Artificial Intelligence (AI) is the future, or so we’re constantly being told. Many of us – including the person writing this piece – are told that our jobs will be scrapped before too long, as AI will be able to do our work for us.
Indeed, so pervasive is ChatGPT in schools, universities and other ‘white collar’ work places, it’s quite possible that a human being didn’t write this column at all –and it’s been generated by OpenAI.
Although it hasn’t. Don’t know how we prove that, but it hasn’t.
Happily, in the commercial vehicle workshop sector, it may be hoped that the impact on jobs will be minimal. From the technician’s perspective, we may see driverless trucks and autonomous fleets serving empty – i.e. peopleless – warehouses, but those trucks and fleets will continue to break and continue to need maintenance and repair like traditional vehicles.
“It’s quite possible that a human being didn’t write this column at all.”
Where the real transformation to the workshop will take place is in the field of diagnostics and maintenance management, where we may expect vehicles to be selfdiagnosing, rather than having their codes read; or where technicians ‘prompt’ a programme which compares and contrasts the data and produces the answer for you.
The problem with this will be the same as with any IT enterprise – the ‘fleshware,’ the human element. When it comes to computing, garbage in always results in garbage out (ChatGPT is a great example of this); and the same applies to AI.
If the data it receives is imperfect, or incomplete or just plain wrong; then it will cease to be useful as a potentially powerful and important diagnostic or management tool.
Patrick Tandy, managing director at Freeway Fleet Systems, makes this point later in this issue. He highlights that for AI to have an effective role to play, workshops need to be fully digitalised first. And there’s more to this than simply having everything on a computer, rather than being paper-based.
A digital fleet management platform should cover everything, from tracking assets and reporting defects to planning maintenance and controlling inventory. AI can then assimilate all the relevant information, discern patterns and behaviours from it and then inform or instruct based on its conclusions.
Furthermore, today’s technology is tomorrow’s electronics waste bin, so it is important to ensure that future proofing has been built into any putative system; and that operatives have the right skills and knowledge to exploit it.
All this is essential if AI is to prove to be our friend, and not a foe that turfs us out of work where our capabilities and technology are found lacking.
Enjoy the read!
CVproduction slips back on summer
British commercial vehicle (CV) manufacturing saw a 10.0% decline in August, with 6,044 units rolling off UK production lines, according to the Society of Motor Manufacturers and Traders (SMMT).
The drop follows a rise in July and aligns with the typical ‘summer shutdown’ period, resulting in 673 fewer units. Despite this, year-to-date volumes remain strong, up 8.8% compared to pre-pandemic levels in 2019.
Exports continued to drive output, with a slight 0.2% decrease year-onyear, a loss of only seven vehicles. More than half of production (59.3%) was destined for overseas markets, with the EU accounting for 97.2% of export demand. Meanwhile, production for the UK market dropped significantly by 21.3% to 2,457 units.
“A best year-to-date performance since 2010 is fantastic news and reflects manufacturers’ dedication, alongside strong overseas demand for British-built commercial vehicles.,” SMMT chief executive Mike Hawes commented.
“While the monthly drop in volumes was expected as output adjusts post-pandemic, the focus remains on working with the government to ensure favourable market conditions and prioritising decarbonisation across the industry.”
So far this year, UK CV plants have produced 78,805 units, marking a 5.8% rise over 2023 and the strongest performance in 14 years, despite ongoing supply chain disruptions.
Export volumes are up 12.0%, with 52,389 units shipped abroad, while domestic production saw a 4.7% decline, with 26,416 units produced for the UK market.
DVS now rules London roads
Two key industry groups –Logistics UK and the Road Haulage Association (RHA) –are warning HGV operators that the latest phase of the Mayor of London’s Direct Vision Standard (DVS) is now in effect.
From October 28th, operators of HGVs over 12 tonnes must demonstrate that their vehicles have a three-star safety rating, as specified by Transport for London (TfL), or be fitted with the Progressive Safe System (PSS) to continue operating in London.
Non-compliance will result in a £550 penalty charge notice, and vehicles will be barred from entering the capital. Operators unable to complete the necessary PSS installation before enforcement began could apply for a grace period, provided that work was scheduled prior to October 28th. Applications for this grace period were required by 23.59hrs on October 27th, and no further extensions will be granted.
Big van boostin September
Britain’s light commercial vehicle (LCV) market saw its second consecutive month of growth in September, with an 8.3% increase, marking the best performance for the month in four years.
According to the Society of Motor Manufacturers and Traders (SMMT), 48,455 new vans, 4x4s, and pickups were registered, driven by businesses investing in fleet renewal and the introduction of the new ‘74’ numberplate. Year-to-date, 267,339 new LCVs have joined UK roads, up 3.6% on 2023 and representing the largest January-to-September volume since 2019.
Demand for smaller vans surged by 34.1%, reaching 1,180 registrations, while medium-sized vans saw a 34.8% increase, with 9,552 units sold. Large vans remained
In a joint statement the two groups remind operators that more than 216,000 vehicles are affected by the new regulations and stress the importance of ensuring compliance.
“Operators need to make sure their vehicles meet the safety standards and, if necessary, have applied for the grace period in time to avoid service disruptions,” the organisations said.
Full details of the new requirements, including technical specifications, are available on the dedicated TfL website, which also provides contact information for operators to liaise directly with the DVS enforcement team. Operators with installation work scheduled after the enforcement date but before May 4th 2025 may apply for the grace period using the DVS enquiry form.
“TFL has been clear from the outset about the leeway on the deadline for implementation,” the organisations added.
the most popular, with an 8.6% rise to 31,645 units, making up 65.3% of the total market. However, pickups and 4x4s saw declines, down 16.0% and 42.4%, respectively, reflecting strong demand for those models last year.
Despite the overall market growth, new battery electric van (BEV) registrations fell for the fourth month in a row, down 0.5% to 3,020 units. This continues a downward trend in BEV demand across 2024, with year-to-date figures showing a 7.7% decline compared to the same period last year, at 14,188 units. BEVs now account for just 5.3% of all new LCVs registered in 2024, far below the 10% required by the UK’s zeroemission vehicle mandate.
Mike Hawes, SMMT chief executive, noted that while overall demand for new vans is growing, there is concern about the slow uptake of BEVs.
He said. “While manufacturers have invested huge sums delivering zero-emission technology and incentivising its sale, consistently low demand is constraining industry from meeting Britain’s ambitious zero-emission vehicles sales mandates.”
CoolKit – the UK specialist in temperaturecontrolled van conversions – is now part of the Mercedes-Benz Bodybuilder Programme as a VanPartner. The accreditation confirms that the company’s refrigerated conversions and bodybuilding for light commercial vehicles meet the quality and safety standards set by Mercedes-Benz.
Following a detailed inspection, Mercedes-Benz recognises that CoolKit’s conversions comply with the standards required by the VanPartner programme. This status highlights converters who meet high standards in product quality, customer satisfaction, and operational efficiency.
CoolKit now enjoys OEM accreditation from all major vehicle manufacturers.
“The launch of our Bodybuilder Programme, centred around the internationally recognised VanPartner accreditation, ensures that customers receive high-quality products and reliable service,” said Marsha Thomas, head of marketing at Mercedes-Benz Vans UK.
Hub streamlines workshop services
Essential workshop services are easier to access using the newly-developed DS Hub, according to Delphi. The hub brings together diagnostics, technical data, training, and parts information into a single platform, which Delphi says simplifies technicians' workflows by providing all necessary tools in one place.
Phil Mitchell, workshop solutions lead at Delphi, explains, “The DS Hub serves as a comprehensive, centralised ecosystem. By consolidating diagnostics, data, training,
Pick-up cab for counselling
Isuzu UK is running a 30-second mental health advert on ITV4, aimed at encouraging open conversations among men aged 35 and over, particularly those working in manual industries. The company says that the advert, which launched on World Mental Health Day and runs through to mid-November, is part of its commitment to raising awareness and supporting mental health initiatives.
and parts catalogues, it helps technicians work more efficiently.”
As the main portal for all Delphi products and services, the DS Hub allows users to access key resources without needing to switch between systems.
Crackdown
A campaign to stem the £1 billion tide of counterfeit vehicle parts is now in operation. The ‘Fake Always Breaks’ campaign, headed by the Intellectual Property Office (IPO) and supported by industry bodies and vehicle manufacturers, aims to warn drivers about the dangers of using fake parts.
Recent seizures by the City of London Police’s Intellectual Property Crime Unit (PIPCU) included 500 counterfeit airbags, alongside brakes, tyres and wheels. These counterfeit parts are not safety-tested, increasing the risk of failure and putting motorists and other road users at serious risk.
The IPO’s campaign is backed by the Independent Garage Association (IGA), Independent Automotive Aftermarket Federation, Mercedes-Benz, and others who are raising awareness among their members and customers.
The campaign suggests that even everyday settings, such as a drive in a truck, can provide an opportunity for meaningful conversations.
“Our trucks aren’t just for work,” said George Wallis, head of marketing at Isuzu UK. “The front seat can also be a space for emotional support – a counselling room on wheels where friends and colleagues can talk side by side.”
The advert specifically targets men who may feel isolated when it comes to discussing mental health, showing how natural these conversations can be during routine activities like driving. The message is reinforced with the #sidebyside hashtag, used across Isuzu's social media channels.
The advert is part of Isuzu’s broader focus on mental health and wellbeing, following its recognition as a runner-up in ITV’s Head First Award.
“Counterfeit vehicle parts pose severe safety risks,” Stuart James, CEO of the IGA. said. “Garages should avoid grey market-supplied parts and stick to trusted suppliers to ensure vehicles meet the required safety standards.”
Cost remains a key factor behind counterfeit purchases, with 31% of buyers citing price as their reason for choosing fakes. Batteries (25%), tyres and wheels (19%) are among the most common counterfeit parts bought by vehicle owners. Worryingly, 14% of those who bought fake parts purchased counterfeit airbags, critical components that may fail during a collision.
PIPCU’s DCI Emma Warbey emphasised, “Counterfeiting safetycritical components like airbags shows how far criminals will go for profit. These parts aren’t manufactured to industry standards, and their failure could be life-threatening.”
Merc chilled about CoolKit
NEWS
Softwareboostto chargerrange
Vestel Mobility, the European manufacturer of electric vehicle (EV) chargers, is integrating its Libra charger range with Electric Miles’ suite of applications. The companies say that this boosts the functionality of the UK-only range, making it more accessible and efficient for installers, fleet managers, and end users.
The integration of Electric Miles software, including the Electric Miles App, Installer Miles, and Partner Miles, into all future Vestel chargers aims to improve usability and control for all customer segments.
The Electric Miles App provides drivers with tools to manage charging, schedule sessions, track energy usage, and take advantage of smart charging features, such as charging during off-peak hours or using solar power, potentially saving users up to £750 per year.
“Take advantage of smart features, such as off-peak charging or using solar power.”
Installer Miles simplifies the installation process for EV charger installers by providing real-time diagnostics, remote configuration, and easy setup. This reduces the time and complexity involved in setting up EV chargers. Partner Miles, designed for fleet operators and managers, offers advanced control over multiple chargers from a single dashboard. It allows for the scheduling of charging sessions to optimize energy use and provides detailed reports on performance and costs, helping businesses manage EV fleets more efficiently.
Go Live Data snaps up MIB
MIB, a leading fleet and automotive data company, is now part of Go Live Data (GLD), the Manchester-based data and marketing specialist. GLD says the acquisition strengthens its existing capabilities by integrating MIB's extensive fleet intelligence into its offering. This will enable businesses in sectors such as fleet management, fuel card services, insurance, and finance to target their markets more effectively with accurate and actionable data.
Adam Herbert, CEO of GLD, commented, “This acquisition gives us a competitive edge and complements our ability to deliver advanced B2B marketing solutions.”
Founded in 2020 by Adam Herbert and Tim Langley, Go Live Data has developed proprietary technology to provide a corporate database that can support B2B marketing campaigns across sectors including fleet, truck, transport, and commercial vehicles.
Celebrating the next generation
Rygor Auto has welcomed its new cohort of apprentices to its annual induction day, staged at Rygor Auto Reading. The company’s has 11 branches, and the apprentices are based at the company’s Swindon, Oxford, Heathrow Truck and Heathrow Van sites; as well as the Reading branch itself.
The newest team members are training as HGV technicians, LCV technicians, customer service experts, and retail parts advisors, joining 22 existing apprentices, working towards Mercedes-Benz Van UK (van) or Daimler (truck) industry recognised qualifications.
At a recent visit to MB World, the apprentices enjoyed an informative visit, including team building activities, a guided tour, and a 4x4 driving experience to round off the day. In March next year, Rygor will open applications for its 2025/26 apprentice intake. Rygor Auto consists of three brands: Mercedes-Benz, SAIC Maxus, andHiger.
Schaeffler wins top aftermarket gong
Schaeffler Automotive Aftermarket was named CV Parts Manufacturer of the Year at the recent Auto Trade Expo in Dublin. CV Territory Manager Graham Andrew accepted the award, which was presented by Automotive Publications.
The award highlights Schaeffler’s commitment to providing original equipment (OE) quality products for truck and bus repairers across Ireland, including
LuK CV clutches, FAG hub repair solutions, and INA drive components.
Schaeffler’s marketleading technical support for workshop owners and technicians was also recognized. The company has now changed its name to Schaeffler Vehicle Lifetime Solutions UK.
Stagecoachdominates UKBus Awards
Stagecoach, the UK’s largest bus and coach operator, has been shortlisted 34 times across 14 categories for the UK Bus Awards 2024, to be presented in London on November 26th.
The nominations cover categories such as ‘Recruitment and Retention’ and ‘Marketing Campaign of the Year’.
TRAFFICNEWS
Fantastic five for Knowles
Cambridgeshire-based
Knowles Logistics has purchased five DAF XG+ 480 tractor units to add to its fleet.
The trucks have been bought to cater to enhanced volumes experienced in recent months, as well as to bolster operational efficiency, support driver comfort, and further expand Knowles Logistics’ overall capacity.
The new vehicles add to its 380 strong fleet, which includes 160 trucks including four electric vehicles and 220 trailers.
Featuring a PACCAR MX-13 engine (480 hp/355 kW) and a spacious cabin, the XG+ has been designed with both the operator and driver in mind, blending a perfect synergy of comfort and optimal performance.
“The tractor also boasts advanced aerodynamics by being equipped witha full Aero kit.”
The tractor also boasts advanced aerodynamics by being equipped with a full Aero kit, which includes, deflectors, fenders and side skirts, helping to reduce drag and increase fuel savings.
The tractor units follow a series of investments the business has made over the past 12 months. These include three Volvo FM Electric 4x2 tractor units and autonomous warehousing maintenance technology, which includes an inventory management drone and two autonomous cleaning robots.
The latest units were acquired from Ford and Slater Wisbech.
G hits the Bespoke spot
G TRANSPORT
Bespoke Handling has developed a joint working partnership with vehicle transport experts G Transport. The partnership brings together two of the UK’s leading names in logistics industry, and through this alliance, clients will benefit from a combined six decades of experience and expertise in specialist vehicle movements.
Customers will benefit from the highest quality, competitive transport options for all forms of vehicle, delivering throughout the UK and Europe, using a fleet of dedicated single- and multicar enclosed vehicle transporters operated by G Transport. This will be supported by Bespoke Handling’s extensive knowledge and expertise in sea and airfreight, vehicle storage, and comprehensive ATA Carnet and customs documentation and management.
Eco-friendly urban logistics
BYD
The ETM6 eTruck from Byd is claimed to be a highly integrated eTruck platform, and designed specifically for the European market, the pure-electric ETM6 is said to a suitable partner for zeroemission inner-city distribution, as well as many other applications.
Byd claims to be the only ‘New Energy Vehicle’ producer to have developed its own powertrain systems, power batteries, automotive semiconductors, motors and motor controller systems.
The ETM6 has a range of up to 200km with a full load, with the asserted convenience of DC (120 kW) charging (20% to 100%) in just one hour.
The exterior adopts Byd’s eTrucks design, incorporating a subtly rounded front face and a diving waistline with dynamic lines giving the ETM6 a modern and streamlined appearance. The doors continue the dynamic theme for optimum effect, with concealed handles for reduced
“It was clear from our early days of working together that we both shared the same core values - the most important being the customer,” explained Graham Taylor, Director of G Transport.
“We are a family run business, drawing on nearly 30 years of expertise and knowledge, operating covered car transporters throughout the UK and Europe. G Transport has always been about the customer and making sure they receive the best possible experience.
Joining with the team at Bespoke Handling, who have demonstrated their strengths on a global level, is an exciting and natural extension for both our companies that will only benefit our clients, as we collectively take that next step to deliver that experience.”
For more information, WWW.RDR.LINK/VBO002
air-resistance. The dimensions of the wheelbase make the ETM6 more manoeuvrable, making it a good option for urban driving. The chassis is also highly configurable for different applications.
The interior cabin mirrors the feel of the exterior, creating a modern space for up to three people. With ergonomically designed seats, it offers superior levels of comfort and a high calibre finish with ample storage compartments.
For more information WWW.RDR.LINK/VBO003
SKYWELL
EV brand Skywell has being previewing its upcoming large all-electric van – the ‘233’. Skywell’s first light commercial vehicle for Europe, the new van will be available in a range of two wheelbases and two roof heights.
The 233 will initially be available in two body lengths (5,490mm and 5,990mm) and two roof heights (2,200mm and 2,700mm) corresponding to a load volume range of approximately 9.5 to 13m3. There will be an option of either a 3.5t or 4.25t gross vehicle mass (GVM); the latter offering a payload of up to 1,755kg.
Customers will also have the choice of either an 88kWh or 105kWh LFP (Lithium-Iron-Phosphate) battery which is mated to a 150kW/370Nm Permanent Magnet Synchronous electric motor.
The cockpit is furnished with a generous level of equipment including a 6way adjustable driver’s seat, 15.6” touchscreen display, wireless phone charging, wireless smartphone connectivity and keyless entry and start.
The 233’s extensive ADAS package includes Intelligent Cruise Assist, Autonomous Emergency Braking System, Lane Keep Assist and Intelligent Speed Assist.
For more information, WWW.RDR.LINK/VBO004
TRAFFICNEWS
D-Max picks up best diesel prize
ISUZU
The Isuzu D-Max has been awarded the title of Best Diesel Pick-up at the Diesel & Eco Car Diesel Top 50 Awards 2024. The award highlights the ongoing popularity of the DMax as a diesel sector performer and adds to a list of industry recognitions this year. The 1.9-litre diesel engine is said to deliver a punchy performance on the road, while its “composed” and "grippy" chassis ensures stability across varied terrains. Whether in entry-level or flagship trim, the D-Max offers a smart and well-appointed interior. Coupled with the company’s smooth sixspeed automatic gearbox, its 3.5-tonne towing capacity, and the peace of mind from a fiveyear/125,000-mile warranty, the D-Max is claimed by the company to be the “definitive choice” of diesel pick-up.
For more information,
WWW.RDR.LINK/VBO005
Silver jubilee
DAF/ LAWRENCE DAVID
Coleshill-based logistics, transport and shipping specialist LTS Global Solutions has celebrated its 25th anniversary with two new commemorative vehicles. The latest investments are a 26-tonne DAF truck and a Lawrence David trailer emblazoned in a specially designed anniversary livery.
RENAULT
The company operates a 60strong fleet of up to 44 tonnes, all of which are Euro 6 compliant. The two new trucks join recent additions such as a fleet of Linde E25 and E35 L electric forklift trucks, a new transport management system and a Volvo FH Globetrotter Aero – also featuring the silver jubilee livery. Also included in the lineup is a Volvo FM Electric truck.
Established in 1999 and undergoing a successful management buyout in 2020, LTS operates from a 133,000ft2 facility at Prologis Park, based at Hams Hall in Coleshill.
For more information on DAF, WWW.RDR.LINK/VBO006
For more information on Lawrence David, WWW.RDR.LINK/VBO007
The Master has landed
The new Renault Master, fresh from being crowned Van of the Year 2025, is now available to order in the UK. The Master is designed to go further, carry more and cost less, delivering enhanced efficiency, plus increased usability, space and comfort. With a fresh and attractive new look, the fourth generation vehicle includes a front end that boasts Renault’s new logo and the extra-large full-LED headlamps in the signature Cshaped array around the grille.
Wates opts for LCEVs
Available in a wide range of versions, spanning load spaces of 11 to 14.8m3, with a 40mm wider opening at the sliding side door and 100mm longer load than the previous version, the New Master’s greater payload capacity and volume redefine convenience in its class.
Three advanced Blue dCi powertrains, delivering 130, 150 or 170hp, are available, all of which consume substantially less fuel and emit less CO2 thanks to the enhanced aerodynamic design. The new model offers a 6-speed manual gearbox or a highly efficient new 9-speed automatic depending on the version.
The OpenR Link multimedia system comes as standard with every model. This is the first time the ultra-modern OpenR Link system with Google builtin is available in an LCV. It includes a 10-inch screen with wired and wireless Android
Auto and Apple CarPlay connectivity. The system includes Google Maps navigation, the Google Play app catalogue and the voicecontrolled Google Assistant. It is also smart and scalable, and will grow to encompass new functionalities over time, with free over-the-air updates and more than 20 apps.
The tech theme continues with the New Renault Master’s set of 20 driver assistance systems that maximise safety for the people in and around it. Its active safety features include its lateral stability, automatic emergency braking and trailer stability assist systems. It also comes with Intelligent Speed Assist, to help the driver stay within the speed limit.
For more information WWW.RDR.LINK/VBO008
ADDITIVE BLUES
It’s been a while since I last worked on a tractor unit and I’d forgotten how impressive and how important these machines are. Keeping them on the road and working is imperative so when an issue arises getting direction quickly, as well as the fix, is vital.
The vehicle was presented with a load of warnings and alarms on the dashboard and so reaching for the scan tool was important to get an insight as to what is triggering the warnings. Whilst the scan tool was busy –scanning – I took the opportunity to chat to the driver. With no apparent drivability issues before the warning lights lit up, the only thing the driver mentioned was the lack of DEF (AdBlue), which was confirmed by the fault codes. Generally, a vehicle like this would get through a lot of DEF as it’s constantly on the road.
A large proportion of the fault codes were pointing towards the DEF system, though there were also some CAN related issues. But the fault code that was labelled as high priority was flagged as a DEF pump failure – Code:P3912. Despite all the DEF trouble codes being inactive, anything related to the DEF system can have a major impact on the engine operation and that would explain the engine protection and engine torque reduction fault codes. Taken together with the customer's observation, this is a clear starting point for investigation.
As with everything, making sure you know how it should work is vitally important. Fortunately, despite the fact this is a Cummins after-treatment system, it shares a lot of similarities to the Bosch Denoxtronic 2.2 after-treatment system. Operationally, it is pretty much the same. There is a pressure building phase, injection events and then purging once the system is switched off. There are however some slight hardware differences in these areas:
DEF reservoir
Filter
4/2 flow control valve
Single direction, fixed displacement pump
Pressure relief valve
Throttle/orifice to generate pressure by restricting flow
Pressure sensor
Injector
Ben Martins, automotive application specialist at Pico, follows the clues that led to a successful diagnosis and repair of issues afflicting a DAF tractor.
The biggest difference between the two systems is that the pressure sensor and the orifice are part of the injector module rather than within the pump. This makes the injector module a lot bigger than the Bosch unit but this means the pump assembly is smaller.
One of the most important checks we can make is simply to look over the area in question – but this is often neglected. You can often tell a lot just by using your eyes but don’t stop there: use all the senses you’ve been given. From the pictures above you will see that we have a slight DEF leak at a couple of the joints between the pump and the injector module. As we have a number of fault codes relating to the pressure being too high, this would make sense if the pressure stepped outside of the rating of the seals in the pipework.
You should also note the fittings on the injector module and the shape of the pipework, especially the bottom hose as it appears to be stretched. DEF is highly corrosive to some metals, so plastic push fit connectors are typical. Could the original fittings have been replaced or modified at some point? It’s good practice to make notes of everything you see, hear, smell and feel.
Almost certain we need to look at the after-treatment system, in particular the DEF pressure. Looking at the wiring diagram we could get these signals at the injector module. The plug is an eight-pin connector but only six-pins are used and, with the positioning of the connector, it was easier to use the breakout leads for ease. This isn’t always practical or typically advisable because disturbing the wiring could actually ‘fix’ the fault being reported, cancelling the fault code and leaving the original issue untouched. But sometimes this is necessary and, in this case, it was the best option for getting the signals we required.
First up then is to take a look at the pressure sensor. We can see if the injector is trying to operate by using a current clamp. By referencing the ground supplied to the injection module we only needed to graph the supply and the output. Should there be an issue with the ground supply we wouldn’t have a stable 5V supply. Unfortunately, just by having the vehicle idling with all the fault codes still present, meant the DEF system would not automatically prime itself. In order to test the unit we had to clear the codes and then manually activate the pump through the actuator tests through the scan tool. This allowed us to perform a priming test as shown.
From this capture we can see that the pressure sensor is responding to the changing pressure where it starts just above 0.5V and then sharply rises during the purging phase and gradually continues to rise before the test is stopped and then the drop in pressure. The pressure sensor is exactly 5V which, as I’m referencing to the sensor ground, gave me confidence that the ground is good.
What is interesting is that the scan tool was reporting a pressure between 10 and 12 bar. The 10 bar reading is slightly above the traditional 9 bar we would expect to be seeing for a DEF system suggesting that the fault codes are correct in reporting over pressurisation.
Using the scan tool again to perform an injection test gave further interesting results. This time though we connected to the pump control to see how the ecu reacts to the over-pressure.
During this test we saw a pattern in which the system never reaches the injection stage. Instead, the after-treatment system primes the DEF, the pressure again rises to around 3V then the system switches the 2/2 control valve to drop the pressure by purging the system and then, once the pressure has dropped, the whole cycle is repeated. We observed this cycle several times and it only stopped when the test ended. The scan tool provided the explanation: the test wouldn’t proceed to the injection stage if the pressure
is too low. Interesting that we have a high pressure issue and so would assume that the test wouldn’t continue for both too high a pressure as well as low.
With having seen both the voltage live on Pico and the pressure reading on the scan tool we can say that the sensor is outputting a value that reflects the fault. Considering there are no burst pipes, just some small weeping around the seals, we have to believe there is a blockage. Looking back at the schematic, one place had our attention.
Based on its position, the filter inside the injector module would be first on the action list. It sits after the pressure sensor and, if we remember the golden rule that pressure is the resistance to flow, then a blocked filter here would result in the pressure sensor reading a high pressure. So, we removed the DEF lines from the injector module –easier said than done – so we could see the filter.
Not only was it so blocked that it had burst but it also appeared to be contaminated with a dark brown/reddish substance like rust. But how can there be high pressure when the filter is burst? Given that pressure is just a restriction to flow, we have in effect created an opening so some fluid can pass through the split in the filter but it is still restricting flow. With the DEF pipes now disconnected and any spillage being caught in a container, we sampled the fluid from the tank to see if there was an issue there.
Using a refractometer designed for DEF we can see we have a clear fluid which is sitting around 33%. Ever so slightly above the target of 32.5% but, given we don’t have a quality issue, it’s not something to be concerned about.
With the driver still with us at this point, the job was more about continuing with the diagnosis and seeing if this was the problem. Fitting the injector module together without the filter is risky and a thorough cleaning of ports was needed. We were glad that we did clean the module as we did find some finer particles which may have also been adding to the restriction but could also cause a blockage at the injector. When we were happy that we’d cleaned the module thoroughly and that the fluid coming from the tank was clear then we ran through the scan tool test, hoping that the DEF pressure had been reduced.
Here we can see that the initial pressure gets to 2.7V and then drops away to around 2.3V and then we see we have activity from the injector. I’m not 100% sure when the
after-treatment ECU determines a high pressure or whether it waits to see if the pressure drops once the pump duty has been dropped to 10%. If we compare the before and after we can see some clear differences.
Using reference waveforms we can bring in the pressure trace captured when the filter was still fitted. Here it’s apparent that without the filter there is a clear drop in pressure yet before the pressure continues to rise. With activation now taking place we carried out a quantity test to make sure there were no further blockages.
The extra detail you can see with Pico compared to the reports given by serial tools allow you to see much more and give you an overview of the health of the aftertreatment system.
By zooming in to the waveform we can see the sawtooth effect that is taking place. This is caused by the pressure drop after an injection event has taken place. This can be useful in determining whether an injector is partially blocked without removing the unit from the exhaust. By zooming in further again, you can pick out the ripple generated by the pump. Here, we would be looking for something that looked different or a repeating pattern.
Having checked that the rest of the system worked correctly and that the blocked filter was the sole cause of the fault codes and warnings all we had to was order
a new filter plus the necessary gaskets and bolts. Once all was refitted and the codes cleared, the vehicle was left to run and observed with Pico to ensure that DEF was injected – which it did. Thankfully for this vehicle the filters are available separately through the VM.
What I find extraordinary is that the same system is used by other manufacturers yet you cannot buy these filters on their own – you have to replace the whole module, which seems extremely wasteful considering you can prove the rest of the system is working correctly. By replacing just the filter we saved the customer just under £1500.
The question still remains though: what blocked the filter in the first place? Given how clean the fluid was from the tank to the injector module was this something breaking down in the module?
One theory brings us back to our observations at the beginning of the diagnosis. The fittings used to join the pipework from the tank to the injector module appear not to be original. We do know that DEF has corrosive properties that may have caused a reaction to these components which has meant the filter has become blocked by doing its job and filtering this contamination. We didn’t have anything to repair or replace these fittings and with a customer that was waiting the best thing we could do was advise that this may happen again in the future and the remedy would be to replace the pipework from the tank to the injector module.
With all the DEF faults I’ve seen more often than not it’s caused by something else and for the most part the aftertreatment systems are pretty reliable. Fortunately the systems have everything already built in which means using existing sensors, feedback and control circuits can all be easily seen with Pico.
However, ensuring you know how something works is also vital when it comes to diagnosis. Pico is there to support and capture the evidence required to back up any repair.
BIG BUS ROLL OUT
CVW looks at how Freeway Fleet Systems is rolling out a new paperless digital system across McGill's Bus Group’s 700 vehicles.
McGill’s Bus Group (MBG), Britain’s largest independentlyowned bus company, is rolling out a digital system to manage the maintenance of 700 vehicles. Supplied by Freeway Fleet Systems, engineers are being equipped with rugged mobile devices as part of a move to paperless working at seven maintenance facilities across Scotland.
McGill's runs local, city, rural and interurban bus and coach services across Scotland and has trebled in size over the past four years. Operating under the McGill's, Midland Bluebird, Xplore Dundee and BrightBus brands, as well as open-top hop on and hop off tours, airport connections, coach touring and private hire, McGills now
also operates up to 40 coaches as part of a leading strategic partnership with Flixbus.
“With the rapid growth of McGill’s Bus Group in recent years, we'd increasingly become overwhelmed with paperwork and our existing workshop system was at best very clunky. We knew we needed to modernise and move to digital working,” says Russell Henderson, MBG group engineering director.
We have been considering a number of different systems over the past few years and, with their track record and reputation, Freeway emerged as our selected choice. In particular, we were impressed with the adaptability and extensive functionality of their software.”
McGill’s Bus Group see the integration of systems as crucial for the future and plans are in place to link Freeway with existing fleet, operations and accounts systems; notably EP Morris, Omnibus and Sage.
“We really liked the way Freeway was an open system developed to ease integration with other systems. Ultimately that will give us seamless visibility of the status and performance of the fleet, across multiple locations and across different bus operations,” says Henderson.
McGill's Bus Group has been at the forefront on the switch to electric and will shortly reach a landmark figure of 8 million electric-only miles.
Xplore Dundee
McGill’s will be equipping engineers with mobile devices, with initial roll-out at their Xplore Dundee business. A Freeway app provides a digital version of paper job cards and inspection sheets and links wirelessly with a central workshop management system.
Freeway will also be used for managing stores and purchasing, and driver walkaround checks are also ‘going digital’ potentially using existing ticket machines that integrate with Freeway. McGill’s Bus Group also sees great potential in Freeway’s application of Optical Character
Recognition (OCR). “With a fleet of our size dealing with paperwork still affects our productivity so we’re always looking for ways to reduce medial administrative tasks through automation,” says Henderson.
One of the biggest burdens is the timeconsuming task of matching invoices with POs. With Freeway’s OCR this matching is automated so we only have to check invoices if there is an anomaly. This automation will significantly streamline the whole process, freeing up staff to do more important work, strengthening the finance team.”
FINGER ONTHE PULSE
Although commercial vehicles serve as the backbone of many fleets, like any vehicle out on the road there is always the risk of accidents. However, to mitigate collisions, Advanced Driver Assistance Systems (ADAS) are now commonplace. If the vehicle is involved in an accident any issues with the ADAS systems will need to be diagnosed and then calibrated back to the manufacturer's requirements in order for the vehicle to be safe out on the road.
There is a big focus on diagnostics, software and calibrations and there are several trends that workshops and their management teams should be aware of.
Diagnosis and calibration
The first is bringing diagnostic and calibration work in-house. In previous years this type of work would need to be booked into a dealership or have a third party complete the work, but it could add days to a job. This outsourcing was because businesses were not equipped with the correct tools and skills to conduct the work on-site.
However, this has started to change as we move towards 2025. There is a definite shift in businesses’ understanding that this work is a growing opportunity for them and that they can bring it in-house. This has removed the need to outsource, which, in turn, makes the work both time and cost-effective.
Martin Brown, director of innovations at Repairify, reckons trend awareness is key when it comes to calibrations and diagnostics.
The second trend is that businesses are investing in products that are simple to use, providing peace of mind to the user and keeping pace with technology. An example from Repairify’s portfolio is Remote Services. This service has been designed and developed with the user in mind, ensuring calibrations and diagnostics are carried out as easily and efficiently as possible.
“The constant evolution of technology and the growth of ADAS means more and more vehicles require calibrating with OEM tools.”
The offering provides garages and body shops with access to every OEM manufacturer diagnostic tool alongside an IMI-trained technician to assist remotely without repairers having to buy the tools themselves. Even for a thorough pre-scan, Repairify ’s technology has shown its importance in identifying faults that wouldn’t be picked up by aftermarket tools with no access to these modules.
Finally, training is vital. The constant evolution of technology and the growth of ADAS features means more and more vehicles require calibrating with OEM tools. These tools require certain knowledge and skills, which is why businesses are investing in training.
This can be done via a recommended training provider such as the IMI and equips the technicians with the required knowledge and skills to keep in pace with the ever-evolving work that comes onto the workshop floor and the technology within the vehicles coming off the production line. In addition, with the upskilling of the work force, it links back to the first trend which is businesses keeping diagnostics and calibrations jobs in-house rather than outsourcing the work.
As technology continues to evolve, it is more important than ever that businesses are aware of these changes and have action plans to ensure that they are abreast of developments so they are able to provide the requisite work and services.
TURN OVERA NEW LEAF
The
Diesel Technic Parts Specialists share 10 tips for when working with leaf springs.
Even in the days of horse-drawn carriages, leaf springs were used to protect the vehicle and its passengers. While vehicles may have changed over the years, the purpose of leaf springs has remained the same. Today they are an important part of the chassis, including their role as a safety feature.
Leaf springs can have a wide variety of designs. One example is a solid leaf spring package, which is mainly used in the construction sector. In this context, the lifetime of such a leaf spring is significantly longer than that of an air suspension.
An effective leaf spring plays a decisive role, as it absorbs longitudinal and transverse forces with the result that it functions as an important component of the chassis. It also provides a safe driving experience and protects passengers, cargo and vehicle components from vibrations.
“Leaf springs are particularly advantageous on uneven terrain or in bad road conditions.”
This is particularly advantageous on uneven terrain or in bad road conditions. Centre bolts, spring clamps and spring clips ensure that the spring stays in place. Depending on the vehicle type, leaf springs can be used in combination with the controllable air springs to enable the raising and lowering of the vehicle.
Here are top ten tips when working with leaf springs:
After repairing or replacing parts within the suspension, the axle must be measured to ensure that the wheels track correctly and are properly aligned. In the case of misalignment, it will be necessary to recalibrate. This will ensure that optimal performance and handling is achieved.
When replacing leaf springs, it is essential to replace them with the same type of spring. This is due to different types of leaf spring being designed to handle specific load capacities. The number of springs used, and the strength of the springs, is particularly important to prevent the risk of failure, complications due to overloading and driver discomfort.
Splish-splash: always ensure leaf springs are completely clean and free from dirt, mud and deicing salt. If leaf springs are not
“When replacing leaf springs, it is essential to replace them with the same type of spring.”
kept clean the corrosion process can be accelerated and lead to premature abrasion. To avoid the buildup of dirt and unwanted debris, it is best to wash the underside of the vehicle as well as the leaf springs regularly with soap and water.
To ensure maximum safety turn the steering wheel straight ahead in the direction of travel.
Before fastening bolts are tightened, the vehicle must be lowered. The bolts must then be tightened to the torque specified by the manufacturer. This is to ensure that the spring is not installed under tension and is installed in the correct position it will experience during normal use.
Ensure the correct assembly/ disassembly tools are used throughout the process.
Clean and sanitize the fixing holes for the bolts to ensure smooth threading.
Before fitting, check that the fixing screw (centre bolt) for the individual leaf springs is tight and not loose.
Spring holders are tightened with a torque. To avoid excessive stress please ensure that spring holders are not under tension after tightening. If necessary, turn the nut back slightly after the torque has been reached so that the spring holder is tension-free.
For heavy commercial vehicles, it is important to check whether both sides of the suspension system are in working order or need to be replaced. If the spring is only replaced on one side, the vehicle may lean slightly as the old spring has already been subjected to a lot of strain.
AXLES & SUSPENSION
READY, THREADY, GO!
The first UK sale of Thread Saver has already shown its potential for cutting costs and saving time. A bus operator with a severely damaged axle thread was able to complete the repair on the same day it received the tool, saving at least £10,000 by avoiding the replacement of costly components, according to the distributor.
Manufactured in Germany and Estonia by Silbertool Solutions, Thread Saver reforms rather than cuts damaged threads. Traditional thread repair tools, such as thread cutting dies, remove material during the process, weakening the thread. Thread Saver takes the opposite approach. Instead it restores the thread without any material loss, maintaining its strength and load capacity after the repair. The result – a reliable repair without compromising the integrity of the thread.
Repair time savings
Workshops using Thread Saver can expect to see time savings during repairs. According to Premier Pits, the tool can repair a damaged axle thread in as little as 31 seconds, with no need to strip down the hub or send axles away for repair, minimizing vehicle downtime and maximizing productivity. The repair process itself is straightforward but requires precision. First, the damaged thread is inspected to determine the extent of the damage. The operator then selects the appropriate Thread Saver tool size based on the thread specifications and cleans the area to remove any debris or contaminants. Once the tool is aligned with the existing thread, a lubricant is applied to ease handling, and the thread is gently reformed using the tool. Afterward, a gauge is used to verify that the repaired thread meets required specifications.
First spotted at this year’s Road Transport Expo (RTX), Thread Saver gives workshops a quick and costeffective method of repairing damaged axle threads and wheel studs. According to UK distributor Premier Pits, repairs can take as little as 31 seconds. CVW reports.
According to tests conducted by the Material Testing Institute Hannover (MPA), threads repaired using Thread Saver can withstand the same static and dynamic loads as new, undamaged threads. The repaired threads even demonstrated a higher fatigue endurance limit, ensuring that they remain robust over time. The tool is versatile too. It comes in kit form, complete with the Thread Saver XR-120 for axles (with 1.5mm and 1.5mm LH, 2.0mm and 12 TPI roller sets), and the X-Nut XL for use on wheel studs. As a result, the distributor says, it is suitable for commercial vehicles, public service vehicles (PSVs), and even rail applications. The tool is also rugged enough to perform reliably in demanding workshop environments. It is made from premium-grade stainless steel that is vacuum-hardened and tempered to 58 HRC, a process that ensures low wear and high ductility. It is also light and compact,
making it easy to store and carry.
Premier Pits suggests that the cost savings achieved through Thread Saver extend far beyond the initial purchase price. By repairing instead of replacing expensive components, workshops can save both time and money. In the case of the bus operator who made the first UK purchase, Premier Pits points to the repair’s rapid completion and the substantial financial benefit as evidence that Thread Saver can provide a quick return on investment.
The manufacturer behind Thread Saver has a reputation for producing high-quality equipment not only for the automotive industry but also for specialized, safetycritical situations. One project involved creating a 300 kg tool for a one-time use, repairing threads on pipes leading into the incinerator of a nuclear reactor. This tool had to be operated from behind a lead curtain, five meters above the ground, through 2mm gaps.
Premier offer
Another project required a tool for fixing hundreds of threads on bridge foundations over a highway, with each thread passing micro-crack detection tests, and another for rolling new threads on studs of a water retention dam, allowing for tension tests.
The manufacturer’s UK partner, Spalding-based Premier Pits has served industries such as HGV, bus, coach, rail, and defence for more than 40 years and is best known for designing, manufacturing, and installing a wide range of prefabricated vehicle pits, under-chassis wash systems, and ATF packages and buildings.
CVW visited Bridgestone’s Bandag Hotread plant in Bourne, Lincs, to find out more about the company’s hot cure retread tyre offering.
SEEKING THE CURE
QWhy the emphasis on hot cure products?
With the launch of Hotread, Bandag now offers both pre-cured and mould-cured retreads product solutions. Due to customer demand, we are now ramping up production of hot-cure retreads. These mould-cured retread tyres feature the same performance as the Bandag premium pre-cured tread range.
We will continue to offer precure (cold) retreads in addition toHotread, allowing fleets to select the right tyre for their application and wheel position. One important feature is the new sidewall design, ensuring the tyres have a look-like-new appearance, which more and more customers want.
QWhat is currently the split between hot and cold?
For many years the plant has used both production processes, but with cold contributing around 60% of the total volume. With the new focus on hotcure products we expect the production to more closely mirror the UK market which is estimated at around 75% hot retreads.
In Europe the market is split roughly 50/50 between hot and cold, while in North America (the world’s largest retread market) cold makes up the vast majority. Both technologies are used in climates ranging from the Northern Scandinavia to the Sahara.
“The UK market is estimated at around 75% hot retreads.”
Q What are the benefits of retread tyres?
There are both environmental and sustainable benefits from retread tyres. Retread is economically good for the customer and it is environmentally good for society, so it makes economic and environmental sense. Retreads extend the wear life and performance of premium tyres, delivering near-new tyre performance while lowering the total tyre cost per kilometre for fleet owners and managers.
Retread tyres use less than one-third the amount of raw materials used in new tyres and enable the reuse of other tyre components, such as the casing. The retreading solution significantly contributes to the reduction of discarded tyres as well as the reduction of waste in communities.
Q Why is retread such a good option?
■ Significantly lower total tyre cost per km
■ Reliability and performance similar to new tyres
■ Reduced waste, raw materials consumption and carbon emissions
■ Fast, flexible and high-quality service
Q Why do casings matter?
Premium quality truck tyres are designed and built to give superior performance through their first life and continue to be robust enough to continue giving great performance in their second or third lives in a quality retread.
It is critical for the overall performance and reliability of a retread that good quality casings are selected and utilised. Only casings that have passed stringent quality checks are used in the latest generation patterns. Other premium manufacturer casings are utilised in our other products, but again only after passing our stringent inspection processes.
QAre retreads enjoying something of a renaissance?
More and more companies are putting sustainability higher on their agendas, and this is leading to increased opportunities to show that retreading has a lot of benefits for fleets. Fleets can save a significant amount of money and contribute to a sustainable society.
For example, Bandag retreads contain up to 75% recycled and reused material, contributing to sustainability and the circular economy. Reusing the worn casing as the main retread component creates a saving of up to 70l of oil, up to 32kg of rubber and 14kg of steel. Bandag also significantly contributes to a decrease in tyre cost per kilometre for fleets, equivalent to an up to 30% reduction in cost compared to a new tyre. Re-treaded tyres generate up to 80% fewer CO2 and green house gas emissions than new tyres in production.
Q Should there be an EU tyre label for retreads? Why?
We are still waiting for the EU regulator to publish a proposal for TBR retread labelling. This means that at the moment we can’t give an answer on how this will impact operations as we first need to get some more clarity around the test method and grading approach. However, we believe in giving customers the information to allow them to make informed decisions and therefore we welcome the opportunity for our retreads to further demonstrate their advantages through labelling.
Q What plans are there for retread business to go carbon neutral? What are the time scales and how does it intend to do this?
Bridgestone has stated its aim for the entire corporation to use 100% sustainable materials and be carbon neutral by 2050. By 2030 it is aiming for a 50% reduction in CO2 emissions from the 2019 level, and steady
progress is already being made towards these targets.
Retreading plays a critical role in improved resource productivity and reduced CO2 emissions and this is why Bridgestone has been accelerating its efforts to promote the benefits of retreading to its customers.
QWhat is Fleetcare?
Fleetcare is an integrated tyre and fleet management solution that combines our premium tyres and tyre management solutions with Webfleet. It provides a host of benefits, with total cost of ownership reduction at the forefront.
Customer satisfaction, time saving, regulatory compliance and increased sustainability, safety and security are also provided in one user-friendly package. Fleetcare delivers business benefits through IoT and data driven insights and services. If you’re looking for a comprehensive and modular solution package that adds cost control and automation to your daily work, then we might just have the answer!
QWhat is Enliten technology?
Enliten is a technology which reduces the rolling resistance of a tyre by up to 30%, and weight by up to 20%. It extends the driving range of EVs and also contributes to reducing environmental impact thanks to improved resource productivity.
“Retreading plays a critical role in improved resource productivity and reduced CO2 emissions.”
This enables tyres with embedded Enliten technology to help reduce fuel consumption and CO2 emissions in combustion vehicles, while also extending battery life and vehicle range in electric vehicles.
QWhat will a connected tyre world look like in the future and how are tyres getting ‘smarter’?
We predict that connected vehicles will soon use data from tyres to feedback real time information about driving conditions (e.g. icy sections on roads) road conditions (e.g. pot holes) and driving styles (e.g. harsh braking) amongst many others. If a council receives data that tyres are slipping or vehicles are braking harshly at a particular junction, they can focus on improving the
conditions there – saving costs and improving safety.
Intelligent tyres are the future. Tyres that communicate both with the vehicle, end user and tyre consultant/fitter will become the norm in years to come. RFID (Radio Frequency Identification) is the starting point and this technology is already advancing at speed with new technology like pressure sensing, temperature reading, tread depth measurement, mileage recording and many more features.
Tyre systems that communicate with the end user on their mobile or send an email message to a tyre dealer are already available for Commercial operations (truck fleets) and these systems will be rolled out to other vehicle groups over time.
Bridgestone is investing heavily and working with IT partners in this area of intelligent and connected tyres.
TUNNELL VISION
point for Surrey-based Tunnell Grab Services. CVW reports.
Since its formation in 2001, Tunnell Grab Services (TGS) has provided specialist grab, plant and digger hire, alongside aggregate supplies and contract work for domestic, commercial and industrial customers throughout the south east of England. Sporting a mixed fleet of specialist vehicles, consisting of tipper grab lorries, diggers and dumper trucks, the operator has firmly established itself as a benchmark for reliability, efficiency, and customer service in the construction and waste management sectors.
It’s a reputation that continues to flourish – and one that is owed in part to the company’s decision to utilise Continental’s multidisciplinary approach to rubber. TGS trucks have, for more than a decade, been fitted with Continental family tyres.
“After we decided to equip our fleet with products from Conti’s tyre catalogue, it wasn’t long before we began to realise the gains of our investment,” said Gavin Tunnell, owner of TGS. “From a lowest overall driving cost perspective, vehicles in our fleet equipped with these tyres can run further for longer periods, with fewer breakdowns. Punctures, in particular, have been majorly reduced.
“Unlike other products we’ve tried before, the tyres are nicely suited for the difficult operating conditions both in and out of landfill sites, and on off-road jobs where large amounts of traction are required,” Gavin explains. More broadly, their holistic approach to tyre solutions directly meets the specific needs of our business, and their premium product offering represents unrivalled value for money.”
For TGS, products alone aren’t always enough to sustain and grow a business relationship. The company firmly believes that quality customer service is a crucial contributor to success.
“Over the years, our relationship with the tyre team has gone from strength to strength, thanks to their unwavering commitment to excellence in both products and services,” says Gavin. Their personalised approach consistently demonstrates an ability to listen to and understand our needs, which are met with carefully tailored solutions.”
Continental maintains strong working relationships with its retail partners. In TGS’s case, the tyres are purchased and managed through Fuller Tyres – one of these business’ authorised tyre distributors.
Initially supplying car tyres to rental fleets at London’s Heathrow and Gatwick airports, Fuller rapidly grew to become a supplier of consumer and commercial vehicle tyres for a wide array of on- and off-
“From an overall driving cost perspective, vehicles equipped with these tyres run further for longer periods, with fewer breakdowns.”
road applications. With a reputation for quality products and services, TGS is one of thousands of customers embracing a positive relationship with Fuller Tyres.
“For operators looking to upgrade their tyres, particularly in industries that heavily rely on off-road rubber such as the grab and concrete sectors, opting for Continental's construction tyres, just as we have, is a nobrainer,” Gavin concludes.
“The tyres offer the reliability and performance essential for our operations –and it’s all complemented by exceptional customer service that ensures we have the support we need, whenever we need it.”
LASER FOCUS
Supertracker has updated its commercial laser alignment system to operate using green lasers. The use of green lasers is well reported to improve the visibility, precision and clarity of the laser line.
The human eye is inherently more sensitive to green light due to the photopic response, a phenomenon where the eye's peak sensitivity falls around 555 nanometres, which coincides with the wavelength of green light. This heightened sensitivity allows green lasers to appear brighter and more visible than red lasers to the human eye.
Green lasers are also visible in a much wider range of light conditions, meaning its effective for all year round work, indoors and out as well as they can travel over longer distances. They also offer clarity and precision due to the brightness, all important factors in environments requiring pinpoint accuracy.
Supertracker has now brought this enhancement to it commercial wheel alignment system. The visibility, battery life and price of the green laser in brighter conditions is claimed to set the Supertracker STRT4 apart from its competition.
Proper wheel alignment in enhances safety, improves fuel efficiency, reduces wear on tires and mechanical components, and lowers overall operating costs. For fleet operators, investing in regular alignment checks is essential for maintaining a productive, cost-effective, and safe operation.
The STR T4 is a straightforward system for wheel alignment checks on twin steer vehicles including; heavy duty trucks, haulage trucks, tipper trucks, cement mixes, buses, fire trucks and emergency vehicles. Manufactured in the UK and supplied as standard with:
■ Two laser measuring heads;
■ Four wheel hangers;
■ Two 2nd steer mirror heads;
■ One trolley c/w battery charging system;
■ Two rear Scales;
■ One steering wheel lock;
■ Two pairs of truck dished turn plates and bases.
Neatly stored on a stylish, manoeuvrable trolley, the complete system provides everything required for easily measuring toe and trust as standard, it can also be upgraded to measure camber and caster with the use of a digital camber caster gauge.
All wheel alignment machines are supported by a national field service aftercare support and wheel alignment sales specialists, as well as readily available parts and accessories.
TO VISIT SUPERTRACKER’S WHEEL
ALIGNMENT STUDIO IN WORKSOP AND TEST THE WHEEL ALIGNMENT RANGE; WWW.RDR.LINK/VBO018
TEMPERATURE MEASURE
ot Spot Markers are small, colourchanging stickers designed to warn of a developing wheel end component failure by visually notifying the user of a hidden wheel issue that could otherwise be dangerous and costly.
Once the hub has exceeded 180°C, the sticker turns orange. Having changed to orange, the sticker will remain that way –meaning the visual cue shouldn't be missed.
Manufactured with durable materials and backed with 3M self-adhesive, the 32mm sticker is small enough to be discreet to the public but noticeable to those doing
The sticker is easy to use: clean the external metallic side of the wheel hub bearing housing with an alcohol wipe, lightly key the surface – and apply.
Melting indicators
Parma sourced the product as an answer to reports of wheel nut indicators designed to withstand high temperatures, were starting to melt, regardless of supplier and brand.
Unfortunately, the answer was not that the indicator product wasn't working as intended, but that wheels were experiencing faults. Vehicles that do not use such indicators could have issues go unnoticed for even longer, and those that do are wasting products. Situations such as these can be extremely costly in further repairs and delays, and dangerous if something were to happen on the road.
“These stickers remove the element of the unknown regarding wheel temperature safety. At 180˚, the hub is far too hot and is usually the result of a parts failure” says Parma Group's Founder and Director, Marc Pittock. “These will enhance the safety of all road users, as well as keeping repair costs down by catching these issues sooner.”
TYRE ABOUT TOWN
Designed specifically for the challenges of city streets — frequent stops, varying road conditions, and heavy traffic — the Conti Urban HA 5 tyre from Continental promises significant improvements in tyre longevity, fuel efficiency, and passenger comfort.
One of the standout features of the Conti Urban HA 5 is its enhanced tread cap and base compound, optimised for urban environments. This results in higher mileage and fewer tyre replacements, lowering overall costs for fleet operators while reducing CO2 emissions. By extending tyre life, operators can enjoy substantial savings, both economically and environmentally.
Fuel efficiency is increased by the tyre’s improved rolling resistance, which reduces the energy needed to move vehicles. This translates into lower fuel consumption for traditional buses and extended battery life for electric fleets –a crucial advantage as urban transport increasingly shifts towards electrification.
The advanced tread pattern not only boosts fuel efficiency but also maintains excellent wet performance, while Continental’s multi-pitch technology earning it an A-rating for noise on the EU tyre label.
For fleet managers looking to optimise performance, the Conti Urban HA 5 can be equipped with ContiConnect sensors. This optional feature offers real-time digital monitoring of tyre pressure and temperature, allowing for predictive maintenance and preventing costly, unexpected downtimes.
Fully compliant with the latest EU regulations on sustainability and environmental impact, the Conti Urban HA 5 is available in 275/70 R 22.5. The following sizes will be launched later: 245/70 R 19.5, 265/70 R 19.5, 315/60 R 22.5.
NEW DIMENSIONS
Apollo Tyres’ EnduRace line is designed to cater to the demanding needs of commercial vehicles, focusing on durability, performance and costefficiency. Recently, Apollo Tyres introduced a range of new EnduRace variants, including launching into the 19.5” category for the first time. This dimension offers a balance between the heavy-duty capacity of larger wheels and the agility of smaller ones. Bridging the gap between the 17.5” and 22.5” commercial vehicle ranges, the 19.5” tyre helps fleet operators for their ability to support substantial loads while delivering durability, stability and cost-effectiveness.
Apollo’s latest products are the EnduRace RD HD drive tyre and the EnduRace RT HD+ trailer tyre. Engineered specifically for heavyduty trucks and trailers, both products exceed the European regulatory standard for durability – by 150% and 170%, respectively. This robust construction not only enhances retreading potential but also significantly reduces life cycle costs for operators.
The EnduRace RD HD stands out with its ‘openblock’ tread pattern, providing all-season traction and water displacement for reliable grip in
wet conditions. Its reinforced casing and slow-wearing compound further extend its lifespan while maintaining low noise levels.
Complementing this, the EnduRace RT HD+ trailer tyre is designed for high-demand applications, featuring wide shoulders and a scrub-resistant compound for even wear and excellent abrasion resistance. Its high mileage and ‘K’ speed rating make it a trustworthy choice for fleet operators.
GTRAILING AHEAD TREAD LIGHTLY
iti Tire has launched the Giti GTR956 HD Combi Road, its latest trailer tyre for severe Heavy Duty (HD) regional applications. Initially available in size 385/65R22.5 – with 265/70R19.5 planned for quarter four – the tyre is designed for rugged working sites, heavy loads, mountainous and winding roads, rough terrains and has limited off-road capacity.
The Giti GTR956 HD will sit alongside the Giti GTR955 Combi Road in the trailer portfolio, with the new pattern having an added emphasis in robustness and chunking resistance. The results are achieved through a reinforced structure and newly developed
Kumho Tyre UK offers an extensive range of tyres, designed to enhance performance and reliability across various driving conditions. Its light commercial vehicle (LCV) offerings include the PorTran KC53, CX11 and CW51. The KC53 is engineered for highway performance, featuring a robust design that ensures outstanding dry handling, even under maximum load conditions. The heavy-duty tyre boasts a wide tread and stable block pattern, broad cross-grooves for
tread compound designed to work in severe regional conditions and heavy duty operations. Solid and wide tread shoulders delivery durability and competitive mileage, especially in rough working sites and during difficult vehicles maneuvers, while longitudinal zig-zag tread grooves ensure effective water drainage, high grip characteristics in all weather conditions and reduced stone trappings. The tyre carries the three-peak mountain snowflake (3PMSF) symbol.
precise steering, and wide straight circumferential grooves that minimise the risk of aquaplaning. Additionally, a robust carcass improves traction and increases mileage, while low rolling resistance optimises fuel efficiency. The KC53 is available in 38 H, T, R and Q rated sizes ranging from 155R13C to 215/60R17C.
The PorTran 4S CX11 is claimed to combine the strengths of the company’s allseason SOLUS 4S HA32 passenger car pattern with the existing winter specification of the PorTran CW51. Available in 22 sizes ranging from 15 to 17”, it accommodates popular models such as the Ford Transit, Mercedes
Sprinter, Vauxhall Vivaro, and Volkswagen Transporter.
The truck tyre range includes the KLT23, a top choice for mega trailers, known for delivering excellent mileage and reliability.
Kumho's multipurpose line-up include the KXA10 and KXA11 all-position tyres, available in sizes 245/70R19.5, 285/70R19.5, 385/65R22.5 and 385/55R22.5. These tyres offer superior all-season performance and increased mileage to meet varied operational demands.
FOR MORE INFORMATION, WWW.RDR.LINK/VBO023
KUMHO TYRE UK
GITI TIRE
STEER, DRIVE AND TRAILER
YOKOHAMA
Yokohama has introduced its comprehensive range of truck and bus tyres to the UK. While the comprehensive range will be available to cover all the major commercial vehicle applications, Yokohama’s flagship products for national and regional operations are already in stock and available to order for evaluation purposes or immediate fleet deployment.
The Yokohama 124R pattern for steer axles, (or 124RA all position pattern in 17.5” and 19.5”), has tread features to improve life and traction, including grooves and sipes specifically designed to reduce premature shoulder step down and uneven wear, stone ejectors and rigid shoulder ribs to aid straight line stability. The 704R drive axle tyre has a variety of design elements to aid mileage and
WHEELY LIGHT, WHEELY TOUGH
MAXION WHEELS
Maxion Wheels, the world’s largest wheel manufacturer, has unveiled a line of lightweight, corrosion-resistant forged aluminium truck wheels designed to meet the diverse needs of truck, trailer, bus, and tanker OEMs, as well as aftermarket customers. The initial product offering will include the most popular wheel sizes, available in three levels of finish, each meeting the highest standards for strength and longevity.
Vehicle efficiency
Maxion says these wheels will boost vehicle efficiency while providing exceptional resistance to corrosion, making them a reliable choice for demanding road conditions.
Manufactured through a joint venture with Maxion’s long-term business partner, Inci Holding, the wheels will be produced at a state-of-the-art, 20,000m2 plant in Manisa, Turkey.
traction – extra wide directional tread, high rigidity blocks and a newly developed compound all contribute to even wear, long tread life and improve traction particularly in wet and cold conditions.
Wet traction
Yokohama’s RY357 trailer tyre with 5-rib tread design is developed for even wear and wet traction with resistance to shoulder wear and the casing is specially designed to be well-suited for retreading.
In addition to its tyres for national/ regional operations, the Yokohama range features products suitable for on/off road applications, long haul operations, coach and city bus fleets.
FOUNDATION COURSE
Fleet maintenance is on the cusp of an Artificial Intelligence (AI) revolution. But without a strong digital foundation, the benefits could remain out of reach, warns Patrick Tandy, managing director at Freeway Fleet Systems.
Artificial Intelligence is about to start a step-change in fleet maintenance, providing operators with greater control over all the many elements than ever before to create leaner, ever more efficient and economical logistics. But tapping into AI’s full potential requires more than just plugging it in. To get it right, fleet operators need a solid digital foundation, structured data, and strong leadership to steer the ship.
Before AI can deliver its benefits, your fleet operations must be fully digital. Paperbased systems or even computerized setups that just mimic paper processes won't cut it. AI needs real-time, accurate data to work properly. Without it, the insights you want –such as predicting maintenance needs or cutting costs –won’t happen.
A common mistake that many companies make is simply transferring their old processes onto a computer. This misses the point of going digital. Instead of entering data at the end of a shift, a true digital system lets your team input and access information
as it happens. Whether it's reporting a vehicle defect or updating maintenance schedules, this live data becomes the backbone of your AI-powered system. AI works best when it has structured data. For example, instead of a driver typing in “mirror broken” as free text, a digital system would let them pick from predefined options like “bent wing mirror arm.” This structured data is easier for AI to analyse, leading to be%tter predictions and faster decision-making. It also speeds up the reporting process and links directly to known repair times and parts needed –saving time and money for your operation. A digital fleet management platform should cover everything, from tracking assets and reporting defects to planning maintenance and controlling inventory. AI can then connect the dots, recognizing patterns and offering suggestions based on the complete picture. If you’re missing key information –maintenance history, for example, or parts usage –AI’s recommendations won’t be as useful.
“Structured data is easier for AI to analyse, leading to better predictions and faster decision-making.”
But AI isn’t a replacement for human expertise. It needs someone with experience to guide it. You need to know your goals before you can make the most of AI. For example, if your priority is keeping vehicle downtime to a minimum, AI can help. But you also need to balance that with the workload on your maintenance team, so they don’t burn out. Clear objectives ensure AI is giving you the right insights for your business.
As AI technology advances, it will open up even more opportunities –along with new challenges. Here are three key points to keep in mind: Future proofing, control and security.
Inevitably, AI will develop so the technology you implement today must adapt to future innovations. Ensure your system connects to cloud-based data tools, so when the next iterations of AI arrive you can adopt them without a major overhaul.
Stay in control of your data: AI may provide sophisticated results, but you should always be able to verify the logic behind its recommendations. Make sure your system allows you to review the data inputs, so you know exactly how AI is arriving at its conclusions.
Keep your data secure: ensure that your AI tools give you full control over how your data is stored and used. Choose systems that use secure methods, like API keys, so your data isn’t stored by third parties. This keeps your sensitive information safe.
In the end, AI is a powerful tool that, when combined with a digital fleet management system, can transform how you operate. But it’s not magic — it’s about working smarter. By building a strong digital foundation, using structured data, and staying in control of your insights, you can unlock the full potential of AI while future-proofing your fleet.
BELT AND BRACES
The team at febi look at the make-up of an auxiliary belt and some problems, causes and solutions when it comes to maintaining them.
The auxiliary belt is responsible for driving auxiliary units such as the alternator, water pump, radiator fan, and air conditioning compressor. The belt is driven by the crankshaft pulley and transmits the engine’s power to the pulleys of the auxiliary units via the friction of the side ribbed flanks on the underside of the belt.
The top surface of a premium belt is made of durable EPDM – ethylene propylene diene monomer (M-class) rubber – a material extremely resistant to wear and temperatures ranging from -40°C to 130°C.
The tension cord layer made of polyester fabric achieves the high tensile strength and stability, which allows very high torque to be transmitted with minimal elongation over the belt’s complete lifespan. The cushion compound made of high-adhesive polychloroprene rubber embeds the polyester fabrics safely and reliably connects the EPDM top surface and the base compound.
The polychloroprene rubber base compound ensures that the belt can reliably withstand the forces generated by transferring large amounts of power while operating at high speeds. This state-of-theart design and the use of high quality materials in construction means febi auxiliary belts are the embodiment of functionality, reliability, and longevity.
Time for a change?
Belt maintenance, both regular and preventative, is essential to ensure reliability. As its functional principle is based on friction, normal abrasion over time causes the auxiliary belt to become thinner.
The good news, however, is that auxiliary belts today are incredibly durable and very rarely break. How frequently one is replaced depends on several factors; including what the vehicle is used for, where it’s driven, how the belt is made, and the recommendations of the vehicle manufacturer. External influences such as environmental contamination or extreme temperatures also have a great influence on the longevity of the belt.
It is not just the belt that wears, other components such as the idler and tensioner pulleys and the belt tensioners are also subject to degradation over time. Typical failures include excessive play or rough running of the bearings. These components don’t have to be changed as often as the belt itself but should be checked every time a new one is installed to ensure the
complete auxiliary belt drive system functions correctly.
To prevent unexpected and premature vehicle breakdowns, checking all auxiliary belt drive components every 60,000km or once a year, and to change all components as a preventive measure every 120,000km is recommended. Vehicles that operate in harsh conditions such as on a construction site should be serviced even earlier.
In addition to auxiliary belts, febi also offers many other aux belt drive components including tensioner assemblies, tensioner pulleys, and idler pulleys. To shorten the search for individual components and minimise the calculable downtime of vehicles, febi offers numerous complete Auxiliary Belt Kits which include all needed vehicle specific components.
Proper storage
The quality of a belt can be maintained for years if stored properly in a dry place between +15 to +25˚C. Incorrect storage, e.g. exposure to oxygen, light, extreme temperatures, or moisture, can change belt’s physical properties and render it unusable.
The drive belts should remain in their original packaging and be stored without tension until they are used. When stacking, a height of 300mm should not be exceeded, otherwise deformation may occur.
FOR MORE INFORMATION, WWW.RDR.LINK/VBO027
Top surface
Cushion compound Base compound
Tension cord
LET IT SLIDE POWER-TEC
Meet the carbon-steel slide hammer (part number 92096) with a hefty 2.5kg striking weight, designed to make paintless dent repair (PDR) easier. Use it with hot glue pads (recommended part number 92096) to effortlessly remove dents from vehicle bodywork without harming the paint. The removable adaptor allows it to connect directly to a wide range of different style glue pads/pulling tabs, Power-TEC part numbers 92095, 92378, and 92401 for example. At 52cm long with a 2.5kg striking weight, it’s designed for precision as well as power. The shape of the weight makes it easily controllable for just the right amount of pulling power.
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DOUBLE TORQUE LASER TOOLS
Laser tools has introduced two new torque wrenches, a 3/4in drive version (part number 8876) that has a range of 200 to 800Nm (150 to 600lb-ft) and a 1in drive version (part number 8877) with a range of 300 to 1000Nm (200 to 750lb-ft). Equipped with a tough 36-tooth ratchet mechanism, these robust tools also feature a push-through drive, allowing for torque application in both clockwise and anticlockwise directions. Furthermore, the breakback mechanism provides a clear indication when the desired torque is reached by pivoting back at the joint, helping to prevent over-torquing. To assist with storage and make transport easier, the torque wrenches feature a two-piece construction and are supplied in a sturdy case.
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LIFTED UP GYS
The GYS multitool truck aims to offer a lifting solution for vehicle maintenance jobs. This heavy-duty workshop crane simplifies physically demanding tasks like fitting or removing tyres, wheel hubs, brake discs/callipers, batteries, and countless other applications. It can lift up to 200kg to a height of 1.8m and includes lifting accessories such as a chain, cable, winch, hook and cylinder. The multitool truck also features lifting hooks for brake callipers and batteries, as well as a lifting fork for wheels, making it indispensable in a vehicle workshop. Its fully adjustable legs and arm allow easy access to confined areas.
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CORDLESS CONVENIENCE MIRKA
Mirka UK is expanding its belt sander range with the new lightweight Mirka FBS-B battery file belt sanders, designed to make cleaning up welding seams and spot welds easier and more efficient. The Mirka FBS-B 13, designed for wider belts, and the Mirka FBS-B 10, designed for narrower belts and because the sanders are both cordless, accessing difficult spots is made easier. The sanders feature a lightweight, ergonomic design which is said to make gripping the tool easier on the hands and joints. They also feature a protective flap on the handle for protection and a step-less trigger to adjust the speed of the sander easily from 2,200 rpm and 17,000 rpm. In
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WRENCHES OF ALL SIZES LASER TOOLS
This ratchet flare nut wrench set (part number 8874) is new from Laser Tools and features six crowfoot-style wrenches, in 10mm, 12mm, 13mm, 14mm, 17mm and 19mm sizes. These are suitable for use on compression joint fittings, brake pipes, hydraulic pipes and wired sensors. A crowfoot wrench allows vertical access to fasteners when access is limited as well as allowing fitment around a brake or fuel pipe or exhaust sensor. They are used with a 3/8in square drive extension bar and feature a spring-loaded quick snap design, allowing them to stay in the open position when placing around the pipe or wiring. This, together with their ratcheting action, makes them ideal for use in confined areas.
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TAKE YOUR PICK LASER TOOLS
Laser Tools has also introduced a new 4-piece mini hook and pick set (part number 8888), that is insulated and manufactured to IEC60900 standards. That means they’re safe to use on live circuits up to 1000V AC and 1500V DC. Each tool is 145mm long and made from sturdy stainless steel. The handles are made comfortable by the PP+TPR soft grip, and there’s even a hanging hole for easy storage. The shaft of the pick is insulated for additional safety, with only the pick-head left bare. The set includes a small angle hook, a 90° hook, a full hook, and a straight pick.
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CV EGR COOLERS NISSENS
As EGR systems are used equally in the CV sector as in the passenger car and light commercial vehicle markets, Nissens has taken the step to embrace the CV service and repair community and offer an initial range of 15 EGR coolers that cater for 37 original equipment (OE) part numbers, covering many of Europe's most popular truck and bus applications.
These new CV EGR coolers are said to be naturally marked out by excellent product quality to allow them to conform to the company's genuine Nissens quality standards. These benchmarks include undergoing a wide variety of tests, carried out both internally and externally, and incorporate many design and material improvements that contribute to their high thermal performance and overall durability.
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UPGRADED PACKAGING LIQUI MOLY
Liqui Moly has made its packaging more environmentally friendly, with its bag-in-box packaging system. Compared to conventional 20l plastic canisters, it uses significantly less plastic waste and the additional variant also fits into the Liqui Moly oil cabinet. The exterior of the bag-in-box packaging consists of coated, waterproof cardboard. It contains a fully recyclable plastic bag, which uses 90% less plastic than a conventional 20l canister. During the development phase, when it came to storage in the garage, a key requirement was the bag-in-box should fit in the Liqui Moly oil cabinet which the company has successfully achieved.
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STORAGE SOLUTIONS STRAIGHTSET
Straightset has launched its latest workshop furniture brochure which highlights its range of storage and benching solutions designed to create professional, organised, and highly efficient workspaces. The workbench system offers a variety of modular solutions, including the single tool bench which features six drawers in various depths, lockable cabinets and non-slip drawer mats with a 100kg capacity per drawer; the double bench which is a larger bench offering ten drawers with a full-width top drawer, lockable cabinets, and the same 100kg capacity per drawer and; the large double tool bench with drawers which includes 12 drawers, offering maximum storage capacity.
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ALL CHARGED UP ODYSSEY
SANDING AWAY POWER-TEC
This new electric dual-action sander from Power-Tech (part number 92696) is designed to accommodate 150mm (6in) hook-and-loop sanding discs, specifically those with dust extraction holes. It also has durable composite housing with a soft rubber grip, which minimises vibration during operation, ensuring enhanced operatorsafety, comfort and control
Additionally, it includes a rear-facing exhaust port, designed to integrate with dust extraction systems. The sander is supplied with a 4-metre power cable, fitted with a 240V 13-amp BS plug, backing pad, wrench, and central vacuum adaptor. CE & RoHS compliant for safety and environmental standards.
At the heart of this tool is a powerful 350W brushless motor, offering a ninestage variable speed control ranging from 2,000 to 10,000 RPM.
Advanced features include a softstart function that prevents accidental gouging of the work surface during startup, together with a downforce overload indicator that alerts users to excessive pressure, helping to protect the motor and improve sanding consistency. The temperature monitor automatically shuts down the unit if overheating is detected, safeguarding the motor and extending its lifespan.
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EnerSys, the global leader in stored energy solutions for industrial applications and manufacturer of Odyssey batteries is launching a new range of chargers. The Odyssey battery to chargers are said to be able efficiently charge high-quality brands of Absorbed Glass Mat (AGM) batteries, including Odyssey battery models, as well as flooded lead acid and lithium chemistries. They are also engineered with built-in temperature controls and a battery status indicator. The portfolio of Odyssey battery chargers can be used to recharge batteries for a variety of vehicle applications including automotive/truck, powersports, marine, recreational vehicles, heavy-duty, fleet and auxiliary. They are also lightweight, highly portable and compatible with most 12-volt battery models.
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DIGITAL DIGEST
NOVEMBER’S TOPFIVE 3
helpful business tips, it’s a great source of information right at your fingertips. This month, CVW’s Freya Coleman takes a look back at the most popular articles on the website this the past month.
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1 TESTING TESTING
Kicking off this month’s list of popular online articles, Chris Bailey from BowmonkTapley walks CVW ’s readers through the important stages of conducting a brake decelerometer test!
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BALANCING THE BOOKS
Everyone is feeling the effects of the ongoing cost-of-living crisis, so in this next top article Bridgestone has revealed a way to help save thousands of pounds each year to help your workshop balance the books.
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BEHIND THE SCENES
Ever wondered what the inside of a Mercedes-Benz approved body shop looks like? Then look no further than this next article, looking inside the Sparshatt Truck and Van bodyshop at its base in Sittingbourne.
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5 IN SUSPENSE
4 BRAKING NEWS
Next up, CV brake specialist Fras-Le discusses the merits of solid and vented discs, how both perform and where they are best suited.
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Rounding off this month’s list of the top online articles, suspension specialists Arnott explain the compromise LCV vehicle manufacturers need to make and why and air helper spring kit might be the solution you’re looking for.
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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.
