On Route Magazine July 2018

JULY 2018 ISSUE 18

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PICK-UP TRUCK RACING CHAMPIONSHIP Lea Wood on track for success

GATES Innovation in the truck and bus industry

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BRAKING RANGE Inside the engineering process

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LUMAG NEW GREEN COAT TECHNOLOGY

Also inside this month’s issue

VARTA

The battery power revolution

THE COMMERCIAL VEHICLE MAGAZINE BROUGHT TO YOU BY G-TRUCK & UAN TRUCK PARTS DISTRIBUTORS

CONTENTS ISSUE 18

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The complete line-up for this issue of On Route

PICK-UP TRUCK RACING CHAMPIONSHIP

G-TRUCK AND UAN TRUCK SPONSOR DRIVER LEA WOOD

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TruckTEC

BTN TURBO

Manufacturing of the highest quality

OE quality guaranteed

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GATES

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MORRIS LUBRICANTS

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JURATEK

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PARKER RACOR

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VARTA

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TMD FRICTION

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LUMAG

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TRUCKTEC

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New heavy-duty tensioner

Interview with Andrew Kibler, Quality Engineer

Batteries must keep pace with today’s requirements

Shorten the braking distance

Advice from the expert oil blender

Lower quality filters are a false economy

Brake friction specialists

LCV clutch expertise

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LED AUTOLAMPS

NEW LIGHTING RANGES ADDED

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36 MANN-FILTER

NEW AIR FILTER FOR DAF TRUCKS

View On Route Magazine on the go on your electronic devices by visiting www.OnRouteMagazine.co.uk

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OSRAM

ZF

Premium truck bulbs

Ensure your compliance

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FEBI TRUCK

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BORG & BECK

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VALEO

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BRIGADE

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HALDEX

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TRUCK-LITE

Febi truck keeps your steering on course

Pull type clutch best practice

New CV brake pads

GDPR and camera recording system guide

Automatic Brake Adjuster technology

New addition to rear lamp range

ISSUE 18 - JULY 2018

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TRADING GROUP SPONSORSHIP

G-TRUCK & UAN TRUCK SUPPORT LEA WOOD IN THE PICK-UP TRUCK RACING CHAMPIONSHIP 2018 RACING SEASON G-TRUCK & UAN TRUCK are sponsoring driver Lea Wood in the Pick-up Truck Racing Championship 2018 season, which opened at Brands Hatch on 31 March (Easter weekend).

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G-TRUCK is the commercial vehicle parts distribution arm of GROUPAUTO and UAN Truck is the commercial vehicle arm of UAN. Both trading groups are owned by Alliance Automotive Group, a European leader in supplying parts and related technical know-how to more than 25,000 car and commercial vehicle repairers, garages, fast fit outlets, body shops, specialists and DIY chains. Alliance Automotive Group is active in France, Germany, Poland and the UK. G-TRUCK & UAN TRUCK supply customers with quality parts they can trust. Priding themselves on a professional service keeping customers vehicles on the road and minimising vehicle downtime of a vehicle because they understand the importance of keeping a commercial vehicle on the road. ‘Time is money’. Visit www. cvdistributors.co.uk to find your local parts distributor.

As well as supplying a range of OE parts and supplies, G-TRUCK & UAN TRUCK distributors also offer you a range of quality own brand product under the private label ‘TruckTEC’.

The range consists of; Clutch Kits, V-Stays, Air Springs, Batteries, Braking and Lubricants. The

TRADING GROUP SPONSORSHIP

“To have such a successful first weekend of the season is exactly where we want to be coming away from this race meeting.”

group is continually working to expand the portfolio of parts and has some exciting new lines to enhance the portfolio in 2018.

Visit www.TruckTECparts.co.uk for more information.

The group also has its own workshop programme ‘TOP TRUCK’. A network of workshops in the UK offering fleets a competitive service including 24hr assistance, not only in the UK but European-wide with over 1300 workshops in the network. Aiming to reduce your vehicle downtime and keep you on the road. Visit www.Top-Truck.co.uk.

BRANDS HATCH RACE REPORT Round 1 & 2 The 2018 Pickup Truck Racing Championship got off to a flying start at Brands Hatch for Lea Wood during the Easter Weekend.

A 22 car field took to the two Qualifying

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sessions at the Kent circuit on the Sunday afternoon in the dry conditions, Hereford racer Lea Wood took second fastest lap in both sessions to secure a good starting

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TRADING GROUP SPONSORSHIP

position for the races the following day.

The Bank Holiday Monday brought heavy rain downpours for the initial races of the season, and starting from the third row (with the reverse grid positions from qualifying) Wood soon surged forward in very wet conditions to fight for the lead of the race, meanwhile posting the fastest lap time of the race (1:02.163).

The new engine and gearbox package has proved the right move for Lea Woods Racing Team, providing a very competitive Truck for Wood to take the first win of the 2018 season.

Once again Wood started from P5 in race 2 in similar wet conditions, this time with 30kg of success ballast now on board. Whilst running in the top 3, with 3 laps left to run, contact between two other drivers allowed Lea to capitalise on their mistake and take the lead of the race, ultimately the second race win of the day.

Speaking after the second race, Wood commented: “To have such a successful first weekend of the season is exactly where we want to be coming away from this race meeting.

I’ve always been a fan of the wet weather and it’s something that’s never phased me.

The new powertrain in the Truck feels fantastic and we’ve put in a lot of preparation coming into this season.

We’re also leading the drivers points standings too, so I’m really looking forward to

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weekend leading the championship by 41 points. With two qualifying sessions at the Darlington venue, Wood, 33, finished both sessions with 3rd fastest lap time.

For the first of three races, the Lea was running in 2nd position, when he hit a tyre barrier that had been dragged onto the circuit by another driver. This damaged some suspension components on the truck, and the TruckTEC backed driver had to limp the car around the remainder of the race to finish in 16th position.

After the team repaired the #43 machine for the second race of the weekend, Wood was able to capitalise on a good grid position to fight forwards to a 2nd place finish, and claim fastest lap of the race in the first of the 2 races Sunday, missing out on the win by just 500ths of a second.

And for the final race, Wood led from lights to flag with a healthy 8 second lead to take the last win of the weekend. Commenting on his performance at Croft, Wood said “I’m delighted with our results here this weekend, despite a tricky race 1 which was extremely frustrating at the time, we showed great race pace all through the weekend which resulted in 2 great finishes and a bag full of points.

1 1 x 1st place Croft in a few week’s time to hopefully build on what we’ve done here at Brands,” added the TruckTEC supported driver.

This season is Woods 3rd in BARC Pickup Truck Racing Championship, having finished 3rd in 2017 & 2nd in 2016. The popular racing series heads to Croft Circuit in North Yorkshire on April 21st & 22nd.

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2 x 1st place

CROFT RACE REPORT - Round 3, 4 & 5 Lea Wood enjoyed a successful second race meeting this past weekend, of the 2018 Pickup Truck Racing Championship season at Croft Circuit in North Yorkshire.

The Hereford racing driver went into the

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2 1 x 2nd place

ROCKINGHAM RACE REPORT Round 6 & 7 It was a busy weekend for Lea Wood at Rockingham, as not only did he star in the Pickup Truck Racing Championship, but also took part in the inaugural C1 Series Rockingham 24hr race.

As he is the current Pickup Truck Racing Championship leader, his priority for the weekend was to get two good results from there. “I qualified quickest for the first race, but was pipped by Carl Boardley in the second by 0.061 secs,” said the Hereford driver.

With the top six then reversed for the starting grid, he started in sixth for the first race and picked off a place a lap over the first two, before charging into second on lap three.

It was the first time the Pickups had used this version of the Northamptonshire circuit,

TRADING GROUP SPONSORSHIP

but Wood was familiar with it from his British Touring Car Championship campaigns. “Most of the passing was into the Deene Hairpin, out braking,” he said.

He gradually edged closer and closer to leader Mark Willis and after a couple of earlier forays, he made his move into the Tarzan Hairpin on lap 10. “The others closed towards the end and I was able to ease off as I had still had enough in hand, taking victory by 0.503 secs, also securing fastest lap of the race in a time of 1:30.656.

Despite starting the second race from fifth on the reverse grid, he had the lead into Deene Hairpin on the opening lap. There was a bit of contact as everyone tried to out brake each other, so I sat back a little and got through,” he said.

He survived two safety car interventions to retain the lead but was finally demoted by Boardley into Deene on the seventh lap, taking the flag a close second to retain his championship lead. “We swapped a couple of times before he finally got me,” he concluded.

That would normally have been the end of his racing, but due to his commitment to the OAP Racing team, made up of mainly seasoned MG drivers, he was forced to run from the Pickup parc ferme to the starting grid for the C1 24hrs race.

“One of our drivers took the car to the grid for me and I offered to let him start, but with 49 cars and we were 14th, he declined,” Wood explained.

It was both wet and gloomy as the race got under way. “I had set the qualifying time so felt fairly happy, but was very cautious early on, as I didn’t want to wreck things for the team who had been there for a few days already,” he said.

It took a while to adjust from the Pickup to a Citroen C1 though, which was basically a road car.

“After the first hour we were 20th but when I brought the car in at 7.20pm we were back up to 12th and looking good,” he added.

While the other drivers had their stints, Lea was back in at 5.40am for his second and final stint, but they had dropped back to 30th again. “The car was good still and I got it back to 20th.

When the chequered flag was waved after 24hrs, the sun was out and the team and had climbed to a satisfying 18th place. “It was a

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fantastic event, the organisation was brilliant and I couldn’t fault it. The only thing we did to the car was change tyres, put fuel in, one set of brake pads and replace a door mirror,” fantastic,” he concluded.

1 1 x 1st place

2 1 x 2nd place

Rounds 8 & 9 of the Championship take place at Thruxton on the weekend of July 8/9.

For more information www.TruckTECparts. co.uk or follow us and the team on Twitter @TruckTECparts

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TRADING GROUP NEWS

BRAKING PRODUCTS FROM TRUCKTEC ruckTEC says its braking products are the result of a careful selection of the best raw materials and the highest quality manufacturing process.

Years of research and development and countless tests have gone in to the production of each of its braking products, leading to the development of a new friction material from TruckTEC, which is capable of withstanding the most extreme working conditions while keeping an efficient and safe braking sensation.

Here, we take a peek behind the scenes at the TruckTEC manufacturing process to see how it works to ensure such high quality products.

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New pad concept All back plates are accurately cut from high quality steel, with an improved underlayer that connects back plate and friction material that has adhesive properties to withstand high temperatures.

Each braking component produced by TruckTEC has undergone more than 25,000 hours a year of testing in a dynamometer, as well as more than 2.5 million kilometres on the road, to ensure the quality of the friction material.

Thanks to working closely with international logistic companies, TruckTEC is able to carry out fleet tests on both tractors and platforms.

Tightly controlled manufacturing process TruckTEC’s manufacturing process takes place on deep molding presses, which control variables like temperature on each individual part. Thanks to the correct dosage mix, with

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TRADING GROUP NEWS

low organic content, TruckTEC parts avoid premature wear and provide stable frictional behaviour once fitted to a vehicle.

By ensuring controlled pressure in a uniform proportion, cracking is prevented on the friction material; carefully controlled temperature ensures all friction components are bonded together evenly throughout the entirety of the pad.

TruckTEC pads tests follow requirements of international protocols; in the most demanding braking conditions showing a behaviour that exceeds competition, giving the best braking response from the very first stop.

OEM-standard discs TruckTEC brake discs are made according to the standards required by vehicle manufacturers. Using grey cast iron in their construction, mechanical and microstructure specifications are similar to the Original Equipment components.

During the casting and, in particular, the cooling process, TruckTEC strives to prevent thermal press - accurate controls constantly check that the castings are free from cracks, micro-suctions and other defects that can affect the lifespan and performance of the discs.

Machining takes place on Computer Numerically Controlled (CNC) production lines, which are capable of maintaining correct parallelism and flatness.

During the machining process, TruckTEC ensures correct disc positioning through the precise placing of the central and radial holes. Sophisticated measuring instruments control the precision of machining as required by technical drawing.

According to TruckTEC, controlling strict tolerances is an absolute guarantee for a minimum Disc Thickness Variation (DTV), as well as for a comfortable braking manoeuvre free of squealing and judder.

the same as those required for Original Components to achieve type approval, consisting of two separate tests: test type 0 checks for performance in cold conditions, and test type 1 examines components for any loss of performance in hot conditions.

Specific tests for replacement parts, further to the Original Components tests are required, which include speed sensitivity tests and cold comparison tests, to give an added layer of reassurance in the replacement parts. In these tests, the admitted deviation can be plus or minus 15% compared to the Original Component.

As you can see from the data, TruckTEC braking parts achieved comparable results that matched, and in some cases exceeded the competition in like-for-like testing for braking performance and in wear tests against competitors.

Confidence TruckTEC’s belief in its braking components has led the parts manufacturer to include a 12 month / 12,000-mile warranty on its brake pads and wear leads. Distributors of TruckTEC parts can be found across the UK at www.cvdistributors.co.uk.

For more information: www.trucktecparts.co.uk

Performance and stringent testing Following the requirements of international protocols, TruckTEC tests its pads under the most demanding braking conditions. In these tests, TruckTEC says its pads demonstrate a behaviour that exceeds competition, which for the driver means the best braking response from the very first stop.

Under Type Approval Regulation ECE R-90, which derives from European Directive 2002/78 CE, all manufacturers of friction materials in the replacement parts market must have all product tyes approved.

Tests to meet Regulation 90 approval are

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GATES CONTINUES TO LOOK FORWARD INNOVATE IN THE TRUCK & BUS INDUSTRY WITH ADVANCED PRODUCT DEVELOPMENT

he new Heavy Duty Tensioner (T38667) on popular Mercedes applications is an example of how extensive product engineering results in a solution that outperforms the Original Equipment (OE) part and helps customers to lower cost per kilometre significantly.

Initially designed to replace the original tensioners on OM470 engine families, this tensioner can also be applied to Actros, Antos and Arocs trucks, and to Travego and other busses.

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Differences with the OE tensioner Gates engineers studied the OE tensioner extensively and made significant adjustments to the design in order to outperform the original tensioner. Compared to Gates’ new Heavy Duty Tensioner, OE tensioners use other pivot bushings which make it difficult to maintain alignment. In addition, the OE tensioner utilises hydraulic struts. These make the whole device slower to react to the constant changes caused by the accessories’ fluctuating power requirements which, in turn, could lead to belt flutter and wear.

“Significant investments made in product design and technology enable us to deliver

total quality OE solutions. By using special technology to improve the T38667 tensioner design for example, the spring and damping mechanism are protected from early failure resulting in a much higher performance of up to 550,000 km,” says Enzo Strappazzon, President, European Region.

Durability and reliability The unique design of the tensioner utilises labyrinth sealing technology, protecting the spring, damping mechanism and bushing from elements that could lead to premature failure, like dirt. The belt tension damping system, in turn, reduces arm movement, eliminates belt flutter and maintains tension, thus extending the life of both the tensioner and accessories. This is crucial given the large amount of tensioner movement that results from the accessories’ typically varying loads.

Once the design phase was completed, the T38667 tensioner was trialled and tested by having it fitted to a high kilometre fleet.

The tensioner demonstrated true heavy duty performance up to 550,000 kilometres.

Benefits of the DriveAlign® Heavy Duty tensioner DriveAlign® Heavy Duty Tensioners T38667 are very easy to install, but that’s not

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the only thing they have going for them.

T38667’s many advantages include: • Larger pivot bushing - Prolongs tensioner life • Longer tensioner arm - Reduces pivot bushing wear • Balance of loads - Ensures proper alignment of the tensioner • Double row pulley bearings - Proven to last longer than other bearings and maintain stability • Higher damping - Reduces arm movement • Heavy Duty performance (up to 550,000 kilometres) - Reduces downtime and lowers cost per kilometre This tensioner will be available in several Extra Service Micro-V® kits, to guarantee an optimal overhaul of the system with a perfectly matched tensioner and belt combination.

For more information: www.GatesTechZone.com

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INTERVIEW: ANDREW KIBLER, QUALITY ENGINEER, JURATEK What key advice would you give to transport operators when purchasing friction materials for commercial vehicles?

A: There are two main factors to take into account when choosing friction material.

1 - Of paramount importance is safety. You need to choose a friction material that can be relied upon in all conditions. The worst feeling any driver can have is when the brakes fail to work effectively; this can be due to is what we refer to as brake fade. Brake fade occurs when the friction material becomes too hot and the friction level between pad and disc reduces markedly causing the brake stopping power to reduce significantly. Imaging this feeling when driving a 44 tonne truck or a bus full of passengers!

2- Second is cost efficiency. It is false economy to buy a cheap friction material that may save you money up front, but will not last as long as better materials. It is often thought that buying OE product is always best. While OE product will give you performance and durability it can also be very expensive. The ideal solution is a material that is tested and approved by the VCA to perform comparably with the OE product and will be just as durable. This is what the Synergy product offers.

So my simple advice is - buy Synergy - they offer great value for money.

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Q - What, in layman’s terms, do ECE R90 regulations mean for the braking industry?

A: R90 raises minimum standards of performance & quality. R90 is not a blanket approval, it is application specific. Approval has to be obtained for each and every application on a part number basis and comprises three main elements.

1 - Compliance with R13 - the braking regulation which governs the braking performance of new vehicles before they can enter the market place.

2 - A direct comparison with the material fitted as OE to the vehicle for which approval is being sought; the replacement product must have a performance within 15% of the OE product and.

3 - Evidence of conformance of production (COP); this ensures that the level of performance and the key mechanical attributes of the product are maintained in routine production, batch after batch.

Andrew Kibler

“Compliance with R90 is a legal requirement so for Juratek it is an absolute minimum requirement but it is not the only thing we consider in developing our materials.”

Q - What does a UN ECE R90 approval number say about your products? How important is traceability and a part number reference in this regard?

A: It says our products meet a minimum standard of performance; the COP element of R90 helps ensure the reproduction of key product performance and mechanical properties for each and every batch produced; traceability is a core requirement of any serious quality control system and not just a component of R90.

Q - Durability and wear rate are key issues to consider when purchasing friction materials. How has the Synergy braking range been designed to be robust in all environments?

A: Durability/wear is indeed a key issue. We have a wide ranging series of rig tests which look at how

Q - How has the Synergy range been designed to meet ECE R90 requirements?

A: Compliance with R90 is a legal requirement so for Juratek it is an absolute minimum requirement but it is not the only thing we consider in

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developing our materials. R90 does not cover some of the more extreme levels of potential service use such as mountain descents nor does it consider the durability of pad and disc - key factors in the cost of fleet operation. Specialised rig testing, fleet trials and our involvement with truck racing provides us with a full suite of data across the whole vehicle operation spectrum and it is this data in total which guides our development efforts.

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durability varies with duty and temperature and once satisfied we then progress to field trials for confirmatory “real world” data.

Q - What kind of issues can arise from purchasing imitation or counterfeit friction materials?

A: Longer stopping distances due to low performance and fade; failure on MoT brake tests, short pad life and disc damage and worst of all the risk of accidents.

Q - What kind of quality control and testing measures do Juratek employ?

A: All our production facilities hold ISO9001 & TS16949 quality accreditation and every batch is checked for friction and physical properties before shipment as a part of our routine COP regime.

Q - What kind of investment do Juratek make into the research and development of their product range?

A: We never stand still, we are always looking for ways to continually improve our products and offer superior performance and value for money and as a result we spend in the order of 2% of our sales revenue on our product development - a year-on-year commitment to continuous improvement and superior value.

Q - Can Juratek assist clients with brake pad maintenance?

A: Of course; we have product leaflets and guides and our technical team can help on the phone or by email.

“An increasing market share as operators realise the benefits Synergy will give them.”

Q - What does 2018 have in store for Juratek?

A: An increasing market share as operators realise the benefits Synergy will give them. We will also have an increased presence in the British Truck Racing Championship this season. In fact in 2018 Synergy product will be fitted by the three top teams in Division 1 and to two of the up and coming teams in Division 2.

Q - Do you have a final take-home message for our readers?

A: Buy Synergy pads - they are a great product and will provide first class performance and life at affordable prices.

For more information: www.juratek.com

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BATTERIES NEED TO GROW WITH TODAY'S REQUIREMENTS INTERVIEW WITH RAUL ARREDONDO, GLOBAL PRODUCT MANAGER AT JOHNSON CONTROLS

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he times when trucks used to be just trucks and the coffee machine was the only amenity are long gone.

Nowadays the battery virtually needs to keep a moving hotel running - 24/7.

We talked with Raul Arredondo, Global Product Manager at Johnson Controls, about the challenges, a joint development and a unique technology.

Q - What distinguishes this battery - the VARTA® Promotive EFB - from the competition?

A - The result of the joint development is a truly unique technology that meets the very highest OEM requirements for the end of frame installation and for the hoteling functions.

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Q - Long-distance trucks have become hotels on wheels.

Would you say that is the most significant market development - leading to an increased demand for premium batteries?

A - Well, it comes down to one important aspect. Due to safety-regulations and longer distances that truck drivers need to manage, they virtually are living in their trucks today. Sometimes they are spending five nights per week on the road - in trucks that are equipped with all sorts of amenities: ranging from kitchen equipment to television, smartphone chargers, laptops and, of course, all the hightech onboard equipment.

Q - In other words: Batteries have to support a large number of electrical components - even when the truck is not moving.

A - Exactly. Today, an overnight stay requires approximately 50% of the battery’s capacity. So, yes, performance demands have greatly increased. In a highly competitive market no truck fleet owner can afford failures of individual functions or even downtimes that reduce the efficiency of his or her fleet. And don’t forget that trucks are built differently today.

Q - You are referring to how the battery is installed at the end of the frame?

A - Indeed. A different installation to make room for diesel fuel additive containers and larger fuel tanks. This trend makes great demands on batteries, because only the most vibration-resistant batteries can withstand the shocks.

Q - According to a Shell truck survey the total mileage in 2030 will exceed 1 billion kilometers in Germany alone.

That surely has an impact on batteries as well?

A - Of course. And while the number of trucks continues to grow, CO2 emissions need to be reduced. Not to mention the constant new safety regulations for trucks. So the bottom line is that high-performance commercial vehicles with heavy cycling use need batteries that are capable to grow with these requirements - today and tomorrow.

Raul Arredondo

“In a highly competitive market no truck fleet owner can afford failures of individual functions or even downtimes that reduce the efficiency of his or her fleet.”

Q - What makes it unique?

A - Well, to start with, the patented mixing element reduces acid stratification and uses the natural movement of the vehicle in the process. We also have injectionmolded supports and an additional connector fixation, which withstands even the most severe conditions on the road. An additional polyester scrim and glued mat ensure excellent adhesion of the grid to the mass. This means the mass is surrounded by a special mat so that it does not detach.

Q - Leading to a longer cycle life?

A - Compared to conventional batteries, yes. Our technology provides up to 40% longer life. Long-term practical tests in trucks with hotel-function have proven that VARTA Promotive EFB gets the job done. Also because the labyrinth cover design was especially developed by VARTA - it provides complete protection against leaks, even when titled up to 90 degrees.

Q - What about maintenance?

A - That’s a worry from the past. The VARTA Promotive EFB is completely maintenance free. Operating times increase as well, and orders can be carried out more quickly, resulting in considerably lower total operating costs and larger profits. And not only for truck companies, of course: Buses and municipal vehicles, tractors, forestry and construction machines are also profiting from this unique technology - developed by a traditionally established brand, I might add, a global market leader.

That are soft factors that cannot be stressed enough as our customer simply know they are getting a product that works, is absolutely reliable and contributes to keep business running.

About Johnson Controls Power Solutions Johnson Controls Power Solutions is the world’s largest manufacturer of automotive batteries, supplying approximately 152 million every year to automakers and aftermarket retailers. The company’s full range of lead acid and Lithium-ion battery technology powers nearly every type of vehicle for our customers- including conventional, Start-Stop, Advanced Start-Stop, Micro Hybrid, hybrid and electric. Johnson Controls’ recycling system has helped make automotive batteries the most recycled consumer product in the world. Globally, 15,000 employees develop, manufacture, distribute and recycle batteries at more than 55 locations.

Q - That’s why you brought Major European truck manufacturers on board to develop a new battery technology?

A - Exactly. As a major supplier to all leading European truck manufacturers we are constantly gaining valuable insights to the latest and greatest in truck technology allowing us to base the development of our batteries on that knowledge. And once our new VARTA® Promotive EFB battery was developed, the OEMs agreed to test and validate its performance ‘in vehicle’.

For more information: www.johnsoncontrols.com/PowerSolutions or follow @JCI_BatteryBeat on Twitter

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LUMAG SHORTENS THE BRAKING DISTANCE BY 3 METRES Lumag, leading Polish manufacturer of friction materials, has recently invested 700,000 PLN to extend its factory with a new production line used for applying a layer of the so-called “Green Coat�.

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wing to this investment, brake pads made by the company will offer even greater safety by shortening the braking distance from 50 to 0 kph during breaking-in of newly installed pads by up to three metres.

All brake pads approved for marketing in the EU have to meet the requirements of the ECE R90 regulation, which, among other things, defines the maximum allowed braking distance. Unfortunately, very often a new set of brakes does not ensure full braking efficiency immediately after installation, and full efficiency is commonly achieved only after covering 200300 kilometres. This phenomenon - referred to

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as “green fade” by experts - is defined as a drop in braking force caused by excessively violent pressing down on the brake pedal, when brake pads have not been broken-in yet.

“Our response to green fade is the Green Coat - a thin layer made of silicates, among other components, applied on the outer friction surface of a pad. Brake pads featuring a layer of the Green Coat provide a higher coefficient of friction right from the first application of the brakes, which significantly shortens the braking distance during the bedding in process. The layer lasts for a few dozen brake applications, which overlaps with the time a new brake needs to reach full efficiency. Tests indicate that the Green Coat can shorten the braking distance from 50 to 0 kph by up to three metres, which can help the driver avoid a dangerous collision”, said Marcin Darowny, Manager in Lumag’s Research and Development Department.

developed by Lumag’s experts. Next, brake pads will be automatically conveyed to a drying module. It is especially worth noting that no solvents are used in the production process, which makes it environmentally friendly.

Marek Żak, President of Lumag added: “Safety and innovation have been the cornerstones of our development for 30 years. That is why our products are made in the most modern friction material factory in Central and Eastern Europe, which is being constantly extended. Another step in our development is the construction of a stand-alone Green Coat application line.

Owing to the line, almost all brake pads we make will feature this new coat, as so far this option has been offered only in selected products.”

Lumag brake pads featuring the Green Coat will be launched in May. Detailed description of new products will shortly be made available on the company website: www.lumag.pl.

New line for the application of the Green Coat As a part of the investment project, Lumag’s factory located in Budzyń in the Wielkopolska region of Poland, will be extended by a stand-alone line used for the application of the Green Coat. The semi-fluid material will be screen printed on the working surface of the friction material, while a laser screen positioning system will ensure the right position of the grid pattern

Find out more Lumag’s latest e-catalogue can be downloaded from www.katalog.lumag.pl/, where comprehensive information on every part is listed. For more information about Lumag’s brands and catalogues please visit www.lumagltd.co.uk.

For further details on Lumag’s range available to the aftermarket, call: 0121 520 1160 or office@lumagltd.co.uk

“Safety and innovation have been the cornerstones of our development for 30 years.”

Pads with Green Coat Pads without Green Coat

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TEST CONDITIONS - ISO 26865 - Green perf. /Caliper: SK7/ Axle load: 10000kg / Inertia:1389 kgm2 / r eff: 0.173m /r dyn:0.527m

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NEW LIGHTING RANGES FROM LED AUTOLAMPS

“With an ingress protection rating of IP69K these Driving Lamps are fully waterproof and built to withstand the pressures of high-power jet washing - an invaluable asset to consider for any hard working fleet vehicle!”

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ED Driving Lamps LED Autolamps’ range of Driving Lamps are fully ECE Road approved and designed with hard working commercial vehicles in

mind.

Perfect for HGV truck bars - the 1786SBM and 2296SBM Round LED Driving Lamps, at 7” and 9” respectively, feature a powerful 5400 lumen driving beam (R112) and an eye-catching 48-LED front position ‘halo ring’ (R7).

With an ingress protection rating of IP69K these Driving Lamps are fully waterproof and built to withstand the pressures of high-power jet washing - an invaluable asset to consider for any hard working fleet vehicle!

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“All of these new Interior Lamps have an ingress protection rating of IP67, making them fully waterproof and ideal for tough working environments. They have a dual voltage design, allowing them to be used on 12V or 24V vehicles, and the high-brightness LEDs give powerful lumen outputs of up to 1500lm.”

LED Interior Lighting Bolstering their already expansive range of LED Interior Lighting, LED Autolamps have introduced 3 new lamp shapes, each available with a choice of switch option; PIR-sensor, touch switch and nonswitched: • PIR-Sensor - These are the first proximity sensor lamps to be introduced by LED Autolamps and have proved instantly popular.

The PIR-sensor (Passive Infrared) will detect movement within a 3m radius of the lamp - ideal for any light commercial vehicles, delivery vans, refrigerated vehicles, utility vans… The lamp will activate when movement is detected, such as the opening of a door, and will turn off automatically 30 seconds after motion has ceased - ensuring that the light is not left on unnecessarily.

• Touch Switch - The touch sensitive versions feature an illuminated on/off button, allowing the lamp to be quickly and easily

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located in a dark environment.

The button also allows the control of three brightness settings, allowing the operator to select the perfect illumination for any given situation - Ideal for cabs and close internal working areas.

• Non-switch - all three interior lamp shapes are also available without an integrated switch, allowing them to be wired into the vehicles interior loom and controlled with an external switching system.

All of these new Interior Lamps have an ingress protection rating of IP67, making them fully waterproof and ideal for tough working environments. They have a dual voltage design, allowing them to be used on 12V or 24V vehicles, and the high-brightness LEDs give powerful lumen outputs of up to 1500lm.

For more information: www.ledautolamps-uk.com

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CHEAPER OILS MIGHT END UP BEING A COSTLY MISTAKE, EXPERT WARNS

Adrian Hill

leet Managers who try to save cash by using cheaper lubricants might well end up shelling out more in the long run, an expert has warned.

Adrian Hill, Automotive Product Manager at leading oil blender Morris Lubricants, said inferior lubricants affect fuel economy, meaning fleet operators will visit the pumps more often than those who use products recommended by the OEM. Adrian said that cheaper products might not always live up to the claims they make on the barrel - and that could lead to problems with components, or even complete breakdowns.

“Using the correct lubricants, at the correct drain intervals as prescribed by the OEM, will maximise the efficiency and the lifetime of the vehicle,” said Adrian.

“People are attracted by the proposition of saving a few pennies on a litre of oil because it looks a good deal, but the down side is that it might not provide the necessary fuel economy benefits and it might not offer the correct levels of protection.

“A lot of the cheaper gear oils claim the 75W-90 or 75W-80 viscosity classifications.

But when they have been checked by

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the industry watchdog, Verification of Lubrication Specifications (VLS), they have been found to be substandard. They are not meeting the 75W claim, which means they are not as fluid at low temperatures as the specification claims they are.

“Fuel economy is mainly attributed to that cold-start period because that’s when the oil is at its thickest. If you’ve got a thick, gloopy oil, some of that energy generated by the engine is not getting to the wheels. It’s needed to churn through the thick oil.”

Adrian said that a sure-fire way to ensure that a lubricant is up to scratch is to check whether it carries an approval for a specific vehicle.

He said that fleet managers should ask for proof from their lubricant suppliers that the oil in the barrel matches up to what is claimed on the label.

Adrian added: “If you use the wrong products in transcontinental vehicles doing many miles, you can rack up a lot of wear and tear. In the medium-term, you start to see downtime and unreliability. If you’re going from Birmingham

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to Venice and you breakdown two-thirds of the way there, that’s expensive as you’ve got to repair and recover it.

“And cheaper products may invalidate a warranty claim.

It’s short-term costs versus long-term gain.

“Anybody who thinks they are getting a really cheap deal on a lubricant, with lots of performance claims should ask for evidence. If they can prove it, great - but nine times out of 10, it’s not going to be a wise move in the long-term.”

Morris Lubricants has rebranded its OEM approved commercial vehicle oils under the new Versimax title, a name which combines the versatility and maximum quality on offer.

Morris Lubricants is a British company that has been manufacturing lubricants in Shrewsbury since 1869. Over 140 years of development has seen the company grow to become one of Europe’s leading oil blenders and marketers with a reputation for quality and service.

For more information: www.morrislubricants.co.uk

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LONG-HAUL PROTECTION FOR COMMERCIAL VEHICLES: WHY LOWER QUALITY REPLACEMENT FUEL FILTERS ARE A FALSE ECONOMY

BY DEREK MARTIN, PARKER RACOR sing OEM diesel fuel filters during a vehicle’s warranty period is the norm and for good reason.

Maintaining this approach after the warranty expires also makes sense.

The risks associated with products that may use lower quality parts, materials or technology can potentially have serious and costly implications for the entire vehicle fleet.

This article considers the commercial and technical reasons why buying approved fuel filters for the entire operating life of fleet vehicles represents the most cost-effective strategy.

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“Further to the block exemption rule are the European emission standards that seek to minimise the harm of pollution from exhausts, with special attention given to heavy goods vehicles. Euro VI emission standards have contributed greatly to the requirement for enhanced fuel filtration efficiency.”

Out-of-warranty replacements In the warranty period, high-quality filters bought directly from OEMs like Renault, Mercedes and Scania, or their official distributors, will have been tested to the highest standards. From an operator perspective their replacement is an easy-tofacilitate process.

If outside the warranty period, however, there is sometimes the temptation to source cheaper alternatives. The detriments of a non-approved filter rapidly become clear when it is opened up and compared, sideby-side, to an approved one. What’s more, in time, the difference in material condition and filter efficiency will widen further.

Often, lower material quality offers poor water separation efficiency, at which point filter life will already be terminally limited. Beyond this time, the capability to remove dirt, particles and microbiological contamination is likely to be inferior, while the risk of more contamination will intensify.

Soon, it will not only be the fuel filter that is showing the effects; damage to the fuel injection system and engine could potentially have a considerable knock-on impact for the whole operation. Vehicles will need reallocation and any damaged parts, including the filter, will require rapid replacement or overhaul at additional cost.

Chances are, when the vehicle fails, the operator that sought to save money on the initial cost of a replacement filter will be aware of the cause. The operator might, however, be unaware of the real dangers to both fleet vehicles and employees.

The dangers of a short-term approach To the everyday person, and indeed many experts, it is virtually impossible to distinguish between a non-OEM approved filter and one tested against the exacting standards set by the manufacturer. The fit will be the same and, apart from colour, the exterior will be nearly identical.

Unfortunately, however, the

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differences will become all too apparent in time.

Milder risks involved with fitting an inferior filter include decreased product life, greater levels of impurities passing the filter and poor engine performance. At the other end of the scale, worst case scenarios could see permanent damage to the fuel injection system, namely the injectors, high-pressure pump and even the engine.

There is no way of telling when and to what extent a non-approved filter could present a problem, until it occurs. If an issue happens halfway through a shipment, the immediate cost implications will be felt hard. A replacement vehicle will need to be despatched, or else the customer reimbursed at the operator’s cost. The damage to finances, resources and reputation is likely to be significant.

Sticking to the rules The EU’s block exemption rule protects the right of an operator to buy non-OEM approved parts, provided they are of equal or better quality. This rule may suggest that all replacement filters are comparable, but it is key to appreciate just how great a difference there is between one approved by the OEMs and one built for value.

Further to the block exemption rule are the European emission standards that seek to minimise the harm of pollution from exhausts, with special attention given to heavy-goods vehicles. Euro VI emission standards have contributed greatly to the requirement for enhanced fuel filtration efficiency.

There is no doubt that operators are already facing increased costs to meet these latest standards. New vehicles and improved infrastructure will, however, be wasted efforts if the diesel filters within them are not up to task. Of course, it makes complete business sense for operators to seek the best possible deal on new diesel filters. However, be wary that if something seems cheaper than it should, chances are it will not provide the long-haul protection required.

For more information: www.parker.com/changinfiltration

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TMD FRICTION “IF IT MOVES, IT’S OUR JOB TO STOP IT” he company’s product portfolio comprises disc brake pads and drum brake linings for passenger cars and commercial vehicles together with friction materials for racing and industrial applications.

TMD Friction is the largest friction supplier in the world to the on-road automotive Original Equipment Market and are the largest producer of air disc brake pads to the commercial vehicle sector.

More than 200 million drivers worldwide depend on TMD Friction to ensure that they have a safe and comfortable journey every day.

TMD Friction produces over 1 million products every day, many of which are bespoke aftermarket solutions for a wide range of vehicles. By manufacturing our aftermarket friction products with the highest quality raw materials, this ensures rigorous quality standards are met for worldwide distribution.

Our products continue to be the driving force in the Commercial Vehicle Aftermarket. With

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over 100 years’ experience, knowledge and research, TMD Friction has a market-leading position in the global replacement parts market.

While other manufacturers focus mainly on price, with TMD the focus is always on premium quality. We spend up to three years developing, testing and releasing each new OE product. The knowledge gained from the development of the original equipment part is transferred across to our aftermarket programme, investing €30 million annually.

TMD guarantee • Up to 1000 hours of dynamometer testing • Intensive NVH (Noise, Vibration, Harshness) and comfort engineering • Computerised evaluation of braking performance and wear pattern • Rigorous homologation testing in real life conditions ECE R90 - Going above and beyond - the maximum standard for most, the minimum standard for TMD Friction

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While the ECE R90 requirements ensure a good standard and quality, it is not enough for TMD Friction. All brake pads are developed to go above and beyond these standards and are only released to the market once they have passed their own strict criteria. The result is a high quality brake pad that exceeds the norm.

Textar Textar is the world’s leading brand for commercial vehicle brake friction and leading supplier of brake pads and linings to both the O.E supplier and the aftermarket. Textar offers the performance and safety that only the original can guarantee. That’s why 70% of all Commercial Vehicles in Europe are fitted with Textar brake linings as standard.

“Innovation, High Performance, Safety” • Yesterday - stands for best braking technology for more than 100 years in the world of Textar • Today - Textar is the world’s leading premium brake friction brand for Commercial Vehicles,

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whether truck, trailer or city bus • Tomorrow - at Textar starts today because it is today that we are developing optimal braking solutions such as “light-weight brake pads” for the vehicles of the future With a range of over 150 disc brake pads, 150 brake discs and 600 drum brake linings, Textar is all about Brake Technology.

DON - Serious Stopping Power DON has been at the forefront of brake friction technology for over 100 years.

With a reputation for uncompromising quality and reliability, DON has retained its position

“More than 150 disc references, manufactured to strict dimensional tolerances and highest metallurgical standards, perfectly complement our pad program.”

as a strong market player in developing and supplying braking solutions for commercial vehicles, buses and coaches.

Backed by the TMD Friction Group and benefitting from their R&D and manufacturing expertise, the DON brand represents excellent value for money, whilst never compromising on safety - a product fit for purpose for fleet operators and workshops worldwide.

The OE derived friction material in the DON range is designed to complement the needs of individual vehicles and their braking system, from lighter commercial vehicles or buses operating in innercity environments, to intercontinental haulage operations and the heavy load vehicles used in mining, quarrying and heavy industry.

Brake Pads The DON brake pad program represents the optimal solution for a cost effective product - backed by TMD Friction quality, engineering and testing and fully produced in the European TMD Friction facilities, the range consists of over 60 references.

Today, whether it’s a Bendix, Brembo, Haldex, Knorr, Meritor or Wabco braking system, DON offers a comprehensive range providing a maximum vehicle parc coverage - all ECE R90 approved.

Where necessary, air disc brake pads in the DON range come with a special surface coating - either red in colour or a clear lacquer. This coating helps cleanse the brake disc during the bedding-in process, whilst providing excellent “first-stop” performance.

In addition, the pad program includes accessories where required. All these are fully tested and technically approved by TMD Friction and independent testing companies, which includes for example a one million cycle endurance test for the springs, vibration- and shaker tests, as well as salt chamber tests.

Brake Linings Don has a strong OE reputation for supplying world class brake linings. With a focus on different types of applications we always offer the right material, be it truck trailer or bus.

The program includes over 400 references to ensure a maximum vehicle parc coverage, and features an easy identification of the friction wear through a visual indicator (where applicable) on the lining edge.

Brake Discs More than 150 disc references manufactured to strict dimensional tolerances and highest metallurgical standards perfectly complement our pad program. A major part of the Don product range is already ECE R90 approved today.

The DON pad, lining and disc programme is completed by comprehensive ranges of: • Wear indicators • Fitting kits • Rivets For more information: 01274 854006 or www.don-brakes.com

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TRADING GROUP NEWS

NOW THERE’S LCV CLUTCH EXPERTISE FROM TRUCKTEC

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TRADING GROUP NEWS

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n top of 240+ CV clutch kits available in the TruckTEC range, over 150 new parts have been added to the TruckTEC clutch range that covers most popular light commercial

vehicles.

These are made of of complete kits as well as indivuidally boxed concentric slave cylinders, allow customer flexibility and choice when it comes to stocking decisions.

Covering applications such as the Iveco Daily and Mercedes Sprinter, right down vehicles such as the Doblo and Partner, the clutch kits are said to offer OE levels of quality and specification, as well as meeting ISO9001 and ISO14001 quality standards.

“These standards mean that products are manufactured to PSW standards (Part Submission Warrant) using PPAP (Production Part Approval Process) minimum level 3 requirements,” said Engineering Manager James Waters.

James adds that all clutches in the range go through a comprehensive 17-step test plan before approval.

“Our testing procedures and standards raise the bar in the aftermarket,” he said.

“We not only carry out endurance tests, but multiple tests covering key technical criteria for cover assemblies, drive plates, bearings and concentric slave cylinders. We want to be sure the product stands up to

“We are careful about what we put the name to and always ensure new kits and components meet our high standards.”

the high standards expected in this market. That is also why all finished units are 100% line tested.”

The LCV clutch range also features a two-year, 20,000mile warranty and the CV range offers a two-year, 200,000 mile warranty, and is surcharge free.

“We understand our customers want to trust the product they fit,” said Martin Sangster, G-TRUCK Business Development Manager.

“On the rare occasions where warranty does come into play, we even offer a no quibble warranty claim option, so long as some very basic criteria are met such as the clutch was fitted correctly to the right vehicle.”

The range, which currently comprises over 200 kits, continues to grow.

“We are careful about what we put the name to and always ensure new kits and components meet our high standards,” added Martin.

“That way our customer can be confident in when they fit TruckTEC, they are fitting a quality kit.”

“The CV clutch kit range is proving very popular in the market, and building on the success of this range to a wider number of commercial vehciles is a natuarl step” he said.

“The number of customers taking TruckTEC clutch as a viable option in the aftermarket continues to grow.”

For more information: www.TruckTECparts.co.uk

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C 26 024 KIT REPLACES C 26 024 ...AND NOW COMES WITH A HOUSING P

opular MANN-FILTER air filter C 26 024 for DAF applications has now been replaced with C 26 024 KIT. So, what’s new with C 26

024 KIT? Unlike C 26 024, C 26 024 KIT consists of both the filter element and an additional plastic housing cover. The plastic housing cover is required to overcome the installation method when fitting the element to the housing patent protected by the OEM. The cover is designed to be geometrically aligned to the filter ensuring optimum performance of the filter even in tough conditions. The cover can be used on both the aftermarket part and the original equipment part.

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MAKE DAF TRUCKS MODEL XF105 NEW XF (XF106) Despite being delivered as a kit, no additional costs are incurred - the whole kit costs the same as a single filter element.

OE REFERENCE 1931685 For more information: www.mann-filter.com

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BTN WARRANTY CLAIMS THOROUGHLY INVESTIGATED BTN Turbo only supplies turbos that are 100% OE, so you can be confident they’ll perform correctly and work reliably.

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TN supports them with their two-year warranty against manufacturing faults.

This is backed by BTN’s No Quibble guarantee for diesel heavy commercials. If a unit supplied by BTN fails for whatever reason within 12 months of purchase, they’ll replace it free of charge - no arguments.

So when they receive a warranty claim, how does BTN resolve it? To ensure the process is scrupulously fair and accurate, they start by checking the part number, to ensure it’s a BTNsupplied turbo and not a counterfeit unit.

Sometimes the fault is obvious, such as damaged turbine blades and vanes. With the blades rotating at up to 6,000rps, even a tiny part sucked into the turbo can cause terminal damage.

The majority of failures are oil-related, and diagnosis usually requires BTN’s specialist test equipment. They take photos to show how the parts are damaged, and their report explains the cause - typically oil contamination, starvation or leaks.

Only 1% of turbo failures are due to

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manufacturing faults, but if BTN finds that’s the case, they’ll replace the turbo quickly and without fuss. When external issues such as oil problems caused the failure, their report will help you find the fault, so you can rectify it before fitting another turbo.

To make sure you benefit from this awardwinning standard of service, make sure you order a turbo supplied by BTN Turbo.

“The majority of failures are oil-related, and diagnosis usually requires BTN’s specialist test equipment.

They take photos to show how the parts are damaged, and their report explains the cause - typically oil contamination, starvation or leaks.”

For more information: 01895 466666 or www.btnturbo.com

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FIT THE BEST 24V BULBS FROM THE BIGGEST OE BULB MANUFACTURER! ehicle bulbs from OSRAM are renowned for their outstanding precision, reliable operation and impressive ruggedness.

As the world’s leading vehicle lighting brand at the forefront of new automotive lighting innovations OSRAM’s range of 24 volt headlight and auxiliary bulbs are manufactured to offer road haulage fleets and commercial vehicle workshops ‘like for like’ OEM replacements.

With the increase of LED products used on new trucks and vans, there is an increased emphasis on lifetimes and performance from lighting. This is why it is so important to use high quality OE bulbs for all HID, halogen and auxiliary applications on a vehicle.

OSRAM manufactures and supplies Original Equipment manufacturers with all types of lighting whether it be LED, HID Xenon, halogen or conventional filament technology.

It is the trusted OE brand.

More and more workshops and fleet managers are recognising the savings that can be made by specifying and fitting Original Equipment (OE) quality bulbs that simply last longer. All OSRAM bulbs are Original Equipment products.

The ORIGINAL 24 volt range covers the most popular headlight and auxiliary applications and the like for like upgrade; TRUCKSTAR® PRO gives a brighter light, with a longer lifetime and increased durability, to withstand the prolonged vibration environments they work in. OSRAM’s genuine Original Equipment (OE) quality offers reliability and customer satisfaction which is especially important for Fleet operators. Genuine OE provides the reassurance, that bulbs purchased as replacements, are the same quality as those fitted on the production line to new vehicles.

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With the complexity of modern vehicles, it makes sense to fit a quality product to avoid repetitive replacement hassle and costs.

Truck manufacturers specify OE quality so why replace them with anything else.

Looking for a way to keep your bulbs neat, tidy and secure?

OSRAM’s range of Workshop Bulb Displays and Bulb Dispensers can assist garages and workshops to stock and store the most

popular 24V OSRAM bulbs. The AVS Cabinet in particular is just perfect for this. Supplied empty and available with or without a lock it allows for secure and easy storage of the 24V OE bulb range that is available to GAU CV Members. It can easily be filled with a wide range of OSRAM bulbs to suit individual workshop requirements. It can house up to 50 single boxed headlight bulbs and up to 130 auxiliary bulbs in 10 way boxes. A recommended stock pack is also available.

Having an OSRAM AVS Cabinet in any workshop will ensure vans and trucks are kept on the road and out of the maintenance bay.

Features of the AVS Bulb Cabinet: • Lockable door for added security • Also available without a Lock • Allows for flexible stocking of boxed bulb types • Can be wall or counter mounted • High quality and robust • Suitable for all workshops • Slot system for easy removal and restocking • Holds up to approx. 180 bulbs For more information: automotive@osram.co.uk or www.osram.co.uk

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FEBI TRUCK KEEPS YOUR STEERING ON COURSE FEBI TRUCK IS AVAILABLE THROUGH YOUR LOCAL G-TRUCK OR UAN TRUCK PARTS DISTRIBUTOR.

he steering range offers top quality steel, and OE grade rubber on all bushes, for a variety of vehicle makes and models.

With over 70% market coverage on steering and suspension, febi Truck has one of the largest ranges available in the aftermarket.

Every second a commercial vehicle is off the road is money wasted, so it is important to use high quality replacement parts, and check any signs of wear or failure as soon as they are noticed. Driving vehicles with worn steering parts can not only lead to expensive bills but also puts lives at risk. febi Truck has an extensive range of OE matching quality steering components ensuring optimum performance and long service life, to keep

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you on the road.

The wide range of OE matching quality ball joints fit track rods, drag links, throttle linkages and steering rams. These safety critical parts keep all vehicles, including heavy goods vehicles, safe and on the road by allowing controlled movement and offering enhanced driver comfort by absorbing vibrations. febi Truck also supplies a range of King Pins, which ensure optimum performance by holding the alignment between the wheels and the axle to ensure steering feels lighter. febi has a long heritage of experience and manufacturing competence within the automotive aftermarket, since 1844 and provides only high quality parts to maximise safe driving.

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“All febi parts are of OE matching quality, with the confidence of first time fit, every time. With over 15,000 applications, febi Truck offers an extensive range for the “big 7” European commercial vehicle manufacturers.”

febi Truck’s quality steering range includes: • Almost 400 drag links • Over 100 tie/track rods • Over 100 tie rod ends • Almost 50 different stabiliser links • Over 100 king pins All febi parts are of OE matching quality, with the confidence of first time fit, every time. With over 15,000 applications, febi Truck offers an extensive range for the “big 7” European commercial vehicle manufacturers. From steering, engine, braking, chassis and wheel mounting technology to vehicle electrics and pneumatics, febi Truck covers all areas of vehicle component replacement.

When you want to be sure of quality and fitment, choose febi.

The febi product brand is part of the bilstein group, which also incorporates the strong SWAG and Blue Print brands.

For more information: www.trucks.febi-parts.com or www.bilsteingroup.com

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HOW TO FIT A PULL TYPE TRUCK CLUTCH TRUST THE SPECIALIST WHEN IT COMES TO CV CLUTCH

VALEO SHOWS BEST PRACTICE TO FIT A PULL TYPE CLUTCH THROUGH ITS NEW YOUTUBE VIDEO AND HERE ARE THE STEPS DESCRIBED IN IT. 7. Clamp for release bearing; 8. Flat wrench for pilot bearing release tool; 9. Pilot bearing disengagement tool.

Valeo’s replacement clutch kit is composed of three components: pressure plate cover assembly, driven plate and mechanical release bearing and always includes a fitting instruction.

Step 2: Dismounting defective clutch

Step 1

1 - Tooling and kit contents check; 2 - Dismounting defective clutch; 3 - Fitting pressure plate cover assembly and driven plate; 4 - Bearing replacement; 5 - Fitting of the gearbox housing; 6 - Reinitialisation and road test.

Step 1: Tooling and kit contents checklist The generic tools you will need to operate successful fitting operation safely are: 1. Lever arm; 2. Torque wrench; 3. Release wrench for cover assembly; 4. Driven plate centring tool; 5. Fitting pins; 6. Crankshaft rotator (Vehicle manufacturer specific);

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“Enter the clamp through the gearbox trap and clip it to the hooking ring. Snapoff the release bearing with the lever arm.”

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Step 2

Before moving the gearbox out, you will have to perform some operations to disengage the release bearing and the fork from the clutch. Open the gearbox housing trap door.

Please note, depending on the vehicle brand, opening of gearbox may vary.

First use the crankshaft rotator from the vehicle manufacturer to rotate the flywheel.

This operation will make the hooking ring on the pressure plate cover assembly easily accessible. Disengage the release bearing

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and fork to enable gearbox detachment from the engine. Enter the clamp through the gearbox trap and clip it to the hooking ring. Snap-off the release bearing with the lever arm. You can now unscrew the gearbox screws and move out the gearbox to access the clutch parts.

Fix the centring tool, which prevents the driven plate from falling down. Unscrew the pressure plate cover assembly. First unscrew two screws of the pressure plate cover assembly and install two fitting pins. Then unscrew the pressure plate cover assembly according to the correct order. Disassemble the driven plate. Remove the centring tool.

Use a disengagement tool to take out the pilot bearing.

For safety of driving, Valeo recommends changing the pilot bearing each time you change your clutch kit. Check that there is no grease around the flywheel. Clean the flywheel using solvent or brake cleaner and 150 grit sandpaper.

Step 3: Fitting pressure plate cover assembly and driven plate

Step 3

Install the new pilot bearing first. Once again, fix the centring tool to prevent the driven plate from falling. Before fitting the driven plate, make sure that its splines do not seize and fit to the gearbox axis.

Make sure you DO NOT put grease on the driven plate; it may alter the friction coefficient! Install the driven plate and the pressure plate cover assembly. Firstly screw lightly the pressure plate cover assembly.

Remove the two fitting pins and the two screws. You may check the tightening torque according to manufacturer recommendations.

Valeo strongly recommends NOT USING an impact driver. It may damage the thread!

Tighten the screws of the pressure plate cover assembly in the correct order by using your torque wrench. When finished, remove the four shipping clips from the pressure plate cover assembly. Finally,remove the centring tool.

its screws. Snap-on the release bearing (accessible through the slave cylinder in some applications). Push twice to ensure it is beated correctly. Check carefully that hooking ring needles are correctly centred at equal distance with the centre part of the ring. They should not touch upwards or downwards.

Ensure to close the gearbox to prevent the gearbox housing from dust contamination.

Step 4: Bearing replacement Step 6: Reinitialisation & road test

Step 4 Step 6

Check the guide tube and primary shaft.

Before replacing your release bearing, you have to disassemble the fork, which may need to be changed depending on the vehicle mileage or fork’s seizing. Now you can access the release bearing and remove it safely. Remove the old release bearing.

Check that there are no grease traces on the guide tube and clean if necessary. If the fork axle is seized up, add some grease to the fork seating axle.

Fit the new release bearing and tighten the fork with the torque wrench. Check that the fork axle is moving smoothly and its condition is good. Change the fork if needed.

Step 5: Fitting of the gearbox housing

Step 5

Reinitialisation of gearbox with diagnostic tool: After fitment of the clutch for a vehicle with Automatic Transmission, it is mandatory to reset the system with the right reinitialisation diagnostic tool. After reinitialisation, you should road test the vehicle.

See for yourself!

Watch the video by here: www.youtube. com/watch?v=sAv5kSW2P3k

Valeo claims to supply one out of every two OE truck clutches and provides clutches for Euro 6 applications for manual and automatic gearboxes. Be Ready with the Valeo Euro 6 range: DAF XF, Iveco Eurocargo, Stralis, and Trakker; MAN TGS, TGX; Mercedes-Benz Actros, Antos, Arocs and Atego; Renault Trucks D ; Scania G, P, R; and, Volvo Trucks FE and FL.

Close the gearbox housing and tighten

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S-ABA INSTALLATION MADE EASY Through its innovative selfsetting flexible design, the Haldex S-ABA Automatic Brake Adjuster offers two benefits which revolutionise brake adjuster fitting: a free selection of control arm position and error-free installation.

he Haldex S-ABA functions correctly whatever the position of the control arm.

Previously a brake adjuster could only function properly with the control arm in one predesignated position.

Self-setting means no more time-consuming adjustments during installation to fix the control arm to achieve the correct predetermined running clearance.

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Key benefits: • Quick and easy installation • Establishes own reference point; no need to preset control arm

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• Durable and with predictable performance • Robust design applicable for all drum brake installations.

What sets us apart: • Global market leader with over 75 Million Brake adjuster sold since the introduction in the late 60´s • Broad product range covering all vehicle applications • Reliable ring seal prevents contamination from moisture, dirt and road salt • A built-in visual indicator verifies proper installation at a glance, eliminating the templates needed to check other ABA installations • Reduces Maintenance Costs and Extends Service Intervals • Unique, fully-sealed control arm eliminates the exposed linkage and rubber boots of linkage style adjusters, improving durability and reliability • Simplifies adjustment during installation and brake lining replacement with an easily accessible adjustment hex - requiring no locking pawls to remove or disengage

“The success of Haldex, the world’s leading supplier of automatic brake adjusters for heavy vehicles, is based on high product quality which maximises safety for road users.“

Inferior copies are potential killers Marking the difference Using a non-Haldex part in a Haldex brake adjuster not only erodes safety and performance, it also invalidates any Haldex warranty. How can you be sure you are buying Haldex original parts?

• Haldex parts are recognisable by their distinctive packaging • Look for the name you can trust. Almost every original component is marked with the Haldex name • Haldex supplies spare parts to all major heavy vehicle producers and leading axle manufacturers. These companies repackage Haldex branded parts in their own spare part kits, for continued quality assurance A dangerous choice A vehicle is only as safe as its brake components. Choose poor quality brake parts which fail or disintegrate on the road and the results can be devastating - for the vehicle driver, other road users and pedestrians. They want to alert you to the dangers of buying inferior copies of Haldex parts. Cheap copies are accidents waiting to happen. The success

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of Haldex, the world’s leading supplier of automatic brake adjusters for heavy vehicles, is based on high product quality which maximises safety for road users. Their patent protection has expired. Opportunists are trying to cash in on the reputation of Haldex by making poor quality copies of its parts. Would you knowingly buy parts which put lives at risk? For safety, it is vital to distinguish between original parts and potential killer copies.

Why take the risk?

Would you choose quality Haldex original parts that maximise safety or low-performance, high-risk copies? Why put lives in danger? Why jeopardise your business? Always fit Haldex original brake parts. Look for the Haldex name on products - it assures quality and vehicle safety.

False economy Buying copies of Haldex parts is a false economy. Poor-quality parts mean more frequent servicing and higher maintenance costs. Cheap copies put your business at risk.

Defective parts mean more breakdowns. Your service to customers suffers. Customers turn to more reliable competitors who use high quality components.

High quality means built-in safety.

Haldex quality is: • Comprehensive: Continual investment in R&D, training and manufacturing plants ensures quality in all stages of production • Long-established: in 1991 Haldex became one of the first ISO 9001 certified Swedish companies • Exhaustively tested: After 30 years of brake adjuster testing at the Haldex brake simulation lab, they are well qualified to judge quality. In the test chamber, brake adjusters face simulated braking forces and driving conditions for up to six months equivalent to many years on the road.

• Guaranteed: Life-saving reliability means longer product guarantees than rivals’ • Profitable: Parts offer higher safety and lower maintenance costs For more information: www.haldex.com or visit Haldex’s YouTube channel where you will find installation videos and other useful tips

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TRUCK-LITE MODEL 900

A REAR LAMP WITH INNOVATION AND STYLE he model 900 is one of the newest additions to the Truck-Lite range of full LED rear lamps.

“The model 900 is the most innovative lamp currently on the market, combining integrated intelligence with boundary pushing aesthetics. This flagship product is not only iconic on the road but also industry leading in the level of flexibility it allows the user,” said Mark Cording, Marketing Manager at Truck-Lite.

With its three dimensional shape, homogenous light pattern and patented progressive direction indicator, the model 900 is a revolutionary design with unique visual features that improve visibility and safety on the road.

Coupled with great visual appeal, the lamp has fully integrated intelligence capabilities that eliminate the need for an additional black box monitoring unit and means this lamp not only looks good but is practical and widely compatible. Furthermore, the model 900 can aid parking and reversing with proximity sensing capabilities in the stalk*, improving safety and driver accuracy.

The model 900 is currently available for trailers with or without the stalk and a further version for truck is now also available. Truck-Lite offer a five-year

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warranty as standard, or alternatively the lamp can be purchased as part of a ‘Lifetime Warranty’ trailer kit providing greater peace of mind and lowering maintenance costs for the fleet.

The model 900 is available from all UK stockists and will appeal to anyone looking for a lamp that combines innovation and safety with a modern signature look.

Truck-Lite have already been supplying fleets in the UK and across Europe.

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For more information: www.truck-lite.eu.com/news/category/5 *optional

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BORG & BECK ADDS CV BRAKE PADS

COMPREHENSIVE COVERAGE ACROSS THE RANGE!

org & Beck, the renowned global supplier of premium quality replacement components for both the automotive and commercial vehicle (CV) sectors, has increased its CV product offering by introducing Brake Pads to its extensive Braking programme.

The range consists of over 35 references providing comprehensive coverage of the UK CV parc. As would be expected with its original equipment (OE) pedigree and impressive 100year plus history of engineering excellence, Borg & Beck CV Brake Pads are manufactured to incorporate a fine semi metallic organic formulation into the friction element, which delivers excellent performance and durability characteristics that ably cater for the considerable safety demands of the modern truck.

However, in keeping with the company’s safetyfirst policies, the range also includes an eightstrong HD contingent for those high demand applications, which uses a low metallic organic formulation, to provide a compound suitable for vehicles such as buses and coaches, that have to deal with multiple starts and stops during their normal operation. This material offers greater wear resistance and remains effective at high temperatures without fade, making it the ideal solution for a host of demanding applications.

These two formulations have been developed in association with the company’s experienced CV product team and its ISO TS16949 accredited manufacturing partners, a combination that allows Borg & Beck to ensure it delivers a premium quality component that conforms to the stringent specifications necessary to provide the very best in terms of performance and durability. In addition, all Borg & Beck Brake Pad sets are supplied as standard with the required fitting accessories, where necessary, for a complete and efficient installation.

Naturally, the entire offering is ECE R90 certified, but as a demonstration of the company’s attention to detail and customer focused attitude, the pads

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also include bedding-in strips to ensure that drivers can rely on their excellent performance from the moment they are installed.

This welcome addition alongside its existing 125 strong Brake Drum and 135 Brake Disc offerings, is further complemented with a full range of Wear Leads. Borg & Beck now enables workshops to source all their Braking requirements from a single source, which provides a greater level of peace of mind. The full range can be viewed online at https://webcat.borgandbeck.com/Home, the company’s parts catalogue contains competitor and OE cross reference information to ensure the correct replacement is located with minimum fuss.

Marry these benefits with a powerful brand name, robust product packaging and a highly competitive

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24-month, unlimited mileage warranty against manufacturing defects and the complete Borg & Beck CV Braking programme makes a very compelling option for the independent sector.

As testament to the quality of the Borg & Beck CV Braking programme, Cole Trucksport, a division 2 British Truck racing team, have fitted Borg & Beck Pads and Discs to their truck, which have stood up to the endurance of a full weekend of racing. After the first race of the season Simon Cole, AKA Big Rev from Cole Trucksport had this to say: “What an awesome Brake set-up! We haven’t changed a pad or disc all weekend. We actually lost water cooling on the Discs during testing due to a water injector failing, however they were still perfectly fine, even after getting extremely hot and still went onto complete the weekend.

“We are also extremely pleased with the Borg & Beck Brake Pads as until now we have never completed a weekend on one set of pads and without deglazing a single set.”

To read the full testimonial and follow the team, visit: www.facebook.com/coletrucksport For more information: 01869 248484 or www.borgandbeck.com

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DETAILED GUIDE TO GDPR LEGISLATION AND CAMERA RECORDING SYSTEMS AVAILABLE FROM BRIGADE rigade Electronics has created a pack that customers can download from their website to provide a detailed guide to new data regulations with regards to cameras and recording equipment.

Emily Hardy, Brigade’s Marketing Manager said: “Many customers remain unsure of the new data protection legislation with some specifying vehicle cameras that do not identify members of the public for fear this will breach people’s privacy. This has not been helped by a small handful of vehicle CCTV manufacturers falsely claiming ‘their product is GDPR compliant’. Added to this information in the media has been general at best. We have created a more comprehensive guide with scenarios to help our customers. Our message is simple. Operators should not fear the use of camera systems and digital recording but should look at what policies they have in place and we can help guide them.”

The upcoming General Data Protection Regulations (GDPR), which comes into force in May 2018, stipulates how data should be protected and how people’s privacy should be respected. Some EU countries are already following these guidelines so effectively the UK is catching up. In a nutshell, GDPR is about the process of how you keep data secure, who has access to that data, how long you keep it for and how you are going to tell people that you are using their personal data and for what reason.

A tangible product therefore cannot be GDPR compliant because it is about handling of data, although customers should look for features and benefits that can help the operator to keep data secure. For instance, Brigade’s MDR-50X series digital recorder has new admin isolation rights which allow operators to control access to data so restricted users can only view footage and are unable to

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Operators should not fear the use of camera systems and digital recording but should look at what policies they have in place and Brigade can help guide them

“Our GDPR pack looks at the use of stickers to inform people that the vehicle is recording, where they should be placed and the sorts of things they should say. In the pack is a new sticker which we can post to customers.”

download or edit. This allows operators greater control over data and helps them to comply with regulations. Another thing to

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consider when purchasing such systems is whether the footage is protected. Brigade’s MDR-50X series digital recorder has a nonvisible watermark so that tampered files will not play. It also features password protected software and a lockable hard-drive to further prevent unauthorised access to data.

Emily continues: “Our GDPR pack looks at the use of stickers to inform people that the vehicle is recording, where they should be placed and the sorts of things they should say.

In the pack is a new sticker which we can post to customers. We also look at; how operators can gain staff approval through training, the type of policies that should be in place, the length of time data may be stored, examples of when privacy should be respected and whether audio in the cab is justifiable.”

The pack does not contain legal documents, it is merely a guide. Legal advice should be sought if they wish to rely on this information.

To download your GDPR guide to cameras and recording visit: www.brigadeelectronics.com/gdpr-vehicle-recording

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STEER CLEAR OF NON-COMPLIANCE xposed to the elements, steering system pivot points and ball joints are prime candidates for wear - faults here can cause failure of a DVSA annual inspection or Fleet Compliance Check.

Fortunately, careful inspection of this critical safety system’s components during routine maintenance can avert non-compliance. Wayne McCluskey, Technical Training Manager at ZF Services UK Ltd (supplier of Lemförder steering and chassis components to the independent aftermarket), recommends the following checks.

Prior to inspection, clean all joints and mating parts of the steering linkage with dry rags (no solvents), being careful not to damage sealing boots. Unless otherwise stated, carry out the following tests with the weight of the vehicle on the wheels.

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Drag link and tie rod • Inspect the tie rod tube for damage or deformation and replace if evident • While an assistant turns the steering wheel from lock to lock, feel for movement between the threaded part of the tie rod and its tube or adjustment sleeve. Any play here suggests the thread is damaged, so replace one or both of the components • Check the condition of the clamp and pinch bolt - the bolt must be straight and both bolt head and nut must bear tightly on the clamp.

Corrosion pitting on the bolt, nut or clamp should be no deeper than 0.5mm. If any of these criteria are not met, replace the affected component

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Fig 1

Fig 2

The earlier Lemförder ball joint design had a flat sealing cap

The current Lemförder ball joint design has a domed sealing cap

Fig 3

Lemförder testing tool LMI 27351.01 is used to assess wear on the older ball joint design

Fig 4

A dial gauge is used to assess wear on the current ball joint design

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Ball joint • Corrosion pitting on the housing, shaft and end cap of the ball joint should not exceed 1.0mm in depth. Pay particular attention to the crimped edges and the end cap walls • Visually check sealing boots for obvious holes or cracking, then squeeze each boot by hand and check for grease escaping under the pressure. A minor escape at the boot opening is permissible but seepage from any holes or cracks means the complete joint must be replaced, as water or other contaminants may have entered it • Check that clamping and retaining rings are present, undamaged and correctly pressing the sealing boot against the housing and/ or stud • Measure the axial play of the ball joint. Two types of Lemförder ball joint are typically found in the vehicle parc; an older version with a flat sealing cap (Figure 1) and the current version with a domed sealing cap (Figure 2). A spring provides preload in the old type, whereas the later type is preloaded by a profiled rubber O-ring. To measure wear in the earlier design of ball joint, use Lemförder testing tool LMI 27351.01, following the directions supplied with it (Figure 3). The current design of Lemförder ball joint cannot be accurately tested with this tool; instead, use a dial gauge mounted on a stand with a magnetic base to measure the axial clearance of the ball joint King pin • Raise the front of the vehicle to unload the steering axle, then check for excessive axial play between the steering knuckle and the body of the front axle (Figure 5)

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• Check for stiffness in the steering return or failure to return perfectly to the straight-ahead position • If either condition is evident, replace the king pin and its bearing components.

but is also a useful additional income stream for the workshop. Lemförder is a premium brand of ZF Aftermarket, providing OEquality steering and chassis components renowned for their safety and durability.

Fig 5

Incorporating this type of pre-test inspection into the routine maintenance schedule not only provides reassurance for the vehicle operator,

King pin axial play is checked between the steering knuckle and the front axle body

For more information: www.ZF.com/aftermarket

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Lemförder is a premium brand of ZF Aftermarket, providing OE-quality steering and chassis components renowned for their safety and durability

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”

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