow even easier access to advanced training courses, as well as self-learning modules, is another planned extension,” Jan continued.

“With several thousand trainees and active users of our electronic courses, the development plans for more NTC learning modules are forging ahead.

This success has spurred the expansion of the product support portal and furthers our aim of driving value to aftermarket professionals by making access to our shared knowledge even easier than before.”

Access to the service is free. To start browsing the technical information library, technicians can scan a QR code from a Nissens' product box or visit www.nissens.com/experts

FOR MORE INFORMATION ABOUT NISSENS, WWW.RDR.LINK/VAN002

MAY 2022 CVW 13

014_CVW_MAY22_Layout 1 27/04/2022 21:05 Page 14

BUSINESS & TRAINING

MAHA UK AND CHASSIS CAB PARTNERSHIP SHOWS IMPORTANCE OF REL ATIONSHIPS Relationships go a long way, and with MAHA UK and Chassis Cab, the partnership travels back to when the workshop equipment manufacturer was awarded the contract to provide an ATF lane at the DAF specialist’s Great Blakenham (Ipswich) site. Several years later, MAHA UK’s sales manager, Nick Austin, paid the Cambridge (Fenstanton) facility a visit to see how the team was getting on following another installation.

F

ormed in 1982 by David Ruffles, the Chassis Cab Group is a family-run business that started life as a body repairer in Bury St Edmunds and is now the DAF truck franchise holder for East Anglia.

It sells new and used trucks, DAF genuine parts, truck and trailer components for allmakes, as well as offer repair and maintenance services and a service workshop.

The Cambridge facility is one of four sites under the Chassis Cab banner, and Andy Ling, general service manager, oversees all four from a servicing perspective. He

explained that the first installation at the Great Blakenham site – preparation, installation, product quality, speed and friendliness of service, and after-sales support – laid the foundations for a long-term partnership: “Immediately, there was a connection,” said Andy. “Nick and the team listened and advised on how to maximise the potential of the site we had, and everything went smoothly from an installation point of view.

Obviously, we’ve gained experience, learnt a lot and with this particular installation, we felt confident in taking the lead.”

L-R Andy Ling and Nick Austin

Andy Ling: "Nick and the team listened and advised on how to maximise the potential of the site we had, and everything went smoothly from an installation point of view."

Nick added: “From my perspective, it’s always very easy when working with Andy!

He now has the experience to manage a project himself, and because of his relationship with Premier Pits, we acted more of a supplier this time – rather than project manage it – but we were always ready to step in if there was a need.”

Premier Pits is one of MAHA UK’s partners, which designs, manufactures and installs pits to help transform vehicle maintenance and inspection.

Premier Pits Sales Director, Dave Sylvester, said: “Andy and the team at Chassis Cab, along with Jeff Hall from Hall Contracts, are always a pleasure to deal with, and we are pleased to have been

14 CVW MAY 2022

014_CVW_MAY22_Layout 1 27/04/2022 15:24 Page 15

involved in another completed project for them at the Fenstanton site, working alongside MAHA UK.” Hall Contracts is Chassis Cab’s longterm building works contractor, and it was responsible for both an extension at Great Blakenham and the redevelopment of Fenstanton.

What’s been fitted?

This new lane comprises of a MBT 7250 EUROSYSTEM brake tester – brake tester for HGV, PSV, along with classes 4 and 7 – MLT 1000 headlight tester and LMS 20.0 axle play tester. Existing equipment was also removed and relocated from Chassis Cab’s original site in Cambridge to this new one in Fenstanton.

Andy added that Chassis Cab is “working on a couple of other developments” that may mean another chat with Nick in the not-too-distant future!

Before diving into another project, though, Andy praised MAHA UK and, in particular,

its after-sales support: “We know MAHA UK has a good product, it knows what it's doing and it’s always comforting to receive the support from the likes of Neil Ebbs, MAHA UK’s managing director, and Tim Davison on the after-sales side. Should we have a question or experience an issue, we know we’re in safe hands and will receive a rapid response – whether that’s a phone call or even someone driving over!

“There are huge demands placed on us, and if we can’t test for a day or if we lose our tachograph rollers, we need our suppliers to react promptly and find a solution quickly – that’s always been something MAHA UK has excelled at.”

FOR MORE INFORMATION ABOUT MAHA UK, WWW.RDR.LINK/VAN003

CPN/CVW page grid_Layout 1 25/04/2022 08:04 Page 1

017_CVW_MAY22_Layout 1 27/04/2022 15:31 Page 17

CV SHOW PREVIEW

‘THE COMMERCIAL VEHICLE SHOW IS THE BUSINESS EVENT YOU C AN’T AFFORD TO MISS!’ The Commercial Vehicle Show returns in 2022 – this time in the spring – and its show director, Murray Ellis, took time out of his hectic schedule ahead of the event, which will welcome more than 200 exhibitors at the NEC between the 24th and 26th May.

Q

The Commercial Vehicle Show is back! Why should visitors be excited about attending this year’s event?

Adams, Kuda, Mandata, NLG, SDC Trailers and many other leading companies from the road transport sector.”

Q

If you were to meet a professional sitting on the fence, what would persuade them to sign up and join the thousands of visitors?

Murray Ellis (ME): “Continuing from the show’s successful return in 2021, this year’s event in the spring timeslot will deliver a larger, unmissable event for anyone involved in the commercial vehicle (CV) industry.

“As the UK’s largest and best-attended road transport exhibition, the show provides the ideal platform for seeing new products and services, gathering information and networking with industry colleagues to discuss the most important issues facing SMEs and large operators.

“Building on the legacy that the show is renowned for, this year has again attracted a broad spectrum of vehicle manufacturers (VMs), suppliers and innovators set to exhibit the latest products, services and technology solutions. This annual gathering is the perfect platform to re-engage with existing contacts and connect with key decision-makers.

“Addressing some of the most prudent and important topics facing the industry, two live theatres – Workshop Theatre, in association with Commercial Vehicle Workshop, and the Road Ahead Theatre – will offer presentations on industry trends and panel discussions over the three days of the show. The theatre discussions will offer crucial advice, guidance and top tips for anyone wanting to keep abreast of the latest developments in regulations, servicing, garage equipment, transport solutions and cost-effective technologies.”

Murray Ellis

Q

The exhibitor list looks packed – does that illustrate the confidence brands have in the Commercial Vehicle Show?

ME: “Yes, as ever the exhibitor list is packed! The Commercial Vehicle Show has been staged for many years and is noted for being the business event to attend – from major VMs to SMEs – demonstrating the confidence companies have in exhibiting at the event.

“As ever, the show has been chosen by many as the place to launch their new products and services, whilst many returning companies view the show as a strategic arm of their annual marketing plan. At the same time, we’re delighted to welcome our new exhibiting companies this year.

“In excess of 200 exhibitors will be displaying at the 2022 show, with new names including Ineos Grenadier, BP Fleet Solutions, Digihaul and NanoSun. Meanwhile, returning brands include Ford, Harris Maxus, Isuzu, Toyota, LEVC, BOTT, BPW, Brigade, Carrier Transicold, Gray &

ME: “If you’re in the CV industry, then this is the business event that you cannot afford to miss! It is the show for the industry. A place to see major VMs, new products and the latest technology – reflective of the innovation from within the sector.

“Remember, live trade exhibitions are an essential part of doing business. They are unbeatable at providing the very best opportunity to see the new products and services available on the market. Nothing beats being able to examine these vehicles and products, along with learning firsthand about future trends in the industry and the opportunity to engage in that faceto-face interaction.

“Many big brand names will join other well-respected companies and start-up enterprises, as the Commercial Vehicle Show continues to provide a platform as the key event in the sector where business gets done.”

FOR MORE INFORMATION ABOUT THE COMMERCIAL VEHICLE SHOW, WWW.RDR.LINK/VAN004

MAY 2022 CVW 17

018_CVW_MAY22_Layout 1 27/04/2022 15:32 Page 18

CV SHOW PREVIEW

쑼 TIP STAND 5A70 Along with associate businesses, Grayrentals and Eurotrail, they will promote their range of rental, leasing and maintenance services for both trucks and trailers. TIP will also be showcasing new initiatives, including its new Earned Recognition service and electronic braking performance monitoring system, BrakePlus.

Earned Recognition by TIP is a service targeted at transport operators aspiring to achieve ‘exemplar’ Earned Recognition status and lists data entry, ‘compliance’ documentation provision, maintenance KPI monitoring, dashboard access and dedicated Earned Recognition support as key features of the service. Stand visitors can sign up for a free trial.

The team will also welcome the opportunity to discuss any requirements to equip trailer fleets with telematics solutions, including BrakePlus, which is aimed at improving safety and reducing costs associated with roller brake testing.

Whilst the TIP team will be on-hand to discuss all things trailerrelated, the Grayrentals/Eurotrail team will be available to discuss any hire or maintenance requirements that stand visitors may have for trucks, tractor units, vans and other specialised vehicles.

쑿 TRUTAC STAND 4D03 The tachograph analysis and fleet compliance expert is showcasing its suite of products. The modular-based package can expand to fit any size fleet and is designed to simplify compliance management by providing a one-stop shop to save operators time and money.

The company’s products are suitable for all fleet sizes and sectors and include: ■ ■ ■ ■ ■

TruAnalysis for complete tachograph compliance TruChecks for daily vehicle driver checking TruLicence, which enables quick driving licence verification TruFleet for complete fleet maintenance management Soon-to-be launched, TruVan which allows complete compliance for van fleets. Earned Recognition reporting is included free of charge

TruTac Managing Director, Jemma James, said: “As always, our mission is to work closely with industry to provide practical and compliance-based fleet management solutions for the HGV, LCV and PSV sectors.

“In that regard, we are delighted to add these innovative management tools to our existing product suite and very much look forward to sharing information about them with customers old and new at this year’s CV Show.”

씰 JAAMA STAND 5B10 With the average age of commercial vehicle (CV) fleets continuing to rise, controlling maintenance costs and retaining high levels of compliance remains a key priority for operators, according to Jaama, and is using this year’s event to help fleets address these challenges: Maintenance Exchange is its new maintenance and compliance platform, which streamlines the exchange of vehicle maintenance information and connects with its fleet, asset, and driver management solution Key2.

Jaama’s Compliance Manager module is fully-configurable to enable managers to create their own regular and one-off vehicle related events to ensure they are never missed, such as servicing in accordance with manufacturer requirements, MOTs, and CV inspections. To learn more and see these new platforms in action, Jaama is offering free demos to visitors.

18 CVW MAY 2022

018_CVW_MAY22_Layout 1 27/04/2022 15:35 Page 19

쑼 TOTALKARE STAND 4C10 The workshop equipment expert is increasing its stand space at this year’s event to accommodate a raft of exciting new additions to its portfolio, alongside some old favourites. New for 2022 will be Totalkare’s Y-MECH Lift, class 7 MOT bay equipment, wheel alignment, tyre changers, compressors, scissor tables and hydraulic presses.

In addition, it will also be showcasing its mobile column lifts, mobile and inground brake testers, headlamp testers, smoke meters, air conditioning service units and workshop equipment – including support stands, transmission jacks and trolley jacks.

씰 MERRIDALE STAND 4G35 The company will return to this year’s event to showcase its range of fuel management equipment and software.

According to Merridale Sales Director, Stephen Hannan, the CV Show has been vital in shaping how Merridale adapts and improves its products by offering a platform for discussion between developers and fleet operators: “Primarily we are concerned with the fleet operators’ operational requirements. We must talk directly to them in order to understand their priorities. By demonstrating our latest products at the CV Show each year, we can obtain valuable feedback from potential users which can help shape our future development and investment.”

“The scope of Merridale’s products has grown from basic reporting systems to sophisticated data analysis and fuel management solutions. On the hardware side, we have a full range of depot refuelling equipment and tank management systems, which include theft and sudden drop detection. Merridale’s willingness to listen to the needs of current and potential customers enables us to incorporate such features and ensure we remain the go-to fuel management solution for all fleet operators.”

018_CVW_MAY22_Layout 1 27/04/2022 15:37 Page 20

CV SHOW PREVIEW

쑼 ATLAS COPCO TOOLS STAND 4A10 Wheel detachment from a LGV is an all too real issue; weighing over 150kgs with the potential to accelerate to around 150 kmh and reach a height of 50m, this scenario is subject to continuing research from the Transport Research Laboratory (TRL), which has previously found that up to 11,000 LGV wheel fastening defects are reported each year.

CV operators are at risk of suspension of their Operators Licence, as well potential litigation and reputational damage. The safety and security of wheel fasteners are, therefore, dependent on several variables, according to Atlas Copco: ■ The quality of the joint to the wheel hub ■ Number of wheel nuts involved ■ Tightening process of each wheel nut and their servicing With a specific focus on helping to improve safety at all levels, Atlas Copco will be demonstrating its SRB HA battery nutrunner on its stand.

씰 FISCHER PANDA UK STAND 5E92 The hybrid power solutions provider will demonstrate its capabilities as an integrated systems partner when it reveals new business growth and projects at this year’s show. With its “most high-profile presence” at the show in 15 years of attendance, Fischer Panda UK will announce an additional brand to “significantly strengthen” its range of equipment and systems, and it will also showcase vehicles on the expanded stand to represent the scope of its installations.

The latest developments are part of the company’s plans to “remain at the forefront” of the latest innovations in customised hybrid and electric power solutions across the vehicle and military sectors, offering key benefits to customers, operators and vehicle builders.

20 CVW MAY 2022

쑿 ECOBAT BATTERY STAND 5C66 One of the main purposes of the battery distributor’s presence at the CV Show is to highlight the need for fleet managers, workshops and logistics providers to consider the total cost of ownership (TCO) of batteries for their vehicles, a subject the company has spent considerable time with long-term partner Enersys to maximise profitability.

Ecobat Battery Technical Sales Manager, John Bentley, said: “The Ecobat Battery approach to business has always been to look strategically at the market, identify the problems faced by the fleet manager and workshops, analyse the options and respond with what is the best and most effective solution.

“This is the reasoning behind our recent announcements regarding the TCO, and the same principle applies to a new development that has the potential to revolutionise battery management in the heavy-duty sector!

“This game changing innovation has been made by Enersys, which has built a battery monitoring system into its ODYSSEY Din B and C commercial vehicle batteries.”

John and his colleagues will be able to provide more details!

018_CVW_MAY22_Layout 1 27/04/2022 15:38 Page 21

씰 COMMERCIAL VEHICLE WORKSHOP STAND 4C33 Readers can come and have a chat with the team. It's a great opportunity for everyone to connect and converse about industry trends, news or even the magazine itself!

What's more, in association with the event organisers, the Workshop Theatre will be up-and-running over the course of the three days. This represents a great opportunity for delegates to sample and absorb the outstanding knowledge and experience that exhibitors possess.

Hopefully, visitors will leave the show having learnt something valuable and appliable to their workshop – both for now and the future.

CVW Editor, Tom Henman, said: “Having recently taken on the editor’s role, the Commercial Vehicle Show represents a golden opportunity to immerse myself in the CV arena and get to know our audience, as well as the many exhibitors looking to make an impression on visitors – I can’t wait!”

CPN/CVW page grid_Layout 1 20/04/2022 09:08 Page 1

023_CVW_MAY22_Layout 1 27/04/2022 15:43 Page 23

EMISSIONS

Eminox Retrofit and Aftermarket Sales Director, Carlos Vicente, looks at the role operators are playing in the journey to achieving net zero for commercial vehicles (CVs):

EMINOX URGES FLEET OPERATORS AND MANAGERS TO 'DRIVE FORWARD CHANGES'

T

he Net Zero Strategy: Build Back Better document sets out policies and proposals for decarbonising all sectors of the UK economy to meet our net zero target by 2050. Within, it is stated the government will “pledge to end the sale of all new, non-zero emission road vehicles by 2040, from motorcycles to buses and HGVs, subject to consultation”.

Directly integrated into the Transport Decarbonisation Plan, the targets are ambitious; however, what it does highlight is that there is no excuse for resting on our laurels with a view only on the end target.

Whilst much work is being done by vehicle manufacturers to ensure new vehicles support this pledge, and no doubt further legislation will be drafted to force this wherever possible, there is still much to be done in the meantime to ensure our current vehicles are as low emission as possible, not to mention compliant.

Only 0.2% of HGVs were alternatively fuelled in the UK in 2020 – according to SMMT report Fuelling the Fleet – highlighting the considerable gap between where we are now and where we want to be.

Perhaps it may seem unlikely that all CVs will be powered by alternatives to diesel in the timescales that have been set; however, it doesn’t mean the current commercial UK vehicle portfolio can’t achieve the lowest possible emissions during the intended transition period.

The road to net zero There are many facets on the road to net-zero,

and there are many businesses working hard to deliver emissions solutions along the way.

It is not only about dissecting the current legislation; it is about understanding what is coming next, being prepared and appreciating how the transition from diesel to alternative fuels can be best managed to not only meet government targets, but also manage business expectations, practicalities and costs.

Great strides have been made in the move to net-zero for cars and vans both in terms of technology development and the infrastructure to support this.

For CVs, the move will be somewhat more complicated, and this is why it is so important for fleet operators and managers to act responsibly and drive forward changes to their vehicles to achieve the highest emissions standards.

This will only benefit fleet operators, as we expect more ULEZ (Ultra Low Emission Zones) to be created very soon which will, of course, impact on CVs operating in those areas. Being ahead of the game will, ultimately, give fleets the greatest control as to where their vehicles operate and the freedom it affords when managing them.

Emissions solutions and the future Establishing this freedom and the business opportunities this brings can be achieved by forming a partnership with a company that not only has detailed understanding of vehicle emissions legislations and compliance, but also designs and develops the technology to deliver the solutions and futureproof vehicles.

Upgrade to meet latest emissions standards By choosing a trusted partner with tried and tested emissions reduction solutions, such as those offered by Eminox, customers can rest assured that compliance is standard. A quality solution must meet exacting standards, approvals and certifications, such as the Clean Vehicle Retrofit Accreditation Scheme (CVRAS), which involves a comprehensive independent testing programme on emission reduction systems which is specific to vehicle/engine combinations.

Replacement Euro 6 DPFs An example of a fully compliant, costeffective solution is the replacement of Euro 6 diesel particulate filters (DPFs). Eminox’s range currently covers over 80% of on-road Euro 6 vehicles, including DAF, Scania, MAN, Volvo, and Mercedes. By choosing type approved, proven technologies, compliance and cost can be managed whilst the transition from diesel powered fleets to electric and other alternative fuel sources takes place.

FOR MORE INFORMATION ON EMINOX WWW.RDR.LINK/VAN005

MAY 2022 CVW 23

024_CVW_MAY22_Layout 1 27/04/2022 15:46 Page 24

EMISSIONS

HELL A REVEALS EXPANSION OF NOX SENSORS RANGE The components are suitable for most of the power units used in popular DAF, Iveco, Mercedes-Benz, MAN, Scania, Renault and Volvo applications, the company announced.

N

itrogen Oxide (NOx) sensors monitor the level of nitrogen oxide being emitted by the diesel engine powering the associated truck, bus or coach etc, to ensure its compliance with UK and European Union Euro 5 and above engine emissions regulations.

The NOx sensor comprises of a probe, which is screwed into the exhaust system, and a control unit that plugs into the vehicle’s electrical system through an electronic control unit (ECU) – these are connected by a cable to form the sensor assembly. The sensor is installed so that the exhaust gas flows across the probe element and is used to recognise the level of nitrogen oxides present in the exhaust gas.

Most engines utilising a generic selective catalytic reduction (SCR) system feature two NOx sensors: the first sensor is located near the turbo downpipe and measures the NOx immediately leaving the engine, while the second measures NOx levels exiting the SCR catalyst.

out. Such particulate filter regeneration is automatically triggered and monitored by the relevant higher-level system control unit.

With the systematic addition of a reducing agent, like AdBlue, to the exhaust gas system, a reaction takes place, resulting in nitrogen oxides being converted into nitrogen and water. Furthermore, in combination with a cleaning catalyser, excess ammonia can be converted into nitrogen.

The detail

The problems

The NOx sensor is an important component in the post-treatment system to reduce NOx, which is used in diesel vehicles with ureabased SCR systems. The sensor enables compliance with the emission values starting from Euro 5 engines-onwards.

Consequently, the NOx sensor guarantees an optimal dose of a reducing agent, such as AdBlue, by the engine system, which brings about an effective reduction in nitrogen oxides, that are harmful to the environment.

If the SCR system has an upstream and downstream NOx sensor, the downstream one has the task of monitoring the effect of the SCR catalytic converter.

The exhaust gas flow, resulting from the running of the diesel engine, enters the diesel oxidation catalytic converter (DOC) and then the diesel particulate filter (DPF).

Once the particulate filter load of the DPF reaches a certain value, cleaning (generally referred to as regeneration) must be carried

The NOx sensor is, therefore, an important component that, due to its location and the hostile environment it must operate in, can fail, according to HELLA.

24 CVW MAY 2022

DAF NOx Sensor

Common causes of failure include: ■ Build-up of soot on the sensor probe ■ Water intrusion into the ECU and

damage to the cable, which will cause the engine check light to illuminate

The HELLA solution In common with other products in the HELLA aftermarket range, its NOx sensors are tested in accordance with the company’s quality standards and comply with the specifications of the original equipment (OE) component.

HELLA said that due to their location and the environment in which they have to operate, its NOx sensors have also been developed with particular attention being given to their resistance to aggressive engine vibrations and high operating temperatures. In addition, although they have been designed to be an easy-to-mount direct, like for like OE replacement, useful fitting instructions are also supplied with the product.

Reflecting the growing aftermarket need for replacement NOx sensors, the current range will increase during the course of 2022 to encompass 35 part numbers.

FOR MORE INFORMATION ABOUT HELLA, MAN NOx Sensor

WWW.RDR.LINK/VAN006

025_CVW_MAY22_Layout 1 27/04/2022 21:07 Page 25

ROAD TO

ZERO

CVW speaks to David Wright, company secretary of the Verification of Lubricant Specifications (VLS) – an independent industry body that provides a means to verify lubricant specifications – about the latest developments in emissions standards and their impact on lubricants:

G

overnments around the world have set out their intent to reach zero emissions, including the UK, which published its Net Zero Strategy last year. This set out how the UK will deliver on its commitment to reach net zero emissions by 2050.

Investment is focused on supporting the electrification of vehicles and their supply chains with the rollout of charging infrastructure. The government is also investing in developing hydrogen as an alternative fuel to reduce emissions. A new road vehicle CO2 framework is being developed, following a consultation in Q3 2021. Proposals for the regulation of new cars and vans were expected in early 2022 but have yet to be published.

In Europe, the European Commission has been working on the next evolution of the European Emission Standards, which define the acceptable limits for exhaust emissions of new vehicles sold in the European Union and EEA member states – Euro 7. According to the Commission, passenger cars and light commercial vehicles are respectively responsible for around 12% and 2.5% of total EU emissions of CO2 , which is the main greenhouse gas.

Completed proposals for Euro 7 were due

to be presented to the European Parliament at the end of 2021 and come into force around 2025; however, the Commission has delayed the adoption date for Euro 7 from Q4 2021 to 20th July 2022 and has yet to indicate what the Euro 7 proposals will look like.

Discussions on passenger car and van CO2 targets have started, with a significant hardening in the level of ambition expected.

This has already caused concern, with the German Association of the Automotive Industry (VDA) warning that the move could result in the combustion engine being effectively phased out from as early as 2025.

“With the introduction of the planned EU-7 standard, the EU Commission will de facto ban cars with combustion engines from 2025,” said President of the VDA, Hildegard Müller, fearing that if the exhaust emission limits are too strict, combustion engines will no longer be competitive.

This view was echoed by the chief operating officer of Nissan, Ashwani Gupta, who confirmed in September 2021 that Nissan had decided to move away from the development of new internal combustion engines in Europe once Euro 7 standards come into force. Mercedes has said that it plans to halve engine variants due to Euro 7 regulations.

Impact of emissions standard changes being felt In the meantime, the US Environmental Protection Authority has recently pressed ahead and published revised national greenhouse gas emissions standards for passenger cars and light trucks for model years 2023-2026. These are designed to achieve significant greenhouse gas emission reductions, along with drops in other criteria pollutants.

Whatever the UK and EU decide, emissions standard changes will impact lubricants and the wider aftermarket supply chain, as consumables cater to the demands of new, increasingly sophisticated engines. VLS will be closely following the progress in this area, as it unfolds over the next few months.

The Verification of Lubricant Specifications (VLS) is an independent industry body that provides a credible and trusted means to verify lubricant specifications. This Lubricant Industry Initiative aims to bring transparency to the lubricant marketplace and protect and educate end users.

FOR MORE INFORMATION ABOUT VLS, WWW.RDR.LINK/VAN007

MAY 2022 CVW 25

026_CVW_MAY22_Layout 1 27/04/2022 15:53 Page 26

EMISSIONS

As the world pledges to cut carbon emissions, reduce pollution and protect valuable resources, the principle of a circular economy takes on new significance, according to Ceramex:

DPF REMANUFAC TURING FOR LGV OPERATORS IN A ‘CIRCUL AR ECONOMY’, SAYS CERAMEX

A

ctivities, such as re-use, sharing, pay-per-use, repair, remanufacturing and recycling all form part of a circular economy with the aim of preserving resources, reducing energy consumption and avoiding landfill.

Remanufacturing sits at the heart of the circular economy, providing a cost-effective alternative to producing brand new products, as well as saving on increasingly expensive raw materials and energy. With UK manufacturers consuming over half a million tonnes of material each year, remanufacturing has become an essential industry.

Historically, automotive remanufacturing has focused on returning major units and components to an ‘as new’ condition, but the remanufacturing of diesel particulate filters (DPFs) has grown exponentially with the rapid increase in the number of LGVs, particularly in the last decade.

As a specialist in DPF cleaning and remanufacturing, Ceramex provides truck and bus original equipment manufacturers (OEMs) with remanufacturing services, as well as LGV fleets operating in the UK and overseas. To help meet growing customer demand and ensure diesel emissions are minimised, Ceramex has doubled its operating capacity with the opening of a

26 CVW MAY 2022

new facility in Reading, which is able to process over 2,000 DPFs per week.

Representing an investment of over £3 million, the 67,000sqft facility also provides increased storage capacity for DPF units, allowing rapid turnaround for deliveries and despatch.

Barney Milles, who was recently promoted to the role of managing director at Ceramex, commented: “Whilst we welcome the work being done to develop the proposed Alternative Fuels Infrastructure Regulation (AFIR) across Europe with the involvement of the European Automobile Manufacturers’ Association (ACEA), there is an immediate need to manage and reduce emissions from the 500,000 LGVs currently in service in the UK, plus thousands more foreign registered trucks.

“Ceramex is seeing customer demand for DPF remanufacturing returning to prepandemic levels, due to increasing demands on the logistics sector. As part of our expansion strategy, we’ve more than doubled our DPF processing capacity since our new facility in Reading has come on stream. This significant investment in our long-term future will enable Ceramex to keep its customer vehicles environmentally compliant and operating efficiently.”

"No risk of particulates entering the atmosphere" Ceramex’s patented Xpurge® DPF cleaning process uses a combination of purified water and air to remove accumulated soot and ash deposits from the filter, which must go through this process according to its mileage, to ensure the vehicle remains road legal.

As the deposits are suspended in water during cleaning, there is no risk of particulates entering the atmosphere.

The contaminated liquid and solids are then separated and disposed of, in accordance with strict environmental conditions.

Ceramex has also developed proprietary technology for drying DPFs, whilst the condition of each unit can be inspected at the customer’s request, using its patented Veritex® inspection system.

FOR MORE INFORMATION ABOUT CERAMEX, WWW.RDR.LINK/VAN008

CPN/CVW page grid_Layout 1 20/04/2022 09:09 Page 1

VLT QXD_Layout 1 09/03/2022 14:14 Page 1

Worldwide solution providers of vehicle safety and emissions testing systems FEATURES AND OPTIONS: DVSA Database approval STGO (Special Types General Order) Pass/fail softwear DVSA connectivity approval for class 4 & 7 Ruggedised WIFI tough book for CAB operation Mechanical roller locking system for easy drive out

ADVANTAGES:

BENEFITS:

* Liftime roller warranty * 5 year waranty on motor gearboxes * One man operation * More than 3000 current active UK customers * Up to 24 Ton axle weight (Model depending)

* Manufacture - Sales - Service in one call * In house nationwide aftersales service * Dedicated installation and delivery service * ATF and ADR specialist salesteam

029_CVW_MAY22_Layout 1 27/04/2022 15:55 Page 29

WORKSHOP MANAGEMENT

PRO-ALIGN: SPEED UP YOUR WORKSHOP WITH HUNTER! Clive Seabrook, CEO of wheel alignment specialist, Pro-Align, outlines how workshop equipment from Hunter can support businesses in improving their workshop management:

C

hoosing the right tools to help manage a workshop is crucial. The developers at workshop equipment manufacturer, Hunter, have created tools to help workshops not only reduce vehicle service times but increase profit, revenue and customer retention – all at the same time.

Choosing the right tools Traditional commercial vehicle (CV) alignment systems do not provide a simultaneous multi-axle measurement, but instead, rely on sensors being moved one axle at a time, in a staged process. The single axle measurements are then combined into a final multi-axle reading; however, the WinAlign Heavy-Duty (WAHD) from Hunter, can measure all three axles simultaneously in one easy action, cutting measurement and servicing times. The system utilises a number of technologies and innovations designed to make a technician’s life easier and processes faster, with accurate alignment results produced in just four minutes.

Saving time With a traditional CV alignment check taking around 12-15 minutes to complete, many workshops have felt that they could not justify the investment in additional labour hours to offer proactive and speculative alignment checks for multi-axle vehicles; however, in order to deliver a faster alignment check, the WAHD does not

require any axles on the vehicle to be jacked. Instead, a simple rolling compensation can be carried out with Hunter’s Truck Pusher, a battery powered multi-use vehicle pusher which is capable of moving vehicles weighing up to 20t.

The number of walking steps required to perform the alignment job and the number of sensor movements are also reduced. Hunter’s engineers calculated that the total steps taken by technicians to conduct an

alignment check can be reduced from 203 to just 81 when switching to the Hunter system.

Increasing customer retention While reducing labour times within a workshop is important, overall vehicle downtime is of major concern to the vehicle operator. Consequently, keeping servicing time to minimum means it is critical to find an alignment system that is accurate but also does the job fast.

FOR MORE INFORMATION ABOUT HUNTER, WWW.RDR.LINK/VAN009

MAY 2022 CVW 29

030_CVW_MAY22_Layout 1 27/04/2022 15:59 Page 30

WORKSHOP MANAGEMENT

IT ALL STARTS WITH A TIDY WORKSHOP, SAYS KÄRCHER UK

T

he growth of national and global logistics solutions to facilitate increased e-commerce demand has led to an enhanced focus on keeping vehicles on the road, resulting in greater pressure placed on the automotive industry.

Naturally, there will be times when vehicle maintenance is necessary to protect the safety of the driver and other road-users and maintaining a clean workshop can help to get vehicles back on the road quickly.

Messy and unkept workshops are a health and safety risk with the potential for trips, slips and injuries as staff move throughout the premises. To help counteract these challenges, battery-powered equipment can help reduce the number of

"Kärcher has developed a range of vacuum sweepers with its EASY operation concept built in, which ensures that the machines are simple and convenient to use."

30 CVW MAY 2022

Jack Cockerham, key account manager – transport at Kärcher UK, discusses the importance of workshop cleanliness to boost efficiency when it comes to vehicle maintenance: wires strewn across the floor, whilst efficient cleaning machines can help whisk dirt away to keep surfaces clean and spill-free.

Battery powered solutions are ideal for use in the workshop due to their highpower output, enabling users to effectively remove unwanted particles, spillages, and stubborn dirt. Understanding which machines to select and when to use them will help boost cleaning productivity.

There are two main solutions that can be applied within larger workshop spaces to tackle dirt in varying ways: vacuum sweepers and scrubber driers. Whilst both come in larger ride-on formats, push behind versions are also highly efficient solutions for maintaining workshops.

Vacuum sweepers Ideal for the removal of coarse and stubborn dirt, dust, and waste, vacuum sweepers disperse dust using a roller brush before utilising a suction turbine (fan) that lifts

disrupted dirt from the surface and deposits it in a filter system. This supports the quick removal of unwanted surface material from hard flooring.

Kärcher has developed a range of vacuum sweepers with its EASY operation concept built in, which ensures that the machines are simple and convenient to use. Each member of the workforce can be trained on how to use the machine effectively and efficiently without the need for extensive courses. To help maximise the full potential of the machines, Kärcher’s in-house Kärcher Academy is able to train staff on the latest techniques and cleaning methods.

Machines, such as the KM 75/40 W Bp push vacuum sweeper, are ideal for workshop environments as they come with a 40l waste container with a trolley system to ensure long, fatigue-free cleaning. This is ideal for pack-downs at the end of the working day, enabling users to swiftly restore the workshop to a clean state ready for the following day.

030_CVW_MAY22_Layout 1 27/04/2022 16:00 Page 31

Additionally, as the KM 75/40 W Bp is battery powered, it can be used during the working day for spot cleaning without causing disruption to colleagues.

Scrubber driers For a more intense clean that utilises cleaning agents and water to break down excess oil and grease build-up, scrubber driers are a suitable solution. Walk-behind scrubber driers offer manoeuvrability that will allow users to get closer to floor edges and move around different objects easily.

For a deeper clean, walk-behind scrubber driers, such as the B 60 W Bp Dose, are ideal as the roller brushes pass over the surface, loosening dirt alongside the application of water, before the dirt and wastewater is collected at the rear of the machine, leaving surfaces close to dry. This swift and productive process allows the team to get back to repairing vehicles quickly.

Built-in functions, such as the KIK system (Kärcher Intelligent Key System), enable facility managers to pre-set different cleaning modes, to ensure the same level of clean is acquired regardless of the user.

Managers can adjust the height of the roller brush, squeegee, and speed of clean.

Operating on battery power, the BR 30/4 C Bp Dose can clear up a quick spillage, as it does not require a plug and long cables to get to work.

In summary...

Guaranteeing and maintaining a clean and tidy workshop is a must to help workers get back to repairing vehicles in a safe environment. Utilising battery-powered machines is one way that dirt and spillages can be effectively and efficiently removed, to allow professionals to focus on getting vehicles back on the road rather than worrying about the surfaces.

FOR MORE INFORMATION ABOUT KÄRCHER, WWW.RDR.LINK/VAN010

032_CVW_MAY22_Layout 1 27/04/2022 16:06 Page 32

WORKSHOP MANAGEMENT

COLL ARD SKIPS FORWARD WITH TRUCKFILE WORKSHOP AND FLEET MANAGEMENT SOFTWARE Waste management specialist, Collard Group, has “revolutionised” its workshop and fleet management, thanks to the support of Truckfile.

With more than 25 years in the business, Collard is a waste management and demolition specialist in the South of England. Trucks work from headquarters at Eversley, near Hook, as well as a network of five other sites across Hampshire, Berkshire and Surrey.

T

he Hampshire-based operator is now using Truckfile packages to keep its fleet of 140 trucks and 110 vans safe and compliant, and to ensure the smooth and efficient operation of its three in-house maintenance sites – which are soon to be joined by a fourth.

For Transport Manager, Lee Troddyn, the benefits are clear: “Probably the most outstanding advantage for me has been the way Truckfile gives me a broad, yet finely detailed overview of everything that’s going on with our vehicles and in our workshops.

“The information is so easily accessible, and I have a level of visibility that I could never have imagined previously, over aspects such as vehicle defects, rectification work, and compliance. The fact that our compliance score has remained very high throughout the challenges of the past 18 months just goes to show what a great team we have here.”

Truckfile’s system means that all vehicle safety checks, workshop inspections and any maintenance or repair activities carried out, from start to finish, are recorded electronically. Details are stored securely and permanently in computer files, which

32 CVW MAY 2022

remain accessible. Truckfile is also a validated IT systems provider for the DVSA Earned Recognition scheme.

“Before installing Truckfile, our recordkeeping was all paper-based – very old-school,” recalled Lee. “We felt it was time to take advantage of the benefits technology can bring. Compared to the way we used to do things, the change is like night and day. From my desktop, I can now click a mouse and see every piece of information I need for any vehicle.

“Keeping tabs on our workshops is far easier too. This is especially advantageous in the case of our busy Eversley site, which has five bays and is open 24 hours-a-day.

“Meanwhile, our technicians find the Truckfile handheld tablets very intuitive to handle. Using the system has speeded up and simplified the process of completing vehicle inspections and reduced the risk of human error in recording to almost zero.

“Importantly, all of this has been achieved with minimal upheaval, thanks to excellent support from the Truckfile team who have guided us through the installation and implementation process. I cannot praise their customer service highly enough.”

Collard’s fleet comprises skip loaders, tippers and ‘roll-on, roll-off’ rigids and concrete mixers, ranging from 7.5 to 32t gross vehicle weight, as well as tractor units that work with tipping, movable floor and low-loader trailers. Two of these are STGO heavy haulage units rated for work at gross train weights of 80 and 150t, respectively. The line-up is dominated by Volvo.

The company operates proudly under an ethos of sustainability and works to a zero-to-landfill target. Services offered to both commercial and domestic customers include demolition, earthworks, skip hire, haulage, waste management and recycling, aggregates and, most recently, sustainable readymixed concrete, produced using recycled construction and demolition waste.

FOR MORE INFORMATION ABOUT TRUCKFILE, WWW.RDR.LINK/VAN011

CPN/CVW page grid_Layout 1 25/04/2022 09:43 Page 1

CPN/CVW page grid_Layout 1 25/10/2021 08:05 Page 1

035_CVW_MAY22_Layout 1 27/04/2022 16:07 Page 1

TECHNIC AL SUPPLEMENT THIS YEAR'S MOST POPULAR TECHNICAL ARTICLES ON THE CVW WEBSITE

036_CVW_MAY22_Layout 1 27/04/2022 16:11 Page S2

TECHNICAL SUPPLEMENT TIMING BELT

SCHAEFFLER REPLACES IVECO DAILY’S TIMING BELT Tim Adams, Schaeffler's REPXPERT technical trainer and belt system specialist, runs through a timing belt installation on the popular Iveco Daily 111/Fiat Ducato 2.3 diesel engine:

T

his engine has been used for many years, and it has always been recommended that a new water pump is installed at the same time as carrying out a timing belt system replacement. It is also considered best practice to replace the auxiliary belt – two in this instance – and all associated auxiliary system parts, as they need to be removed to access the timing belt drive. This particular unit has been in constant service from 2002 up to the present day and the expected labour time for this repair is almost fourand-a-quarter hours.

It is important to advise vehicle owners that the FEAD belt system will have covered the same mileage as the timing belt drive, so will have been subjected to the same amount of usage and wear. Of further note is that the air conditioning (AC) drive belt has to be cut to be removed and, therefore, cannot be reused.

There are two different original equipment tensioner designs which have been fitted to this engine during its lifespan.

Both are completely interchangeable, but it is essential that the correct set-up instructions are used for the specific tensioner design that has been supplied. To identify the type of tensioner, the obvious visual differences are the number of cutouts on the installation eccentric plate. The tensioner pictured on the left in Fig 1 has three notches on the eccentric plate, while the tensioner on the right has just one.

���

S2 CVW MAY 2022

���

���

Step-by-step guide It is essential that the engine is left to cool to ambient (room) temperature before carrying out this repair, to ensure that no anomalies occur during tensioning. Allow approximately four hours for this, following the first of our ‘4T’ principles: temperature, tools, torque and tension.

Raise and support the front of the vehicle, then remove both front wheels, wheel arch liners and undershield. Drain the cooling system. Remove both headlamps, radiator grille, front bumper, bonnet release cable and lock and bonnet shut panel. Next remove the cold air intake pipe, AC condenser from the radiator (if fitted). Do not disconnect pipes.

Disconnect the coolant expansion tank multi-plug before removing the radiator and intercooler assembly. Remove both

auxiliary drive belts, viscous fan, tensioner and idler. Slacken and tilt the alternator (the upper bolt will also need to be removed).

Support the engine and remove crankshaft pulley bolts and pulley, along with the timing belt cover (check for any damage to the cover). Now remove the camshaft cover blanking plugs along with the blanking plug from the cylinder block.

Note: During the installation process, keep a sharp lookout for any oil or coolant leaks and double check that the timing cover is free from damage.

Next up in our 4T process is tools; always use the correct engine locking tools. Turn the crankshaft to just before TDC No 1 cylinder and fit the crankshaft locking pin tool 99360615 (Fig 2).

Turn the crankshaft clockwise until it stops against the locking pin. Insert both camshaft locking pins tool 99360614 (Fig 3).

Slacken the timing belt tensioner pulley bolt and move the tensioner away from the belt, then lightly tighten the bolt and remove the timing belt. Install a new water pump. Check that the camshaft and crankshaft locking tools are located correctly. Using a counter hold tool (Fig 4), hold the camshaft sprocket (do not rely on camshaft locking tools alone, as damage could be caused to the camshafts). Release

���

036_CVW_MAY22_Layout 1 27/04/2022 16:13 Page S3

and rotate the engine in the direction of rotation for eight full revolutions.

Note: Don’t allow the crankshaft to rotate anti-clockwise.

As before, on the last revolution, bring the crank up to just before TDC and fit the crankshaft locking pin. Turn the crank until it touches against the pin. Ensure the camshaft locking pins can be easily inserted.

If not, repeat the installation procedure.

���

the sprocket until it rotates freely without tilting. Using a locking pin tool 99360608, locate the sprocket at the three o’clock position (Fig 5).

Loosen the tensioner bolt and, using an Allen key, rotate the installation eccentric plate to the position shown in Fig 6 before fitting a new belt, aligning any timing belt marks (if present) on camshaft and crankshaft sprockets.

Then remove the camshaft sprocket locking pin and slacken the tensioner bolt.

���

Three-notch tensioner setup STEP 1: Using an Allen key, rotate the tensioner installation eccentric anticlockwise until the left-hand notch aligns with the dot on the tensioner body (Fig 7). Tighten the tensioner bolt to 36Nm (±4Nm). This is the third of our 4T principles: torque.

STEP 2: Counter hold the camshaft sprocket and tighten the bolt to 130Nm, then remove the crankshaft and camshaft locking pins

���

STEP 3: Slacken the tensioner bolt and use an Allen key to turn the tensioner until the central notch window aligns with the dot on the tensioner body (Fig 8). Tighten the bolt to 36Nm (±4Nm). This should correctly tension the belt – the final 4T principle.

STEP 4: Remove the camshaft and crankshaft locking pins and rotate the engine in direction of rotation for two full revolutions until just before TDC and insert crankshaft locking pin. Turn the crankshaft clockwise until it touches the pin. Ensure the camshaft pins can be easily inserted. If not, repeat the tensioning procedure.

Remove the locking tools and reinstall all components in reverse order and tighten crankshaft pulley bolts to 30Nm. Fill and vacuum bleed the cooling system using new coolant in accordance with the vehicle manufacturer’s specifications and recommendations. Always carry out a full road test to ensure the heater works correctly and the coolant level remains steady.

"This engine has been used for many years, and it has always been recommended that a new water pump is installed at the same time as carrying out a timing belt system replacement."

���

One-notch tensioner setup STEP 1: Turn Allen key anti-clockwise until the single notch goes past the white dot and covers it completely (Fig 9), which is the high-tension position.

STEP 2: See three-notch tensioner setup.

STEP 3: Now turn tensioner clockwise to reveal the dot in the notch window (Fig 10), which is the nominal position.

STEP 4: See three-notch tensioner setup.

쐅

���

FOR MORE INFORMATION ABOUT SCHAEFFLER, WWW.RDR.LINK/VAN012

MAY 2022 CVW S3

038_CVW_MAY22_Layout 1 27/04/2022 16:15 Page S4

TECHNICAL SUPPLEMENT FLYWHEEL CHECK

The commercial vehicle (CV) experts at ZF Aftermarket explain why checking the flywheel during a clutch replacement is vital:

WHY CHECK THE FLYWHEEL? ZF AFTERMARKET EXPLAINS I n most CV engines, the flywheel is a massive component, but, despite its size, it can wear out – on the starter gear ring or the friction surface, for example. This is because the flywheel is tapered by only a few tenths of a millimetre in order to ensure smooth clutch engagement.

After a clutch change on a truck, if the clutch engage is still jerky and affects the starting behaviour, it may be because the flywheel is worn. Although this component is extremely durable and, therefore, not included in the usual clutch spare parts kits, even this massive component is subject to wear and tear over time.

The friction surface, for example, has a conicity that is barely visible to the naked eye. It is tapered by a few tenths of a millimetre, so that the friction disc does not abruptly apply, but instead makes the startup process as smooth as possible.

However, this taper can wear out after long use. If this happens, the frictional connection is established without transition when the clutch is engaged, which leads to the inharmonious starting behaviour, as described above. Incidentally, this jerky behaviour is not only a comfort

S4 CVW MAY 2022

disadvantage, but can also result in consequential damage to the driveline.

In addition, another point on the flywheel that is subject to wear is the starter ring gear. The engine is likely to be started several thousand times during its service life, meaning that the starter pinion meshes with the corresponding ring gear frequently, wearing away the material. This can result in starting problems.

Other criteria for assessing the condition of a single-mass flywheel are local thermal overloads or cracks in the contact surface.

The experts from the aftermarket division of ZF, therefore, recommend that the vehicle’s flywheel is intensively inspected every time the clutch is changed.

It is recommended that the customer replace it at an early stage or at the same time as the clutch if there are any signs of wear. Replacing the component does not incur high additional costs but can prevent expensive consequential damage.

FOR MORE INFORMATION ABOUT ZF, WWW.RDR.LINK/VAN013

KEY POINTS ● The starter pinion repeatedly

meshes with the flywheel ring gear and causes abrasion ● The taper of the friction surface can

also wear after repeated use, leading to clutch vibration ● Proactive replacement of the

flywheel prevents expensive consequential damage

CPN ad grid_Layout 1 28/04/2022 11:20 Page 39

040_CVW_MAY22_Layout 1 27/04/2022 16:24 Page S6

TECHNICAL SUPPLEMENT ELECTRICAL COILS

FEBI DISCUSSES ELECTRICAL COILS Ensuring the electrical coils have a safe and flexible connection between the trailer and towing vehicle is of paramount importance – febi explains everything technicians need to know:

E

lectrical coils are necessary to provide a flexible connection between the electric and electronic systems of the trailer and the towing vehicle. Not only does this include the lighting of the trailer, but also tail lifts and other electrical components are supplied with power by the towing vehicle. The ABS or EBS system must also communicate signals with the towing vehicle via the data bus system. For all these systems to function correctly, they need a secure connection.

What to know…

While the distance between the electrical coil connections, between the cab and trailer, is relatively small when driving straight ahead, the situation is quite different when driving around curves. This is because the towing vehicle swings out strongly in tight curves and the coils are therefore stretched. Different coil lengths are required depending on the type of vehicle. A distinction is made between the working length of the spirals and the maximum length. Ideally, the maximum distance corresponds approximately to the working length of the coil. Under no circumstances should the maximum working length be exceeded; otherwise, the coil may be damaged. Without a

���

S6 CVW MAY 2022

functioning electrical connection to the trailer, it is not possible to continue the journey for the time being.

Since most defects in electrical coils are caused by plug connections, we have taken a closer look at them. In addition, the mechanical load capacity, which is relevant for practical applications, was also examined.

���

Plugs The connection points of electrical circuits are the most common sources of error in electrical coils. Poor contact, due to loose contacts or moisture, is typically the cause.

Sometimes, the quality can already be seen in the processing of the plug: Poor processing of the connector housing can lead to insufficient fitting accuracy and problems when inserting the connector. The position of the contacts is not optimal. They can be damaged by the mating part of the socket or pressed backwards out of the plug. Inserting the plug can be problematic if the contacts collide (Fig 1).

The febi plug (Fig 2) is well manufactured and offers an optimal fit. The contacts are in the correct position so that plugging in the connector is easy.

Mistakes can be made during production. Here, you can see the damaged

040_CVW_MAY22_Layout 1 27/04/2022 16:24 Page S7

insulation of the cables of a new plug (Fig 3). This can lead to short circuits that disable the electrical system. The cables of the febi plug are properly processed and show no signs of damage (Fig 4).

The kink protector of the plug should be stable and firmly connected to the plug and give the cable support. In this case (Fig 5), the kink protector can be pulled out of the plug by hand and the cable is not sufficiently protected by the soft material. Both of these factors severely limit the service life.

The kink protection of the febi plug (Fig 6) is firmly attached to the housing and cannot be pulled out. It is stable, gives the cable a good stability, and protects it.

"The kink protector of the plug should be stable and firmly connected to the plug and give the cable support."

If the sealing of the cable to the plug is poorly constructed, moisture can penetrate the plug. Corrosion can then occur, which in turn can lead to poor electrical contact.

Here, there is a overly large gap between the cable and the seal, through which water can penetrate (Fig 7).

If special requirements are placed on waterproofness, febi offers a plug for retrofitting (Fig 8). It has a screwed seal which presses the sealing rubber firmly against the cable and effectively seals the plug.

Other aspects also play a major role when it comes to durability and safe functioning; for example, in the case of very inexpensive electric coils, cables with wire cross-sections that are too small are sometimes used. This is because the expensive copper in the cables is a cost factor. However, a wire cross-section that is

���

���

���

���

���

���

too small can lead to the heating of the cables when the current flow is high. If the cable becomes extremely hot, the insulation can melt and cause a short circuit.

Sometimes, savings are also made on the processing of the contacts in the connector.

A poor connection between the contact and the cable can quickly lead to problems in the electrical system, which can result in time-consuming troubleshooting.

Tensile test In order to check the mechanical load capacity of electrical coils, tensile tests were carried out on state-of-the-art test equipment. The force at which the cable is pulled out of the plug was measured. The 15-pole and seven-pole electrical coils were compared; in each case, the febi product and two competitive samples were put to the test.

MAY 2022 CVW S7

040_CVW_MAY22_Layout 1 27/04/2022 16:26 Page S8

TECHNICAL SUPPLEMENT ELECTRICAL COILS

���

The strain relief in the 15-pole coils plug gave way at 1090N and 1320N in the competition samples. The febi electrical coil withstood tensile forces up to 2160N (Fig 9). The deviation of the tensile forces of the seven-pole coils are not as large as with the 15-pole coils, since the connection between plug and cable held for all test candidates. In the end, the weak point was the cable, which withstood 1703N and 1930N in the competition samples. The cable of the febi electric coil only broke at over 2000N (Fig 10).

쐅

Electric coils specific to Euro 6 vehicles Vehicles that meet the Euro 6 emission standard are efficiently designed. The engine and its surroundings have a modern thermal management system, which ensures smart control of the water pump and cooling water temperature. Also, the air flow of the engine waste heat has been optimised.

For example, when driving slowly in traffic jams or in the city, in combination with high outside temperatures, the air temperature in the area between the

쐈

Standard-Coil

Coil for Euro VI vehicles

S8 CVW MAY 2022

쐉

driver‘s cab and trailer can rise to as much as 125°C due to heat waste from the engine.

For this reason, there are electrical coils that can withstand these temperatures without damage. We conducted a test and compared a coil that is suitable for temperatures of 125°C with a standard coil (Fig 11). For both coils, the restoring force was measured at room temperature and when heated up to 125°C. It can be seen that even at room temperature, the 125°C coil has a higher restoring force than the standard coil.

When the coils are heated up to 125°C, the restoring force of both coils decreases considerably; however, the 125°C coil has a more than 40% higher restoring force in the heated state compared to the standard coil.

The following picture (Fig 12) shows the dimensional stability of both coils after the tensile test in the heated state.

The 125°C coil still has sufficient restoring force to retract. The coil, which is not heat-resistant, remains elongated and cannot be used any further, as it will sag and could come into contact with other vehicle parts. The result of the tensile test shows that Euro 6 vehicles should be equipped with heat-resistant electrical coils. febi Truck offers a comprehensive range of electrical coils, plugs, sockets, and adapters in original equipment-matching quality for all common applications in the commercial vehicle sector.

FOR MORE INFORMATION ABOUT FEBI, WWW.RDR.LINK/VAN014

CPN ad grid_Layout 1 28/04/2022 11:24 Page 43

044_CVW_MAY22_Layout 1 27/04/2022 17:03 Page S10

TECHNICAL SUPPLEMENT BRAKING SYSTEMS TEST

DVSA PRESENTS BRAKING SYSTEMS TEST GUIDE Braking systems remain one of the top causes of failure at annual test. DVSA presents its guide to passing the test to help operators prepare their vehicles, complete with best practice advice: Brake test checklist: ● ● ● ●

● ● ●

Load the vehicle Have all the brakes had time to bed in?

Do you know the correct method of inspection?

Avoid steam-cleaning; steam-cleaning the vehicle brake system immediately before test is highly likely to reduce the brake performance Is the roller brake tester (RBT) calibrated and in good condition?

Has the vehicle exceeded the minimum efficiency required in the manual?

It shouldn’t be necessary to alter the Load-Sensing Valve (LSV) settings outside of the manufacturer’s pre-set limit to achieve a satisfactory brake result. Altering the LSV settings can lead to over-braking of the rear wheels, which is a potential road safety hazard.

This will result in prohibition action

S10 CVW MAY 2022

●

Secondary braking systems: vehicles are fitted with a secondary brake, typically either through a split braking system, or a progressively applied hand control valve. Make sure you know which type your vehicle has, and if the other system can be used as an alternative. Secondary brakes using split systems are no longer assessed at annual test

Locked wheels and the brake test DVSA insists that vehicles must be fully loaded at test because the grip between the tyre and the RBT rollers is more effective that way and the load sense valve will be opened. The wheels keep turning for longer and a higher brake force will be achieved.

If the vehicle is empty or only lightly loaded, the grip between the tyre and the road (or the rollers on a roller-brake tester or RBT) will be lower, and a relatively small

brake force will cause the wheels to lock and stop turning. Once locked, no matter how much more the brakes are applied, the recorded brake force won’t increase.

This means that if the vehicle’s load is too light, the wheels may lock before achieving the required brake efficiency, resulting in a test failure.

Testers can also pass a vehicle on locks, provided more than half the wheels on a system lock. Front wheel lock allowance (FWA) takes into account the weight transfer to the front axle(s). DVSA warns, however, that operators should not rely on these two concessions when preparing vehicles for a brake test.

How to prepare for the brake test Loading ATFs will check vehicles are loaded to 65% of design axle weight. Load simulators are

044_CVW_MAY22_Layout 1 27/04/2022 17:06 Page S11

permitted, and some ATFs may have a ballasted trailer available for hire. Where load simulators can’t be used, vehicles or trailers – unless exempt by design – must be loaded when tested. Tractors must be coupled to a loaded semi-trailer, so that the drive axle is loaded at or very close to the plated weight shown in column two of the plate and plating certificate.

When loading a vehicle for brake test, DVSA advises: ● Ensure loads are adequately secured ● Aim to apply at least 65% of the design axle weight to each axle (not less than 50%) ● Use similar loads to add weight to the vehicle – this will help in placing the loads correctly and achieving consistency between tests.

Pre-test brake performance checks With an RBT ●

Ensure the rollers are clean, in good condition and well gritted, and the RBT

is calibrated Present the vehicle loaded to at least 65% of design axle weight ● If you have a computerised RBT, ensure it has the current version of DVSA’s DTp (now DfT) number database installed in the machine, so that new vehicles are recognised ● If you have a non-automated RBT, decide what the vehicle’s braking requirements are to help calculate brake performance ● Decelerometer testing is available at a limited number of ATFs, but only permitted if testing the vehicle with an RBT is not possible ●

“DVSA insists that vehicles must be fully loaded at test because the grip between the tyre and the RBT rollers is more effective that way and the load sense valve will be opened. The wheels keep turning for longer and a higher brake force will be achieved.”

Without an RBT ●

Local franchised dealers, vehicle repairers and local authorities may offer RBT brake check services. Ensure brake performance is included in routine maintenance

FOR MORE INFORMATION ON THE DVSA, WWW.RDR.LINK/VAN015

046_CVW_MAY22_Layout 1 27/04/2022 16:37 Page S12

TECHNICAL SUPPLEMENT SEAM SEALANT

HENKEL ADVISES ON APPLYING TEROSON MS 9320 SF

I

n order to keep a fleet looking top standard, it is crucial to reproduce the same quality and visual appearance that is provided by the original equipment manufacturer (OEM) seams, which will also help to avoid corrosion caused by environmental factors.

Sealing technologies allow commercial vehicle workshops to reproduce all kinds of OEM textured beads with just one seam sealant product, Teroson MS 9320 SF. This product can produce ribbed beads, as well as traditional textured beads, and standard seams are also possible with its isocyanate and solvent-free modified silane polymer.

Henkel gives pointers on how to correctly apply its Teroson MS 9320 SF seam sealant to keep vehicles looking brand new:

How to...

Teroson MS 9320 SF can be used for both sprayed and brushable applications, and it exhibits very good adhesion to a wide range of substrates without the use of a primer.

The fast-curing sealant may be overpainted, and it has excellent UV resistance and weathering performance. With the following instructions, workshops can recreate those traditional, textured seams with spray seam sealing/spray surface coating.

Tools: ● ● ● ● ●

Chemical resistance gloves Masking tape Safety glasses Spray nozzles Application gun

Preparing the cartridge Remove the bottom cover and open the cartridge. Screw the dispensing nozzle required (inner nozzle) onto the cartridge.

Attaching the air cap Insert the cartridge into the spray gun and screw on the blue screw collar. Screw with air cap fully into the blue screw.

“Teroson MS 9320 SF can be used for both sprayed and brushable applications.”

S12 CVW MAY 2022

046_CVW_MAY22_Layout 1 27/04/2022 16:39 Page S13

a

"Adjust the compressed air gun and the screws. The supply pressure must be between 6 bar and 10 bar." a Spray seam sealing

Using the air gun Adjust the compressed air gun and the screws – the supply pressure must be between 6 bar and 10 bar. Start the closed sealant flow and open the air flow completely. Position the gun towards the substrate and press the trigger. Slowly open the sealant flow to get a base structure (different ratios of sealant and air supply will produce the required texture).

b

Hold the nozzle in the vertical position and move it at a right angle to the seam approximately 4cm above the surface. In case of overspray, adjust the distance. Let the product cure.

b Spray surface coating For coating larger areas, adjust the distance of the nozzle to the surface to approximately 20cm. Let the product cure.

FOR MORE INFORMATION ABOUT HENKEL, WWW.RDR.LINK/VAN016

048_CVW_MAY22_Layout 1 27/04/2022 16:42 Page S14

TECHNICAL SUPPLEMENT DIAGNOSTICS

BOSCH EXAMINES ESI TRUCK’S ADVANCED MODE In part eight of the series, Bosch takes a look at the two levels of advanced mode, why they are important, and how to access this additional information:

W

ithin ESI Truck, there are three levels of information: standard diagnostics content, Advanced Mode, and Advanced Mode (Trailer).

The standard diagnostic content, which we have seen in the previous parts of ‘KTS Truck made ESI’, allows diagnosis on trucks, buses, and off-highway vehicles. But sometimes, under the Adjustments and Settings section, you may need to update the parameters of a specific system or component – such as recoding injectors.

For this feature, you will need to activate Advanced Mode (Fig 1). Bosch recommends setting this up when your ESI Truck is installed. The advanced mode password is specific to the KTS Truck module that you are using. To request this, simply fill in a form, which Bosch will provide, send it to the Bosch service team in Germany, and you will receive your fourdigit password, usually, that same day.

���

���

��� For trailer diagnostics, you will need to apply for Advanced Mode (Trailer) in order to change any parameters of the braking system. Diagnosis of the other systems is possible without this extra level of information. However, as the braking systems are such safety-critical components

of the trailer, Bosch requires evidence in the form of training certificates that you are qualified to work on these systems. The password that is generated for Advanced Mode (Trailer) is technician specific, as it matches the training certificate which the Bosch service team has received to release the password (Fig 4).

FOR MORE INFORMATION ABOUT BOSCH, WWW.RDR.LINK/VAN017

��� If you haven’t entered the password and you try to access this information, ESI Truck will prompt you to enter the password before it will allow you to access the information (Fig 2). Once this has been entered and accepted, an additional note will appear at the top of the ESI Truck screen to show that you are in Advanced Mode (Fig 3).

S14 CVW MAY 2022

049_CVW_MAY22_Layout 1 27/04/2022 16:43 Page 49

WHAT’S NEW?

씰쑼 GATES HEAVY DUTY WATER PUMPS Gates has added belt-driven original equipment (OE) quality water pumps to its specialist range of aftermarket products for heavy duty trucks and buses. Heavy duty water pumps will become part of its FleetRunner range. For the first time, truck and bus operators will be able to carry out a complete accessory belt drive system overhaul using heavy duty parts (water pump, coolant hoses, belt, tensioner and idler) covered by the same extended Gates warranty.

Water pumps are among the key components powered by the belt, and with a track record for supplying heavy duty water pumps in the US and Canada, Gates said it appreciates the particularity of fleet engineers when it comes to the quality of the drive system parts fitted to their fleets. The heavy duty water pumps in the FleetRunner range are an ideal fit for any preventive maintenance strategy.

A computer-tooled manufacturing process, with assembly lines that are subject to strict quality controls, ensures the water pumps all match or exceed OE quality standards and conform with various international standards (such as ISO/TS 16949). A precisely balanced impeller ensures OE fit and function. Finally, all units are subject to a rigorous leak-testing programme that checks all seals and bearings, as well as the individual casings.

For parts distributors, the new FleetRunner heavy duty water pumps offer a wide range of benefits, including the ability to stock parts for which there is already rising demand and an opportunity to supply water pumps covered by the extended Gates warranty programme.

Installers benefit from a first time fit and a comprehensive level of technical support, which often takes form via direct training or online training for workshop mechanics. In addition to basic fitting instructions and information around the importance of flushing out the cooling

system after installation, the available technical support also extends to webinars that cover more complex areas such as cooling system diagnostics and how to maintain optimum coolant condition.

Bert De Lange, business development manager for heavy duty aftermarket sales and marketing, of Gates Europe, said: "Our initial range of FleetRunner heavy duty water pumps is well-researched and only stocked with popular applications that are already in demand.

We will be able to cover over six million trucks and buses on EMEA roads from day one. That’s all possible thanks to our OE drive systems development experience, coupled with water pump manufacturing expertise and extensive knowledge of the heavy duty drive systems markets.”

GO TO WWW.RDR.LINK/VAN018

MAY 2022 CVW 49

049_CVW_MAY22_Layout 1 27/04/2022 16:44 Page 50

WHAT’S NEW?

LAUNCH 씰

DIAGNOSTIC EQUIPMENT

Technicians specialising in heavy commercial vehicles (CVs) can bolster their portfolio with Launch Tech UK's new PRO 5 HD+ equipment. Following continuous innovation and software development across Europe, the US and Asia, the company has designed the equipment with extensive coverage of global heavy commercial vehicles and systems.

The PRO 5 HD+ offers a “faster, smoother experience”, developed on the foundations of the latest Launch PRO 5 diagnostic equipment on the reliable Android 9.0 operating system. Diagnostic functions include read and clear codes, view live data streams, bi-directional control, and actuation tests.

The Launch HD Box 3, an additional module for car-based tools, is available to use with the PRO 4, PRO 5, and Euro Tab II and III, and is an add-on module for customers working with heavy CVs. It enables technicians using this range of tools to perform comprehensive diagnostics on a wide range of heavy-duty vehicles, including trailer ABS systems, Cummings, Detroit Diesel, and Caterpillar engines. The PRO 5 HD+ links up with HD Box 3 using 2.4GHz and 5GHz dual band communication, which ensures a quick and stable connection. The HD+ comes with a comprehensive set of manufacturer specific connectors, which includes OBD connectors and switching line test cables.

Available separately is the Launch Professional HD database; the electronic version offers guided diagnostics from fault code to a test plan to a final fix. The database includes wiring diagrams, component locations, ground points, fuse, and relay information and more.

GO TO WWW.RDR.LINK/VAN019

051_CVW_MAY22_Layout 1 28/04/2022 11:10 Page 51

ADVERTISEMENT INDEX Here is a useful summary of all the adverts that appear in this issue of Commercial Vehicle Workshop.

Each is listed with its page number and a direct URL that will get you straight to the relevant online information.

Autolift Ltd .................................................................. (page 50)

Merridale Ltd .............................................................. (page 50)

www.rdr.link/VAN100

www.rdr.link/VAN113

Bailey Morris Ltd ...................................................... (page S11)

Premier Pits .................................................................. (page 7)

www.rdr.link/VAN101

www.rdr.link/VAN114

Castrol UK Ltd ........................................................ (pages 8, 9)

Pro Align Ltd ...................................................... (bound outsert)

www.rdr.link/VAN102

www.rdr.link/VAN115

Checkpoint Safety ...................................................... (page 19)

Pro Align Ltd .......................................................... (back cover)

www.rdr.link/VAN103

www.rdr.link/VAN116

Commericial Vehicle Show ........................................ (page 16)

Ring Automotive ........................................................ (page 21)

www.rdr.link/VAN104

www.rdr.link/VAN117

Ecobat ........................................................................ (page S9)

Robert Bosch Ltd ........................................................ (page 27)

www.rdr.link/VAN105

www.rdr.link/VAN118

Eminox Ltd .................................................................. (page 31)

Rotronics .................................................................... (page S5)

www.rdr.link/VAN106

www.rdr.link/VAN119

Group Tyre .................................................................. (page 22)

Sampa UK & Ireland Ltd ............................................ (page 11)

www.rdr.link/VAN107

www.rdr.link/VAN120

Hope Technical Developments .................................. (page 34)

S. Catterall Ltd ............................................................ (page 33)

www.rdr.link/VAN108

www.rdr.link/VAN121

Jack Sealey Ltd .......................................................... (page 12)

Schaeffler Automotive Aftermarket (UK) Ltd .............. (page 15)

www.rdr.link/VAN109

www.rdr.link/VAN122

Knorr Bremse .............................................................. (page S5)

Stertil UK Ltd ................................................ (inside front cover)

www.rdr.link/VAN110

www.rdr.link/VAN123

Liftmaster Ltd .......................................................... (page S13)

Totalkare Heavy Duty Workshops ................................ (page 4)

www.rdr.link/VAN111

www.rdr.link/VAN124

Mannol ........................................................................ (page S9)

VL Test Systems Ltd .................................................. (page 28)

www.rdr.link/VAN112

www.rdr.link/VAN125

KEEP UP TO DATE WITH CV W

A

B

FOLLOW US ON TWITTER

LIKE US ON FACEBOOK

VISIT OUR WEBSITE

@CVWMAGAZINE

@CVWMAGAZINE

WWW.CVWMAGAZINE.CO.UK

MAY 2022 CVW 51

CPN/CVW page grid_Layout 1 20/04/2022 09:11 Page 1

CPN/CVW page grid_Layout 1 20/04/2022 09:16 Page 2

CPN/CVW page grid_Layout 1 20/04/2022 09:21 Page 1

CPN/CVW page grid_Layout 1 20/04/2022 09:22 Page 1

CPN/CVW page grid_Layout 1 20/04/2022 09:19 Page 2