5 Viewpoint
News
Cover story – IMI Skills Heavy Vehicle Technology final
12 Reader profile: Marshall Truck & Van
Euro Bus Expo preview
What’s new?
Mechanex
Digital digest
17 Brake discs and calipers can be damaged, and tyres exposed to unnecessary wear and tear if regular service intervals are missed. Rozone looks at means to avoid this.
When its ATF lane commercial brake tester broke down, help for Optimus Commercials and Engineering was just CVW reports.
Charles Figgins, Technical Marketing Manager at Blue Print, takes readers step-by-step through a clutch replacement on a 2014 Hilux.
29 Dayco’s national sales manager Steve Carolan highlights the importance of regular maintenance of belt in oil (BIO) engines in line with VM scheduled service intervals.
35 Shaftec’s Marketing Manager Adrian Kitchen discusses the importance of flushing steering systems and why corners should never be cut.
36 Keeping the wheels in motion during the worst of winter weather is a major concern for many businesses and it pays to be prepared. Tom Hyde, technical manager, Lubricants at TotalEnergies Marketing UK, tells us how.
38
As the temperatures drop and the light fades, attention to maintenance basics becomes more crucial. Draper Tools runs through a few of the tasks not to be overlooked, no matter how simple.
40 What's new?
Editors
JOHNNY DOBBYN
JOHN LEVICK workshop@cvwmagazine.co.uk
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
Commercial Vehicle Workshop is a business magazine for companies and individuals involved in all aspects of commercial vehicle servicing.
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©Melanie Kocheva/AdobeStock (pg 24)
In August, the Institute of Motoring Industries put out a pretty demoralising announcement predicting a 160,000 shortfall of workers in the UK automotive sector in the next decade. Factors contributing to this are identified as an aging population, reduced immigration and “the green agenda.” These issues wouldn’t be problematic in themselves if the replenishment were there, with young people and career changers – there’s been enough of those thanks to the pandemic – migrating into the industry.
Of course automotive isn’t unique. Hospitality, healthcare and construction, at least, are crying out for people. But it is the STEM-type sectors where the problem is the most pressing, not least given the relatively unpopularity of relevant subjects in schools and colleges.
One problem, also encountered in construction, is a negative perception of the work (dirty, hours etc ) and a lack of understanding about the range of roles, qualifications needed and salary levels.
Thus any initiative that supports and encourages people, particularly young people, into the industry has to be welcome. The IAAF has just launched an academy and partnered with leading colleges to drive that; Logistics UK has teamed up with the Government to create a recruitment campaign that encompasses engineering, and Volvo, for instance, sponsors its own Apprentice Awards. Awards like these, and the IMI Skills Competition (p.10) serve to acknowledge the UK’s most promising apprentices and reward them for their commitment, ability and potential.
It’s important to nurture this next generation because, by doing so, we are helping to ensure that automotive sector, and the economy, flourishes and sees the high-quality workmanship to which the industry aspires and our end-user customers deserve. By working together to develop and maintain a healthy skills base through recruitment, apprentices and quality training, we will all be contributing to reducing such shortages and – in the grand scheme of things –improving national capacity.
Finally, we remember HRH Queen Elizabeth. Unknown to many, she trained as a heavy vehicle mechanic and driver in WW2, and we briefly consider her service on p.6.
The CVW Team
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
“It is the STEM-type sectors where the problem is the most pressing, not least given the relatively unpopularity of relevant subjects in schools and colleges.”
Morris Lubricants has released a video series on how oil is made, and the factors that should be considered when choosing a supplier, featuring its brand ambassador and all-round bonkers good bloke Guy Martin.
In the series of five short films, Guy is taken through the production process and shown the key areas that should be considered when selecting oils and lubricants to ensure maximum fuel efficiency, emission compliance by protecting after treatment devices, improved component longevity and greater reliability.
As the nation mourns the passing of Queen Elizabeth II last month, we are reminded that, for all the regal graces, she was, for a short time, one of us – a commercial vehicle technician.
The UK has been shortlisted as a potential location for global battery manufacturer ProLogium to establish is first gigafactory outside Taiwan.
Investment in the new factory will total US$8bn over the next decade and the plant is expected to be one of Europe’s biggest gigafactories, with a threephase construction and an annual capacity target of 120 GWh when the third phase is completed.
The construction and operation of the gigafactory are expected to generate substantial economic benefits for the chosen region, creating thousands of highly-skilled jobs both at the plant itself and within the supply chain.
The then Princess Elizabeth reached her teens in April 1939 and, following the outbreak of war late that summer, began to enter the life of service that characterised her reign: broadcasting to the nation, visiting factories, launching ships and meeting the troops. Upon reaching 18 in 1944 and becoming eligible for national service, she lobbied her father King George VI for a role in the armed forces, rather than be sheltered from the reality of war at her home in Windsor.
Eventually the King relented and, in February 1945, she enlisted in the Auxiliary
The Queen’s commissioning in the ATS was published in the London Gazette on March 6th 1945.
Territorial Service (ATS) as 230783 2nd Subaltern HRH The Princess Elizabeth. The ATS provided clerks, telephonists, storekeepers, cooks and anti-aircraft gun crews to the army. More importantly, it also supplied drivers and mechanics, and Elizabeth elected to train as a heavy vehicle mechanic and driver at the ATS’s No. 1 Motor Transport Training Centre in Camberley.
It was this war service that led news agency Associated Press to dub her “Princess Auto Mechanic” in April 1945 and this war service and adherence to duty that formed her bond with the armed forces that we saw in evidence on the day of the funeral.
There has been much written and more said since The Queen’s death on September 8th, and we need not add unduly to that other than to say that in the realm of the commercial vehicle, we like to remember her as “Princess Auto Mechanic”.
“In February 1945, Elizabeth trained as a heavy vehicle mechanic and driver at the ATS’s No. 1 Motor Transport Training Centre.”©Mirrorpix
The Independent Automotive Aftermarket Federation (IAAF) has launched a new training academy, designed to train, develop and upskill new and existing people working within the automotive aftermarket.
The academy will evolve substantially when the new IAAF website goes live later this year, but IAAF has moved quickly to implement and promote initiatives and courses that support its membership.
From virtual to practical training, the IAAF Academy will cover all areas of an automotive aftermarket business, helping
companies and their teams learn and familiarise themselves with new technology and legislation, while also enhancing personal development skills.
A key focus of the academy will be engaging with schools, colleges and universities. The IAAF has set up partnerships with Heart of Worcestershire College, West Notts College, and East Coast College as it looks to provided education settings with a deeper look into the workings of the trade.
IAAF members are being encouraged to get in touch with the federation to register interest in supporting the academy.
The Shaikly Motor Company, of Colchester, Essex, has won Large Independent Garage in this year’s Independent Garage Awards.
Starting life as Frank Shaikly & Son in 1977, the company has grown – with two sites – to be one of the most successful garages in the Colchester area. Still family-run, Shaikly offers service, repair and MOTs alongside commercial vehicle sales. The company is currently led by managing director Rob Porter who puts Shaikly’s success in the awards to good people, good processes and even better customer service.
The DVSA has released its latest vehicle database update for Commercial Vehicle Roller Brake Testers.
Will Guest of the Hartshorne Group’s has become the first HGV apprentice technician in England to be awarded a distinction for the Institute of Motor Industry’s (IMI) Heavy Vehicle End Point Assessment. The Level 3 apprenticeship, supported by Remit Training, involved academic learning and on-the-job training at the Volvo Trucks dealer Hartshorne’s Shrewsbury depot.
The culmination of the course sees the students undergo a two-day assessment including written tests and practical exercises, producing a portfolio of repair and maintenance work under the eye of an exam assessor. At the end of the assessment
the participants are awarded a pass, merit or distinction depending on their results.
The heavy vehicle apprentice qualification is undertaken by all truck manufacturers, and Will is the first technician in England to gain a distinction. “It’s fantastic that all the hard work has paid off,” he says. “The majority of my learning has been through working alongside my colleagues at the Shrewsbury depot. They have supported me every step of the way and I couldn’t be more thankful.”
Will has been working for the Hartshorne Group for five years but, due to two years of disruption caused by the pandemic, finished his apprenticeship just over a year late.
All Authorised Testing Facilities have until November 1st to install this newest version of the Designated Test Programme (Dtp) data to ensure that vehicle tests on a range of additional models are conducted following model-specific test routines. This latest DVSA update includes new Dtp numbers 10090 to 10238, one of which relates to a two-axle Citroen ridged, 3800kg GVW, (Solo) parking on axle two, with the split service brake as the nominated secondary.
The DVSA is also trialling remote tachograph sensing equipment in Britain to make it easier to detect drivers and operators who are breaking driving time rules. The agency says that while “it knows most operators follow drivers’ hours rules, we are still finding offences at the roadside. This technology means we can identify many kinds of tacograph violations when travelling alongside vehicles, or from the roadside."
Commercial Vehicle WorkshopThe European Automobile Manufacturers’ Association (ACEA) has published the 2022-2023 edition of its annual pocket guide which it claims provides a clear and comprehensive overview of one of the European region’s most strategic and innovative industries: the automotive sector.
Amounting to 106 pages, the new edition of the ACEA Pocket Guide contains the latest data on employment, vehicle production and sales, trade flows, the vehicle fleet, road safety, the environment, innovation and taxation – making it a useful reference guide for anyone interested in automotive issues and policies.
Transport for London’s (TfL) Direct Vision Standard (DVS) is behind a sharp drop in serious accidents, new figures have revealed.
TfL’s stats show serious injuries are down by 64% compared to 2017 thanks to the DVS scheme, which requires owners of HGVs weighing more than 12-tonnes to apply for a safety permit that assigns vehicles a star rating based on how much the driver can see directly through their cab windows.
The DVS is based on a ‘star rating,’ indicating how much a driver can see from the cab and was developed to protect vulnerable road users such as cyclists and pedestrians. TfL research shows HGVs accounted for just 3% of the overall miles driven in London from 2018 to 2020 yet were involved in nearly half (41%) of fatal collisions involving cyclists and 19% involving pedestrians. The DVS standards are set to tighten further in 2024.
“HGVs accounted for 3% of the miles driven in London yet were involved in 41% of fatal collisions involving cyclists and 19% involving pedestrians.”
Winsford-based Tiger Trailers has launched a coachbuilding apprenticeship in partnership with the Heritage Skills Academy, offering apprentices an opportunity to gain skills working on classic vehicles – including trucks and vans – at Brooklands Museum and Bicester Heritage.
The new Heritage Engineering Technician Apprenticeship in Classic Vehicle Coachbuilding combines old-school skills with cutting-edge technology. Working with highly specialist teams, apprentices will be taught about the history and development of materials and vehicle construction, hand
skills, design and pattern development while working with composite materials, welding, fabrication including bending, folding, creating jigs and frames, and the removal and replacement of components.
The specialised apprenticeship leads to a nationally-recognised Heritage Engineering Technician Level 3 Apprenticeship qualification at the end of the 42-month course. Employment with Tiger Trailers in a skilled role is guaranteed to apprentices graduating from the programme, with the prospect of a long-term career with progression opportunities including managerial roles.
Courtesy of Brigade Electronics
“The pocket guide provides a clear and comprehensive overview of one of Europe’s most strategic and innovative sectors: autmotive.”
Last month CVW reported on the announcement of the finalists of the 2022 Institute of the Motor Industry’s (IMI) Skills Competition. In anticipation of November’s finals, we focus in on the Heavy Vehicle Technology (HVT) category.
With the industry desperately short of skilled workers, it becomes increasingly important not only to motivate young people or career changers to join the sector; but also acknowledge and reward the efforts of those apprentice entrants who have excelled themselves, and the IMI Skills Competition aims to do just that.
One of the most keenly contested categories is that of Heavy Vehicle Technology, and a team of expert judges has whittled down the hundreds of applicants down to six who now proceed to the national finals on November 14th. The winner will be crowned at a ceremony hosted by presenter Steph McGovern from
her Channel 4 Packed Lunch studio on November 25th. Competitors that impress in the national final could be in with a chance of representing the UK in the WorldSkills finals in France in 2024.
To be in contention, the HVT entrants had to pass a ‘passive online test’, the scores of which determined who went through to the digital and practical national qualifiers. Having qualified for the finals, the contestants will face technical challenges that test their ability to set up and use diagnostic equipment; carry out diagnostic procedures; follow correct technical and manufacturers procedures; work efficiently; accurately use scan tools, multimeters and DTI gauges; efficiently complete systems
■ Nicholas Garrett, Gateshead College;
■ Stephen Hill, Bridgend College;
■ George Hinckley, Remit Training and Scania;
■ Daniel Noddle, Northside Truck and Van;
■ Max Winter, Skillnet and Adam Morey; and
■ Aleksander Zielechowski, Remit Training and MAN Truck and Bus.
repairs and inspect vehicles ready for use.
Six tasks are set covering engine diagnostics, vehicle inspection and assessment, transmissions, electrical systems, steering and suspension systems, and braking systems.
For example, the braking challenge requires competitors to diagnose and repair a fault in a trailer braking system that has been previously repaired but now has a warning light on in the tractor unit and has harsh braking when unloaded. The engine diagnostics test asks competitors to diagnose and repair a two-stage fault in a vehicle that has been towed in as it will not start. In both cases, the competitor will need to log all related fault codes, diagnose those faults and rectify them. Once correctly rectified, the fault codes should be cleared
Richard Hutchins, IMI Skills Competitions Manager, has the last word. “The Skills Competition is designed to raise standards, esteem and the level of expertise in technical skills, and it is clearly doing just that. It is incredible what these apprentices have achieved so early in their careers and under such difficult circumstances, It has been great to see such enthusiasm and dedication from the next generation of automotive experts, and we can’t wait for this stage of competition.”
IMI SKILLS Nicholas Garrett Stephen HillDaniel NoddleGeorge Hinckley Aleksander Zielechowski Max WinterOperators of Mercedes-Benz and FUSO trucks in north-west Hampshire and beyond can now reap the benefits of a £1m facilities upgrade by Marshall Truck & Van in Andover. CVW reports.
Established in 2016, Marshall Truck & Van was created out of the acquisition of the Ridgeway Group by the multi-franchise Marshall Motor Holdings (MMH) Group, whose various businesses included the former MercedesBenz commercial vehicles franchisee for Hampshire and Dorset. The £100m deal was claimed at the time to be the biggest in the automotive sector for 10 years. The
company took on its predecessor’s sites in Fareham, Andover and Croydon, and continues to operate from each of these locations to this day.
It also ‘inherited’ an aftersales facility on the Nursling Industrial Estate in Southampton. However, at the beginning of 2020, Marshall relocated its operation to a purpose-built, flagship facility on the other side of the road. The new branch, which represented a £4 million investment, had been talked about by the previous franchisee for years; it was Marshall that made it a reality.
The opening of its new site coincided with the arrival of Wayne Edwards as the company’s new head of business and Wayne continues to lead the 155-strong company team.
Hard on the heels of the investment in its Southampton site, the company recently completed the extension of the workshop at its Andover branch, adding an additional couple of bays to the previous four. One of
the new bays is equipped with rollers and other equipment required to undertake tachograph installations, calibrations and repairs. These tasks were previously assigned to an independent specialist that only worked during normal working hours –and Marshall’s decision to bring this service in-house means it can carry out such tasks late into the night, increasing convenience and restricting downtime for customers.
The nine-month project also entailed the creation of a new waiting area for drivers, while members of the Marshall team have benefited too – offices have been facelifted, with a new meeting room installed, and technicians who previously took their breaks in a portable unit now have their own canteen and washroom.
Wayne Edwards says: “The very substantial investment we’ve made at Andover is benefiting customers and
colleagues alike and reflects a desire on our part to be the number one provider of truck and light commercial vehicle maintenance and repair, parts services and sales on the South coast.”
Wayne continues: “David Collard (Andover general manager) and his team have made great strides with local operators. The timely, customer-focused back-up they deliver has been instrumental in enhancing established relationships, and – as word of mouth has spread locally – in winning new converts to our brands.”
David comments: “The development is great news, not least because it means that if a truck comes in at night with a tachographrelated issue we can jump straight on it, rather than having to tell the customer they’ll have to book a separate visit during the day. We aim, as far as possible, to provide a ‘one-
stop shop’ service, so the tacho bay adds another important string to our bow.”
He continued: “Colleagues are delighted, too. From a motivational point of view, this is now a smarter, more appealing place to come to work. We’re now trying to bring in more technicians and the enhancements we’ve made can only help with recruitment.”
Operators that rely on Marshall Truck & Van’s Andover team to maintain their vehicles include electrical goods distributor Ken White Distribution and Downes Transport of Amesbury.
Until five years ago, Ken White only ran Swedish-built trucks but today all but three of its 26 vehicles are Mercedes-Benz, and the transformation of its fleet owes much to the aftersales support it receives from Marshall Truck & Van. “The maintenance contracts are very cost-effective and the
At your service: Andover Workshop Manager Kate Leonard is pictured with technicians, from left, Gary Hayward, Chris Ward (Technical Specialist), Tayler Machin, Simon Causley and Stuart Glover
Leading from the front: David Collard, General Manager at Marshall Truck & Van’s Andover branch, has long experience of the MercedesBenz and FUSO brands
service we receive from the Andover workshop is absolutely fantastic,” says director and transport manager Ian Reeve. “They’re very flexible and when an issue crops up, as one always will from time to time with even the best trucks, they can always be relied upon to resolve it quickly and efficiently.”
He added: “We still have our own workshop, but we entrust the maintenance of our MB trucks to them because it makes our lives so much easier.”
Downes undertakes some maintenance work in-house, but also signs-up to Mercedes-Benz Complete Service Contracts and relies on the support of Marshall’s in Andover.
“The back-up is excellent,” said proprietor Douglas Downes. “Its workshop team are very flexible and will always attend to our trucks in the evenings or on Saturdays. On the rare occasions we’ve had a problem, the 24-hour breakdown service has also performed every bit as well as we could have hoped.”
In addition to its new Southampton site and the Andover extension, Marshall’s dedicated van site in Croydon was extensively refurbished last year, and it recently began servicing vans from MMH Group’s MB passenger car outlet in Portsmouth.
It seems that the future holds no bounds for Marshall, given the given the continuing commitment to investment in its sites. The company has further plans, but perhaps not unnaturally, is being coy about them at the moment – although the track record suggests that, whatever they are, they’ll be big!
Playing their parts: Supervisor Anthony Gillmore and Advisor Wendy Miller ensure the shelves are always well stocked
Point of contact: Service Advisors Kim Banwell and Charlie Francis, a relatively new member of the team, are ready to help customers
The free-to-attend, three-day trade show aims to showcase everything needed to manage and maintain a fleet of passenger service vehicles, now and in the future. With the industry developing at pace to decarbonise, it’s never been more important to keep informed about market and product advances. Attending Euro Bus Expo presents an excellent opportunity to do that.
The three-day show will bring together a sector rife with innovation. Alongside vehicle stands from major manufacturers, there will be a vast range of suppliers and a free seminar programme.
Visitors will be able to explore 100+ of the latest buses, coaches, mini-and midi vehicles from over 20 manufacturers, converters and dealers. Early vehicle confirmations include Alexander Dennis’s double deck hydrogen fuel cell-electric Enviro400FCEV, and firsttime exhibitor eVersum mobility solutions’ eShuttle battery-electric single decker. Pelican Bus and Coach will showcase an E12 battery-electric bus, and the only fullsize battery-electric coach available in the UK - the Yutong TCe12. Elsewhere, Irizar UK’s line-up includes its luxury i4, i6S and its i8 coaches.
Further vehicle suppliers include BASE Coach Sales, Equipmake, EVM, Harris Group, Ilesbus Automotive, Karsan, Mellor, Noone Turas, PHVC Minibus & Fleet Suppliers, Scania (Great Britain) Ltd, Switch Mobility, Temsa, Van Hool and Volvo Group (UK). Many will be revealing enhancements to their current range.
This dedicated area will bring together specialist suppliers in the small and medium PCV market. These include GM Coachwork, London Hire, Nu-Track, TBC Conversions and Treka Bus. Exhibitors will showcase the latest lifts, ramps, seating and safety equipment.
As well as the crowd-pulling vehicles, there will be more than 200 product and service suppliers attending. Visitors will find almost everything they can touch or use in an operational depot.
All essential vehicle maintenance requirements will be represented, including the latest emission-reducing, battery and retrofit technologies, and systems to aid with compliance, vehicle tracking, and security. Visitors can expect to see vehicles on lifts allowing for underside inspection, and a range of equipment providers. From pits to ramps, washing systems, separation collectors, rolling roads, fuelling and more. Training bodies will also be represented.
Seminars will be taking place throughout the show - all curated to help operators to prepare for challenges and opportunities ahead. Several sessions will focus on decarbonisation. These will inform about the milestones, challenges, and possible solutions to make the vision for carbon free transport a reality. Visitors will hear about the practicalities of implementation, infrastructure requirements, and how others are adapting.
No doubt there will be familiar names, products, services, and capabilities across the show. There will also be new finds and learning opportunities for those responsible for commercial vehicle fleet maintenance and repair. Visitors can get hands on with products and equipment and speak directly to developers. The knowledge gains may help with improving efficiencies, reducing vehicle downtime, emerging skills gaps, and solving future challenges.
Euro Bus Expo is free to attend, centrally located and well connected by road, rail and air. What’s more, attendees can now travel free of charge. Zeelo, specialists in finding and fulfilling demand from corporates and schools for coach services, are offering free coach transfers. They will journey to and from Brighton, Cardiff, Colchester, Liverpool, Portsmouth and York across the three days. Additional stops will be planned on route, based on demand.
Euro Bus Expo, the coach and bus industry’s major biennial showcase and meeting place, comes to the NEC, Birmingham, UK on 1-3 November 2022.
When focusing on brakes, the critical issue is driver and passenger safety, says Rozone. Poorly maintained braking systems are not only dangerous but can be costly if regular service intervals are missed. Brake discs and calipers can be damaged, and tyres exposed to unnecessary wear and tear.
When it comes to brake servicing, corners cannot be cut. Technicians need a safe,efficient and non-hazardous process to clean and bleed braking systems. Many methods in use across independent workshops involve time consuming processes, aggressive solvents and overspray inhalation.
These methods can have a negative environmental impact and can be unpleasant for technicians to use in the workplace.
Exposure to brake dust is a known hazard. Inhalation of these particles can damage employee’s health, so it is vital to prevent dust becoming airborne when servicing brakes.
Traditional, brake cleaning involves aerosol brake cleaners which are expensive and contain aggressive solvents. These are not good to breathe and release harmful VOCs, which are not good for the environment. There is also a potential slip
hazard from brake cleaner overspray on the workshop floor and they produce hazardous waste in the form of aerosol canisters and dirty rags – both of which need to be disposed of properly.
Proprietary air-powered brake washers – such as that from Rozone – stop brake dust from being dispersed into the atmosphere by saturating the brakes with non-hazardous aqueous-based cleaning solution. They are a great safe alternative to solvents, and easy to use.
Servicing brakes can be costly and such a vital element of a vehicle`s maintenance must be done accurately, otherwise the safety of a car will be affected. Old brake fluid becomes discoloured as it takes on contaminants from the environment and dirt, air and water can cause major issues in a vehicle`s braking system. By replacing the brake fluid at the manufacturer’s
recommended service intervals (usually every two years or 24,000 miles, whichever comes first) these contaminants are kept to a minimum and a vehicle’s braking performance will be like new.
The best bleeder technology available for brake (and clutch) servicing jobs enable technicians to fulfil brake servicing tasks safely, faster and more efficiently. This saves both time and money. Mobile units only need one-person to operate them and in around five minutes, a brake and clutch fluid change will be achieved, quickly, safely and easily. As they work electronically, no compressed air is needed.
In the case of appliances such as Rozone’s SE14 Brake Bleeder, brake fluid is pumped from the tank into a master cylinder fluid reservoir fitted with a special quick-lock adapter. When the electric pump is switched on, pressure in the tank builds up slowly to prevent the brake fluid from churning. The flow flushes and vents the smallest of air and moisture locks and any
dirt and debris out of the hydraulic system for a complete flush and bleed. The integrated shut-off valve allows a leakage test to be performed after repair of the brake or clutch system.
Fluid levels are monitored using a floater valve. On reaching the minimum fluid level of 1.5 litres, the pump automatically shuts off to avoid air being inadvertently pumped into the hydraulic system. An audible buzzer or traffic light system warns the operator of low fluid level.
Rozone’s Pentosin and DOT brake machines are colour-coded to derisk any cross contamination if workshops handle both fluids. The Romess range is specially designed to hold 30L and 60L cans of fluid, to avoid the risk of decanting. This saves time at the fill stage and also when disposing of packaging waste.
The Rozone BCE500 Brake Washer is a mobile, air-powered cleaning system. Bright yellow, it’s easy to spot in a busy workshop, and made of roto-moulded plastic to limit any damage if bumped into a `s vehicle. It come with all the attachments needed for a quick, easy clean – including an air blade to dry the brakes off. Removing the risk of corrosion. The unit can be wheeled directly under a vehicle on scissor ramps, so the cleaning fluid falls straight back into the sink. It can also be used on standard ramps, and a tray is provided to sit on the ramp under the brakes and catch the cleaning solution before it is poured back into the sink. Either way there is no need to remove the brake drum – all cleaning can be carried out in-situ without the dismantling, lifting and carrying of heavy parts.
For more about the Rozone BCE500 Brake Washer, WWW.RDR.LINK/VAR004
FOR MORE ON ROZONE’S BRAKE SERVICING EQUIPMENT, WWW.RDR.LINK/VAR003
When its ATF lane commercial brake tester broke down, Optimus Commercials and Engineering couldn’t afford to wait for a replacement, so when it discovered one available from stock immediately, it was a nobrainer. CVW reports.
Optimus Commercials and Engineering is based in Oakington, Cambridge – just off junction 25 of the A14 – and was founded last June. It took over a previous garage business, saving jobs in the process, and continued the wide range of DVSA MOT testing and vehicle servicing for cars, vans, HGVs and other specialist vehicles. It also helps customers maintain and repair bespoke machinery, like farm equipment.
Optimus’s manager Sharron Barrett relates the tale: “About 18 months ago, the unit (garage) was handed back to the landowner. However, the landowner also owns a concrete company and possesses a fleet of around 25 lorries and needs somewhere local to maintain them. We were then approached about starting up a new garage, which we agreed to so long as it had a new identity and a fresh start – and here we are!”
At present, there is a staff roster of five people, including four mechanics.
When the existing ATF lane rollers “went bang,” Sharron frantically began her quest in finding a replacement and picked up the phone, using her contacts within the trade to find out which brands were trusted.
Sharron continues: “The timescale was the most important thing – we didn’t have time to lose! – so we quickly obtained some quotes, but some lead times were six to eight weeks, and we couldn’t afford to wait that long.
It was over a weekend and a lot of companies were away at the same show (Road Transport Expo). In the case of MAHA UK, I received a call back within
minutes, a quote within the hour and an engineer came out to see me first-thing on the Monday – that impressed me straightaway. Thankfully, MAHA had what we needed in stock, so we quickly went ahead with the order.
Within a couple of days, my staff were able to complete the necessary groundwork, put the frame in and then MAHA’s engineers installed and calibrated the whole system quicky afterwards – from distress call to finished installation, it took a week, which was mighty impressive.”
Optimus Commercials and Engineering is now the proud owner of a MAHA UK MBT 7250 Eurosystem, the company’s flagship commercial brake tester.
Hailed as the ‘workshop platform to build on,’ it is relied on in ATF stations across the country. It has the ability to measure brake system performance quickly and accurately over a long period of time. It also boasts a large roller sensor, with a diameter of 100mm and axle load of 18t, so there is excellent coverage across each tyre’s dimension.
Where this brake tester excels, though, is its ability to include other modules. Users can then watch the MBT 7250 evolve into an all-encompassing workshop platform.
Tachograph calibration, headlight testing, automatic number plate recognition and axle play detection: these can all be managed on Eurosystem, which can be controlled via desktop or a tablet.
While the new brake tester won’t increase Optimus’s workload or the number of tests conducted, Sharron identified one key area that will give her and staff peace of mind: “It’s the reliability. Hopefully, we’ll have fewer down days and we’ll be able to maximise the brake tester’s capability.
The aftercare is clearly there – the speed in which quotes, and the equipment, were delivered was testament to that – and with MAHA UK nearby, we’re comfortable with the new partnership forged.”
FOR MORE ON MAHA'S MBT 7000 SERIES, WWW.RDR.LINK/VAR005
“From distress call to finished installation, it took a week, which was mighty impressive.”
A new range of floating calipers and brackets for light commercial vehicles has been introduced by Brembo. The new calipers and brackets are derived from the company’s experience in the OE sector and are said to deliver the same quality and performance as their OE counterparts.
The calipers are claimed to guarantee excellent reliability by, among other things, ensuring better resistance to atmospheric corrosion through the design of propriety seals that prevent infiltration. The new offering comprises 86 unique part numbers covering vehicles from the leading LCV manufacturers.
WANT TO KNOW MORE?
WWW.RDR.LINK/VAR006GOTO
The Mintex product range has been expanded by six new brake pads and eight new brake discs. The additions to the brake pad range cover as many as 38 vehicle models across ten vehicle manufacturers, while eight new products encompass discs for Renault and Vauxhall van models. All new references have been added to TecDoc and MAM cataloguing systems, and are also accessible via the online catalogue Brakebook. Mintex Brakebook allows users to create catalogues tailored to their individual requirements, whether for the entire product range, a selection of products or even for special models
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TMD Friction has expanded its Textar brand’s brake pad product offering with 13 new-to-range parts. Three new brake pads are introduced to the Textar product lines covering, for example, Citroen, MAN, Vauxhall, Peugeot, and Volkswagen; and including commercial vehicle applications. In addition to the new pads, a new ABS sensor becomes is now available for the 2010 onwards Nissan Juke van. These latest products are featured online via the Textar Brakebook.
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Brembo has launched an extensive range of aftermarket brake pads and discs for the commercial vehicle sector. The brake discs and pads are claimed to effectively withstand the repetitive thermo-mechanical stresses experienced by braking systems thanks to use of a special cast iron alloy, pillar venting technology and a co-casting process. These lead to greater heat dissipation, superior resistance to thermal cracking and an increase in the life of both the brake discs and pads, even in extreme conditions.
Pads suitable for trucks, buses, trailers and semi-trailers are available, and the company says that the new parts – 100 discs and 67 pads – cover more than 95% of European commercial vehicles.
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A new high pressure brake bleeder from Laser Tools (part number 8395) has been developed in response to some manufacturers specifying bleeders that can operate at a higher pressure than required with conventional systems. The new bleeder can also be adjusted for lower pressure applications when required.
The 12V powered bleeder has an adjustable fluid pressure output from zero to 3.5 bar (50psi) and is powered from the vehicle battery via the 12V auxiliary socket or a suitable 12V power source. For maximum portability, the unit has been designed to be used with a 5-litre brake fluid container which is also included. It also features a durable, brake fluid safe paint finish with clearly marked switches and dial. Safe for use with DOT 3, 4, 4+ and DOT 5.1 brake fluids, the unit shuts off automatically when empty.
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The Toyota Hilux pickup is a mainstay of the brand and more than 18 million have been produced since 1968; yet not always under the Hilux name, as the North American market embraced the rather straightforward ‘Toyota Pickup’ title for models sold between 1972 and 1995. Naming differences aside, the Hilux has gone through eight makeovers in its time and the current generation model, introduced in 2015, is known as one of the best pickups available.
It is a further continuation of the Hilux’s reputation as being tough and reliable even in the harshest of conditions. Reviews for the latest Hilux praise its safety, strength and reliability as well as the comfortable ride and spacious cabin and load areas.
The vehicle featured in this article is a seventh-generation example from 2014 which has had a life of continuous use on a farm – being used mainly for towing and off-road duties, exactly what a Hilux was designed to do. Although proven to be a very reliable ‘workhorse’ around the farm, the clutch was showing signs of slipping after 112,000 miles of driving. Therefore, it required a replacement clutch kit.
The vehicle was brought into the workshop and the bonnet was raised to start the procedure. To begin, disconnect the two batteries.
Being a four-wheel drive vehicle of traditional design, with the powertrain mounted longitudinally in a ladder-frame chassis, the two gear sticks in the cab need to be taken out in order to remove the transmission. Firstly, remove the gear sticks and the centre-console surround, before carefully folding back the carpet surrounding the gear sticks; this is to reveal the gear stick gaiter-retaining bezel. Remove its four screws and two clips, along with the two gear stick gaiters, to enable access to the gear sticks mounted on top of the gearbox (Fig.1).
With these parts removed, both gear sticks can then be unbolted from the transmission, ready for work to continue underneath the vehicle.
With the vehicle raised, mark the alignment position of the front and rear prop shafts and undo all of the bolts that retain them to the drive flanges. Remove the prop shafts from the vehicle, checking all four universal joints for any excessive ‘freeplay’ or ‘stiffness’, and put them to one side.
Next, remove the two bolts and the one bell-housing bolt retaining the clutch slave cylinder. Put all of them out of the way, ready for when the transmission is to be removed.
Disconnect the three exhaust-gas temperature sensors and the oxygen sensor from the wiring harness, in preparation to remove the diesel particulate filter (DPF) and the differential-pressure sensor hoses (Fig.2).
Support the transmission with a transmission jack, unbolt the crossmember from the chassis and the transmission mounting, and remove. This now gives enough room to remove the DPF. Undo the two exhaust bolts at the rear that secure it to the exhaust, then the three bolts retaining it to the exhaust down-pipe. Once released, carefully lower the DPF to the floor.
Disconnect all other remaining switches, sensors, breather hoses and cables from the transmission and secure them to one side.
Charles Figgins, Technical Marketing Manager at Blue Print, takes readers step-by-step through a clutch replacement on a 2014 Toyota Hilux.“Remove the prop shafts from the vehicle, checking all four universal joints for any excessive ‘freeplay’ or ‘stiffness’”
Unbolt and remove the drive flange from the front axle in order to give extra clearance. This is because the transmission has very limited clearance between the transmission tunnel, the exhaust downpipe and the front-axle drive flange (Fig.3).
With the transmission and transfer box assembly securely supported, unbolt all of the bell housing nuts and bolts. Note which bolts are from which location, because they differ in length. The starter motor can be left in place because it does not need to be removed completely for the removal of the transmission. Then, carefully separate the transmission assembly from the engine and lower it to a working height.
Remove the clutch-pressure plate and friction disc from the flywheel, and inspect them for any ‘unusual’ wear issues. In the case of this Hilux example, the flywheel was in good condition and only needed a clean before fitting the new clutch. However, the friction disc material was very close to being worn out. Therefore, it was concluded that this clutch assembly required replacement, using Blue Print clutch kit ADT330285.
Align and attach the new pressure plate and friction disc to the flywheel, and tighten all six bolts in a ‘star’ pattern to the required torque. This is to give an even spread of pressure during the tightening processpreventing twisting and vibration of the cover and the lifting of the pressure plate (Fig.4).
Turning our attention to the release mechanism, it is important to clean the bell
housing thoroughly to free it from all grease, dirt and old friction fibres from the previous clutch. Remove the release bearing from the clutch fork and inspect the guide sleeve for wear. Remove the clutch fork and release lever and inspect them for any fractures or other damage. Apply grease to the pivot points before refitting. Next, fit the new release bearing whilst securely locating the retaining clips on the fork and noting the correct orientation of the release bearing. Failure to do this can create operational issues with the clutch mechanism (Fig.5). Apply a small amount of grease to the input shaft splines before reinstalling the transmission...
With the new clutch kit fitted, the transmission assembly can be reunited with the engine. Install and tighten all bell housing nuts and bolts.
Locate and align the wiring harness for the transmission and the DPF – this is to allow for the reconnection of all the sensors and switches for the transmission. You can then refit the DPF to the exhaust system and reconnect the hoses and sensors.
Next, return the chassis crossmember to the chassis, which supports the transmission. As a result, the transmission jack can now be safely removed.
With the transmission securely in place, refit the clutch-slave cylinder, front-axle drive flange and the front and rear prop shafts. Lower the vehicle.
Now working inside the vehicle, refit the gear sticks to the transmission, followed by the rubber gaiters. Secure them to the body with the bezel surround (FR denotes the direction of fitment). The carpet can now be put back in place, followed by the centre-console surround.
Reconnect the batteries and close the bonnet. Reset the clock and carry out a full road test to check the operation of the new clutch. For the Hilux used in this article, the vehicle was then sent back to work on the farm.
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Dayco’s national sales manager Steve Carolan highlights the importance of regular maintenance of belt in oil (BIO) engines in line with the vehicle manufacturers (VM) scheduled service intervals to ensure their ongoing reliability.
Taking the Ford 1.0-litre EcoBoost ‘Fox’ engine, which is used in Ford light commercial vehicle applications including the Fiesta van, as an example, according to the manufacturer’s service schedule, the timing belt must be replaced at 150,000 miles or every 10 years, whichever comes soonest. When it comes to the Tourneo Connect, however, the replacement mileage is slightly lower, at 140,000 miles.
Although the BIO innovation is a great solution which helps this small and efficient engine to deliver great levels of power, alongside low emissions and excellent fuel economy, depending on the quality of the fuel it uses and the type of journey it undertakes; the engine can sometimes be prone to oil contamination, which has the potential to affect the belt. It is therefore imperative that workshops highlight the importance of following the
VMs scheduled replacement intervals to their customers.
On a practical level, there are also some best practice guidelines that technicians can follow to help them assess the condition of the belt in between the specified replacement interval, the first of which is to assess the condition of the oil.
This is easier than it might appear as the presence of petrol in the oil is generally noticeable due to its strong odour, so rather than undoing the drainplug and walking away, whenever carrying out a scheduled oil and filter change technicians should check for the smell of petrol fumes. If this is detected, further investigation must be made as the failure of the belt will have catastrophic consequences to the engine. Unfortunately, checking the condition of the belt is not straightforward, but a
sensible starting point is to check the strainer that the oil will have passed through when draining from the sump, because it’s possible that fragments of the belt or deposits of material that have been dislodged as the fuel attacks the belt material, will be left behind.
If any evidence of debris is found, the next step is to remove the camshaft cover as this is the only practical way to properly assess the belt’s condition as it allows technicians to examine the back, which will reveal whether the contaminated oil has begun to degrade the surface of the belt. “At this point it’s important to state that some moderate increase in the width of the belt, commonly referred to as belt swell, is not an issue, unless of course it’s so excessive as to cause the belt to foul, but this will be evident if there is damage to its edges.
Naturally, should the belt need to be replaced, as the original equipment supplier for both the timing and oil pump drive systems for these engines, Dayco has replacement kits – either KBIO02 or KBIO03 – in its aftermarket range.
Finally, we’d encourage workshops to be proactive with their customers and, in addition to highlighting the necessity of the belt checks and replacement interval, make them aware of the consequences in terms of tthe damage to the engine, and the cost to repair it, should the belt fail.”
For a technical video on the installation procedure, which highlights the key points that must be noted,
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“Make customers aware of the consequences in terms of the damage to the engine, and the cost to repair it, should the belt fail.”
Shaftec’s Marketing Manager Adrian Kitchen discusses the importance of flushing steering systems and why corners should never be cut.
The steering system consists of several items: a rack and pinion connected to the front wheels; a piston inside the rack and pinion, which is moved by pressurised fluid from the power-steering pump that helps to turn the wheels; and a cylinder containing fluid mounted on the pump or remotely mounted for easier access.
Leaks in the system allow foreign particles to enter more easily and with low fluid, steering becomes more difficult, and parts can become damaged.
If you discover a leak in a customer’s system either by fluid on the ground or by a low power steering fluid, you should check it immediately. Low fluid levels can be a warning sign: if everything is working as it should, the fluid levels should never drop. It’s therefore vital to regularly check power-steering fluid levels and top up when necessary.
Pumps and racks will live longer if the system is flushed regularly as systems deteriorate over time. As the system ages, small particles start to break off – then it can get really tricky. Contaminants are suspended in the steering fluid which then becomes abrasive. The abrasive action then speeds up wear in other parts. Contaminants from rubber pipes and particles of metallic swarf from other areas –
such as the impellers of the pump –gradually build up, causing more wear.
This, together with fluid oxidisation which propels the build-up of air and results in further inefficiencies and noise, causes ongoing deterioration until, eventually, the system fails.
As all contaminants originate from inside the enclosed circuit, the only way to prolong the life of a pump is to change the fluid regularly and flush the system thoroughly each time. The contamination collects inside the system where you can’t see it, so the effects may be barely noticeable until the system fails. By the time the system fails, you are in trouble.
Because of this, there is an ongoing debate as to whether fluid change should be a standard part of the service schedule. Of course, if the system has failed on a vehicle it’s highly likely that there are raised levels
of contaminants in the lines, making it even more important to flush the whole thing out before fitting a new part.
Fitting a new part without flushing out the system would be somewhat counterproductive. With raised levels of contaminants in the lines, the fluid would still be abrasive. You can sometimes see if
the fluid is contaminated by its darker colour, or if you feel particles between your fingers, you shouldn’t take the risk, or it can be costly. Before any change, the system should be flushed properly using a professional machine which sucks out all of the old fluid and any contaminants. Only after washing it through thoroughly with a
flushing agent until it runs clear should new fluid be added.
A single litre of flushing agent to flush the system is never enough. It should be five litres, every time.
It’s also important to clean out the reservoir because any larger particles will settle at the bottom as the fluid circulates. If you don’t, when the new fluid is poured into the reservoir, any remaining silt at the bottom will be forced straight back into the system, causing a leak almost instantly.
“As all contaminants originate from inside the enclosed circuit, the only way to prolong the life of a pump is to change the fluid regularly and flush the system thoroughly each time.”
check to test the battery, top up fluids and inspect tyres, wipers and lights before the dark nights set in.
However, to be best prepared it is also vital that the right engine lubricant and coolant are being used, and in the right way. A basic understanding of some of the chemistry behind these products can make a huge difference when carrying out winter servicing, helping drivers and fleets tackle whatever weather the winter throws at them.
High-quality lubricants that can protect engine components from friction, corrosion and deposit formation are essential at any time of year, but particularly so when cold starts and treacherous road surfaces put even more pressure on engines. Using oils that are specifically designed to reduce wear and improve performance, as well as extend drain intervals, will ensure that engines continue to work well during bad
weather. However, oil viscosity – i.e. the lubricant’s resistance to flow (rather than its thickness) – is a key factor too, because it changes with temperature.
The viscosity of oil is very different to that of water. It increases at lower temperatures, meaning that it will not flow as easily in wintry conditions as it does in warmer weather, with potential implications for its effectiveness. Using a multi-grade oil provides a solution to this problem, because it reduces the differential
between viscosity at cold temperatures, and viscosity at engine running temperature.
For example, 5W30 oil is a popular choice because its formulation means it can flow sufficiently freely when the engine is started at low temperatures to coat the engine components. This is not (as is commonly thought) because it has a lower viscosity in the cold and a higher viscosity at running temperature. Its viscosity is still higher in the cold; it’s just that its viscosity range can cope well with temperature variations.
Keeping the wheels in motion during the worst of British winter weather is a major concern for many businesses – whatever the size of their commercial fleets – and it pays to be prepared. Tom Hyde, technical manager, Lubricants at TotalEnergies Marketing UK, tells us how.
Coolant and antifreeze (terms which are often used interchangeably but are in fact slightly different) also have an important role to play in winter by preventing vehicles from either freezing up or overheating due to the strain that ice and snow can put on the engine. Both products should contain high-performance additives
to protect against corrosion, overheating and freezing; deliver long drain intervals to help lower maintenance costs; and be designed to maximise engine efficiency, as well as being environmentally friendly.
Engine coolant is a mixture of antifreeze and distilled water, and pre-mixed coolants usually consist of a 50:50 ratio, which will then have a freezing point of -37°C. Using pre-mixed coolants is convenient and should be suitable for most hot or cold weather conditions. Caution should be exercised, however, if considering changing this ratio during periods of extreme temperature.
For example, using 60-70% antifreeze is not recommended as it will reduce cooling efficiency because the specific heat capacity of glycol is lower than water, so the more antifreeze used the poorer the cooling efficiency.
Use of greater concentrations of antifreeze is only advised for arctic conditions due to the poorer cooling performance (i.e. 60% antifreeze can be used down to -50°C and 65% antifreeze to -65°C). Antifreeze must also be changed at the appropriate intervals – every two years for traditional antifreeze and five years or more for high-performance, long-life products.
Finally, additives have a key role to play too when considering suitable preparations for winter. More specifically, AdBlue is now a critical fluid for pollution control on diesel engines to reduce NOx levels using Selective Catalytic Reduction (SCR) systems. This is affected by cold weather as crystallisation of the standard AdBlue can occur in pipelines exposed to the cold. Additionally in the SCR other crystals can form which inhibit the efficiency of the system and flow of exhaust gases through it, particularly for vehicles which stop and start frequently under low load such as bus fleets. Using a solution like CLEARNOX – i.e. AdBlue with a patented special additive – in place of standard AdBlue will help to avoid the formation of deposits, thus improving efficiency and lifespan of the SCR.
Winter can certainly make life difficult for drivers and it is without doubt a time for extra caution. But bad weather needn’t keep vehicles off the road if mechanics go the extra mile with their seasonal servicing checks to make sure that lubricants and coolants are not just topped up but are calibrated for the conditions. It’s easy to do, for those in the know.
The winter is a key time for maintenance, with temperatures dropping and driving conditions getting worse, it’s vital to prepare for the challenges the season brings. A few straightforward checks, together with having the right tools on hand, can significantly reduce the risks the season brings. It’s equally important to consider the conditions in the workshop during winter and plan ahead with the necessary equipment.
Seeing clearly when working on a vehicle, especially in enclosed spaces, is not always easy at the best of times but with it getting dark so early in winter, having plenty of additional sources of light in the workshop is essential. Torches are great but for hands free working why not opt for an LED headtorch or an inspection lamp with magnetic base? Rechargeable chip-on-board (COB) LED head torches will run hours after charging via a micro-USB cable, making it a great option for winter working. Getting some portable LED work lamps in can also make a huge difference if seeking to boost workshop lighting levels.
In bigger sheds or where doors are left open continuously for come-and-go reasons, internal temperatures can be as low as those outside. First is to layer up, using multiple thin layers rather than a few thicker ones –it is easier to take stuff off than put it on if overheating. Cotton is pants in the cold, so look for thermal base layers and, if minted, go for merino. Furthermore, it might sound simple, but having the right gloves for the job can really make difference to winter working. Invest in some heavy-duty thermals to keep your hands warm during pre-drive vehicle inspections and during deliveries. It’s also a good idea to choose gloves with a latex coating to aid grip when everything is soaking wet.
It’s hard enough for drivers to see in winter, with the poor weather conditions and the darkness, so it’s especially important to keep lights and windscreens clean and clear at this time of year and inside-and-out windscreen cleaning should be an automatic courtesy. Anti-freeze is obviously a must, and
As the temperatures drop and the light fades, attention to maintenance basics becomes more crucial. Draper Tools runs through a few of the tasks not to be overlooked, no matter how simple.
wiper blades should be in tip-top nick too.
Winter puts additional load on vehicle batteries with cold starts, so keeping some suitable booster cables handy is necessary. Look for booster cables that are up to the job, such as Draper Tools 6.5M Heavy Duty Booster Cables, made from 50mm² pure copper cables, insulated with high quality TPE, which makes them ultra-flexible at the extreme low temperatures you’ll see this year.
For those times when a vehicle really won’t start you need a big boost from a battery starter, capable of an 800 amp boost as a minimum. For maximum safety and efficiency in the workshop look out for models with a fast-charging facility, terminal overload protection and polarity protection.
Winter can play havoc with vehicle electrics, which can create additional workload at this busy time of year. It’s always advisable to have a quality auto-ranging multimeter on hand, so the next time there’s a lot of head scratching of the ‘is it the bulb, is it the fuse, is it the earth?’ kind, you can find out with speed and accuracy.
■ All the basic checks are absolutely essential at this time of year – be sure to check the lights, oil levels and coolant levels before any vehicle leaves the workshop
■ It’s widely acknowledged that tyre condition can really affect vehicle performance, so tyre care is especially important in winter. Tyre pressure should be checked more regularly in winter as cold weather can see tyre
pressure dropping. And don’t forget to check the wheel nuts.
■ Use an anti-freeze tester to check the anti-freeze is correct and check the entire cooling system for leaks and other issues.
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The SL200 Series scene lamp, the latest from LED Autolamps, can provide 1,980 raw lumens of white light, making an area workable and safe as the nights start to draw in. Tested for shock and vibration, the lamp has a tough aluminium housing and provides a 40° angle of downlight. Available in range of five colour finishes, the SL200 Series is R10 and IP67 certified.
The company’s new 385 Series rear combination lamps feature a progressive indicator sequence similar to that found on many premium vehicles and are doubly distinctive by their diffused ‘glow track’ tail light that encircles the units. Several variants are available, giving the choice to include reverse and fog lamps. The lamp is fully waterproof with an IP67 certification alongside those for R6, R7, R23 and R10.The SL200 range comes with a three-year warranty while the 385 Series has a five year warranty.
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The 11 Series RefleXL™
lightbar from Ecco is said to be the company’s most compact and lowprofile warning lightbar yet. Featuring amber LEDs housed in clear lenses, the 11 Series is ideal for vehicles that require a simple lightbar that is larger than a minibar. Available in three different lengths, all models are just 33mm high and 127mm wide, providing discreet but powerful warning. The polycarbonate lenses and aluminium frame ensure that it is a durable option, and the range is R65, R10, CISPR25 Class 3 and IP69K certified. For maximum versatility, both bolted and magnetic mounts are available. The 11 Series really is the perfect fit for any vehicle where compact warning is essential.
Beacons provide an alternative option for warning lighting, and the new EB5100 Low Profile Beacon takes beacons to a new level. This high-performance beacon, built to OEM specifications, combines strong warning with an ultra-compact shape, measuring just 63mm high. Offering the flexibility of Single Bolt, 3 Bolt, DIN Pole or Magnetic mounts, both amber and clear lenses are available with either amber or green LEDs. As would be expected, the range also has R65, R10, CISPR25 Class 3 and IP69K certification; additionally, EB5100 beacons with amber LEDs can produce a simulated rotate that is R65 Class 1 compliant, ensuring vehicles meet the requirements of sites demanding this feature.
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HELLA has introduced a new range of LED work lamps for offroad applications. The robust Black Magic series features a dustproof and waterproof housing and combines a typical high LED light output of up to 15,000 lumens with a sleek allblack design. A special reflector provides eye-friendly homogeneous off-road illumination. The series also features integrated thermal management and intelligent adaptation to the respective ambient temperature optimises both luminous efficacy and LED service life.
The Black Magic LED series is available as a floodlight or spotlight and in different housing shapes as cubes, lightbars and mini-lightbars. The work lamps can be mounted upright or in a suspended manner and they can be integrated into the bodywork or bumper.
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Truck-Lite Europe’s flagship LED multifunction rear lamp, the Model 900. The Model 900 features progressive indication and a distinctive red homogenous outline to enhance visibility. Away from its stylish looks, its integrated intelligence eliminates the need for a separate black box monitoring unit and will inform the driver of any light failures. The Model 900 comes with a five-year warranty as well as being part of the company’s Lifetime Warranty Trailer Kits.
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Machine Mart offers a comprehensive range of welding for everyone from the novice to those with previous welding experience.
The Clarke MIG102NG MIG Welder is suitable for automotive and general fabrication, providing optimum performance and reliability. It does not require a gas cylinder as it uses flux cored steel welding wire which produces its own gas shroud as it burns. This welder produces a maximum power of 90A and can weld mild steel up to 4mm thick. Sold complete with a range of accessories including welding mask, earth clamp and welding wire. Other features include turbo fan cooling for greater efficiency and multiple power settings for accurate welding power control.
For industrial environments such as a busy automotive repair shop, the Clarke MIG255TEC MIG Welder is the good choice thanks to its combined power and extended duty cycle. It has a maximum power of 250A and the capability to weld steel up to 11mm thick. It has turbo fan cooling and an extra-large transformer. The integral wire feed system accepts spool sizes up to 15kg whilst this unit also includes fully variable wire speed control 022 mtrs/min, plus a timer for spot welding.
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Saint-Gobain OneBond has extended its product offering to include degreasers and protective sprays, cutting and protective oils, as well as technical and tack wipes. The newest additions complement Saint-Gobain's existing range by keeping equipment, machinery, vehicles and workspaces clean, helping maintain a safe and productive working environment.
OneBond's degreaser lifts surface contaminants from all surfaces, including metal, wood, glass, ceramic and even painted surfaces. The protective spray and oil cleans the application surface and coats it with an invisible coating that helps prevent rust and corrosion. The spray can be used as a rinse aid on stainless steel. For threading and drilling jobs, OneBond's synthetic cutting oil is a powerful lubricant that administers a professional cut on ferrous and non-ferrous materials.
The range of four technical and tack wipes provide exactly what any workshop or production line needs on hand. Technical wipes deliver fast absorption and extra cleaning power, while tack wipes are explicitly designed for particle capture, making them the perfect solution for dry dust removal.
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Winter can play havoc with windscreen washer systems, and repair can be problematic at times; especially when needing to replace split, degraded, kinked or rodent-nibbled washer hose, or even stuck one-way valves and leaking connectors. A windscreen washer pipe repair kit from Connect Workshop Consumables (part number 36757), has been compiled as a one-stop box, offering the most common components found in windscreen, headlamp and rear-window washer systems, allowing the technician or owner to quickly get the system working again. The kit even includes a pipecutting tool to ensure straight, clean cuts every time.
Included are 3/16" (4.7mm) 90° elbow joints (x5), straight joints (x5), T-piece connectors (x5), one-way valves (x2) and 4 metres of clear PVC tube. No clips are required; the clear, quality PVC hose is sized to fit securely to the kit connectors, especially helpful where space is at a premium. Additionally, all the components are available separately, to replace them as they are used.
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Brigade Electronics UK has launched Brigade Van: a new product range featuring a variety of vehicle safety solutions that are specifically designed for the van market. It is a range of high-quality vehicle safety solutions that will reduce the risk of collisions, eliminate blind spots, cut insurance premiums, encourage driver best practice and serve as a deterrent against theft, vandalism and insurance scams.
The Brigade Van portfolio includes a camera monitor system featuring forwardfacing and rear-facing cameras that provide real-time images of objects and people in the vehicle’s front and rear blind spots. These images are fed back to the driver via a ‘mirror monitor’ which clips onto the van’s existing rear-view mirror, making it quick and easy to install.
The camera monitor system can be integrated with Brigade Van’s MDR Digital Video Recorder and dash cams. This vehicle CCTV system, which records and saves footage, provides invaluable and irrefutable evidence in the event of an incident and acts as a deterrent against thieves and crash-for-cash insurance scammers – helping to cut insurance premiums and provide peace of mind for van drivers.
For electric and hybrid vans, the absence of a combustion engine means that when the vehicle travels at speeds below 12.5mph it is almost silent. Since 2021, every electric and hybrid vehicle on the road has to be retrofitted with devices that can be heard at low speeds.
Brigade’s QVS Quiet Vehicle Sounder integrates its patented bbs-tek technology that creates a highly directional and instantly locatable sound to warn vulnerable road users of approaching silent electric and hybrid vehicles.
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The MagiX scissor lifts from Autopstenhoj offer lifting capacities from 4.3 tonne and provide a solution for direct reception, repair and maintenance, main inspections in conjunction with headlight testing; and measuring axle geometry with testing and adjustment of ADAS. The MagiX platform scissor lifts are available for various installation options: on-floor or recessed, in rectangular or strip foundations. These lifts are available with flush platforms, alternatively with platforms with integrated wheel free device and/or with a play detector. Variable installation widths are available, depending on the customer's requirements.
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Tenneco’s Powertrain business group is launching a range of industrial Champion spark plugs for the aftermarket which enable long life and increase service intervals for heavy-duty on- and off-road applications. The newly-designed double Iridium M14 J-Gap high performance spark plugs with HEX16mm feature an advanced ceramic formula for improved electrical and mechanical strength. They are offered with two different nominal electrode gaps: 0.25mm for stationary usage with biogas and 0.40mm for natural gas commercial truck, bus and construction machinery applications.
A new ceramic formula for improved electrical and mechanical strength enables greater resistance against high-voltage failures. An Ni-plated shell hot-locking assembly increases mechanical robustness against dynamic combustion pressure. Further, the combination of laserwelded iridium pads and a tailored mass of precious metals provides lifetime improvements and service intervals over similar spark plug technologies.
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Optifarm HP from Exol is the company’s the latest gear oil and one especially designed for use in JCBs. Formulated with advanced additive chemistry and premium quality, thermally stable base oils, Optifarm HP is claimed to provides outstanding component protection to extend equipment life and eliminates squawk and chatter in oil immersed braking systems.
Other benefits of Optifarm HP include improved anti-squawk performance in brake systems, excellent oxidation stability, outstanding anti-wear properties and low foaming. It is a suitable alternative for use where JCB standard 4000 / 2200 is specified and is recommended for use in certain models of JCB, John Deere, Massey Ferguson, Case and Caterpillar where a high-performance gear oil is required in axles and transmissions.
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WWW.RDR.LINK/VAR028
A new Electro-hydraulic Control Flow (ECF) water pump from Airtex is now available to the independent aftermarket. The ECF water pump is an aftermarket alternative to the OE version used for 1.6 and 2.0-litre VAG engines found, for example, in the MAN TGE and VW Caddy and Crafter 35 from 2012 onwards. Using a similar technology, the pump varies flow rate according to the requirements of the engine, which results in improved engine warm up times, leading to gains in fuel efficiency and lower emissions.
The pump uses Airtex’s own patented SWITCH ECF technology to vary the flow rate without infringing the original patent. The company claims that this makes it the first manufacturer to offer a replacement to the OE water pump with matching ECF technology. The Airtex ECF pump (reference 1978) is available as a single water pump unit, or as part of the water pump kit programme, with reference WPK-197801 including the water pump, timing belt, tensioner and pulley.
WANT TO KNOW MORE?
GOTO
WWW.RDR.LINK/VAR029
Allison has introduced a new eGen Power family of electric axles for construction trucks alongside the new TerraTran fully automatic transmission for toughest offroad applications. The eGen Power is a drop-in solution compatible with many existing truck chassis. It features fully integrated electric motors, a twospeed gearbox, an integrated oil cooler and pump for optimal efficiency and performance and is compatible with battery electric vehicles and fuel cell electric vehicles as well as hybrid applications.
The twin-motor eGen Power 130D, a 13-tonne variant has a continuous output of 454kW and a peak output power of 652kW, making it one of the most powerful electric axle solutions on the market. It is designed for great starting and climbing capabilities, high speed and impressive efficiency. This allows heavy duty trucks to offer substantial performance and reliability, rapid acceleration and excellent manoeuvrability.
Allison also offers the eGen Power 100D, a 10tonne variant of the 130D, and the single motor, 10.4 tonnes rated eGen Power 100S, with a continuous output of 227kW and a peak output of 326kW, which is suitable for multiple medium and heavy-duty applications.
The TerraTran transmission is a version of the proven Allison 4000 Series on-highway transmission for the extreme demands of the global construction and mining markets. TerraTran offers a maximum power capability of up to 800hp, and torque capability up to 3200 N-m. The transmission also features seven forward and two reverse gears. TerraTran offers the proven reliability and durability of 4000 Series transmissions, but with increased horsepower, torque and gross vehicle weight capability, while also adding fast reverse capability.
WANT TO KNOW MORE?
GOTO
WWW.RDR.LINK/VAR030
Lightweight and comfortable, a new USBrechargeable head light from Laser tools (part number 8330) is packed pull of features. The rubber-coated, shockresistant main body is waterproof and includes an LED spotlight as well as the main COB (chip-on-board) strip light.
Each of the lights has a high and a low setting, with the spotlight also featuring a strobe function for emergencies. A nice touch is the infrared auto-sensor function allowing the light to be turned on and off with a simple wave of the hand.
It is fitted with an adjustable elasticated headband, and the 1200mAh lithium battery is conveniently charged via a USB cable that is included. It offers a working time of 2-6 hours with a charging time of two hours. This is ideal for dark working areas and is suitable for use by mechanics, mobile repairers and patrol men and women.
WANT TO KNOW MORE?
GOTO
WWW.RDR.LINK/VAR031
TruTac has launched a brandnew driver app, making a wealth of additional features and functions available to operators and drivers alike. Formerly known as TruChecks and now simply called the TruTac app, it has been completely overhauled and has enhanced capabilities which, in addition to the core vehicle walkaround checking function, now include much closer integration with the company’s other software products. Those using TruTac’s other systems, such as TruAnalysis, TruTime, and TruDocuments Premium can now access all such systems directly though the app. In addition, the app can seamlessly send data from walkaround checks straight through to the TruFleet system for ease of fleet maintenance planning and to minimise vehicle downtime.
It also features an improved user interface, including clearer notifications, a dedicated accident reporting system, an updated traffic reports page, and a new light and dark mode. The app is available on both Android and Apple platforms, which is rare within the transport industry, because many organisations provide apps solely for Android, due to the complexity of tailoring products for Apple systems.
WANT TO KNOW MORE?
WWW.RDR.LINK/VAR032GOTO
Pico Technology has launched a set of new off-highway kits for Heavy-Duty vehicle and OffHighway (HD-OH) equipment testing built around a dedicated PicoScope oscilloscope. Created for fault diagnosis on trucks, tractors, combine harvesters, excavators and more, the off-highway kits contain a modified PS4425A PicoScope having additional protection to better withstand off-highway conditions.
The scope is fully supported by Pico Technology’s class-leading, and free, PicoScope 7 Automotive software. The included accessories help users quickly connect and easily carry out non-intrusive and non-invasive measurements on a wide variety of systems and components found in these vehicles. There are three kits, respectively labelled the Entry (PQ324), Expert (PQ331) and Elite (PQ332) kits. All kit accessories have been selected on their suitability for testing in the HD-OH environment. For example, 5 m test leads are included as standard to ensure that users have longer lead lengths available, as required to reach test locations around the vehicles and equipment encountered. Likewise, sets of breakout leads that fit typical HD-OH electrical system connectors are included to facilitate non-intrusive measurements on these specific vehicles and equipment.
WANT TO KNOW MORE? WWW.RDR.LINK/VAR034GOTO
Winter servicing is not just about the challenges faced by vehicles, but also the workforce when it comes to cold weather working. In these circumstances, technicians can ‘suit up’ in Snickers’s layers for consistent comfort and protection in cold and wet weather.
Snickers Workwear offers ‘head to toe’ functionality and protection from ergonomic base layers, insulating mid layers and weather-protective outer layer clothing. They not only allow technicians to quickly adjust to changing weather conditions, but also give them the opportunity to make sustainable choices about the clothes they wear at work. This winter’s new jackets, trousers and top wear feature high-tech, breathable fabrics that not only deliver dryness and warmth but also advanced ventilation for controlling body heat.
WANT TO KNOW MORE?
WWW.RDR.LINK/VAR033GOTO
PCL has introduced an easy to install and advanced range of fixed tyre inflation equipment, including the user-friendly Accura Qube. The Accura Qube electronic pre-set unit offers good value and fast, accurate air and nitrogen inflation, saving time and money through increased efficiency, uptime, and safety; while reducing fatigue associated with inflating large, high-pressure tyres from flat. This space-saving indoor inflator, made from high-performance engineering plastic, can inflate up to 174 psi (12 bar) and is suitbale for garages, dealerships, roadside assistance vehicles and MOT centres; where inflation and deflation with repeatable accuracy and ease of use are essential.
WANT TO KNOW MORE?
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WWW.RDR.LINK/VAR035
The UK’s only regional tradeshow dedicated to garage business is in only a few short weeks’ time and the team are looking forward to welcoming you to the show!
The automotive aftermarket sector continues to evolve at pace, so it’s more important than ever that you stay on top of the latest technology, training and products available to your business. Attending November’s MECHANEX – the only regional show dedicated to the specific needs of garages in the UK – is a great way to ensure you are up to speed. The show at Sandown Park, Surrey, takes place on:
Readers of CVW magazine have the unique ability to jump straight from the printed page to a web page specifically chosen to provide a follow up with exactly the information you want to know.
So how does it work, and how do you access the information you need?
Locate an article either in the printed magazine or from one of the magazine in our digital archive at
CVWMAGAZINE.CO.UK.
Then, either click on the RDR LINK at the bottom of the chosen article (if reading the digital version) or make a note of the URL and enter it into your browser.
With the printed magazine, you have two options. Either go to WWW.RDR.LINK and type in the unique five-digit code for that article and press enter. Or, as above, you could type the entire URL into your browser and press enter. Either method will get you to the page you need, with more information available.
TO KEEP UP TO DATE WITH ALL THINGS MECHANEX IN 2022, VISIT WWW.MECHANEX.INFO, LIKE US ON FACEBOOK AND FOLLOW US ON TWITTER. WWW.RDR.LINK/VAR036
If you’re in the unfortunate position that you don’t have a paper copy of CVW to hand, our website is a fantastic place to read an array of technical articles and business tips. It’s especially handy to stay on top of the latest industry news as online is not limited to the magazine’s monthly publishing schedule. This month, CVW’s Freya Coleman takes a look at some of the most popular articles on the website from September. As you’ll see, apparently oils and lubricants were of particular interest!
For both light commercial and heavyduty trucks, you can read all about how this new range from Petronas which is said to deliver durability in the face of extreme engine temperatures, oxidations and damaging deposits.
WWW.RDR.LINK/ VAR037
In this article, CVW caught up with Mike Bewsey, the Chairman of VLS, to find out what workshops should know about new heavy-duty oil sequences. This includes coverage of the two entirely new categories ACEA E8 and E11, what these are recommended for as well as updated piston deposit tests in the categories ACEA E4 and E7.
WWW.RDR.LINK/ VAR038
Juddering or slipping is one of the most common issues when clutches are concerned, and this is found to be from grease not being applied correctly. Lipe Clutch explores grease contamination, giving advice to workshops on avoiding it. It recommends using Lipe’s clutch kits as a sachet of grease is provided, ensuring the correct amount is applied.
WWW.RDR.LINK/ VAR039
Read about the launch of EcoLife Coachline from ZF which aims to increase the digitalisation of servicing and maintenance. This is suitable for all kinds of coach applications whether you’re operating in a city or more challenging terrains – check out this online article to find out all the updated features.
WWW.RDR.LINK/ VAR040
In this technical article, Valeo addresses a number of calls regarding an issue with Ford Transit 2.4 diesels not starting with a Valeo conversion kit fitted. Read all about the possible causes of this problem and how to resolve it.
WWW.RDR.LINK/ VAR041
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
www.rdr.link/VAR100
BEN
www.rdr.link/VAR101
Bowmonk
www.rdr.link/VAR102
Clarios/Varta
www.rdr.link/VAR103
Cummins UK/Fleetguard
www.rdr.link/VAR104
Drakefield
www.rdr.link/VAR105
Freeway Fleet
www.rdr.link/VAR106
Jack Sealey Ltd
www.rdr.link/VAR107
47)
45)
45)
www.rdr.link/VAR113
Merridale Ltd ..............................................................(page 47) www.rdr.link/VAR114
Motul SA ....................................................................(page 45) www.rdr.link/VAR115
insert)
47)
Osram ........................................................................(page 42) www.rdr.link/VAR116
Premier Pits ................................................................(page 13) www.rdr.link/VAR117
28)
14)
Pro-Align ......................................................................(page 40 www.rdr.link/VAR118
Robert Bosch Ltd ........................................................(page 31) www.rdr.link/VAR119
27)
Rotronics Battery Management Solutions ..................(page 41) www.rdr.link/VAR120
Juratek Ltd
22) www.rdr.link/VAR108
Schaeffler Automotive Aftermarket UK ......................(page 39) www.rdr.link/VAR121
Knorr-Bremse Truck Services
41) www.rdr.link/VAR109
Liftmaster Ltd
www.rdr.link/VAR110
Machine Mart
www.rdr.link/VAR111
MAHA UK
www.rdr.link/VAR112
Mann & Hummel
Stertil UK Ltd ................................................(inside front cover) www.rdr.link/VAR122
42)
32)
35)
9)
TMD Friction UK Ltd
19) www.rdr.link/VAR123
Totalkare Heavy Duty Work ....................................(back cover) www.rdr.link/VAR124
UFI Filters
47) www.rdr.link/VAR125
16) www.rdr.link/VAR126
VL Test Systems
