Commercial Vehicle Workshop May 2024

COMMERCIAL VEHICLE WORKSHOP

9 Electric Avenue: Stuart Cottrell from Tevva exhorts the Government to take action.

Data is key to workshop growth, says Garage Hive.

RTX preview: CVW gives you the full picture on what’s happening at Stoneleigh.

TYRES & WHEELS

AES helps truck and bus dealership halve customer downtime.

26 It’s all about talking the torque if you want safety and performance, says Norbar.

29 BD5 is here, the new retread tyre from Bandvulc, that, it claims, has outstanding sustainability credentials.

30 Continental offers some tyre advice and introduces its app for better rubber management.

AIRCON & REFRIGERATION

33 Aircon is a delicate subject. Nissens looks at why components need careful handling.

36 Auto Air Gloucester has a few cool tips on keeping everything chilled.

38 Refrigerated transport: CoolKit says keeping the right temperature is key.

AXLES & SUSPENSION

40 Cool running – the axle that cools as it cruises. BPW explains.

VIEWPOINT

Editors

JOHNNY DOBBYN

JOHN LEVICK

workshop@cvwmagazine.co.uk

Editorial Assistant

FREYA COLEMAN

Group Editor

KIERAN NEE

Digital Manager

KELLY NEWSTEAD

Digital Assistant

LYDIA PROCTER

Advertising Sales Manager

MATTHEW BOASE

Group Manager

ROBERT GILHAM

Graphic Designer

GEMMA WATSON

Group Production Manager

CAROL PADGETT

Subscriptions

Commercial Vehicle Workshop is a business magazine for companies and individuals involved in all aspects of commercial vehicle servicing.

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Copyright © 2024

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JUST THE TICKET

The exhibition season is upon us. The Commercial Vehicle Show is happening as we put pen to paper and reports from the CVW team on the ground indicate that it is busy, which is good news for exhibitors and organisers alike.

If going to the NEC isn’t your thing, then RTX’s appearance at Stoneleigh might appeal. It’s big, it’s outdoors (and indoors), has the feel of a county show – substitute trucks for livestock – and, weather permitting, can offer a sunny and absorbing day out. There’s plenty to see and do, much chat to be had, parts and tools to be examined and purchased, and above all, it’s an opportunity to appreciate just what an interesting place the CV industry has become.

There’s an A to Z of exhibitors that really reflects the sheer diversity of products and services that constitute the commercial vehicle arena. In other words, there’s something for everyone whether apprentice or seasoned technician or mechanic. Whether you want to know more about DVS, unlock the ingredients behind HVO, bone up on TPMS or simply have an ALE, then RTX is the place to be.

Of course, CVW will be there – stand GR38 – so feel free to visit, pick up a copy of the latest issue and chat to our friendly staffers. We are always keen to hear what readers think, what you’d like to see featured in the pages of the magazine, what improvements we might make. We’ll also be out and about, touring the exhibitor stands to find out what’s new, what’s interesting and what’ll make a workshop’s life easier.

Don’t forget to have a read of our preview, pages 18 to 23, which hopefully will give you a flavour of what’s in store at the beginning of June.

And it’s worth bearing in mind that the exhibitors really appreciate your attendance. For them it is a significant investment but the payback can be even more significant, not just in monetary terms, but in starting new relationships and cementing existing ones. E-commerce, websites and doing business digitally might be the way things are done these days, but nothing beats face to face meetings, discussions and a bit of banter.

Many commentators have, over the years, harped on about the decline of trade shows, and when Covid was at its height, you could be forgiven for thinking that their demise was sealed and that nobody would ever venture forth again, whether to exhibit or to visit. Happily, the naysayers have been proved wrong; people actually enjoy going to these industry events, especially after the bunker-like existence we all endured during the pandemic. It’s good to get out, good to meet new and old, good to talk!

We’ll see you there.

Enjoy the read!

Overseas demand drives CV manufacturing

LCV values bounced back in January, reaching their highest point since September of last year and reversing a run of three consecutive monthly falls, according to resellers BCA.

Performance against guide values lifted by one percentage point to 99.3% over the month and sold volumes increased significantly as momentum continued from January. The slowly improving economic backdrop continues to support the rising confidence felt in the used LCV sector and there was further encouraging news in the new van sector, as February 2024 recorded the 14th consecutive month of growth, albeit at a gentler rate (2.2%) than has been seen in recent months.

UK commercial vehicle (CV) production almost doubled in February, with 12,927 vans, trucks, taxis, buses and coaches leaving factory lines, according to figures released by the SMMT. The 98.4% uplift in volume was the best February performance since 2008.

DVS test pass buoys Brigade LCV

“...there’s a good balance between supply and demand...”

Stuart Pearson, BCA COO UK commented “The confidence we saw emerging at the start of 2024 has continued into February with excellent buyer engagement, firm prices and an improved churn of stock. Our daily online light commercial vehicle sales allow us to track sentiment very closely and ensure our sellers and buyers are aligned on market valuations.”

“Whilst only a few months into the new year, the feeling of seasonal trends previously talked about is getting further established and there’s a good balance between supply and demand, which is welcome news for both sellers and buyers alike.”

The production boost was driven by significant demand for British-built vehicles in overseas markets. Exports increased by 188.0% to 10,011 units, representing 77.4% of all CVs made in the month, with more than nine in 10 (97.6%) destined for the EU. Conversely, output for the domestic market

fell for the second month in a row, down -4.0% to 2,916 units, although this represented a decline of just 123 vehicles.

“CV manufacturing has kickstarted the year with two months of impressive growth as robust overseas demand for British-built vans continues. The challenge now is to maintain this success amidst fierce global competition, accelerating production of zero emission vehicles to enable the fast paced delivery of these critical models. Strong performing economies at home and abroad will be key to this ambition,” commented Mike Hawes, SMMT chief executive.

Brigade Electronics has had products independently tested to meet the requirements of the Direct Vision Standard (DVS) Phase Two.

Changes to the DVS from October 2024 include an increased star rating from one star to three stars. If operators fall short of the minimum star rating, they must fit extra equipment to minimise blind spots. Previously the scheme for fitting extra safety equipment was called the safe permit but in October 2024 it will become the Progressive Safe system (PSS).

As well as more stringent requirements for operators, Transport for London (TfL) has also increased the responsibility for original equipment manufacturer (OEMS) and component manufacturers, such as Brigade Electronics, to demonstrate the

quality of devices for indirect vision. One of these requirements includes conducting a test as laid out in the PSS technical specifications for both the side detection systems or blind spot information systems (BSIS) and front detection or moving off information systems (MOIS).

Brigade presented products for testing to Loughborough University including Sidescan Predict for rigid vehicles and Radar Predict for both rigid vehicles and articulated vehicles, also enabling coverage of the trailer. In addition, Brigade's Front Radar was tested for the MOIS solution.

Based on the vehicle presented, Loughborough University provided a test report to confirm that Sidescan Predict and Radar Predict had passed the requirements to meet the PSS specifications for BSIS and Front Radar for MOIS.

EATS on the menu for PCS

To support its on-road customers Eminox, the designer and manufacturer of exhaust aftertreatment systems (EATS), has contracted Paul Clark Services (PCS) as its field support services provider. The contract will support Eminox's customers to ensure fleets can operate to the latest emissions standards.

The agreement will provide Eminox's customers with fast response and support for on-going maintenance plans to ensure retrofitted exhausts fitted to their vehicles are optimised and maintain Euro VI compliance.

Online improvements

Diesel Technic’s partner portal, its information and e-commerce procurement platform, has been enhanced and updated with extended functionality that significantly improves its use to make everyday work easier, it says.

Cool move for CoolKit

CoolKit, the specialist in temperaturecontrolled vans, has been recognised by Ford Motor Company as one of its preferred Ford Pro Convertors, reflecting the company’s commitment to exceptional quality in the design and build of refrigerated conversions and body building for light commercial vehicles (LCVs).

The Ford Pro Convertor agreement is entered into with convertors that are acknowledged by Ford to be delivering the highest quality products and supplying converted vehicles that are expected to improve customer

Jamie Tolson, operations director, Paul Clark Services, said: “We have over 120 trained subcontractor PCV engineers across the UK, all up to speed with our strict health and safety and technical training. For over 25 years, PCS has established and proved its high-quality support for the road transport industry. Working with bus and coach operators nationwide and helping the NHS shows we understand the challenges the industry faces. Our services cover everything from training to repairs, maintenance, and servicing for buses and coaches. We look forward to a new partnership.”

LCV sales motoring in Q1

According to the SMMT more than 50,000 new light commercial vehicles (LCVs) hit the road in a bumper March for fleet renewal as more businesses upgraded to the very latest models than in any other month during the past three years.

52,916 new vans, 4x4s and pickups were registered, up 11.1%. As a result, the van sector in 2024 delivered its best first quarter for three years, with volumes now just -7.7% below Q1 2019.

Users will now benefit from optimised product search which can be easily customised to respective requirements, increasing efficiency, for example when searching for specific vehicle makes and models. It has also been optimised for use on smartphones and tablets. This gives field technicians the opportunity to work easily on site at customer’s premises and retrieve the required information directly.

Mark Todd, general manager, Diesel Technic UK, said: “Online procurement plays a crucial role in maintaining and optimising business processes and has become indispensable today. This applies equally to the Diesel Technic partner portal.”

satisfaction and productivity.

Commenting on the certification, Daniel Miller, CoolKit’s managing director, said: “Being designated as a Ford Pro Convertor is a great opportunity to build further on our relationship with Ford. It’s also a highly sought-after seal of approval endorsing the quality of our engineering.”

Registrations were driven by popular demand for the largest models, up 16.1% to represent more than two thirds (67.3%) of the market. The biggest percentage increase in uptake was of the smallest vans, up 44.8% to 986 units, while demand for medium-sized vans fell slightly by3.6% to 8,939 units. Pick-up volumes increased to 5,767, up 0.1% compared with a particularly strong month last year, while demand for the latest 4x4s rose by 29.1% to 1,632 units.

More fleets went green last month than in any other new numberplate month to date, with new battery electric vans (BEVs) continuing to rise, up 14.7% to 2,906 units. It means the very greenest vans represented 5.5% of the whole LCV market, but up only slightly from 5.3% in March last year.

Mike Hawes, SMMT chief executive, said: “A strong new plate month with the greatest number of zero emission vans joining UK roads is a bellwether of the sector’s progress, cutting emissions while keeping British businesses on the move. Industry is ready to deliver further, but with green uptake still below mandated levels, swift action is needed to give new van buyers the confidence to go electric.”

FORS for good Double top for Philips

Philips Xperion 6000 workshop lights have, for the second consecutive

Auto Express inspection lamp mega test, come out as the pick of the bunch – taking the top two places in the UK’s most respected testing forum for automotive products.

Topping the test, again with a superb five-star rating, was the Philips Xperion 6000 Slim, while its larger sibling, the range-topping Xperion 6000 UV Pillar, also secured a coveted Recommended Buy award.

According to Auto Express, the Best Buy, Philips Xperion 6000 Slim “is a winning package.”

FORS, the fleet operator recognition scheme, has released its annual review 2023. The analysis represents a collation of all key metrics from the scheme, including operator figures, audit statistics and total attendees on FORS professional training courses.

The year ended with a total of 4,600 FORS accredited operators across the UK, representing 101,000 vehicles. A further 400 operators are now registered with FORS. There were 4,617 bronze audits, while the scheme received and reviewed 2,821 silver and gold applications.

FORS professional training, arguably the jewel-in-the-crown of the FORS offering, returned impressive figures in 2023. Over 17,000 drivers attended safe urban driving, safe driving or van mmart courses. A total of 279 manager courses were delivered, with an average of 18 individuals on each course (over 5,000 individuals). This resulted in 293 managers attaining FORS

practitioner or advanced FORS practitioner status. Over 118,000 e-learning modules were completed.

“We’re very pleased and encouraged with progress in 2023,” said FORS concession director, Geraint Davies. “We’re growing the scheme, and we’re streamlining the accredited operator experience, which I believe is to the benefit of everyone. We aim to improve further in 2024, to win the support and confidence of more fleet operators and to ensure the scheme is relevant to all.”

FIVE STEPS TO EVV’EN

Stuart Cottrell, Tevva’s head of energy services and Government partnerships, says there are five actions the Government must take on electric trucks.

The lack of any EV incentives in the spring budget was largely seen as a missed opportunity. In fact, several vehicle makers reacted furiously, with one UK boss claiming the Government was 'sleepwalking into an electric vehicle crisis'.

While the calls for incentives and other stimulation measures for the EV passenger car market become louder, the <26 tonne elephant in the room continues to go largely ignored. The Government has laid out ambitious targets of no new ICE HGV under 26t from 2035, yet tangible actions to facilitate progression towards this goal simply do not exist.

At Tevva, we've been discussing five areas where the next Government can make a difference, and provide some much needed support to the electric truck market in the UK.

Plug-in truck grant

This needs to be more generous to have an impact on operators' decisionmaking. The current fixed grant (£16k for our 7.5t vehicle size) still leaves the operator with a large price increase over ICE. There are also too few grants available, with large trucks likely to spill over into the small truck grants this year, increasing the likelihood that they will run out. Countries on the continent have more generous schemes where the grant is calculated based on a percentage of the price difference between the zero emission vehicle and ICE.

ZERFT Extension

The Zero Emission Road Freight project was exclusively for vehicles at the larger end of the market (artics). While this is a good initiative to support a sector which is challenging to decarbonise, it does risk pushing this sector before it is ready, at the expense of a potential easier win with a bigger bang for the taxpayer buck by including smaller HGVs. The vehicle parc is split approximately 70/30 between rigids and ZERFT-qualifying artics (but we do acknowledge that artics generally carry out longer journeys).

Working Capital Loans

It's been a challenging time for all EV startups. Scaling businesses like ours struggle to manage the financial flows required to procure parts and services to build products, with the delayed revenue stream it incurs. Government could bridge that gap by providing working capital loans, allowing businesses to kick start this cycle rather than be stuck in the chickenand-egg impasse.

Grandfathering extension

The existing 7.5t GVW sector is being extended to accommodate the increased weight of alternatively-fuelled trucks. At Tevva, we wholeheartedly support this to protect the payload and thus the useability of this vehicle type. A driver who passed their car test prior to 1997 is allowed to drive vehicles up to 7.5t (known as grandfather rights). Many businesses use this allowance to employ drivers of 7.5t vehicles.

We believe the grandfather rights should be extended in-line with the GVW extension, allowing these drivers to continue to drive heavier vehicles on their existing car licences. To not do this would risk slowing the uptake of zero emission HGVs as companies would have to recruit new drivers who hold the required licence.

Fit-for-purpose infrastructure

Fast, reliable, and strategically positioned charging infrastructure, at both a depot and national level, will be a key enabler to the roll-out of zero emission HGVs. This will allow a wider range of use cases to be tackled beyond the middle-mile back-tobase operations that are the focus today. It will give operators the confidence that they can get the job done.

Government action in this area is too slow, with the consultation only happening

late last year (2023). It will be many years before there is a coherent network of chargers for HGV operators to be able to rely on. The Government needs to go further, faster on this.

Its hesitation to support and stimulate the transition to zero-emission HGVs is not just a missed opportunity, it's bordering on a dereliction of duty. The impact of climate change, coupled with the UK's potential to lead in the electric truck market, calls for bold and immediate action. The path forward is not through half-measures or delayed consultations but through a decisive, comprehensive strategy that addresses the urgent needs of the electric truck industry.

HIVE OF ACTIVITY

Insight driven by data has fueled growth at EAC Telford by transforming the way in which its workshop operates. CVW reports.

“... it was always a dream of mine to own a three or four garage business...”

EAC Telford, an established independent garage in Shropshire which opened the shutters to its brand-new commercial vehicle workshop for the first time in March, stands as a testament to the transformative power of management software.

At the heart of its journey towards expansion lies a garage management system which garage owner, Mark Kettle, says played a pivotal role in the success of his business. Having easy access to reliable business data, such as insightful management reports, can be transformative to the way in which a workshop operates. By streamlining workflows and tracking the complete customer journey, garages can make big business gains.

With the help of detailed garage management reports and streamlined workflows, EAC Telford experienced a surge in productivity. Demand for commercial contracts was on the rise,

prompting Mark to seize the opportunity to expand further into the commercial vehicle sector, culminating in the recent opening of a third site.

Effective decision making

The newly built workshop covers 7,500ft2 and is staffed by eight technicians and two front of house service advisors. Upstairs, a new spacious office area serves as the headquarters for EAC Telford. From here, Mark, along with his wife Jane and their general manager, oversee all operations with an impressive three-screen setup, positioned to overlook the office, enabling them to monitor and make decisions effectively.

It’s by observing this business data that Mark has successfully grown his business. Having quickly outgrown a second site, Mark invested more than £100,000 into the opening of his new flagship centre which caters to the needs of his growing list of commercial clients.

“It was always a dream of mine to own a three or four garage business,” says Mark. “I genuinely don’t think I’d have been able to push the boundaries and realise that dream without Garage Hive.”

Mark’s decision to first embrace Garage Hive in 2019 was met with initial scepticism. Having experienced promises of revolutionary software solutions in the past, Mark was understandably cautious. However, his reservations were quickly dispelled as Garage Hive proved to be more than just another system – it became an indispensable tool, driving efficiency and growth.

“There’s nothing else like it out there,” continues Mark. “We have a real-time

overview of everything. We track activity, analyse performance, and implement improvements. Only by monitoring and acting on this data have we managed to maximise efficiency, boost sales and improve customer retention.”

The success of EAC Telford's expansion is in part due to the adoption of Garage Hive. Mark’s certain that it enabled better management of the business, allowing him to focus on strategic growth initiatives.

“With reliable data, garage owners and workshop managers can analyse workflows, pinpoint where efficiencies can be made and implement them,” explains Ray Dilsons, managing director of Garage Hive.

An intuitive service schedule serves as a

central hub for all workshop activities, providing instant access to essential information such as bookings, workload, and staff availability. Designed to be efficient even under pressure, creating and managing job sheets is a straightforward process using the system.

Milestone

Checklists and vehicle health checks, mean technicians can perform inspections and provide updates as work progresses. Meanwhile, notifications ensure front-ofhouse staff are kept updated of pending checklists, promoting timely approval and action. Garages can customise items, descriptions, and categories, as well as import supplier part numbers, adding flexibility and convenience to inventory management.

The system also supports the creation of default labour lines and categories. It means job sheets are automatically populated with predefined data, particularly beneficial for fixed-priced servicing.

The opening of EAC Telford’s new commercial site marks a significant business milestone, showcasing Mark and Jane’s ambition, dedication, and keen eye for market opportunities within the automotive industry.

TRAFFICNEWS

FM hits the spot for LTS

The Birmingham area now has its second all-electric Volvo truck as LTS Global Solution has just taken delivery of one from the Hartshorne Group.

Working within a 50mile radius of the company’s 130,000ft2 site in Coleshill, Warwickshire, the Volvo FM electric truck was bought after a three-week trial.

“We are always looking at new ways to improve our carbon footprint,” said managing director Dave Hands. “Adding a Volvo FM electric truck to our fleet is simply the latest step.”

The company is in a partnership with Planet Mark, a carbon reduction and net zero specialist, to make annual carbon reductions of at least 2.5%, targeting 5%.

The Volvo truck is not only liveried with the Planet Mark logo but with the phrase “I’m electric”.

With an operational range of 280km, the truck boasts a six-

FIRST HYDROGEN

First Hydrogen has successfully completed hydrogen fuel cellpowered vehicle (FCEV) trials with gas distribution network Wales & West Utilities (WWU), accruing the vehicle's highest ever mileage.

battery energy storage capacity to enhance range, as well as three electric motors to provide instant power and energy savings. Using a 46A charger, the charge time for the vehicles is

between eight and 10 hours.

Also featured on the Volvo FM Electric is an I-shift gearbox, globetrotter cab, Volvo dynamic steering as well as front and rear air suspension. The vehicle is on

a full repair and maintenance contract with Hartshorne Group.

Want to know more about these models?

WWW.RDR.LINK/VBJ003

Hydrogen van excels at call outs

The first-of-its-kind van completed more than 1,200 miles over the four-week trial, travelling up to 117 miles per day on mostly urban roads and highways in some of South Wales' coldest conditions, demonstrating there was no decrease in vehicle performance or range when operating in colder temperatures.

The vehicle also revealed the fullpowercapabilityof the fuel cell module, with outputs higherthan 60kW in transient accelerations, showing a capability for demanding duties, such as carrying heavier payloads, towing and powering auxiliary equipment.

The trial also proved that hydrogen mobility is still possible for fleet operators without access to fixed hydrogen refuelling infrastructure, says First Hydrogen. The trials were supported by Protium Energy Solutions, which provided green hydrogen to fuel the vehicle and Hyppo Hydrogen Solutions, who supplied a re-deployable hydrogen refuelling unit.

The FCEV was shared by two drivers from WWU's network emergency and metering services team which is responsible for emergency metering work for more than

7.5m customers across Wales and the south west of England. Most of the vehicle's journeys were travelling to customer call outs, averaging five to six visits per day.

“Sharing the van between two drivers, neither of whom has driven a zero emission vehicle before, has given us insight into how different driving styles can affect performance,” said Steve Gill, executive director automotive, First Hydrogen.

For more information on First Hydrogen WWW.RDR.LINK/VBJ004

TRAFFICNEWS

Asda at the double

TIGER TRAILERS

The sharp-sighted among you might have already spotted the first of 167 double deck trailers that Asda has ordered from Tiger Trailers. Most of the order has already been delivered and is on the road and, with three vibrant livery variations and snappy slogans, they are distinctive.

The Cheshire-based manufacturer is delivering tri-axle box van moving deck double decks for Asda’s UK operation.

MERCEDES-BENZ

Mercedes-Benz Trucks has unveiled its new updated Actros L. The truck features a redesigned body known as ProCabin, which promises fuel savings of up to 3% as a result of improved aerodynamics.

In addition, the manufacturer claims further efficiency from its third generation 12.8-litre OM 471 engine, which has been given two new turbochargers and a revised exhaust gas after-treatment system.

Full cab paintwork, dark chrome badging and LED lighting makes for a stunning exterior while the interior is available in three styles –StreamSpace, BigSpace, or GigaSpace.

These trailers provide up to a 44-pallet carrying capacity, and incorporates a ¾ length moving deck for versatility, powered by Tiger’s own in-house, four-ram hydraulic system.

The company prides itself on manufacturing bespoke articulated trailers and rigid bodywork to meet its end users’ specific requirements. In this case the double deck trailers are designed to transport both cages and UK pallets.

147 trailers are intended for UK operation, with 20 more destined for the retailer’s Northern Ireland ferry-use operations.

A ferry trestle support is built into the neck area for Asda’s RoRo operations, air suspension and a roll stability programme enhance cargo integrity, and the controls for the moving deck are positioned to enable operation from both ground level and from store loading bays.

“Working with the Asda team has been a great experience,” says Darren Holland, Tiger Trailers’ sales director. “From the initial on-site meetings to view their operations to sharing the 3D model of their precise trailer at the factory, and finally presenting the trailer in our showroom.”

For more info on Tiger Trailers, WWW.RDR.LINK/VBJ005

White in trial to go green

HYDROGEN VEHICLE SYSTEMS

A scheme to test the practicality of hydrogen fuel cells for commercial fleets is to be run by Hydrogen Vehicle Systems (HVS), the UK's first hydrogen fuel cell truck OEM, and White Logistics.

The two companies have signed an agreement under which White Logistics will test hydrogen fuel cell HGVs on its 150-strong fleet, which includes more than 90 trucks.

Among the safety enhancements is the fitment of active brake assist 6.0, which can perform automated maximum full-stop braking at speeds of up to 60 km/h ahead of crossing, oncoming traffic, or other road users in the same lane. The company says the new safety systems exceed the required standards of the General Safety Regulation (GSR), which will be effective from July 2024.

The second-generation active sideguard assist monitors traffic on both the driver’s and front passenger sides and with its two-stage warning system it can alert drivers to potential dangers. The active warning zone

extends up to 30m behind and seven metres in front of the vehicle, operating at speeds of up to 30km/h.

A new front guard assist system helps prevent accidents with pedestrians or cyclists who may be directly in front of the truck when it moves off.

For more information on Mercedes-Benz WWW.RDR.LINK/VBJ006

The agreement means White Logistics can collaborate with HVS on all aspects of hydrogen electric vehicle technology, hydrogen infrastructure and refuelling equipment and share operational data that will ensure a successful trial introduction.

This would then put White Logistics in a favourable position to convert part of its fleet to these zero-emission HGVs once this trial is completed.

“White Logistics’ decarbonisation vision aligns perfectly with our own,” said John McLeister, chief commercial officer at HVS. “We are delighted to have the opportunity to work with Graeme and his team to integrate our hydrogen fuel cell HGVs into their vehicle fleet.”

For more info on HVS, WWW.RDR.LINK/VBJ007

L of a truck

IT’S SHOWTIME!

It’s only weeks away from Road Transport Expo 2024 (RTX). With more than 250 exhibitors and a three-day drop-in conference programme, there should be plenty to keep you busy during your visit. Here’s a quick A to Z of what’s what.

IMEXPART (IMEX) Stand G16

Visitors to the IMEX stand can see the brand's complete product portfolio across its truck, engine – and new –car and light commercial vehicle (LCV) parts product groups. IMEX will also be giving away a selection of branded merchandise including water bottles, pens and USB sticks containing essential company information for access to valuable resources to explore IMEX offerings further.

Martin Butterworth, managing director at IMEX says:”This year's RTX Show presents an exciting opportunity for us to connect with our valued partners and customers, show off our full product range, which includes our new car and LCV parts, plus attendees will be first to know about the latest news updates from the brand.”

A‘ALL ABOUT THE TRUCK’:

this has been the RTX motto since its launch in 2022 and still remains at the heart of everything the show has to offer.

BBODY BUILDING:

a strong line-up of leading body manufacturers will be at NAEC Stoneleigh, bringing along a dazzling display of specialist skip-loaders, tippers, hotboxes, utility bodies and anything else you might need for bulk haulage needs.

CCAMERAS AT THE READY:

check out the latest in vehicle-mounted safety systems.

DDAILY NEWS:

this year sees the launch of the RTX daily newspaper, which will bring you a roundup of event highlights, hot off the press each morning!

EELECTRIC DREAMS:

if you are looking to electrify your vehicles, then a wide range of experts will be on hand to get you started, from choosing the right vehicles, through to charging infrastructure and route optimisation.

FFREE TO ATTEND:

RTX is completely free of charge for all visitors, so register today for your ticket at roadtransportexpo.co.uk

BPW LIMITED Stand B19

BPW’s stand promises to be a hub of activity. On display will be its ECO Hub and to demonstrate how easy and simple the hub is to remove, its engineers will be delivering handson sessions. Also on show is the company’s tyre inflation system, AirSave, that continuously monitors and regulates tyre pressure while on the move, significantly enhancing road safety.

BPW’s telematics experts are also on hand to discuss all things telematics, including the electronic brake performance monitoring system (EBPMS). With the ability to monitor in-service braking performance and generate real-time data reports, EBPMS can be presented during safety inspections and could be used instead of a roller brake test.

GGETTING HERE:

NAEC Stoneleigh is close to major transport links. If driving, it is served by both the M6 and M40. It is also only five miles from Warwick Parkway and Coventry train stations and just over onehour travel time from London Euston.

HHIRED!

Contract hire, leasing and rental firms will be heading to RTX to share expertise on helping future-proof your fleets as the industry looks to transition towards a netzero ambition.

IINN ON THE GREEN:

new for 2024, the Inn on the Green will be a sociable two-storey pub, where you can meet up in a relaxed setting.

JJOURNALISTS:

the editorial team from your favourite industry magazine, Commercial Vehicle Workshop, will be in attendance at RTX, stand GR38 or you can find us at the Inn on the Green.

MAHA UK Stand G45

The garage equipment specialist is displaying its new C_RGA mobile column lifts, that are available in both 7.5t and 8.5t formats. The new lifts increase safety, offer smart connectivity and reliability in abundance, not to mention more lifts and less recharging thanks to its lithium-ion battery, says the company.

In addition, an array of DVSAapproved equipment – LMS axle play detectors, MLT 1000 and 3000 headlight alignment testers, MBT 4250 and 7250 brake testers – and MCD 2000 communication cabinet, all connected with the newly-compliant EUROSYSTEM V8 soft-ware, will be available for visitors to experience.

ISN GARAGE ASSIST Stand N15A

Another first-time exhibitor, ISN Garage Assist is bringing live demos to its stand with the Hofmann Megaplan megamount 352 tyre changer and Junior Truck wheel balancer in action.

Also on display are two recent additions to its commercial vehicle equipment range, the Balco i-Lign XL wheel aligner and the Luxus HML85 column lift.

KKNOW-HOW:

drop-in conference sessions will be taking place across all three days of the show. Topics ranging from truck safety and compliance through to fleet decarbonisation and operator innovation are on the agenda.

LLIVE DEMONSTRATIONS:

there’ll be plenty of live demonstrations taking place every day, such as welding technology, lifting expertise and autonomous vehicle coupling.

PREMIER PITS Stand B15

RTX regulars, Premier Pits, will be showcasing a range of products at the show and is telling visitors to come and experience firsthand the advantages of its prefabricated steel pits over traditional brick and concrete methods. According to the company they offer a secure, well-illuminated, and waterproof workspace for vehicle technicians, along with various health and safety features.

Also, discover BrakeMate, its elevated platform aimed at enhancing the safety of brake disc assembly replacements. As the UK distributor of BrakeMate, Premier Pits claims it significantly reduces manual lifting, as well as reducing service time and turning what was traditionally a two-person task into a streamlined process achievable by a single mechanic, while also slashing downtime by up to 50%. For insights on how Premier Pits can revolutionise your workspace, make sure to drop by.

MMATERIALS HANDLING AND LIFTING EQUIPMENT

is well covered, from forklifts and truckmounted cranes, through to moving floor technology and storage bins.

NNETWORKING:

there is plenty of seating and space around the show for you to relax with colleagues in the British sunshine, have those allimportant business meetings or make new industry connections over a beer or coffee.

OOPENING TIMES:

this year’s event will be open from 9am to 5pm on Tuesday 4 and Thursday 5 June, and 9am-3pm on Thursday 6 June.

PPLAN YOUR DAY:

use the dedicated app and free printed show guide to help navigate the vast site. A top tip is to also make use of the handy online product locator tool before the show to help you pinpoint your ‘must-visit’ stands.

KNORR-BREMSE SFCV Stand N8A

The trailer OE team will be presenting the latest generation trailer EBS system, iTEBS X, which will be released to UK trailer manufacturers during 2024. The electronic braking system combines the control unit, sensors and pneumatic braking control in a single, compact assembly. ABS functions and load-dependent braking are both managed electronically within the module. The new iTEBS X will be on display along with all new available peripheral components including the latest generation iTPMS, iReverse systems and diagnostics.

The aftermarket (TruckServices) team will present information on existing and new product ranges via the interactive TruckServices app, and can advise on technical and training requirements for the Knorr-Bremse commercial vehicle product range. In focus will be trailer refurbishing requirements, something which has become popular in the UK over the last few years. Knorr-Bremse offers trailer EBS retrofit kits to replace any existing ABS/EBS system, bringing the trailer up to date with the highly reliable TEBS G2.2 system.

S CATTERALL Stand GR45

S Catterall, the workshop equipment fit out specialist, is exhibiting its gas detection system and key pieces of commercial vehicle workshop equipment such as its reel frame stands as well as exhaust and weld fume extraction, oil and fluid monitoring, pit waste collection units and compressors.

And the company is inviting visitors to its stand to take advantage of its ‘special show prices’, so you may pick up a bargain!

QQUALITY CATERING:

eat, drink and be merry with a great selection of catering outlets, a farm shop and bars located around the venue, as well as the usual top-notch hospitality you can expect to find on exhibitor stands.

RRIDE N DRIVE:

take your pick from the manufacturers’ latest truck ranges, including diesel, electric and those operating on renewable fuels such as biogas and HVO. If you have a valid HGV licence, you can drive them on the bespoke course around local roads, or around the on-site course.

SSTUDENTS

are welcomed at RTX to help inspire the next generation of road transport industry professionals.

CONTINENTAL Stand B32

Continental Tyres is once again reinforcing its ‘Your trusted fleet partner’ message at this year’s Road Transport Expo. Returning for a third consecutive show, the multi-solutions tyre brand will showcase its comprehensive range of products, services and technologies to Stoneleigh’s attendees. Continental’s signature fleet management offering, Conti360° Solutions, will also feature alongside a varied selection of haulage-focused Continental, Bandvulc and ContiRe tyres.

Visitors will have the chance to speak with Continental’s fleet experts, who will be on hand to help identify opportunities to increase efficiency and reduce overall driving costs. For fleet operators, this could be how lower rolling resistance characteristics can contribute to reduced fleet costs, and how retread tyres can contribute to a reduction in a business's carbon footprint.

TTRAILERS,TANKERS& TYRES:

you will be spoilt for choice with a wide range of cutting-edge technology on display from the well-known names you’d expect to see. From chemical and liquid tankers to specialist urban trailers, rugged off-road tyres, EVready tyres and everything in-between.

UURBAN:

vehicles and products aimed squarely at those operating in towns and cities will be showcased in abundance at the show, including electric vehicles.

VVIP EXPERIENCE:

the organisers have pulled out all the stops to make sure visitors have the best experience during RTX. A dedicated team of showmakers will be on-hand to answer your questions and guide you around the venue.

WWORKSHOP WOW FACTOR!

If you are looking out for new kit for your workshop, or want to explore the latest fleet management software or mobile repair and maintenance options, then you’re in the right place. From vehicle washing systems and underfloor pits, to weighing technology and hydraulic lifts, you will find all you need to keep your trucks in tip-top condition.

XTRA XTRA!

This year has seen the show expand both inside and outside with more than 250 exhibitors attending in what promises to be the biggest and best to date.

YYOUR SHOW:

RTX is a show designed specifically for the needs of the industry and and your feedback helps to shape the event and keep it relevant.

ZEHID:

This is the acronym used for the latest £200m government-funded Zero-Emission HGV and Infrastructure Demonstrator programme, which you can hear all about on day two at the RTX Knowledge Zone.

WINNARD Stand N8B

A first-time exhibitor, Winnard will be displaying a range of products including its ECE R90 approved brake discs, brake pads and brake drums. It will also be showcasing its hubkits - a wheel end repair solution fitted with FAG bearings – and its lined brake shoe kits.

The company says its key message will be one of focusing on product quality, reminding customers of the importance of quality control and design.

IT’S RIM UPNORTH

Wheel alignment technology is helping a Volvo dealer provide a faster and more accurate service, saving both time and money. CVW looks at how Liverpool-based Thomas Hardie Commercials has halved customer downtime using the new system.

for trucks and trailers.

the only Volvo Truck & Bus-approved wheel aligner on the UK market – the Josam Cam-aligner from Automotive Equipment Solutions (AES UK). Hardie’s equipped one of its service vans with the kit, giving it the flexibility to provide faster and more accurate wheel alignment services, either at its own workshops or at customers’ premises.

Chris Whalley, group truck and bus manager, said: “We have already seen a return on investment as we have been able to take wheel alignment completely inhouse. We carry out tracking checks on new vehicles as part of our PDI. In

addition, for wheel alignment we can now go to the customer rather than have them bring their vehicles to us. This saves on fuel and tyres and reduces vehicle downtime for our clients.”

Easy and quick to use, the Josam Camaligner uses wireless technology to transmit data between measuring units and the computer, while the software guides the user through the measuring process and produces reports of before and after alignment. Using centerline technology, the system helps align all axles to the vehicle chassis, ensuring each alignment is correctly carried out first time.

technology, the system helps align all axles to the vehicle chassis, ensuring each alignment is correctly carried out first time.

The system works seamlessly with Thomas Hardie’s other diagnostic tools, especially for adjusting electronic steered axles – a simple process whereby the technician calibrates the steering system while monitoring the wheel angles in real time on a laptop.

“Thanks to this, customer vehicle downtime has now halved,” added Chris. “The accuracy of the tracking is also saving our customers money, and they absolutely love that. Our data shows that identifying and replacing worn steering components can add up to 10% extra mpg to a vehicle, which is a huge difference.”

Swift resolution

AES UK delivered in-depth training for Thomas Hardie’s 11 master technicians as well as Chris, ensuring the entire team were fully confident and comfortable with the technology.

“The support we received has been second to none,” added Chris. “While we were getting to grips with the technology, any time we encountered an issue we called and it was either fixed over the phone or someone came in

TALKING TORQUE

Chris Bull, applications specialist, Norbar Torque Tools, looks at the critical role of torque control in vehicle maintenance and how precision must be embraced for performance and safety.

With automotive maintenance and repair, precision isn't a luxury: it's a necessity. And one key element where acknowledging the need for precision is essential lies in torque control, a fundamental aspect that goes beyond merely tightening nuts and bolts.

Effective torque control ensures that every component of a vehicle is assembled to the exact specifications required for optimal performance and safety. With the advent of digital torque wrenches equipped with data collection capabilities, the industry is witnessing a revolution in how maintenance tasks are performed, enhancing both reliability and traceability.

Understanding torque

Torque, in simple terms, is any force or system of forces that tends to cause a rotation about an axis. For vehicles, proper torque application is crucial as it affects everything from the wheels to the engine. Incorrect torque can lead to a host of problems, such as parts that are too loose and fail to perform as intended or too tight, causing undue stress and premature wear. Therefore, the precision in torque application cannot be overstated.

From analogue to digital Historically, torque wrenches were mostly analogue, requiring a keen sense and experience to gauge the correct torque. However, digital advancements have led to the development of torque wrenches that not only provide precise measurements but also offer data collection capabilities. These

modern tools have transformed maintenance practices by ensuring accuracy and providing feedback that can be analysed to improve safety, procedures and training.

Digital torque wrenches represent a significant leap forward. They allow technicians to apply exact torque settings, reducing the risk of human error. The realtime data collection feature provides a digital footprint for each action, creating an invaluable record for quality control and accountability. This aspect is especially critical in scenarios where maintaining and proving compliance with safety standards and specifications are required.

Business benefits

Incorporating digital torque wrenches into vehicle maintenance routines offers numerous benefits for businesses. These tools not only enhance the quality and reliability of work but also elevate the business's credibility. The data collected serves as evidence of due diligence and adherence to best practices, which is essential for building trust with customers. Moreover,

the ability to track and analyse maintenance actions opens avenues for continuous improvement, potentially reducing the occurrence of costly errors and rework.

More than just compliance

Traceability provided by these digital tools goes beyond mere compliance. It's about creating a culture of transparency and excellence. Having detailed records of maintenance activities can be invaluable during audits, warranty claims, or when diagnosing recurring issues. This level of detail ensures that businesses can stand behind their work with confidence, knowing that they have the data to support their practices.

As the automotive industry continues to evolve, embracing technologies that enhance precision in maintenance tasks will become increasingly important. Digital

torque wrenches with data collection capabilities are at the forefront of this change, offering a blend of accuracy, efficiency, and traceability. Workshops that adopt these tools not only set themselves apart in terms of quality and reliability but also demonstrate a commitment to safety.

The integration of precise torque control into vehicle maintenance is not just about following best practices; it's about setting new standards. As we move forward, the

tools we use not only define our work, but also the trust and reliability that customers place in us. In an era where every detail matters, precision is the key to unlocking superior performance and safety.

SIZE MATTERS

Bandvulc is increasing the range of available sizes for its fifthgeneration BD5 ultra-high mileage drive tyre. Launched at the inaugural 2022 Road Transport Expo, replacing the BD08 in the Fleetmaster range, the BD5 will now also be available as a 315/80 tyre from now.

Engineered with long-haul operators in mind, the BD5 combines the latest in innovation and design. The result is claimed to be a dependable, highperforming retread tyre that boasts outstanding sustainability credentials.

More miles

To maximise the BD5’s useable lifespan, Bandvulc utilises a purpose-formulated Long-Life Tread+ rubber compound. Its hard-wearing and thermal-resistant properties help customers maximise vehicle uptime and reduce routine service costs. In independent trials commissioned by the company, the BD5 tyre was shown to deliver a 40% increase in lifetime mileage compared to the older BD08.

“...retread tyres offer operators cost-effective, sustainable solutions for their fleets...”

Bandvulc has increased the number of sizes available for its BD5 retread tyre.

The BD5 also commands greater driving dynamics than its predecessor, thanks in part to a completely redesigned directional tread pattern. Through extensive testing and refinement during the development process, Bandvulc was able to achieve superior wet and dry handling, higher levels of real-world grip and exceptional water dispersion and stone ejection. Every BD5 is certified 3PMSF.

Tony Mailling, head of hot retread production EMEA and ContiLifeCycle plant manager, says: “It has always been our

intention to grow the range of fitments available for the BD5 tyre and with its increased popularity are pleased to launch the new size. Our in-house team was responsible for the entire development process for the BD5 and is indicative of how retread tyres offer operators cost-effective, sustainable solutions for their fleets.”

RUBBER ONTHE ROAD

maintenance topics amongst LCV operators, Steve Howat, general manager, technical services at Continental Tyres, addresses some frequently asked questions.

If you drive or operate a van to support a business, it’s vital, that you take the time to ensure your tyres are safe and suitable for the task at hand. Sadly, however, the use of illegal van tyres remains an issue for the sector. Statistics gathered by the UK tyre safety charity TyreSafe, as part of its 2023 tread depth survey, reveal that almost 18% of van tyres were found to be below the 1.6mm legal tread depth limit at the point of replacement.

Is there a difference between car and van tyres?

Put simply, yes. Although they may look similar at a glance, a van tyre is specifically engineered for the work it needs to carry out. Not only could it be unsafe to fit a car tyre to a van, but it could also be illegal. A major difference between car and van tyres relates to operating requirements which include the tyre’s load rating – the gross weight that the tyre has been graded to support, durability in both mileage and robustness and inflation requirements.

In many cases, the whole purpose of an LCV is to carry heavier, bulkier payloads than would be suitable for a car. The exact same should be said for a van’s tyres, too.

What should I be doing to look after my tyres?

There are some easy steps any owner/ driver can take to look after their tyres. First and foremost, a regular visual inspection cannot be underestimated. Look for damage, especially to the sidewalls, and check for anything embedded in the tread grooves.

Spotting a screw, nail or other puncturecreating object early could be the difference between an inexpensive repair or a replacement tyre. It’s also vital to check your tread depths. If your tyre tread is below 1.6mm, the tyre is not road-legal and must be changed.

A major contributing factor to premature tyre failure is underinflation. You should regularly check that your tyres are inflated to the manufacturer’s recommended pressures. Don’t just rely on your vehicle’s in-built tyre pressure monitoring system to

warn you they’re low, either. Even a few psi short of the recommendation can have an impact on tyre reliability and fuel economy.

What are the consequences of poor tyre maintenance?

As mentioned, low tyre pressures can cause a reduction in fuel economy and cause premature damage to a tyre. It also makes them more susceptible to picking up a puncture. These are just tyre-related issues – think about the cost and business implication of taking the vehicle off the road at short notice and potentially having to let customers down.

Continuing to use a damaged tyre may not only be illegal, but it will significantly increase the risk of a tyre blowout. A blowout happens when there is a sudden depressurisation of the tyre – a bit like popping a balloon. The forces exerted from the explosion can cause fatal injuries to anyone standing in proximity to the tyre and can easily cause a loss of vehicle control if it’s heavily loaded and travelling at speed.

Only connect

ContiConnect Lite from Continental is claimed to provide a a simple and free-ofcharge gateway into digital tyre management by enabling access to selected ContiConnect functionalities via smartphone. The new app version is also available for digital tyre monitoring for agricultural, earthmoving and port operation tyres.

ContiConnect Lite helps drivers to monitor the condition of their tyres. This brings added value, in particular for smaller fleets using intelligent tyres or Gen2 sensors. No additional hardware is required to use ContiConnect Lite.

After the self-registration is complete, the vehicle can be modified and connected via Bluetooth. This then also enables access to a limited version of the ContiConnect OnSite App. In total, five vehicles and three users can be registered free of charge.

When tyre sensors identify a change in pressure or temperature, drivers are alerted via push notification, enabling immediate action. The real-time data from the tyres enables predictive maintenance, cuts costs, saves energy and reduces emissions.

Continental claims to be the first manufacturer to offer an entire family of tyres with sensors, allowing it to continue driving forward to fleet digitalisation. Smart

tyres additionally help users to ensure efficient vehicle operation with lower costs during the mobility and energy transition.

For example, the Conti Urban bus tyre is a specialist in mastering the demands of urban traffic. Customers can choose from the Conti Urban HA3, Conti UrbanScandinavia HA3+ and Conti UrbanScandinavia HD3 –all of which are intelligent.

The various ContiConnect digital solutions are a boon for efficient fleet management. Integrating the new Conti Urban tyre into the ContiConnect digital tyre management platform enables both city and public transport operators to provide a dependable, efficient, and eco-friendly public transportation system.

Keeping commercial cabs comfortable and drivers in good shape is a year-round job.

Nissens Automotive looks at what makes aircon work and why maintenance is important.

A CONDITION OF THE JOB

One of the critical elements of driver safety and comfort is the air conditioning (AC) system. It ensures comfort in the cabin, regardless of the season, by heating or cooling the interior. Regardless of the type of vehicle, it is highly advisable to ensure the proper operation of its AC system through regular and professional service and the use of appropriate quality replacement parts. To make sure AC specialists and distributors stay ahead in the busy climate season, it’s important to prepare sufficiently because both drivers and operators count on their climate system competencies!

Sensitive types

AC systems operate using the thermodynamic properties of chemical refrigerant circulating inside, and thanks to the medium looped inside the system, and the operation of individual components that control its flow and pressure, the system can exchange heat between the medium inside the system and the surrounding elements. In this way, the system regulates the temperature of the air supplied to the cabin by cooling it.

In addition to wear of the elements within the system during its normal use, it can also suffer other damage. The

“ ...for both highly experienced system specialists and those who are just entering the business, it is important to learn how to avoid common issues...”

conditions needed for its operation, namely high temperature and pressure inside the loop, and the precise and, in some cases, fragile components, including some mechanical and electrical control parts, means servicing the AC system is not straightforward. Hence, it requires solid knowledge to diagnose and repair, which starts with the basic understanding that its longevity is very sensitive to the wrong operating conditions.

These factors must be considered when thinking about the upcoming busy service season and beyond, as in many vehicles, the system is required to be in operation all year long. Therefore, for both highly experienced system specialists and those who are just entering the business, it is important to learn how to avoid common issues. For example, wrong service procedures, the use of inappropriate consumables and agents,

using poor quality parts, neglecting what might just seem to be light damage such as dirt (inside or on the surface) or leaks, and other system faults, e.g., airflow disturbances, may all lead to severe system issues and the need for costly repairs.

Wide coverage

One way to avoid mishaps is to source components from a reputable supplier, such as Nissens. We offer an extensive and competitive range that covers a wide variety of products, and decades of experience in designing, developing, and manufacturing thermal system components for vehicles, and provide aftermarket solutions for many automotive systems. Today, the company's CV parts programme includes more than 800 part numbers that cater for 4,400 OE numbers, offering excellent truck parc coverage of over 85% within key product lines and Euro 6 applications.

Nanotubes are a common design application in condenser construction. They offer high efficiency but are sensitive to inner contamination. The wrong fluid viscosity or particle formation and lack of system flushing can quickly clog the channels.

Our CV climate system parts offering consists of eight key AC product lines, encompassing more than 200 items. As vehicle fleets develop and change, so does the range, which continuously expands to best match the most popular applications and address the recent technology evolutions.

While the range, coverage, and availability of reliable quality parts are obvious, it is also essential to ease the strain on the technicians undertaking the work. So, assembly related features that make the replacement process safer and faster, and technical support from the manufacturer to help avoid common problems are priceless.

All Nissens components are manufactured to the genuine Nissens quality standard, which ensures outstanding performance and durability and easy installation of the part through

perfect fit and with additional items included in the (First Fit) set, for example suitable O-rings, mounting screws, or the appropriate oil in the compressor, are inside the product box. In addition, safe packaging and transport protection ensure that sensitive components arrive safely from the warehouse to the workshop.

We also provide a wide range of technical support targeting industry specialists on various levels and technicians can benefit from the using our recognised quality training and technical support material. The expert knowledge portal, for example, includes a broad library of technical tips and service procedures, as well as great tools, such as the oil and gas finder, with hundreds of vehicle makes and models.

LEARN ABOUT OTHER PARTS IN THE COMPREHENSIVE NISSENS

CLIMATE RANGE AND DISCOVER THEIR QUALITY FEATURES AND THE RANGE DATA AT WWW.NISSENS.COM/CLIMATE OR WWW.RDR.LINK/VBJ012

Traces of lubricant attracting dust on the outer part of the system signal potential leaks. The seemingly mild failure can quickly develop into performance loss of the system and severe damage to the compressor.

THE HEAT IS ON

Diagnosing, fixing and testing the aircon is a routine matter normally but occasionally a bit more troubleshooting is needed. Auto Air Gloucester offers a few cool tips to get you started.

‘The aircon isn’t blowing cold enough’ is probably a phrase repeated time and time again across the UK’s workshops as disgruntled customers complain about the sweltering conditions in their cab. Diagnosing why a vehicle’s AC isn’t blowing cold enough can be tricky. As you know there are many components that form the AC system and any of them can cause poor performance.

A common cause can be low refrigerant levels. Even a slight loss of refrigerant, possibly due to leaky O-rings or seals, can affect the

temperature through the vents. A sign of low refrigerant is the compressor short cycling (clicking off and on). Locating refrigerant leaks can be difficult even for you professionals. Oil stains on the condenser, compressor, hoses or fittings are a good clue to the whereabouts of a leak but remember to check the service ports where Schrader valves, caps and O-rings are located.

“... oil stains on the condenser, compressor, hoses or fittings are a good clue...”

Check to make sure the cooling fans are running when the AC is operational. Leaves, dirt, debris or bent cooling fins blocking air from passing over the condenser and/or evaporator will increase the refrigerant pressure –raising the temperature and resulting in poor performance.

Symptoms and diagnosis

The compressor can be a shared cause. Check to make sure the clutch assembly is engaging. With the engine running, the blower fan on max and the AC controls set to the coldest temperature the clutch should be spinning. You may hear a click or a change in the engine when the clutch engages. If the clutch is not engaging the refrigerant is either very low, the clutch itself has failed or there could be an electrical problem.

Also check the accumulator / receiver drier where desiccant bags are used to

Damaged blower

absorb moisture running through the AC system. Moisture can enter a leaking system and react with refrigerant to form a corrosive sludge. As a result, oversaturated desiccant can ooze into the AC system, blocking every AC component.

Contaminated refrigerant from corroded internal parts can also block components but most importantly will eventually damage the compressor. This is why it is essential to flush the system every time it is opened up to the elements.

Then again, it could be something more complex such as any number of fuses, pressure/temperature sensors or switches that can affect the AC systems operation and cooling performance. Check all electrical connections are clean, tight and secure. Remember the engine control module which can keep the AC from turning on.

“... contaminated refrigerant from corroded internal parts can also block components but most importantly will eventually damage the compressor...”

There is one component which is often overlooked when diagnosing an AC system problem. A dirty cabin air filter can lead to poor AC cooling output, but it is easy and inexpensive to replace. It’s worth telling the customer to run the AC 10 minutes a week, even in the winter, because it helps circulate refrigerant oil and lubricate the compressor and condition the O-rings/seals.

Remember refrigerant freezes skin quickly and can be painful so take care. Use specialist tools and equipment to accurately diagnose the problem, safely reclaim and recycle refrigerant and make sure your repairs to keep your customers cool while driving.

Contaminated oil

Sheered scrolls inside compressor

Sheered scrolls from compressor

Excess UV dye

THE CHILL FACTOR

Protecting perishable goods like food and beverage, pharmaceutical, or biomedical supplies in transit is paramount and refrigerated vans play an indispensable role. Paul Barton, aftersales manager at CoolKit, tells CVW how vital it is to carry out regular servicing and maintenance.

Any business involved in delivering goods that require a refrigerated or temperature-controlled environment must view their vehicles as their most valuable asset because the company’s success and reputation depends on them.

So, regular servicing and maintenance isn’t just a recommendation –it’s an absolute necessity. And at this time of year, as we are moving into the warmer months, it is more important than ever.

Without such investment, breaking down during a delivery could result in product loss, client loss and even the replacement of the vehicle – all extremely costly consequences.

Full check up

Maintaining a consistent temperature within a refrigerated van is essential to preserve the quality and safety of perishable goods. Any change in temperature will compromise the integrity of the load and possibly result in substantial losses.

Legislation requires properly functioning refrigeration systems. Failures can pose significant workplace hazards. Servicing and maintaining vehicles’ temperature control systems and bodywork ensures that drivers are confident delivering and meeting customers’ needs. If the thought of any of the above is causing you to sweat –fear not. There is a way to keep your cool –proper aftersales maintenance and care.

Routine maintenance includes full servicing, calibrating, and inspecting the refrigeration system to ensure it operates within specified parameters.

In addition, temperature monitoring systems in conjunction with telemetry provide real-time and historical alerts and reporting that helps carriers meet compliance, reduce rejected loads, and enhance operational efficiency. Generally, routine check-ups help to identify potential issues early, reducing wear and tear and thereby extending the lifespan of both the van and its refrigeration equipment.

It would be a mistake simply to rely on scheduled services. To guarantee maximum performance, before using any temperaturecontrolled van, drivers should conduct checks on a daily basis to include:

● Ensuring the inside of the container is clean to avoid any contamination.

● Examining the insulated area to check for holes or punctures that could affect the temperature control.

● Checking all seals and locks on the door.

● Reviewing the temperature settings to

“...we try to identify potential issues before they escalate into costly breakdowns...”

ensure they match the requirements of the load (ever frozen a lettuce?!)

● Inspecting any drains present for contamination or blockage.

● Evaporator and condenser fan functioning.

● Ensure that the load space is cooled prior to loading – and don’t expect the van to cool a warm load.

At CoolKit, we actively contact customers to remind them to keep on top of routine maintenance checks. In that way, we try to identify potential issues before they escalate into costly breakdowns. A routine refrigeration unit service should usually include:

● Inspecting the amount of refrigerant charged and the extent of any contamination.

● Checking for refrigerant leakage.

● Checking the functioning of electrical fans

in the evaporator and condenser units.

● Checking for excessive electrical consumption.

● Inspecting compressor drive belt wear and alignment

● Cleaning the surfaces of the evaporator and condenser fins to optimise their efficiency for transferring heat.

● Calibration to give you confidence that the temperature that you see is the temperature you get.

Finally, watch for the warning signs. While out in a van the driver should be aware of any changes from its regular performance whether that be unusual noises or on-board technical irregularities. If something doesn’t feel or sound right, it probably isn’t right. However, regular servicing and maintenance should reduce those instances to an absolute minimum and optimise your refrigerated van fleet reliability.

COOL RUNNING

In the ever-evolving landscape of refrigerated transport, where energy conservation and eco-friendly options are a necessity, BPW ePower is proving to be a symbol of innovation and sustainability. Unlike other systems that constantly engage the generator, contributing to increased emissions and fuel consumption, the technology stands out as a smart solution designed to operate intelligently, optimising energy usage and minimising environmental impact.

It is the result of a pioneering partnership for a greener future between BPW and Thermo King, two companies at the forefront of transitioning technology in the industry. Their collaborative effort is helping to shap the future of sustainable and efficient climate-neutral refrigerated transport.

CVW hears from BPW about its work with Thermo King to develop refrigerated trailer technology that cools on the move and is chill when still.

What is ePower? In brief, it is a cuttingedge generator axle designed to propel the transportation industry into a greener future. With its dual generators, it doubles power output and reliability. However, what truly sets ePower apart, says the company, is its intelligent energy management system, ensuring that the cooling system always has access to sufficient battery reserves without unnecessary engagement, thereby minimising fuel consumption and CO2 emissions.

Developed by engineers at BPW, the system is designed to adhere to automotive safety standards. It recovers energy when the trailer is moving, enabling a carbon-neutral and quiet supply of power to refrigeration units for temperature-controlled transportation. depending on the usage and equipment. This innovative solution not only presents the opportunity to save up to 4,000 litres of fuel annually per trailer, but also has the potential to reduce CO2 emissions by up to 10 tonnes per year per trailer.

How does it work? Unlike traditional systems that remain engaged throughout the journey, ePower does not engage or carry current until the vehicle reaches 15 kmh. Operating similarly to a bike dynamo, it efficiently converts wheel rotation into energy and temporarily stores it in a backup battery before feeding it into the system as needed.

It combines several standard components from BPW’s TS2 disc brake and ECO air suspension, including brake discs, and pads. it also integrates a slightly modified ECO Plus hub. It is important to note that the two generators are connected to the battery pack, meaning technicians must undergo high-voltage training before attempting to maintain the system.

The battery pack has two options: a standard (19 kw) or an extended (38 kw) autonomy pack. These were created with the help of telematics experts to ensure that drivers and fleet managers can get the best fit for their fleet. This way the kinetic energy typically lost by a trailer during transit is recycled efficiently.

Generator modes

Equipped with intelligent smart power management, which controls the engagement and disengagement of the generators, ePower additionally reduces resistance on the tractor unit and offers real-time battery charge status to both the driver and fleet manager. The settings for the system can be changed on demand via the BPW idem telematics Cargofleet portal, as well as Thermo King’s tracking web portal and the TK reefer app.

It is equipped with four generator modes and offers huge versatility tailored to various driving situations. Different operating modes make sure that energy is managed intelligently and, therefore, that the system in question is ideally supplied with electricity as needed – even during longer journeys or in congested traffic conditions.

active: the generator produces electrical energy depending on the power demand and driving situation. active fast charge: continuously produces electrical energy with full power until the battery is charged.

recuperation-only: the axle produces electrical energy by recuperation only (i.e., while braking); this avoids additional fuel consumption of the vehicle.

passive: the axle generator will not produce electrical energy and remains on standby.

In an era when climate change and environmental concerns are at the forefront of global challenges, BPW and Thermo King are taking a proactive approach. They

recognise that there is a perpetual urgency when it comes to developing new sustainable products. Partnering with industry experts is speeding up progress in bringing new solutions to the refrigeration industry and instigating change. BPW maintains it is committed to sustainability, and this partnership demonstrates its dedication to preserving the environment and supporting a cleaner, more sustainable future.

For those interested the system only comes factory fitted as an OEM trailer option.

SEALS THE DEAL

It’s often the smaller components that can cause the most damage when things go wrong and a water pump’s mechanical shaft seal fits that bill. Febi pinpoints what can go wrong and why.

With higher power requirements and reduced emissions on the agenda, newer commercial vehicle engines have to work more efficiently. The materials used are pushed to their limits, with higher pressures and temperatures. As a result, engines need to be cooled more efficiently.

In the cooling system, the water pump carries out the majority of this task. The pump’s successful operation depends on the smallest, most important and sensitive component, next to the bearing assembly that is. Yes, we’re talking about the mechanical shaft seal which can’t be seen from the outside but which deserves closer

observation given its intricate make-up. The mechanical shaft seal sits on the water pump shaft and serves as a seal between water pump bearing and coolant. It is made up of many parts, some of which rotate and some of which are stationary (Fig. 1).

The sealing surfaces of both rings (rotating seal ring and stationary seal ring) slide against each other under the pressure of a spring so that sealing is guaranteed. The seal ring pairings are made from highgrade, wear-resistant materials, such as silicon, graphite or ceramic. The mechanical shaft seal’s service life is significantly shorter if savings are made on these materials. This is also the reason why, although similar on the outside, water pumps can be very different in quality.

Film stars

Constant lubrication and cooling between the two rings is necessary to guarantee that the mechanical shaft seal will function steadily throughout its service life. This is achieved via lubricating film which forms between the two pairs of seal rings during rotation. This 1-2 µm thick lubricating film should always be present both to reduce friction and also so that any heat produced can be dissipated (Fig. 2).

Figure 1: Construction of the mechanical shaft seal

Figure 2: Desired flow from water pump (1μm = 0.001mm)

“... continuously escaping coolant, however, is a sign of a faulty mechanical shaft seal...”

It is normal for a certain amount of leakage between the rotating seal ring and the stationary seal ring. However, this is very small and may even evaporate in the pump. Sometimes coolant can also get into the free space behind the mechanical shaft seal and may escape at the drainage hole. This is normal in small quantities, particularly after initial fitting, and does not constitute any reason for complaint. Some pumps have evaporative canisters, where the escaping coolant is collected and kept in the pump until the liquid has evaporated. Continuously escaping coolant, however, is a sign of a faulty mechanical shaft seal and therefore signifies a leaky water pump (Fig. 3).

The mechanical shaft seal is a very sensitive part that can be damaged for the following reasons:

Transport damage: the mechanical shaft seal may be damaged during transport or due to external impacts on the water pump shaft (e.g. knocks).

The use of old and/or dirty coolant: in this case, rust, limescale or dirt may destroy the surfaces of the mechanical shaft seal. As a result, the sealing of the water pump bearing is no longer guaranteed.

Dry running of the pump due to lack of coolant: the coolant lacks lubricating properties if the wrong mixing ratio of antifreeze to water is used. The result is that rotating seal ring and stationary seal ring dry rub against each other without the protective lubricating film. This causes friction heat which can destroy the mechanical shaft seal.

Fitting errors: the use of additional sealant when fitting (silicone) can destroy the surfaces of the rotating and stationary seal rings.

Dry running of the pump due to lack of pressure in the cooling system: the pressure in the cooling system may be too low if the valve of the radiator filler cap is faulty. The result is that the compression spring exerts too much pressure which means that both rings lie completely on top of each other. This prevents the formation of any lubricating film, and the mechanical shaft seal runs dry.

Figure 3: Leaking indicates a faulty mechanical shaft seal

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PICKUP LINE TRUCKMAN

Built from high-density polyethylene (HDPE), the latest version of Truckman’s decked drawer system for pick ups will take up to 181kg in a single drawer. Durable and weatherproof, the decked drawer has a payload of 454kg and can be used with or without additional covers and locked using the tailgate. The drawer system is made from 100% recycled steel and HDPE materials and backed by a three-year warranty.

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HAPPY ISOLATION LASER TOOLS

Technicians working on EV and hybrid vehicles can work in safety using the insulating matting from Laser Tools, a flame-retardant floor mat that ensures safety for working voltages up to 1000V (tested to 5000V), in accordance with the IEC61111 standard. Acid and alkali resistant, the mat provides Class 0-rated insulation in a full 1m² size and is 1.5cm thick, with a fine ribbed non-slip underside for grip and a fabric-textured upper side. It can be stored or carried in its own 1.1 metre-long reinforced nylon bag. The matting is also available in a 10-metre-long roll.

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SMILE FOR THE DASHCAM BRIGADE ELECTRONICS

Said to be simple to install and calibrate, the AI connected dashcam from Brigade Electronics is a compact, windscreenmounted dual camera system that uses AI technology to provide event warnings, high-definition incident recording and monitor driver behaviour. The forwardfacing camera's AI technology can identify and audibly alert a driver to a hazardous situation, such as the risk of colliding with a vehicle ahead or switching lanes without signalling. Through the delivery of real-time audio alerts, the driver can take immediate action to prevent an incident. Alerts and video are sent to a remote dashboard as events happen. This can prove invaluable for fleet managers and allows them to review in-cab footage and analyse driving habits. With this information they can see high risk situations and behaviours that might require extra training for the drivers involved. The AI connected dashcams work in conjunction with Brigade video telematics – a fully managed service that allows users to receive event alerts and video clips from the dashcam while being able to live stream footage in real time and download past data.

AIR TODAY FPS AIR COMPRESSORS

Arriving on site ready to use, the Contain-Air solution from FPS Air Compressors is a portable compressed air room that sidesteps the complex installation, high costs and considerable space demands associated with conventional compressed air systems. By integrating all components into one compact unit, the containerised solution reduces the need for on-site assembly and minimises the risk of errors. The unit is plug-and-play so it can be put to use immediately after it has arrived – all it needs is power and connection to the air network.

The complete compressed air station includes all the air treatment necessary to meet the demands of any air quality standard. Available in oil-free and lubricated formats, this compressed air cube offers working pressure of 6 to 400 bar, capacity from 1500 to 20,000 l/min and installed power from 11 to 160 kW. Each self-contained unit features lighting, heating and ventilation. These weather-proof and durable units also provide maximum security and safety for site personnel.

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NUT JOB LASER TOOLS

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Designed specifically to remove damaged wheel fixings, the wheel-nut extractors developed by Laser Tools have spiral sockets and are engineered from SCM440 medium-carbon chromium-molybdenum alloy steel for strength and wear-resistance. It works as follows: use the equivalent wheel nut socket to drive the extractor –as it turns the spiral grooves bite into the damaged wheel nut or bolt and grip securely – then use a punch to pop the nut out from the extractor once it is out.

The extractors come with fitted plastic sleeve to protect the finish on alloy wheels and are available in three sizes: 17mm, 19mm and 21mm.

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BREAKING NEWS LASER TOOLS

To deal with very tight and corroded fasteners on larger wheel and chassis nuts and bolts, Laser Tools has developed two extendable ratchet handles, a 3/4in drive version and a 1in drive version, that are equipped with a ratchet lock-out button so they can also be used as breaker bars.

Both have telescopic handles with six fixed positions. The smaller extends from 620mm to 1020mm and will handle a load of up to 1,412Nm, while the 1in drive version can extend from 610mm to 1000mm and has a maximum load of 2.515Nm. Both tools are manufactured from strong, shock-resistant chromevanadium steel, with a smooth chromeplated finish and knurled hand grip.

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GYS

TOUGH GLOVES BOOST SAFETY UNIGLOVES

Developed by Unigloves for the automotive sector, Nitrex 241WP gloves offer comfort, grip, dexterity and safety. The palm has a highly flexible polyurethane coating for good grip whether wet or dry while the 13-gauge seamless nylon, spandex and cut resistant liner provides the comfort, fit and feel. To stop hands getting sweaty the PU coating is breathable and the glove is treated with Sanitized Actifresh to neutralise odours and reduce microbial growth.

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BATTERY-LESS BOOSTERS

GYS has developed a range of battery-less boosters. The GYSCAP 24V is a dedicated super capacitor booster capable of starting HGVs and other large vehicles. It has a peak current of 10000A and a cold cranking amperage of 4500A. GYSCAP combines powerful boosting with a maintenance-free and almost limitless life. Unlike a traditional booster, it does not require any maintenance or charging. Simply connect it to a working battery for a few seconds and it’s ready to go. It can be stored for years, and its performance is unaffected by extreme temperature or rain.

Once connected to a working battery, the GYSCAP booster charges to full capacity in seconds. It can then start a vehicle, providing its full working voltage until discharged. The process is almost infinitely cyclable, with a lifetime of over one million charge and discharge cycles.

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LIGHTEN THE LOAD LABCRAFT

Originally developed by Labcraft for cattle trucks, the Lunalux is a tough and compact interior LED light system rated to IP67 that is ideal for a wide range of applications. Housed in an aluminium casting, the Lunalux features a potted resin over the LED optics to protect the lamp and its components from damage. At just 15mm, the low-profile design means it has virtually no impact on internal vehicle space. Although tiny, the Lunalux generates over 655 lumens from just two LEDs. It suits a variety of general applications, including ambient and refrigerated trailers, luton-bodies, rigid vans and HGVs as it is less prone to damage that loading and unloading can cause.

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FIVE TO ONE BABY LASER TOOLS

To cut down the amount of pliers that need to be carried around, Laser Tools has produced a set of pliers with five interchangeable heads, including combination pliers, wire strippers, shears, cable cutters, and crimping pliers. The pliers are 212mm long and the springloaded handles have a PVC soft grip.

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CUT TO THE QUICK NORTON

Superior grinding performance, lower operating costs and increased efficiency are just three of the claims that Norton is making for its RazorStar range of ceramic belts and fibre discs. According to Norton, RazorStar belts cut faster and remove more material, reducing machine time and energy consumption by up to 20% on stainless steel and 34% on carbon steel, compared to other ceramic-shaped grains.

This contributes to the belt's durability and long life in high-pressure grinding applications, reducing belt waste by up to 57% on stainless steel and up to 74% on carbon steel. In the company’s trials, it says the cut rate of RazorStar fibre discs improved stock removal by up to 50% on carbon steel during bevelling applications using a low-powered angle grinder, compared to other ceramic-shaped grains. During trials with a 1900W high-powered angle grinder, stock removal improved by 93% and the cut-rate improved by 44% on carbon steel. Operators also reported the fibre disc being smoother and easier to use, providing a much more comfortable experience.

RazorStar products can be used on many materials, including stainless steel, Duplex and exotic alloys, carbon steel, cast iron, non-ferrous metals, high nickel superalloys, and titanium alloys.

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■ FORWARD LOOKING QUARTIX TECHNOLOGIES

Quartix Technologies is launching a connected dashcam that it promises will not only be affordable but will also have a technical specification that is comparable with other dashcam service providers in the market. With three camera options available, the connected dashcam can be configured to match the needs of fleets of varying sizes and so enhance safety, monitor driver behaviour, and safeguard against fraudulent claims.

The forward-facing connected dashcam attaches to the windshield and records the road ahead in high definition, capturing clear footage at speeds of up to 25 frames per second. It provides a wide viewing angle of 118°, which can be adjusted up to 90° vertically, ensuring a clear view for the vehicle.

An optional driver-facing camera can be added to complement forward-facing dashcams. This camera assists in identifying driver behaviour concerns or defending against fraudulent claims. It offers a 100° viewing angle, records in 720p at 12.5 frames per second, and features infrared illumination for night driving.

Alternatively, users can opt for an integrated system with both forward and driver-facing cameras. This single device records events on the road and inside the cabin with a full HD 1080p camera, 118° view, and a 90° driverfacing camera with night vision.

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STUCK ON YOU LASER TOOLS

Components to be welded can be clamped accurately in place using a magnetic welding corner clamp developed by Laser Tools. It is fitted with an easily readable gauge with a range of 20˚ to 200˚. Once the desired angle is set, it can be securely locked in place using the included 4mm hex key. The 120 x 80 x 20mm clamp’s magnetic properties extend to both the internal and external surfaces of the support, so it can be used inside and outside workpieces.

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APRIL’S TOPFIVE 1

source of information right at your fingertips. This month, CVW’s Freya Coleman, rounds up the most read articles on the website from the past month.

1

DATA DRIVEN

Topping this month’s list of popular online articles is a news report announcing a partnership between tyre manufacturer Goodyear and Mercedes Benz with an aim to offer operators real-time tyre data.

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2

STAYING IN LINE

Next up, workshop equipment specialist Straightset shares details of its Beissbarth and Supertracker wheel aligner ranges. Also covering details of the importance of wheel alignment, it’s no wonder this article was popular amongst our online audience.

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3

TALK TO ME

This next popular online article is a case study, following leading MercedesBenz dealer Intercounty Truck & Van and its experience adopting Truckfile voice and the subsequent slash in vehicle inspection time Intercounty experienced.

WWW.RDR.LINK/ VBJ032

4

CRACKING JOB

Looking for a step-bystep guide for windscreen repairs?

Then look no further than this next article from Dean Procter, head of training and technical at Esprit Windscreen Repair Equipment. In it, he also highlights how lucrative it can be for workshops.

5

GENERATION GAIN

Rounding off this month’s top five list, ZF discusses its e-axle for low-floor buses including details of advantages of the AxTrax 2 LF such as a 10% energy saving compared to the previous generation.

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.

BG Products ..........................................................(page 49)

www.rdr.link/VBJ100

Borg Warner Aftermarket Europe GmbH ................(page 11)

www.rdr.link/VBJ101

CVW Online ............................................................(page 45)

www.rdr.link/VBJ102

Eminox ....................................................................(page 39)

www.rdr.link/VBJ103

Febi ..........................................................................(page 4)

www.rdr.link/VBJ104

Frase-le/Juratek Ltd ..............................................(page 17)

www.rdr.link/VBJ105

Fronius UK Ltd ........................................................(page 23)

www.rdr.link/VBJ106

Jack Sealey Ltd ......................................................(page 35)

www.rdr.link/VBJ107

Machine Mart ..........................................................(page 46)

www.rdr.link/VBJ108

MAHA UK ..........................................................(front cover)

www.rdr.link/VBJ109

Mann+Hummel (UK) Ltd ........................................(page 28)

www.rdr.link/VBJ110

Mechanex ..............................................................(page 42)

www.rdr.link/VBJ111

NAPA Autoparts ......................................................(page 14)

www.rdr.link/VBJ112

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

www.rdr.link/VBJ113

Road Transport Expo ..............................................(page 32)

www.rdr.link/VBJ114

Schaeffler Automotive Aftermarket UK Ltd ..............(page 8)

www.rdr.link/VBJ115

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

www.rdr.link/VBJ116

Totalkare Heavy Duty Work ....................................(page 31)

www.rdr.link/VBJ117

Totalkare Heavy Duty Work ................................(back cover)

www.rdr.link/VBJ118

Truckfile ..................................................................(page 19)

www.rdr.link/VBJ119

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