Commercial Vehicle Workshop October 2020

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The trade magazine for servicing and repair professionals

COMMERCIAL

VEHICLE WORKSHOP OCTOBER 2020

UNDER EXAMINATION Don’t get caught out by the updated Maintenance Investigation Visit Report forms

Also in this issue…

■ How specialist tools can save you time and money without compromising safety ■ Can engine oil actually freeze during winter?

■ What the future of compliance might look like

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CONTENTS

Volume 17

18

Issue 8

REGULARS 5

Viewpoint

13 Business & Training

6

News

48 What’s New?

10 Tech Tips

SPECIAL REPORTS 14 The fuel efficiency calculator that can make savings for workshops 15 How to optimise emissions control through effective engine cooling

BRAKES 17 The specialist tools that can save you time and money without compromising safety 18 How a mobile brake tester has benefitted two companies 20 One company goes the extra mile when testing its brake discs and pads 22 Why vehicle manufacturers prefer vented discs to solid discs 25 Guide to the most likely causes of brake pad wear

COMPLIANCE 26 Looking at the update to the Maintenance Investigation Visit Report forms 28 What the future of compliance might look like 30 Why Earned Recognition is the transport industry's best-kept secret

30

32 Take your legal compliance to the next level

WINTER SERVICE & LIGHTING 35 The benefits of full LED high beam headlamps 36 Demonstrating the cold weather properties of lubricants 37 Ensuring you get the best out of your batteries 39 The advantages of LED lighting for the CV industry 40 Replacement tips for CV lighting 41 The important regulations to be aware of for emergency vehicle lighting

BODY REPAIR & MAINTENANCE 42 What the 'new way of working' looks like for bodyshops 44 CVW talks to Mirka about the company’s abrasive solutions and the challenges it faces

42

46 Leveraging today’s customers and turning impatience into profit

COMPETITIONS 47 Get your hands on an Amazon Echo Dot in this month’s Tea Break Teaser!

OCTOBER 2020 CVW 3

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VIEWPOINT

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2021 VISION

Editor CIAN BRITTLE Editorial Assistant

T

LAURA GUALDI Consulting Editor SHARON CLANCY Group Editor DANIEL ARON Digital Manager KELLY NEWSTEAD Account Manager ALEX DILLEIGH Group Manager ROBERT GILHAM Graphic Designer GEMMA WATSON Group Production Manager CAROL PADGETT Publisher BRYAN SHANNON Subscriptions Commercial Vehicle Workshop is a business magazine for companies and individuals involved in all aspects of commercial vehicle servicing.

It is published 11 times a year and is available on free subscription to qualified readers.

Subscription rates: UK £30 To be removed from this magazine’s circulation, please call 01923 237799 or email circulation@hamerville.co.uk.

Printed by Walstead Peterborough Published by HAMERVILLE MEDIA GROUP Regal House, Regal Way, Watford, Herts WD24 4YF Tel: (01923) 237799 Website: www.hamerville.co.uk Copyright © 2020

his month, we should be informed of when the Direct Vision Standard (DVS) will be implemented. Initially, it was set to be introduced on 26th October 2020, but the current COVID-19 climate has put paid to that plan. Now, it will be rolled out from 1st March 2021 at the earliest, although the exact date is to be announced.

The idea is to give businesses more time to adjust to the new standards in light of the pandemic. The Transport for London (TfL) website defines the DVS as a measure of “how much an HGV driver can see directly through their cab windows. This indicates the level of risk to vulnerable road users, such as people walking and cycling, near the vehicle.” This all plays into an overall plan from the Mayor of London to eliminate all transport-related deaths and serious injuries by 2041 in the capital.

The definition of DVS stems from the initial belief that improving the driver’s field of view was the only necessary safety measure. However, a study from the Transport Research Laboratory (TRL) and Centre Européen d’Etudes de Sécurité et d’Analyse des Risques (CEESAR) changed this stance. They found that vehicle safety devices, such as cameras and sensors, are 50% more effective in reducing fatalities and injuries than modifying truck design.

So, it’s important to remember that there are multiple points to consider when it comes to the DVS. The crucial areas are Class V and VI mirrors, a side-view camera system, and a sensor system with audible alert fitted to the front and nearside of the vehicle. The difference between DVS and a voluntary operator best practice scheme such as FORS is that DVS is mandated in legislation, so once the start date is confirmed, it will be illegal to operate in London without a DVS permit.

This month’s issue of CVW places a big focus on compliance in order to ensure that all i’s are dotted and t’s crossed. On page 32, FORS talks about how it can help in relation to the DVS being postponed, and even complement the scheme. After all, any operator that achieves ‘FORS Silver’ accreditation will be well on its way to being compliant with DVS. Before having to worry about compliance with DVS, however, we sift through the updated Maintenance Investigation Visit Report forms – used by DVSA examiners when carrying out checks at operator premises – and what this means for you moving forwards (page 26). There is also a view into the future as to what compliance might look like and how it will work from Continental Group (page 28).

Rumbling in the background, as it has been in recent times, is the Coronavirus pandemic. Last month, the new ‘rule of six’ came into law, an unfortunate reminder that, even though we seemed to be emerging from restrictions, this is far from over.

Hopefully, this new rule will have the desired effect on reducing the reproduction, or R, number. This doesn’t apply to workplaces, however, but workshops must continue to ensure that social distancing and correct sanitisation procedures are being followed.

Be safe and enjoy the issue,

Cian B rittle 9,572

Editor

From 1 July 2019 to 30 June 2020

Associate member

The publishers and editor do not necessarily agree with the views expressed by contributors, nor do they accept responsibility for any errors of translation in the subject matter in this publication

OCTOBER 2020 CVW 5

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NEWS Logistics UK issues ADAS guidance The lack of available guidance on Advanced Driver-Assistance Systems (ADAS) is leaving workshop staff and engineers unclear on effective maintenance practices and functionality checks. To provide standardised information for use on all commercial vehicles, the forum has launched the industry’s first generic ADAS guidance document.

Working with members of its Engineering Forum, Logistics UK produced some simple guidance to assist those responsible for safety inspections, maintenance, and repairs on commercial vehicles.

Phil Lloyd, Head of Engineering Policy at Logistics UK, commented: “ADAS is becoming increasingly more common on today’s trucks and trailers.

However, there is very little guidance available from manufacturers or the authorities on how to check the functionality of these systems as part of a vehicle’s maintenance regime.

“The forum members hope that this guidance will provide workshop staff with useful insights that will ensure that their vehicles’ ADAS systems are working effectively, providing engineering managers and transport managers with the confidence that their vehicles are maintained safely.”

The guide can be found at WWW.RDR.LINK/VT001

“There is very little guidance available on how to check the functionality of these systems.”

©metamorworks/AdobeStock

6 CVW OCTOBER 2020

DENSO extends its webinar programme DENSO Aftermarket has added more modules and dates to its free technical training platform.

The company’s existing air conditioning and thermal management modules are set to continue after three dates were added last month. These were supplemented by two more modules, one concentrated on correctly identifying counterfeit spark plugs, and another addressed glow plug fault finding.

The diesel theme continues in October with two brand new modules, the first

concerning fourth generation common rail systems, and the second being previous generation systems.

“There is still a demand among professional technicians for relevant technical information delivered by knowledgeable experts,” said DENSO Europe, Pan European Strategic Marketing Manager, Fatiha Laauich.

“To take part in the training is straightforward – technicians simply sign up to the webinar programme and book a slot through the training calendar via the following link.”

HB Commercial puts the brakes on operator costs as new remanufacturing facility gears up Vehicle service, parts, rentals and sales group HB Commercial has opened a new remanufactured caliper and brake-shoe profiling facility at its parts supply centre in Bury St Edmunds.

With its head office based in Ipswich as well as workshop and support hubs in Harwich, Felixstowe and Witham, the company services commercial vehicle traffic flowing through each ferry port. The new service aims to cut costs and improve reliability for operators across most transport sectors.

“As friction specialists, we have been relining brake shoes since the 1980s,” said Operations Director Oliver Brunt. “So, the addition of the new facility is a natural fit.

Our customers are now benefitting from the low cost, wide choice and fast supply, which the new service brings.”

To ensure maximum reliability, HB Commercial uses pre-made caliper housings which are first shot-blasted and then cleaned, before checking for possible defects. The carrier, bushes, pins, sensors, and general mechanism undergo a stringent

quality inspection, prior to further scrutiny.

“Being able to produce 90% of the market requirement on a same-day basis enables us to quickly respond to a wide range of parts requirements at an affordable rate,” Brunt explained. “Furthermore, operators can reduce running costs, minimise down-time and, by re-using the components, make a positive contribution to the environment.”

Not only does remanufacturing remove the need for new calipers to be imported, but existing units are also effectively given a second life. HB Commercial keeps the whole process local, which apart from accelerating the supply process, avoids unnecessary transport and saves on emissions.

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Commercial vehicle production seen to rise 3.6% in July UK commercial vehicle (CV) production grew 3.6% in July, according to the latest figures released by the Society of Motor Manufacturers and Traders (SMMT), with 5,234 commercial vehicles rolling off production lines.

However, performance for the year to date shows output to be down by more than a

fifth to 31,655 vans, trucks and buses – a combined shortfall of 8,529 units.

Mike Hawes, SMMT Chief Executive, said: “This month’s increase in output is undoubtedly welcome news, but the uncertainty is far from over. The industry is still fighting an uphill battle to make up the lockdown loss of more than 8,500 vehicles.”

Roll out of bodycams for DVSA frontline enforcement staff DVSA is investing in body cameras for all frontline enforcement staff to reduce physical and verbal assaults.

Mercedes-Benz joins The Climate Pledge Amazon announced it is adding more than 1,800 electric vehicles from Mercedes-Benz Vans to its delivery fleet in Europe this year, in accordance with the The Climate Pledge, a commitment to reach net zero carbon by 2040.

Amazon is adding 1,800 electric delivery vehicles from Mercedes-Benz as part of the effort. More than 1,200 EVs in the order will be comprised of the newest electric commercial van available at Mercedes-Benz – the eSprinter, a larger model than the manufacturer’s first zero-emission vehicle, the eVito. Amazon’s Delivery Service Partners will have access to the new fleet of zero-emission vehicles to make deliveries to

customers in Europe this year, helping to save thousands of metric tons of carbon.

“We need continued innovation and partnership from auto manufacturers like Mercedes-Benz to decarbonise the transportation sector and tackle the climate crisis.” said Jeff Bezos, Amazon founder and CEO. Marcus Breitschwerdt, Head of Mercedes-Benz Vans, commented: “The electric vehicles in our portfolio, are ideally suited for the requirements of the courier industry.”

‘Bodycams’ are small devices slightly larger than a credit card which are usually worn on the chest, and record video and audio much like a personal CCTV device.

There were 35 assault incidents on enforcement staff in 2019/20 – a 25% increase on the previous year. Cameras are being rolled out to all areas in the coming months following a training programme for staff on how to use the devices. DVSA Director of Enforcement, Marian Kitson, said: “Whilst the majority of drivers are courteous to our roadside enforcement staff, they need to be able to protect the public without fear of violence.

“We take a zero-tolerance approach to physical and verbal assaults, and the bodycams will act as a deterrent.

They will also enable us to manage, support and respond to any assaults that takes place.”

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NEWS

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Parker opens first Truck Hydraulic Centre in the UK Parker Hannifin, the global motion and control technology company, has opened its first official Truck Hydraulic Centre in the UK. The new ‘one-stop truck shop’ in Normanton, West Yorkshire is a partnership between Parker and longterm distributor BSP Hydraulics. The partners will provide high-quality truck parts, repairs, and diagnostic services to help fleet managers and maintenance engineers keep their vehicles roadworthy. This includes expert support for construction, waste management, agricultural, bulk transport, and passenger vehicles.

BSP Hydraulics has recruited a new store manager to run the service. The distributor has also invested £50,000 in the venture.

Martyn Allen, Parker’s Distribution Manager for the UK and Ireland, commented: “This is Parker’s first certified truck store in the UK and the EMEA region, and highlights the strength in Parker’s distribution network and its capabilities.

“BSP’s specialist truck and mobilerelated knowledge is reflected in its growing business success and strong customer base, which includes both significant direct OEM customers and MRO aftermarket business. We’ve worked extremely well with the team for many years and look forward to continued partnership success.”

Software use now back to pre-coronavirus crisis levels, says FleetCheck FleetCheck has reported that the use of fleet management software is now back to pre-coronavirus levels, with businesses having used the lockdown period to rethink their whole approach to transport.

Peter Golding, Managing Director at FleetCheck, explained that the company has witnessed the majority of users who were active before mid-March return, and that the volume of work being processed was at levels that could be described as normal. In addition, more than 100 new companies have started using the system since lockdown began.

“We can clearly see that our customer base appears to be back to work and at levels of activity comparable to six months ago,” Golding explained.

“What is interesting is how many customers have used the time created by the

Exide launches battery sale and test app What is claimed to be the first ever battery testing app has been launched by Exide Technologies, which will make it easier for workshops to test and replace batteries.

The app lets workshops analyse battery test results and give customers battery replacement options within five minutes.

The device performs analysis on the battery, and tests produce a QR code. The web app can scan this code to import the test results, which cover cranking health, voltage, temperature, reserve health capacity and recommendations for further battery treatment such as recharge.

“Testing, charging, and replacing batteries using Exide’s workshop tools is an excellent way for motorists to reduce the

8 CVW OCTOBER 2020

coronavirus crisis to take a good look at their transport activities.”

Peter Golding explained that much of this activity seemed to have been based around the digitisation of operations, using technology to make new levels of efficiency possible.

“What we have seen is a drive to realise the further efficiencies available by simply adopting more of our technology to deliver present and future gains," he said.

He added that growth in FleetCheck’s customer base meant usage of its fleet management systems were now around 20% higher than at the same time last year, with the FleetCheck Driver app proving especially popular, exceeding one million checks a month. Fleet management software is now absolutely central to the operation of companies running vehicles and their value is very much recognised.

risk of breakdowns, and for workshops to increase revenue and improve customer satisfaction,” said Michael Geiger, Vice President, Sales and Marketing, Exide Technologies, EMEA.

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TECH TIPS

CLUTCH AND DMF REPL ACEMENT ON A NISSAN NAVARA This month, REPXPERT Alistair Mason replaced the clutch and dual mass flywheel (DMF) on a Nissan Navara 2.5 DDTI, which had covered more than 103,000 miles.

F

ollowing complaints of the clutch ‘slipping’, Alistair’s assessment confirmed the cause, and a clutch and DMF replacement was advised. For this repair, Alistair used a four-post ramp, transmission jack, and a self-adjusting clutch installation tool.

Step-by-step procedure With the vehicle placed on the ramp, open the bonnet and disconnect the negative battery terminal. From inside the vehicle,

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10 CVW OCTOBER 2020

remove the centre console from around the gearstick (Fig. 1), the six bolts that retain it, and the gearstick itself. Raise the ramp to gain access to the underside of the vehicle; start by disconnecting the prop shafts from the gearbox – it is always best practice to mark the flange positions before removing them to eliminate any balance issues when the repair is completed. The front prop shaft can be removed from the gearbox flange then stowed and secured to the chassis.

Switching to the rear, unbolt the rear prop shaft at the rear flange, disconnecting from the rear axle, then remove the centre bearing fixing bolts. Slide the front joint out of the gearbox and remove the rear prop shaft. Now disconnect the exhaust, which can be achieved by removing the two nuts on the centre joint (Fig. 2), part the exhaust and ease the rear section off its mountings.

The rear section can then be stowed against the O/S chassis to give clearance for removing the gearbox.

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Support the gearbox using a transmission jack and remove the gearbox cross member by taking away the four retaining bolts (Fig. 3) and three gearbox mounting bolts. Work the cross member out of the chassis – this is a tight fit – and stow to the side or support against the O/S chassis. With the cross member removed, disconnect the gearbox wiring loom from the gearbox, remove the two fixing bolts for the clutch slave cylinder, disconnect from the gearbox and stow in a safe area.

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Next, remove the lower bell housing bolts, lower the gearbox on the transmission jack to gain access to the upper bell housing bolts, then remove them – there is one bell housing bolt behind the starter motor inserted in the opposite direction. Once all the bell housing bolts have been cleared, ease the gearbox away from the engine and, when clear, lower the transmission jack and place the gearbox in a safe area.

With the gearbox away, remove the old clutch assembly (Fig. 4) and DMF. Clean and inspect the back of the engine for any leaks and rectify if required, so not to contaminate the new clutch components.

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“Torque specifications are available on the REPXPERT platform and on Schaeffler’s DMF Checkpoint app.� manufacturer’s specification. Torque specifications are available on the REPXPERT platform and on Schaeffler’s DMF Checkpoint app.

Now, remove the release bearing and arm assembly from the gearbox bell housing and clean the inside of it, removing the old clutch dust. Once cleaned, inspect the release bearing guide tube for any wear and replace if required.

Place a light smear of high-melting point grease on the gearbox input shaft splines, mount the new clutch plate onto the input shaft and guarantee that it moves back and forth freely. This will help confirm the clutch plate is correct for application and it will also evenly distribute the grease. Remove the clutch plate and wipe off any excess.

The release bearing centre boss needs to be pressed out of the old release bearing and carefully pressed into the new one (Fig. 6 & 7). Once complete, check the release arm for any wear and replace if required, and then refit to the bell housing and input shaft (Fig. 8).

í˘ś Ensure the new flywheel is correct and mount onto the crankshaft, checking that the alignment pin locates correctly (Fig. 5) – there is a bulletin in the box advising this.

Using new flywheel bolts, tighten in an evenly and sequentially, and torque to the

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Fit the new clutch assembly, which can easily be identified as self-adjusting, as it has the three small yellow springs in the centre and a red information sticker on the outside of the clutch box, advising the use of a self-adjusting clutch mounting tool.

Mount the clutch plate using a clutch alignment tool and ensure ‘Gearbox Side’ or ‘Getriebe Seite’ marked in the centre of the clutch plate is facing the gearbox. Plate the clutch pressure plate, checking that it aligns on the flywheel dowels, then attach three long studs from the tool kit. Fix the tool onto the studs and secure in place with three large retaining nuts from the tool kit, ensuring the studs come level with the large nuts, but do not protrude. When in position, tighten the tool, which will ease the new clutch pressure plate into position, with no risk of damage to the new clutch or flywheel (Fig. 9).

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When the clutch pressure plate/cover is in the home position, secure it using three bolts and remove the self-adjusting clutch tool. Insert the remaining three bolts and torque to the manufacturer’s specification.

This is a great example of how Schaeffler aids aftermarket installation.

Check to make sure everything is fitted correctly, the gearbox alignment dowels are installed, the back plate is in position and that nothing is restricting the gearbox fitting.

Using the transmission jack, ease the gearbox into position and align onto the dowels.

When the gearbox is in, secure it into place using the bell housing bolts and reinstall in reverse order of removal. After the battery has been reconnected, reset all electrical systems as required.

FOR MORE INFORMATION ON SCHAEFFLER PRODUCTS, FITTING INSTRUCTIONS, LABOUR TIMES, AND MUCH MORE, WWW.RDR.LINK/VT002

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BUSINESS & TRAINING

SAFETY FIRST A

imed at the commercial vehicle market, the E-Workshop solution has been designed and developed

by Inspire International UK, the UK’s leading provider of health and safety management solutions for commercial vehicle workshops, offering 16 health and safety e-learning modules, plus many more which are soon to be released.

Recent statistics show that over half of companies expect an increase in their risk profile, with 71% expecting to have to increase investment in legal compliance, with the largest anticipated risk increase from health and safety. To address this, Inspire, through its E-Workshop solution, is offering a COVID-19 Return to Work programme, which explains the changes that have been introduced into the workplace and what employees must do to protect themselves and others from the spread of infection.

Inspire International UK is a family-run business, managed by Jagjeet Singh Virdee, Managing Director, and his father, Harvinder Singh Virdee, Technical Director.

The father and son duo have provided commercial vehicle health and safety solutions to over 250 commercial vehicle workshops across the UK, working with well-established and leading businesses in the industry, including the likes of Keltruck, Scania (Great Britain), MAN Truck and Bus UK, Haydock Commercials, Ford and Slater Group, Europa Worldwide Group and RH Commercial Vehicles.

In a first for the industry, Inspire International has launched a new commercial vehicle workshop safety elearning solution, E-Workshop.

CVW finds out more.

Jagjeet Singh Virdee, Managing Director at Inspire International UK, explains why now is the time for businesses to invest in health and safety e-learning that is specific to their commercial vehicle workshop.

He says: “In light of COVID-19 and the challenges this presents commercial vehicle dealerships now and over the next few years, we have worked with senior commercial vehicle leaders to ensure they can maximise workshop hours/utilisation whilst complying with health and safety regulations that are applicable to their operations.

“E-Workshop is the UK’s first commercial vehicle specific health and safety e-learning solution that will help to ensure commercial vehicle dealerships remain compliant with applicable health and safety regulations through the use of elearning. E-Workshop is ideal for the current economic climate and will be the future of health and safety training within the commercial vehicle industry.”

The easy-to-use e-learning solution caters for all personnel, from directors to workshop controllers and technicians, educating them on the importance of effective health and safety management within a commercial vehicle workshop.

Inspire advises that by investing in the elearning training modules, it will ensure workshops remain compliant, workshop hours are maximised, the correct type of health and safety training for the correct job role is delivered and teams are educated to effectively avoid and manage health and safety within their working environment.

Jagjeet Singh Virdee continues: “We are a one-stop shop for all areas of health and safety management that relates to commercial vehicle businesses. With the launch of eworkshop, we look to further strengthen our position as the experts in commercial vehicle health and safety solutions that are effective, efficient, pragmatic, and proven.

“We are the leaders in our industry and truly passionate about what we do, so we will continue to invest in developing solutions that will benefit both our existing and new clients. We plan to continue to listen to the needs of our customers and monitor any changes to the health and safety regulations to ensure our customers continue to introduce best practices in order to remain compliant.”

With over 30 years’ experience and having worked with over 250 client locations, Inspire has a proven track record of ensuring risks are managed effectively and efficiently through the implementation of 'proven' solutions.

FOR MORE INFORMATION ON INSPIRE INTERNATIONAL UK, WWW.RDR.LINK/VT003

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SPECIAL REPORT

THIS

M

ADDS UP

orris Lubricants has launched a fuel efficiency calculator to show clients in the heavy-duty diesel market the savings and benefits that can be made by using low viscosity high performing engine oils. By entering details about their current consumption – including the number of vehicles in their fleet, annual mileage, oil sump size, oil drain interval, fuel usage, and diesel cost – the calculator will forecast the financial and environmental benefits that a customer could expect by upgrading to one of the lower viscosity oils produced by Morris Lubricants such as 5W-30.

Adrian Hill, Automotive Product Manager at Morris Lubricants, explains: “It’s important to realise we are talking solely about viscosity characteristics here, and not performance level. Any lubricant should be selected based on the performance level and viscosity specified by the manufacturer. This will ensure service intervals are reached and the components get the maximum level of protection.”

Available online and in the Morris AR smartphone and tablet app, the calculator will display how much money could be saved annually. It will then convert this figure into tangible assets that this amount could be spent on, such as the number of tyres or vehicle services, or how many extra miles could be gained – all of which are significant factors when calculating the future prosperity of a fleet.

14 CVW OCTOBER 2020

CVW takes a closer look at the recently launched fuel efficiency calculator from Morris Lubricants and how it can help workshops.

“Any help we can give to our customers to save money is really useful,” says Ian Douglas, Morris Lubricants’ Business Development Director, who believes the digital tool comes at a useful time as remote meetings continue to take place instead of face-to-face ones where appropriate due to COVID-19.

He continues: “To be able to show a customer how the use of modern, technologically advanced lubricants can make their fleet more efficient and add to their profits is really important. They are tested in the field, under real working conditions, and will also give greater protection to our customers assets.

“When someone is investing huge amounts of capital in their fleet, they need peace of mind when it comes to the lubricants they choose. The real advantage of this tool is that it shows how the different lubricants have an impact on their fleet and what real savings can be gained, such as how many tyres they could purchase with the savings.”

Recognising the need to reduce vehicle emissions in this sector, the Morris Lubricants fuel efficiency calculator also highlights CO2 savings. To produce enhanced engine oils that to help achieve these savings, Adrian Hill says it’s necessary to look at how they behave on a molecular level, where friction reduction takes place.

“If we look at the oil film generated between bearing faces and journals, compression rings and liner, for example, a certain ‘thickness’ is required to keep these components apart,” comments Adrian Hill.

“15W-40s and 10W-40s, for example, generate a nice lubricant cushion which protects bearings, and maintains a good seal between ring and liner. However, energy is expended moving the oil through these lubrication areas. This energy burns additional fuel, which in turn increases CO2 output.”

He concludes: “So, as we move to 5W30s, a thinner oil film is generated, reducing internal ‘drag’ and making the most of the energy generated in the combustion chamber to drive the wheels and, of course, produce less CO2.”

TO SEE THE MORRIS LUBRICANTS FUEL EFFICIENCY CALCULATOR FOR YOURSELF, WWW.RDR.LINK/VT004

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COOL IT OFF CVW takes a closer look at Dayco’s ability to provide effective engine cooling through its water pumps in order to optimise emissions control.

A

lthough the current Euro VI engine emissions regulations are primarily achieved through the use of exhaust treatment systems, the control of the engine’s temperature remains an incredibly important factor to provide the stability that is required to ensure the process is carried out effectively and the designed emissions reductions are delivered in practice.

The auxiliary drive system and the water pump it powers are, therefore, vital elements within the engine. These must operate correctly to allow the entire unit to work in the optimum temperature window to ensure the inlet and exhaust gases are not unnecessarily influenced by avoidable temperature fluctuations. Only when the overall thermal system is managed effectively will the engine run at its greatest efficiency and its emissions potential be realised.

Dayco, an engine products and drive systems supplier for the automotive, industrial, and aftermarket industries, is a major player in the heavy duty (HD) sector, where it supplies important original equipment (OE) components, such as tensioners, idlers, dampers, and belts to HD vehicle manufacturers (VMs) across Europe and around the world.

The company’s engineering pedigree equips Dayco with the expertise required to design and manufacture the components within the drive system that best suit the needs of the application and work in unison with the engine’s other crucial elements, including the water pump, to guarantee

“The control of the engine’s temperature remains an incredibly important factor to provide the stability that is required to ensure the process is carried out effectively.” its thermal management is controlled well.

To ensure the aftermarket has access to the high quality replacement products it needs to enable it to provide a first-class and reliable repair solution, Dayco has introduced six water pumps – produced and supplied to Dayco by the OE pump manufacturer – for the 10.8 and 12.9-litre, MX11 and MX13 engines used in a number of popular DAF applications.

These OE water pumps, which Dayco identifies with the part number prefix DP, cater for two MX11 (DP1979 and DP1980) and four MX13 (DP1975/6/7/8) applications and are supplied with or without speed sensor, in line with the original specification stipulated by DAF. Steve Carolan, National Sales Manager for Dayco, explains: “By providing the OE water pump for these popular vehicles, we can supplement our existing, premium quality range, and give commercial vehicle workshops and fleet managers the tools they need to compete with the VMs dealer networks.

“These OE water pumps and the existing poly-v belts, tensioners, and idlers in the Dayco aftermarket range allow technicians in the independent sector to maintain this standard. It also ensures these vehicles not only remain reliable for their owners and their customers, but also operating within their intended design criteria, which correspondingly benefits the nation’s overall health.”

FOR MORE INFORMATION REGARDING THE OEM QUALITY POWER TRANSMISSION PRODUCTS IN THE DAYCO RANGE, WWW.RDR.LINK/VT005

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BRAKES

TIME TO INVEST IN TIME-SAVERS? Under pressure to get vehicles out of the workshop and back on the road quickly? Specialist tools can save you time and money without compromising safety, says Knorr-Bremse.

TEBS tool kit

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orkshops often have to operate against the clock. At the same time, high levels of precision are essential for safe, clean, and reliable repair and maintenance operations. Some jobs are trickier than others and Knorr-Bremse has expanded its range of special and auxiliary tools to make those jobs that little bit easier.

The tools have been developed in cooperation with specialist tool manufacturer GEDORE. Some are designed to make it easier to correctly fit replacement parts; others are designed to save valuable workshop time by speeding up essential safety checks. There are complete kits and individual tools available.

Air disc brake tool kit

installation.

Furthermore, during maintenance with an original Knorr-Bremse actuator kit, or when fully replacing a spring brake with a rationalised unit, the gauge helps the operator to correctly re-assemble the components.

Brake disc measuring gauge

The brake disc measuring gauge enables technicians to check brake disc wear within a few seconds, without having to remove the wheel first. It works with 17.5, 19.5, and 22.5in brakes. As the wheel remains on the vehicle, downtime is reduced.

Clutch compressor kit Before

After

The tools for almost all current Knorr-Bremse brake types have been brought together in a single new tool kit. Everything you need to carry out professional maintenance is supplied in a compact box so that you can move seamlessly from one operation to the next without wasting valuable time.

Actuator maintenance gauge The actuator maintenance gauge enables the height of the seal and push rod to be rapidly inspected, ensuring that orientation of the actuator corresponds exactly with the original

Special tools for clutch compressors make easy work of assembling and dismantling the clutch, assembly of the actuator piston, and fixing the toothed drive-wheel.

Special bayonet ring tool This intuitive tool was developed to enable fast and simple release and tightening of the ring on bayonet-style air drier cartridges.

FOR MORE INFORMATION ON KNORR-BREMSE’S RANGE OF SPECIALIST TOOLS,

The problem: TEBS modules can be mounted in various places on the trailer – the surrounding area may be narrow, or there may be limited space to exert the necessary force on the release plugs and connectors.

The solution: Using the Extractor Tool avoids damage and simplifies the release and tightening of the power supply connectors for the trailer EBS module, for both those with a bayonet fitting and those with pole-connector style fittings. Technicians can work overhead so the job is more comfortable and, because the technician has better control and is able to exert more force, it’s faster and easier.

How it works: There is a two-part handle so getting a comfortable fit is easy. The Bayonet Removal tool is simply placed on the bayonet and turned clockwise. It can be used on its own or, if access is extremely limited, in conjunction with a ratchet. It has a square key, making it possible to use a standard ratchet. The Socket Connector tool is used to release pin pole-style plug connectors. The kit contains three separate tools for removing 2-pole, 6pole, and 12-pole connectors.

WWW.RDR.LINK/VT006

OCTOBER 2020 CVW 17

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BRAKES

TotalKare outlines how it has benefitted two companies with its mobile brake tester and lifting solutions.

TESTING, TESTING Tyrers Coaches Northwest bus and coach operator Tyrers Coaches has upgraded its Farnworth workshop with state of the art lifting and testing equipment from heavy duty workshop experts TotalKare.

Covering Greater Manchester and South Lancashire, Tyrers Coaches has been offering group travel services – including day excursions, private hires, and home-toschool transport solutions – for over 40 years, with a fleet of over 100 vehicles.

Now, the operator is set to benefit from increased fleet availability following the installation of brand new mobile column lifts and a mobile brake tester from Totalkare.

TotalKare’s T8AC mobile column lifts provide workshops with quick and easy access to the underside of vehicles for repair and maintenance. Each column has a safe working load of 7,500kg and can be synchronised in sets of four, six, or eight, which enables the safe lifting of vehicles weighing up to 60,000kg. The T8ACs adjustable wheel forks facilitate the lifting of vehicles with a range of wheel diameters without the need for additional wheel adapters.

18 CVW OCTOBER 2020

By introducing a TotalKare mobile brake tester, Tyrers Coaches immediately benefit from time saved by no longer having to visit an external test centre with their fleet of 122 vehicles and should see a return on their capital investment inside 12 months, with projected cost savings over five years in excess of £100,000.

The DVSA-approved mobile brake tester from Totalkare can accommodate up to 20,000kg per axle and a number of wheel bases up to 4,000mm. It comes with cabinet and computer display and a touchscreen tablet device enabling brake tests to be conducted from the driver’s seat in a matter of minutes.

Lewis Holmes at Tyrers Coaches explains: “We were in need of a new set of column lifts as our old ones were coming to the end of their life cycle. As these new lifts were required in our workshop, we had no hesitation on which company to turn to – Jack Longstaff at TotalKare helped us select the perfect option that would suit our vehicles and lifting requirements. We also opted to purchase a TotalKare mobile brake tester, which is helping us to test our vehicles on a daily basis without any downtime.”

Jack Longstaff, Area Sales Manager at TotalKare, comments: “We were keen to ensure Lewis and his team had the best equipment to achieve maximum productivity in their workshop, which is why the T8AC was the perfect solution for them. By offering a lease purchase option over five years, the monthly payments are spread, giving a lower month by month cost to the business. The mobile brake tester included extended ramps to accommodate the company’s tri-axle coaches.”

Geesinknorba Geesinknorba Group, the waste management specialist that operates workshops across the UK, has been working with TotalKare for more than a decade, primarily sourcing all of its mobile column lifts from the Halesowen-based firm.

Impressed by the quality of product and service provision, the company decided that it would turn to Totalkare again, this time for help in reducing the costs it was experiencing when testing the brakes on all of the council vehicles it manages.

“We build a lot of our business on long-

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standing customer relationships, whereby we listen to the client, understand the issues it is facing and then look at our product mix and where we can add real value,” comments Brian Young, National Account Manager for TotalKare.

“This is exactly what we’ve done with Geesinknorba, installing our mobile brake tester at its workshop on Buntingford Business Park in Hertfordshire.

Immediately, this has stopped the firm having to drive vehicles to an external contractor to complete all of the tests.”

He continues: “Being mobile, it gives the client complete flexibility in its facility and no infrastructure work was required.

Importantly, completing the tests on site also means the fitters have more time to focus on their core roles. It’s a win-win for Geesinknorba – it can offer a more efficient

service, it cuts lead times, and it saves costs, all with one investment.”

TotalKare introduced its first non-lifting product to its portfolio at the CV Show last year, launching its technically advanced mobile and in-ground brake testers, viewed by many experts as being amongst the strongest and most reliable systems currently available.

These were supported with the appointments of two sector specialists in Graham Simmons and Luke Simmons.

Young concludes: “It certainly proved a wise decision. Our sales targets for the first twelve months were surpassed in just 100 days and our systems are installed and currently being used in the bus and coach, commercial vehicle, and waste and recycling sectors, along with several local authorities – ably supported by our nationwide team of field service engineers.

FOR MORE INFORMATION ON TOTALKARE’S MOBILE BRAKE TESTER, WWW.RDR.LINK/VT007

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BRAKES

BRAKE IT DOWN Brake discs are indispensable parts of the braking system on trucks. febi goes into more detail on its available range.

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or optimal braking performance and long service life, febi brake discs are precisely manufactured from highquality casting materials. The friction rings thickness ensures high heat resistance in conjunction with low and even wear, providing road safety under all conditions.

Due to the thermal stress, internal ventilation ducts were designed for optimal cooling performance to prevent overheating and cracks. Precise manufacturing ensures no rubbing or vibrations, resulting in the safe operation and longevity of brake discs.

The brake discs are carefully protected on their way to the customer thanks to anticorrosion oil and sturdy packaging. febi offers a wide range of more than 154 brake discs for all common trucks from the European commercial vehicle manufacturers. febi brake pads are specially designed to meet high standards, and all febi brake pads are delivered with the necessary accessories.

New brake pads normally need a being-in period, but this isn’t required with febi brake pads. Featuring the high friction bedding-in compound – also known as the tiger stripes – on the brake pads, the user has full braking power from the beginning.

To prove their quality, the company’s commercial vehicle brake discs are not tested just anywhere; they have been regularly used in truck racing for years. Professionals including the experienced racing driver Steffi Halm and the former European champion Gerd Körber rely on brake discs from febi.

20 CVW OCTOBER 2020

Advantages of febi brake pads: ■ Friction value comparable to OE brake

pads ■ High material quality, compression, and

shear strength

Brake pads Brake discs and pads are subject to very high mechanical and thermal loads (up to 800˚C) this impacts wear, together with environmental factors such as water, grit, and dirt from the roads. febi offers products with OE matching quality, with safety as a core focus. febi’s internal quality control tests ensure that its braking products can meet the increasing demands of the road whilst contributing to road safety.

All febi brake pads are finished using the so-called ‘scorching’ process after manufacture. This involves ‘baking’ the brake pads at high temperatures (approx.

700˚C). Any remaining non-cured binding material leftover from production is extracted this way. As a result, reduced bedding in or conditioning of the brakes – as it has been known in the past – are no longer necessary.

■ ECE R90 certified ■ Reduced bedding-in period, fully

resilient after installation

Safety is paramount With safety in focus, febi’s internal quality department ensures that brake components are tested for various requirements and loads. The company’s strategy is to go beyond just accepting a UN/ECE R90 approved product.Wear, performance, and service life are crucial aspects that febi looks at to meet its quality promise. To underline its high product quality standards, febi provides a three-year manufacturer’s guarantee for all of its replacement parts.

TO SEE A COMPLETE OVERVIEW OF FEBI’S BRAKING COMPONENTS, WWW.RDR.LINK/VT008

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BRAKES

VENTED OR SOLID? Why do vehicle manufacturers prefer vented discs to solid discs? Juratek answers the question.

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t is well recognised that brake friction components are critical to vehicle safety. With heavy demands on performance, these components need to be robust and to work efficiently and effectively in all operating environments, temperatures, pressures, and speeds. This is in addition to satisfying legal requirements for safe braking at the specified test speeds and pressures.

The worst feeling any driver can have is when the brakes fail to work effectively; this can be due to brake fade. Brake fade occurs when the friction material becomes too hot and the friction level between pad and disc reduces markedly causing the brake stopping power to reduce significantly.

Brakes work by converting kinetic energy (the motion of your vehicle) into heat so that your vehicle can safely come to a stop. This means that it is completely natural for brakes to get hot in order to stop your vehicle. However, this heat can be dissipated and its negative effects minimised by cooling the discs down as

quickly as possible.

The overwhelming majority of heavy vehicles fit vented brake discs as OE. Without doubt, solid discs have their place – off road and quarry applications, for example, where mud, sludge etc. can fill the vents, reducing their effectiveness.

However, for on road applications, vented discs are generally a superior choice; they cool up to 40% faster than solid discs so other wheel end components – such as rubber seals, tyres, and bearings – in the vicinity of the brake are exposed to high

“Vented discs cool significantly quicker than solid discs; therefore, with repeated stops, a vented brake will be less prone to brake fade.”

temperatures for less time providing longer life and better safety. Also, the friction material is not overwhelmed with heat that it cannot handle.

Because of its larger mass, a solid disc has a bigger heat sink. So, on a single brake stop, the temperature rise during braking will be less with a solid disc than a vented disc, but this advantage is not maintained when repeated brake stops are carried out.

This is because vented discs cool significantly quicker than solid discs; therefore, with repeated stops, a vented brake will be less prone to brake fade.

Because of their mass, solid discs may be less prone to distortion when hot, but generally this is not an issue with properly designed vented rotors, especially those designed to prevent coning. Thermal ‘hot spotting’ and crazing and cracking is more to do with the composition of the cast iron and the choice of friction material and how well it conforms with the disc to ensure uniform pad/disc contact.

There are other reasons why vehicle manufacturers use vented discs on most applications. These discs weigh less than an equivalent solid disc, typically by 7kg, which amounts to 14kg per axle. Extra weight reduces vehicle payload carrying capacity and increases fuel consumption and, because of their extra mass, solid discs are also much more expensive than the equivalent vented rotor by at least 30%.

FOR MORE INFORMATION ON JURATEK’S COMMERCIAL VEHICLE BRAKING RANGE, WWW.RDR.LINK/VT009

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BRAKES

TROUBLESHOOTING TIPS: BRAKE PAD WE AR Being subject to considerable wear and tear, brake pads need to be periodically maintained and replaced. Lumag provides CVW readers with a guide to the most likely causes of wear.

ISSUE: EVEN WEAR The pads have approximately the same amount of friction material on both.

CAUSE: Proper brake function.

SOLUTION: Replacement of the brake pads and hardware such as abutment and antirattle clips is required, as well as servicing the caliper guide pins and slides.

ISSUE: OUTER PAD WEAR The outer pad continues to ride on the rotor after the caliper releases, resulting in the outboard pad having markedly less friction material than the inboard pad.

CAUSE: Seizing guide pins, bushings and slides are usually the cause of the issue.

damage, or corrosion; it can also be caused by a problem with the master cylinder.

SOLUTION: Take the same steps as fixing the outer pad wear, as well as inspecting the hydraulic brake system and the caliper for residual pressure and guide pin hole or piston boot damage, respectively. If the pin holes or piston boot are corroded or damaged, then replacement is necessary.

ISSUE: TAPERED PAD WEAR The friction material is worn in a horizontal or vertical wedge pattern.

CAUSE: Improper pad installation, as well as guide pin wear, or having a single guide pin or slide seizing.

SOLUTION: See outer pad wear.

SOLUTION: Correcting this issue is usually fairly straightforward, and is normally rectified by servicing or replacing the guide pins, bushings, or the entire caliper, and replacing the brake pads.

ISSUE: CRACKING, GLAZING, OR LIFTED EDGES ON THE PADS The friction material is physically damaged and shows signs of thermal distress.

ISSUE: OVERLAPPING FRICTION MATERIAL The top edge of the pad overlaps the top of the rotor.

CAUSE: Wear on the guide pins, caliper or caliper bracket or having the wrong rotor or pad on the vehicle.

SOLUTION: Replace the pads and fit the vehicle with OE specification diameter rotors.

Fact and friction Following this advice, Lumag has highlighted two of its key brake pad ranges below: LU 801 is a modern friction material meeting the requirements of brake manufacturers for OE installation in vehicles. The material boasts: ■ Environmentally friendly composition,

free of heavy metals, such as antimony ■ High cold and hot braking efficiency, in

temperatures reaching as high as 850°C ■ High braking efficiency across the whole

ISSUE: INNER PAD WEAR The inboard brake shows more wear than the outboard pad.

CAUSE: The caliper piston doesn’t return to the rest position due to a worn seal,

CAUSE: Overuse, improper break-in procedure, hydraulic system problems, seized caliper components, defective pads, and the parking brake not fully retracting are some common problems.

SOLUTION: Replacing and breaking-in the new pads properly. The parking brake may also need adjusting.

range of speeds used ■ High resistance to wear

LU 903 is ideal for bus and municipal vehicle applications. These vehicles, especially inner city vehicles, brake often, resulting in high temperatures, leading to greater wear and tear. Benefits include: ■ A lower friction coefficient than typical

CV materials ■ Brake pad material featuring chamfers,

reducing the risk of vibration and squeal during braking ■ Designed with the comfort of bus passengers and drivers in mind

FOR MORE INFORMATION ABOUT LUMAG’S BRANDS AND CATALOGUES, WWW.RDR.LINK/VT010

OCTOBER 2020 CVW 25

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COMPLIANCE

The Maintenance Investigation Visit Report forms used by DVSA examiners when carrying out checks at operator premises have been updated. Sharon Clancy picks out the highlights.

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he Maintenance Investigation Visit Report (MIVR) form is the document that DVSA staff complete during inspection visits to operators’ premises to check that satisfactory systems and facilities are in place for safety inspections to maintain vehicle roadworthiness.

CVW readers will, of course, know that inspection and maintenance records should comply with DVSA’s recommendations in the ‘Guide To Maintaining Roadworthiness’ (GTMR) and these basic record-keeping requirements have not changed; for example, safety inspection intervals must be in accordance with those specified on the operator licence and records must be kept for at least 15 months for all vehicles.

However, in the new guidance, there are additional vehicle systems that examiners will now to check to confirm the operator is monitoring satisfactorily, including exhaust emissions, wheel security, tyres, and safety recalls. DVSA explains what examiners will look for and how they assess whether your systems are satisfactory, mostly satisfactory, or unsatisfactory. Operators will always receive a copy of these maintenance inspection reports along with other feedback to help them improve if necessary.

Some fleets will already be recording these items as they are included in the GTMR, but here’s a checklist of the main ones:

AN

INSPECTOR CALLS

26 CVW OCTOBER 2020

■ Emissions control checks

Examiners will expect evidence that effective maintenance and monitoring systems are in place to ensure all vehicles operated have correctly functioning emissions control systems.

Unless approved, no other equipment may be fitted to the vehicle, nor may any equipment be removed, such as to reduce the effectiveness of the original fitted system.

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■ Wheel security

methods: roller brake test (laden where possible); decelerometer (rigid vehicles); electronic braking performance monitoring system for trailers; and a road test with brake temperature measurement. However, DVSA warns that a road test to check the braking performance for all planned safety inspections will usually be inadequate: “It is, therefore, normally expected that the vehicle or trailer should complete at least three successful brake efficiency tests spread throughout the year in addition to the annual MOT test.”

The operator must have systems in place to ensure wheel security is maintained.

The system needs to include effective daily monitoring of wheel security and ensure correct wheel fitment maintenance and torqueing procedures are followed.

■ Tyre management

The operator must have arrangements in place to ensure vehicles’ tyres are legal, safe, and effectively managed. Examiners will assess the effectiveness of tyre management systems by reviewing tyre failures and/or encounters resulting in tyre-related prohibitions. The system should monitor that drivers are properly trained and equipped to recognise and report tyre issues. Tyre age and pressures must be monitored and maintained, and tyres regularly and closely examined for damage and wear, with mechanisms in place to address any identified issues.

There also should be evidence that processes are in place to ensure best practice in tyre management is followed throughout the fleet. Staff dealing with tyre management are properly trained and empowered to act with sufficient authority. Any technician dealing with tyre inspections or repairs must be trained and qualified.

■ Safety recall rectifications

Any safety recall notifications for specific vehicles and evidence of rectification must be recorded on the vehicle maintenance file. Normally it would be expected that safety recall rectification work should not extend past the next scheduled safety inspection.

■ Prohibitions

Any roadworthiness prohibitions issued during the period under review will be assessed by examiners, including roadside enforcement encounters, the current fleet check, and prohibitions issued at annual test. Prohibitions, both immediate and delayed, will be categorised as ‘S’ if the examiner considers that any of the defects which led to the prohibition are indicators of a significant failure of roadworthiness compliance and are defects that the operator and/or driver should have been aware. This includes long-standing defects that should have been detected and repaired at the last

■ Driver defect reports

At least one walk-around check must be carried out in any 24-hour period of vehicle use. Reports must include details of the defects or symptom, the driver and who it was reported to, the assessment, and when the defect was rectified. DVSA is encouraging the use of ‘nil defect’ reports: “It is good practice to have ‘nil defect’ reports as they are a useful means of checking that drivers are carrying out their duties and these forms can be used for audit purposes. A ‘nil defect’ reporting system demonstrates a check has been conducted and is a positive report that the vehicle is free from defects.” safety check; any issues that should have been detected at the first use/daily walkround check; defects recorded at annual test which should have been found before the vehicle was presented for test; or simply that the number and nature of defects present indicate a significant failure in maintenance. Prohibition will be categorised as ‘X’ if examiners consider the defects(s) not to be maintenance related and where it is also apparent that it would not have been noticed by the driver.

Back to basics The DVSA’s ‘Guide to Maintaining Road Worthiness’ includes all the information needed to help ensure records are satisfactory when an examiner comes calling.

Here is a reminder of some of the basics: ■ Braking performance records

Examiners will expect to find that every safety inspection includes an assessment of the braking performance of the vehicle or trailer. There are four possible

■ VOR records

A vehicle that has been logged as VOR and has missed the scheduled safety inspection should only be brought back into service after a safety inspection confirms that it is roadworthy.

■ Outsourced maintenance

Operators who have contracted out their safety inspections must have a written contract that sets out the details of the vehicles covered, inspection interval and the work which will be carried out.

■ Annual test records

Failure of safety-critical defects, multiple failure items, and multiple retests indicate poor maintenance standards. Check out the various guides available from DVSA to minimise risk of test failures.

TO SEE DVSA’S ‘GUIDE TO MAINTAINING ROADWORTHINESS’ IN FULL FOR YOURSELF, WWW.RDR.LINK/VT011

OCTOBER 2020 CVW 27

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COMPLIANCE

GET TING SMARTER ON

COMPLIANCE Continental Group has been revealing its view of how future compliance might work – and it starts with a much-enhanced role for the digital tachograph.

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egislation to improve road safety and the environmental impact of vehicles is the driver between many of the compliance demands made on truck operators. So, although the UK has left the EU, it is hard to see that the DfT will want to revoke or water-down regulations such as emissions limits or drivers’ hours that are accepted as important contributors to road safety and reducing emissions.

“There is increased demand for legislation on secure transport, clean transport, and for connected services,” says Gilles Mabire, Head of Continental’s Commercial Vehicles & Services Business Unit. “However, there needs to be a trade-off between the legitimate intention to protect the environment and industry’s need for efficiency.”

Continental sees connected truck services as a key enabler in reducing total cost of ownership for operators. Mabire predicts there will be demand to integrate various fleet management systems so they are available as modular items from the ‘cloud’, as well as a shift from stand-alone systems to a modular approach where fleets can select which systems to integrate into their management systems and monitor compliance.

28 CVW OCTOBER 2020

The Smart Tachograph

The smart key fob

Last year saw the mandatory introduction of the Smart Tachograph, also known as the Intelligent Tachograph, with integrated GPS and telematics interface capabilities.

Continental says these additional functions transform the Smart Tachograph from being an advanced tool for recording drivers’ hours to a connected device that can be a secure portal for data transmission to and from the truck.

For Mabire, it’s all about the trustworthy data and the automated exchange of data from truck to operator and between operators.

He comments: “The Smart Tachograph is an opportunity for fleets to access secure, tamperproof data on a range of operational activities. Companies can also use it to establish new services and business models.”

Continental provides 40% of the world’s electronic keyless vehicle fobs and has now developed a system for commercial vehicles that allows any authorised person to unlock the vehicle and drive it without a mechanical key. Because this smart-key system is connected in real-time to the operating base, Continental predicts it will enhance security, operations, and compliance.

Physical key transfers become unnecessary because vehicles can easily be opened and started with a smartphone app.

Keys won’t have to be left in the vehicle for the next driver or for technicians, as well as no time wasted hunting for missing keys – the transport or workshop office keyboard could become a thing of the past.

Workshops will be able to have a master key for each vehicle in the fleet, or for customer vehicles. Mechanics can gain access to the cab and engine without bothering the driver – the virtual key is transmitted directly to the mechanic’s or workshop-specific smartphone.

The system enables users to open their vehicles and start their engines with a simple command via smartphone or Bluetooth card. Mabire explains: “By taking

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advantage of the technology in our car solutions and tailoring it to the needs of trucks, vans, and coaches, we’re bringing products onto the commercial vehicle market that are both innovative and affordable.”

The system relies on secure communication between the remote key system and the vehicle’s ECU. Then, the module in the vehicle uses its integrated SIM card to authenticate the smartphone via Continental Cloud. Opening and starting are possible only if the virtual key from the cloud confirms that the smartphone is authorised for that particular vehicle.

Smart weighing Real-time On-Board Weighing System (OBWS) will help driver and operators comply with axle and gross weight regulations. The OBWS will measure the vehicle weight and send an alert as soon as the truck is overloaded – even before the start of the journey. On the positive side, it can also help reduce operating costs by making the best possible use of the load potential and maintenance costs by preventing component damage from excess weight.

The Continental system works by placing ultrasonic sensors on the air spring or on the shock absorber, as well as with elongation sensors on the axle for steel-sprung vehicles and mixed fleets. The OBWS collects the data, forwards it for evaluation, and makes it available via an interface in the office via a smartphone app or on a display in the driver’s cab.

“Physical key transfers become unnecessary because vehicles can easily be opened and started with a smartphone app.”

FOR MORE INFORMATION, WWW.RDR.LINK/VT012

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COMPLIANCE

REAPING THE REWARDS Earned Recognition might be the best-kept secret in the road transport industry.

Truckfile reveals all.

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he DVSA scheme has been around since 2018, when Earned Recognition was launched in pilot form, but still only 79 vehicle fleet operators across the UK have signed up. There are some good reasons for this: in the two years since the project’s introduction, the transport sector – and wider business community – have had to deal with the upheaval caused by Brexit, successive General Elections, and, most recently, the global COVID-19 pandemic.

The first and last of these are still sources of some uncertainty, of course, but there are tangible incentives for fleets to join the Earned Recognition programme. Since day one, it has been the case that vehicles covered by the scheme are subject to fewer

30 CVW OCTOBER 2020

roadside checks – inspectors already have the evidence that the trucks are fully compliant, so there is simply no need.

Now, there’s an added bonus. DVSA has announced a 12-month exemption from MOT testing requirements for some fleets, in an attempt to keep a lid on demand at Authorised Testing Facilities (ATFs). After all, they will have to deal with an ever-increasing backlog as the country continues to emerge from COVID-19 lockdown restrictions.

Amongst the operators to benefit is Staples Vegetables. Staples was the first truck fleet to join the Earned Recognition scheme, with the help of IT provider Truckfile. The use of an approved supplier of computer technology to harvest, manage, and transmit the required data is key to attaining Earned Recognition.

Truckfile has worked with Staples since 2016. Transport Manager Dave Baker explains: “We take compliance very seriously and will always avail ourselves of any opportunity to demonstrate that we operate responsibly. Reducing the number of roadside checks on our trucks is welcome, but our main motivation is to stay abreast of what we see as an important new development.”

Staples’ aim is to reap the benefits of Earned Recognition without adding onerous extra layers of administration to its business. With help from the Truckfile team, the operator has made the necessary transition to electronic record-keeping smoothly and efficiently. Staples’ Actros tractor units were supplied by Mercedes-Benz Trucks dealer Intercounty Truck & Van, and they are maintained in its Boston workshop. Intercounty, like all the German manufacturer’s dealers, utilises Truckfile to create, update, and store all maintenance records.

Therefore, setting up a software system to send the relevant information to DVSA was a simple and painless process.

Inspectors are given regular, comprehensive

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updates showing only what they need and, because the information is all stored electronically rather than on paper, they can view these remotely.

“We’ve received tremendous support from the team at Truckfile,” says Dave Baker.

“We now use the system to maintain service records of our trailers and our extensive line-up of vans, forklifts, and plant too – in total that’s around 600 pieces of equipment.

Compared to the headache of compiling and storing paper records, it’s been a revelation in terms of both ease and efficiency.

“Truckfile has become just like any other tool we use on a daily basis to keep our operation running smoothly. It does the job we ask it to, and has made itself an indispensable part of our business.”

What is Earned Recognition?

The DVSA scheme relies on operators installing a system that will monitor their compliance against a set of key performance indicators (KPIs). Crucially, any exceptions can be viewed and addressed by the operator before a KPI notification is sent to

DVSA. And, because the reports can be checked by the Agency online, there’s less need to stop trucks for roadside checks.

Approved providers of digitised compliance systems typically use Internetbased recording which makes easy work of supplying the required information to DVSA, to meet the terms of the scheme. The advantages of using a good computerised system go further, however.

For workshops, going digital means there is no longer any need to fill in and store paper forms. All maintenance records are updated and stored automatically, with complete security. Technicians use hand-

held tablets – or, in the latest development, cutting-edge voice recognition equipment – to check off repair jobs and inspections as they are completed. Recording is quicker, easier, and more fool-proof than ever before.

For fleet operators, all documents relating to any individual vehicle, its compliance status, and related maintenance data are available on-screen at the click of a button. Soiled, damaged, or missing paperwork becomes a thing of the past.

Crucial for any business looking to install a new IT system, though, is the ability to do so with the minimum of disruption.

Professional suppliers will ensure expert help is on hand to support new customers throughout the implementation. Universally, firms making the digital leap report that their lives have been made far easier, rather than more complex, by using the system.

FOR MORE INFORMATION ON HOW TRUCKFILE CAN HELP WITH EARNED RECOGNITION, WWW.RDR.LINK/VT013

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COMPLIANCE

TAKING THE NEXT STEP Much work has been done in recent years to improve safety for vulnerable road users, with the industry working hard to advance standards. John Hix, FORS Director, talks about how the company is taking legal compliance to the next step.

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oluntary accreditation as offered

by FORS – the Fleet Operator Recognition Scheme – gives commercial vehicle operators a chance to go far above basic legal compliance, with safety at the top of the agenda.

The recently postponed Direct Vision Standard (DVS) is, in many ways, an extension of the strides the road transport industry is already taking to reduce collisions and help vulnerable road users.

Whilst the pandemic has pushed back the enforcement of DVS until at least March 2021, operators are still fully aware of their safety obligations, and those who are FORS members will be well used to thinking about visibility as one aspect of a complete approach to protecting vulnerable road users.

More than simple legal compliance Since it began 12 years ago, FORS membership has grown to almost 5,000 nationwide. This is testament to the value operators of all types place on the voluntary accreditation scheme, and how it helps drive safety and efficiency through a unique mix of driver and management training, robust auditing, and performance monitoring.

FORS members can point to improved performance, total safety and security, and environmental practices – offering members a far broader remit than legal compliance.

32 CVW OCTOBER 2020

Training

Clear safety guidelines are set out at the entry-point ‘FORS Bronze’, with operators required to have basic safety equipment in place, including side under-run protection and Class V and VI safety mirrors and warning signage on all commercial vehicles over 3.5 tonnes.

‘FORS Silver’ is the second level of accreditation, and many of the requirements set out at ‘FORS Silver’ relate to ensuring vehicles are equipped with safety technology to improve driver visibility, to ensure vulnerable road users are as aware as possible of the truck’s onward movements. Operators must prove all trucks over 3.5 tonnes GVW are equipped with an audible means to warn other road users of a vehicle turning left and reversing, and blind spot minimisation measures.

Throughout the FORS Professional training programme, the importance of safety is clear; at all levels of accreditation, safety procedures are reinforced with regular driver training to fully embed a thorough understanding of the many challenges which come with driving and managing commercial vehicles.

FORS has adapted its training offering in light of the COVID-19 pandemic, moving many driver and management courses online. In April 2020, all FORS Professional manager courses were amended to suit an online format. A new secure ‘virtual classroom’ platform, launched in early September, was developed by FORS to enable delegates and trainer to see each other and engage in a classroom-like environment.

FORS urges drivers to refresh their FORS Pedestrian Safe eLearning training, in order to understand the specific dangers faced by pedestrians and learn how to protect them.

FORS accreditation is about continuous progression, so the organisation’s members can become safer, smarter, and greener, offering customers a service far exceeding basic compliance, which has safety of all road users at its core.

FOR MORE INFORMATION ON FORS, WWW.RDR.LINK/VT014

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WINTER SERVICE & LIGHTING

IT’S ALL LIGHT HELLA recently launched full LED high beam headlamps for commercial vehicles. Here, the company advises on how it benefits the user and important regulations to be aware of.

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he demands on commercial vehicle lighting are high, particularly when it comes to ensuring road safety and the best visibility in every situation. To provide a premium solution, particularly with winter on its way, HELLA, the lighting and electronics expert, has launched the Jumbo series of LED auxiliary headlamps.

The Jumbo LED auxiliary high beam headlamp combines function and design into one product. When switched on, the light signature, with its high recognition value, presents a characteristic lighting design during both the day and at night.

This is ensured by the EdgeLight technology that HELLA has transferred from its development in the automotive sector. The light signature and the striking design trim in the top part of the full LED auxiliary headlamp were inspired by the design of the round Luminator LED auxiliary headlamp, which HELLA launched in 2019.

Another advantage of this LED series is the light colour which is similar to daylight.

It creates fatigue-free driving and the instantaneous high beam light signal enables the use of a superb headlamp flasher function. In addition, it features an impact-resistant, lightweight plastic housing made of thermoplastic and offers high energy efficiency, with low power consumption. Thanks to its multi-voltage function, the Jumbo LED is suitable for 12and 24-volt applications and is available in two mounted versions, either for upright or pendant installation.

Naturally, lights periodically need to be replaced and, as they are critical safety components, CV operators need to be aware that any replacement must comply with the certificated regulations for that specific application. The Jumbo LED is tested according to the new ECE regulations (ECE R149 high beam, ECE R148 position light, ECE R10 EMC). The auxiliary high beam headlamp is supplied in the illumination variant ECE Ref. 25 and is ideal for mounting on a roof bracket.

When it comes to driving lights, operators should always fit quality replacement headlight lenses that bear the correct ‘E’ marking. This ensures that the lenses have been tested and approved by a photometric laboratory and have met the standards of the European Commission. In addition, even when quality lighting is fitted, it must be checked to make sure it is correctly adjusted. This ensures that it not only delivers the right spread of light to effectively illuminate the road ahead for the driver, but also does not dazzle oncoming vehicles.

HELLA’s ELIVER app is a valuable interactive tool for operators which offers access to a great deal of product information online, as well as to download. It also gives the option to directly compare various HELLA auxiliary headlamps and work lights, whilst viewing in realistic 3D environments.

HELLA’s comprehensive CV lighting range includes headlights, side markers, outline markers, daytime running lights, stop, reversing, tail and fog lights and direction indicators.

FOR MORE INFORMATION ON HELLA’S ELIVER APP, WWW.RDR.LINK/VT015

OCTOBER 2020 CVW 35

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WINTER SERVICE & LIGHTING

THE BIG

FREEZE L

ower temperatures during winter can have a physical impact on engine oil, with colder temperatures causing the oil to become thicker. This can lead to starting problems if the lubricant can’t circulate through the engine as easily and effectively as it should, leading to accelerated wear. The last thing any haulier wants on a cold winter morning is an engine refusing to burst into life, ruining the journey ahead.

Today’s advanced lubricants should be capable of providing sufficient lubrication for engines whatever the weather. Thanks to specific chemical formulations, the same oil should be suitable for use all year round.

However, VLS, the independent industry trade body set up to investigate and verify lubricant specifications, discovered an engine gear oil that wasn’t able to cope during extreme temperatures.

In independent laboratory testing, the lubricant was found to turn solid at -40⁰C. Whilst the temperature in some parts of the country rarely stays below freezing for a sustained length of time, extreme temperatures are not uncommon in Scotland.

For long distance hauliers travelling across the European continent, this could pose a severe risk, especially in the Baltic States or Scandinavia. To be within specification, lubricants must be able to perform – even in these extreme conditions – to avoid accelerated wear to gears and bearings during low temperature operation and start-up conditions.

36 CVW OCTOBER 2020

Can engine oil actually freeze during winter? This case study from the Verification of Lubricant Specialists (VLS) demonstrates why the cold weather properties of lubricants are so important during winter.

VLS worked with the supplier concerned to initiate a product recall, remove the old stock from sale, and reformulate the product to meet the specification. Trading Standards were involved to ensure the required action was taken and that products were fit for purpose, whatever the weather.

Andrew Goddard, Chairman of VLS, comments: “This was one of the first cases VLS investigated and it was a highly significant one. As a result of the process, the supplier involved was much more aware of the aims and objectives of VLS and how important adhering to specifications was.

“Lubricant blenders may be tempted to reduce the amount of additive treat in a blend as they don’t expect to reach ambient winter temperatures that low. However, products still need to meet their specification in order for the trade and the public to have continued confidence that

the products they are buying are fit for purpose and will help protect against damage to vehicles.”

VLS continues to investigate complaints about engine oils and other lubricants, including referring cases to Trading Standards if required to ensure the appropriate action is taken by lubricants manufacturers and distributors.

VLS also works to educate workshops, technicians, motorists, and the wider automotive industry to improve understanding about oil choice. Increasing general knowledge about vehicle lubricants is key to ensuring standards remain high and that lubricants being sold really can deliver what they claim.

If you have any concerns about an engine oil or lubricant product, you can report them to VLS by calling 01442 875922 or emailing admin@ukla-vls.org.uk. VLS handles all cases anonymously through a clearly defined process which includes technical review by a panel of experts from across the industry and dialogue with the manufacturer and all relevant parties to work together to resolve any issues. Since 2014, VLS has independently verified over 65 lubricant specifications, to ensure products really can deliver what they claim.

FOR MORE INFORMATION ON VLS, WWW.RDR.LINK/VT016

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WRAP UP FOR WINTER CVW teams up with Rotronics to ensure that you get the best out of your batteries during winter.

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reparing your fleet and workshops for winter, whilst also managing the fluctuations of the COVID-19 emergency, may provide some additional battery-related challenges for fleet managers and owners. The initial COVID19 lockdown, in theory, should mean that there is a reduced requirement to replace batteries; but this period has also meant that many batteries have not been maintained.

ROBIS is an industry-first, web-based dashboard and proactive battery management reporting system from Rotronics, which is ideal for remote working. The system allows remote access to workshop battery data and reports, with wirelessly uploaded test results as they happen, giving clear visibility regarding workshop productivity.

The following analysis shows ROBISreported testing by commercial workshop customer segments over Winter 2019 (Nov 2019-Feb 2020) during routine maintenance and represents 93,000 battery tests.

to this summer’s performance and it doesn’t get much better. However, we have had the impact of COVID-19 with vehicles having been ‘laid up’ and inoperative sometime during this period.

“Temperature drops will alter a battery’s performance and, in extreme chill, this can be as much as a 50% dip. The shorter days increase power demands on all vehicles with lighting, heating systems, electrics, heated seats, and de-misting windows, etc.”

The Rotronics Battery Management Programme will help you focus on key points for success. Ken Clark states: “Prepare the fleet well in advance because battery problems can account for around 20% of costs.”

Step – Visual inspection

The data shows that dealer workshop vehicles are least prone to battery-related issues. However, 27% of batteries that have been tested still require attention. Whereas, fleet vehicles were most exposed to problems, with a staggering 64% of all batteries tested – as part of routine maintenance – requiring either charging or replacement.

Ken Clark, Managing Director at Rotronics, comments: “Compare this trend

Check batteries for any damage; you should be looking for corrosion, excessive electrolyte staining, and gassing. Can you hold down the clamps? Are the terminals secure and free from dirt or corrosion? Are the electrolyte levels maintained?

Step – Test and charge batteries As part of regular vehicle inspection, make sure that: ■ Batteries are charged at every opportunity ■ Any batteries that have been jump

started are tested as this can disguise an underlying problem

■ The batteries are above 12.5V to prevent

excessive deep cycling and risk of sulphation – the root cause of premature battery failure and unnecessary replacement costs.

■ Batteries are in balance – 24V battery sets will only perform efficiently with both voltages and cranking amps being of similar values ■ Never top up batteries that are FLAT with electrolyte ■ Always charge first, providing that the cells aren’t exposed Top tip: If you are using non-maintenance free batteries, be mindful when checking the electrolyte levels that if the battery is in a low state of charge, the electrolyte will be lower than expected. If a flat battery is topped up with electrolyte, there is a high risk that the battery will be overfilled, and the cells expand as the battery takes on board current.

Step – Vehicle health check Once the batteries are in good health, balanced and charged, ensure that the charging system is also performing as it should. You must: ■ Ensure the starter system is working

correctly ■ Check the alternator output ■ Ensure there are no excessive drains

present, which can cause batteries to go flat very quickly.

FOR MORE INFORMATION ON ROTRONICS, YOU CAN CALL 0121 526 8185, OR WWW.RDR.LINK/VT017

OCTOBER 2020 CVW 37

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WINTER SERVICE & LIGHTING

THE FUTURE IS BRIGHT LED lighting is becoming standard for many companies, including OE manufacturers.

Truck-Lite talks about the advantages of this to the commercial vehicle industry.

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here are numerous advantages of this move in the market; one of them being the extended lifespan of the product, with many LEDs running up to 100,000 hours. This is drastically longer than most bulbed lamps and they are much less likely to need replacing.

LED lights are less fragile because they are a solid state unit with no filament and are less susceptible to breaking. LEDs also have a 70% lower power draw than bulbs which means less drain to the vehicle battery and monetary savings in fuel economy due to increased efficiency.

LED lighting seems to be much more suited to the heavy-duty and commercial vehicle industry due to their robust structure and design. LEDs are more likely to withstand impact from uneven road surfaces, falls from height, and minor collisions.

Truck-Lite Europe was the first company to introduce a full LED rear lamp to the market with the Model 756 back in 2006.

Since then, the Model 756 has become very popular across the board. In 2012, TruckLite’s Lifetime Warranty Trailer Kit was introduced, featuring the Model 756 along with many other LED products.

Truck-Lite’s five-year and lifetime warranty packages are testament to the confidence it has in the quality and durability of its lamps and harnesses. TruckLite has been supplying European vehicle manufacturers for over 95 years.

Its expertise and experiences from working with OEM’s and end-users has allowed it to transition from pre-wired components to complete trailer kits, and now to even specialising in ‘plug and play’ systems. Truck-Lite can meet the needs of all its customers in any trailer market and its lifetime warranty kits provide a wide range of unique features and benefits.

Some of the key features of its lifetime kit include: ■ Full LED lighting kit ■ Lifetime warranty (including parts and

labour) ■ Dedicated trailer support team ■ Easy connection through Truck-Lite

■ ■ ■ ■

‘Rapide’ Junction Plate and loomed system Easy Maintenance – dielectric connections Free of charge maintenance training and certification Dust and water tested to IP69K Meets TUV ADR

Both its five-year and lifetime warranty kits offer the company’s most intelligent products, including the recent Model 900 LED rear lamp with homogeneous outline markers, progressive indication, and

additional take-offs to eliminate the need for a junction box. The Model 900 also includes a built-in take-off to incorporate flashing side markers which will comply with the REG 48 Issue 6 requirement.

All of its trailer kit components are vigorously tested in its UK-based laboratory and test facility. Only the highest quality lamps, harnessing, and connectors make it onto the road. Its lifetime warranty kit is dust and water tested, EMC approved, and meets TUV ADR standards.

This warranty enables fleets to have confidence in their vehicle lighting, contributing to a safer vehicle on the roads.

TO SEE TRUCK-LITE’S FULL LED PRODUCT RANGE AND OPTIONS FOR TRAILER LIGHTING KITS, WWW.RDR.LINK/VT018

OCTOBER 2020 CVW 39

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WINTER SERVICE & LIGHTING

LIGHTING THE WAY OSRAM gives its top tips for lighting as the winter months edge closer.

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y choosing OE-quality bulbs over low cost and poor quality alternatives, workshops can rest assured that customer satisfaction will increase, as they will not have to keep returning to the workshop for failed bulbs to be replaced.

OSRAM believes that workshops should apply and consider three key facts of lighting when servicing commercial vehicles and fleets, including changing in pairs, putting the driver’s vision first, and having easy and quick access to replacement products.

Change in pairs Even if a commercial vehicle enters a workshop and only one bulb is blown, technicians should always look to change bulbs together. Not only is it a safer and more practicable option, but it presents a profitable opportunity to upsell.

Most importantly, both headlights are subject to the same stresses, so they will both be deteriorating together. Replacing just one failed bulb can result in an unbalanced or unpredictable headlight beam that can cause serious hazards for the driver and other road users.

A commercial vehicle is designed so that it works best when both headlights are functioning equally. Only then will the driver get the full advantage of the combined headlight beam on the road ahead, which is essential when driving at night – a requirement for many fleet drivers.

Upgrade your customer’s vision When it comes to lighting, only the best quality products should be fitted on commercial vehicles, and workshops should look out for products that are OE quality and offer the same reliability and performance as those provided and fitted on the production line.

For example, OSRAM has a wide range of OE products, as well as a vast array of ValueAdded Products (VAPs) that are perfectly suited to varying customer demands.

40 CVW OCTOBER 2020

Truck and commercial vehicle lighting must withstand the toughest conditions, be highly reliable, and provide perfect lighting for every trip. For vehicles required to drive more at night in poorly lit rural areas, a brighter light such as Night Breaker Laser (12V) or Truckstar Pro (24V) would be recommended.

The range OSRAM’s award-winning Night Breaker Laser range features innovative laser ablation technology and the highly engineered filament enables the bulbs to shine up to 150% brighter. They also provide up to a 150-metre long beam and 20% whiter light compared to the minimum legal standard, and the product offers a wide hot spot beam and sharp cut off. OSRAM has constantly developed the range over the last 10 years to maximise safety and visibility to ensure drivers can spot hazards quickly.

Truckstar Pro is a unique heavy duty, long-life range of bulbs that OSRAM has developed to meet the high demands of truck fleets. These 24-volt, high-performance bulbs deliver increased illumination intensity whilst also offering longer lifetimes and better vibration resistance.

Truckstar Pro halogen headlamp bulbs produce up to 100% more brightness on the road ahead thanks to its unique single-coil technology. They help drivers to see obstacles and signs early, and thanks to the heavy-duty, long-life construction they also significantly reduce bulb replacement cycles.

This in turn reduces downtime and, therefore, helps reduce vehicle-fleet costs.

The Truckstar Pro range is able to offer superior performance compared to conventional 24-volt bulbs.

Many fleet drivers are also required to drive with their lights on for long periods of time, and as a bulb change can be complex or not an efficient way to maximise time, a longer-life bulb could be beneficial. OSRAM Ultra Life bulbs offer complete durability as they have a lifespan up to four times longer compared to standard halogen bulbs and last up to 100,000 km (with an average annual mileage of 14,259 km and 60% light on).

Thinking ahead Bulbs naturally degrade over time and, as a result, light output deteriorates. At the end of their service life, headlight bulbs can project less light, and this reduces a driver’s nighttime visibility, which can be dangerous.

OSRAM recommends checking and changing bulbs before they have the chance to burn out and some OE quality brands will offer useful tools to help technicians find the appropriate bulb quickly and easily.

Customer satisfaction and an enhanced business reputation go hand-in-hand with fitting a high-quality OE product that workshops and their customers can trust. It is, therefore, important to take all these factors into consideration when opting for the right bulb for any specific vehicle.

TO SEE OSRAM’S BULB REPLACEMENT GUIDE FOR YOURSELF, WWW.RDR.LINK/VT019

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WATCH FOR THE SIGNS As LEDs become an increasingly common feature of emergency vehicle lighting, Roadcrew takes CVW readers through what regulations suppliers need to be meeting.

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any technicians will be aware that the lighting technology used in both workshops and vehicles has changed in recent years.

Options for installers of interior lighting, work lighting or warning and safety lighting used to be based on simple bulb lamps. Then xenon strobe lamps were introduced, followed by LED. With the benefits of LED lighting, the move towards this trend is hardly surprising. LED lighting requires a lower power source, as well as the flexibility to have different flash patterns. Roadcrew has seen that the marketplace is in the midst of a big changeover to LED products, with LEDs now present in the majority of lighting products for both vehicle and trailer, as well as lighting for the workshop.

As ever, more complex and stringent regulations have followed the move towards LEDs. When purchasing replacement bulbs for vehicles, there are a variety of standards to be aware of, covering headlamps, brake lights, position lights indicators, fog lights, and more.

Regulations also play a key role in the purchasing decisions for warning and emergency vehicle lighting, with two key standards that workshops need to pay particular attention to.

UN ECE Regulation 65 Often mistaken as a European standard, it is in fact a United Nations Document, which covers the requirements for special warning lights. The standard specifies the colour of

light, brightness at specific horizontal and vertical angles, and flash frequencies – for both on and off times. For example, blue or red is specified for emergency services, whilst amber is used by nonemergency vehicles (recovery/commercial vehicles).

It also outlines the requirements for different types of warning light.

Type T is used for light sources such as lightbars or beacons, and Type X is for directional light sources, such as strobes.

While Regulation 65 for amber warning lights has been adopted across Europe, in the UK it is not mandatory unless fixed to a vehicle which may enter roadworks – this is covered by the UK Government traffic signs manual, under chapter eight. In reality however, most specifiers and end users will still fit warning lighting to Regulation 65 as standard.

Workshops should also be aware that secondary warning lights, such as strobes, do not have to meet Regulation 65, so long as the roof mounted beacon or lightbar is compliant with the standard. This decision is at the discretion of the vehicle operator or installer.

UN ECE Regulation 10 This is another regulation technicians should be aware of, with the standard based on uniform provisions concerning the approval of vehicles with regard to electromagnetic compatibility (EMC).

This standard covers both emitted and received EMC. Something as simple as a small LED strobe lamp, for instance, could emit radiation which could affect other systems on the vehicle. Roadcrew’s advice to specifiers, installers and end users would therefore be to ensure the LED lighting they install is certified to UN ECE Regulation 10.

“There are a variety of standards to be aware of, covering headlamps, brake lights, position lights indicators, fog lights, and more. Regulations also play a key role in the purchasing decisions for warning and emergency vehicle lighting, with two key standards that workshops need to pay particular attention to.”

TO FIND OUT MORE ABOUT THE RANGE OF VEHICLE WARNING LIGHTING AVAILABLE FROM ROADCREW, WWW.RDR.LINK/VT020

OCTOBER 2020 CVW 41

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BODY REPAIR & MAINTENANCE

FEWER STEPS, MORE DISTANCE Now the first measures are in place to overcome today’s acute challenges, a ‘new normal’ has begun in bodyshops. Standox explains how it’s supporting the new ways of working.

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any workshops and bodyshops are permanently changing processes and rethinking which tools and products support them the best.

Social distancing in the bodyshop requires planning of the processes as well as training for employees. Every business should have a clear COVID-19 plan that details the distances that need to be maintained in order to avoid unnecessary contact between the employees – vital when assigning staff to repairs.

This can be achieved with wireless colour measuring devices such as Genius iQ and the Standowin iQ app from Standox.

Colour measurements can be carried out on the vehicle with these, and mixing formulas can be selected on any internet-compatible device without refinishers having to go into the mixing room. This not only ensures some social distancing when determining the shade, but also working more efficiently as refinishers move around the bodyshop less.

Olaf Adamek, Standox Brand Manager for Europe, Middle East, and Africa, comments: “Bodyshops currently have to master many challenges, but thanks to our flexible products, tools, and services, we can take some of their worries away. It is becoming evident that modern, digitallysavvy bodyshops survive these challenging times better. We have been supporting our customers by consistently advancing bodyshop digitisation with our forwardlooking offers for years.”

Standowin iQ app Standowin iQ, the Standox colour software, is now available as an app designed to complement the Standowin iQ Cloud solution delivering mobile digital colour management.

Plan ahead When the refinishers’ work plans are changed, processes must be reconsidered and rescheduled. Products that dry at room temperature and do not require forced air drying can be dried outside the spray booth.

The Xtreme System from Standox is perfect for this and offers high quality with low energy consumption and short drying times.

Digital contact, full support And if there’s a problem with a particular colour? The full team of Standox experts is still available even if they can’t be there in person. For complicated colours or an unsatisfactory result, the Standovision videos on the Standox YouTube channel and on the Standox website offer practical help that is available any time.

Refinishers can access the features of Standowin iQ Cloud on WiFi-enabled smartphones and tablets with just one click and even connect to local devices.

From the reception area to the preparation area and office, digital colour retrieval and shading becomes even easier with mobile networked devices and the Standowin iQ app, regardless of location or device – whatever works best for the bodyshop.

In addition to the familiar functions of the Standowin iQ software, the app offers an integrated scanner function that can accelerate job management, and automatic updates provide up-to-date information, formulas, and products.

TO SEE THE STANDOVISION VIDEOS ON STANDOX’S YOUTUBE CHANNEL FOR YOURSELF, WWW.RDR.LINK/VT021

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BODY REPAIR & MAINTENANCE

ABRASIVE MANOEUVRES We spoke to Steve Smith, National Sales Manager ART of Mirka UK, about the company’s abrasive solutions and the challenges it faces.

Q

How have Mirka’s abrasives evolved over the last decade or so to meet the demands of the industry?

Steve Smith (SS): As with everything in life, change is a certainty and as a business you have to adapt to these changes. The CV sector is no different to any other with new technologies evolving within vehicle repairs and refinishing. The customer’s expectations are for the manufacturer’s R&D to meet these demands and new challenges, this is an area within Mirka given a high priority status.

Q

How has Mirka had to adapt to meet the current challenges?

SS: By working closely with the customer and understanding their needs and challenges, Mirka set to work on providing solutions to ensure the customer can tackle any given sanding application with confidence.

Q

What do you see on the horizon when it comes to abrasive evolution? And what is the most popular abrasive?

SS: The requirement for abrasives within the repair process is a key factor and

unlikely to change in the foreseeable future, however new technologies will drive any change. PSA discs in roll format, which have been around for many years, are still one of the most popular products used within the CV sector today, especially with vehicle refurbishments, whilst cost is certainly an influencing factor.

Q

How does Mirka ensure that it can meet the demands of users in the CV sector?

SS: Working hand-in-hand with your partners is key, the need to understand their requirements, challenges, and frustrations, then by working together to ensure all these demands are met.

Q

What are the benefits of Mirka’s abrasives for end users in the CV sector?

SS: Benefits to the end user from using Mirka abrasives is having the peace of mind that the quality and performance of the products is consistent throughout. The end user also has access to our experienced technical team, the technical team cover everything from problem solving through to training, process, product, and profitability to ensure maximum benefits are gained from using the Mirka products and systems.

FOR MORE INFORMATION ON MIRKA’S ABRASIVE SOLUTIONS, WWW.RDR.LINK/VT022

44 CVW OCTOBER 2020

Just the trick For two decades, Mirka has been at the forefront of dust-free sanding, thanks to an invention that revolutionised workplaces all around the world. By developing an abrasive that features a net structure instead of a conventional paper backing, Mirka was able to introduce extremely efficient on-tool dust removal that improves both the work quality and working environment. Mirka simply called the new abrasive Abranet.

Manufactured with Mirka’s patented technology, the net structure of the Abranet abrasive ensures a sanding particle is never more than 0.5 millimetres from a dust extraction hole.

This means that sanding grains are able to retain their cutting power and the resulting dust is safely removed.

Abranet is highly resistant to dust pills and clogging, and is easily cleared to ensure optimal use out of every abrasive.

With every coarseness grade providing excellent results, the original Abranet and its many versions are best combined with Mirka’s efficient and ergonomic power tools and dust extractors. New versions of the Abranet continue to be developed and patented.

“The Mirka Abranet net abrasive is a product of true Finnish ingenuity and ability to think outside the box. What started out as a laboratory experiment quickly proved its worth, and it’s a perfect example of the Mirka way of doing things,” says Hans Hede, Development Engineer and one of the ‘fathers’ of Abranet.

20 years later, dust-free sanding is widely accepted as an industry standard, with many competitors having seen the advantages of the Abranet approach.

Original Mirka Abranet abrasives and their patented technology come from the Mirka factory in Jeppo, Finland, where it all started.

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BODY REPAIR & MAINTENANCE

BEST FOOT FIRST

Kevin Torfs, Cromax Brand Manager for Europe, Middle East, and Africa, explains how to leverage today’s customers and turn impatience into profit.

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t’s widely known that consumers across the world are growing increasingly impatient as a result of constant technological innovations. There is a clear demand for better and faster services from customers in all industries. A recent study revealed that 79% of management believes that consumers are more impatient than ever before and that customers will leave if they do not get what they want when they first make contact with a brand.

Kevin Torfs explains: “In today’s ondemand world, technology has created the belief that everything happens quickly.

Google research shows that 40% of customers will leave a web page that takes longer than three seconds to load, so it’s fair to say that people are more impatient than ever and that companies need to adjust their product and service offerings accordingly.”

Capitalising on impatience On the face of it, the increasing impatience of customers may seem like a negative trend, but in fact it has important implications and exciting opportunities for bodyshops.

“It might sound unconventional, but the truth is that bodyshops can profit from the impatience of their customers. Today, the time-saving, material-saving, and energysaving tools and systems from Cromax drive productivity like never before and help bodyshop owners capitalise on customers’ demands for swift turnaround times on vehicle repairs. The bottom line is that convenience and speed will ultimately give bodyshops a competitive edge.”

46 CVW OCTOBER 2020

Implications and opportunities Rather than viewing customer impatience as a thorn in their side, bodyshops should evaluate their operations. By identifying where they can improve throughput, they will be able to drive productivity whilst satisfying their customers’ need for speed.

“With the right Cromax product system, the possibilities to capitalise on customer impatience is endless, regardless of the size of the repair,” says Torfs.

For jobs that involve minor damage to the vehicle, small area repairs can be carried out with special techniques that speed up the repair process. These repairs give bodyshops the opportunity to profit on small repair jobs whilst providing a quality service to their customers in a short time frame. The Ultra Productive System enables bodyshops not only to reduce waste and to optimise their workflow, but also to achieve greater cost-efficiency and increase profit margins.

For larger paint repair jobs, the Cromax Ultra Performance Energy System can be used in an optimised timeframe – a vehicle part can be refinished in just 36 minutes. It allows refinishers to achieve a high-quality appearance with outstanding gloss hold-out after top coating and as a system it is flexible too. Torfs explains: “Even if a bodyshop decides to let a repair fully airdry, the overall process time is only 74 minutes and still enables outstanding results.”

Torfs concludes: “The only way to stay in the game and to increase profitability is to understand what customers want and figure out how to give that to them.”

Cromax introduces ChromaWeb The new ChromaWeb app from Cromax for smartphones and tablets is now available in the AppStore and on Google Play. The ChromaWeb app is free of charge and offers the same functionality as ChromaWeb, the comprehensive cloud-based colour retrieval software from Cromax, but it has some additional features that provide a value-added solution for digital colour matching.

The ChromaWeb app helps refinishers work faster and with more precision, allowing them to access and to share colour data with the IP scale for mixing the formula, the bodyshop or with an entire bodyshop network on the go. In combination with the spectrophotometer ChromaVision Pro Mini, the ChromaWeb app forms the most advanced digital colour management system ChromaConnect, which is available from Cromax.

FOR MORE INFORMATION ABOUT CROMAX, WWW.RDR.LINK/VT023

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TEA BREAK ROW, ROW, ROW YOUR BOAT…

teaser

A farmer lives on a small stretch of land next to a river.

One day, he travels across the river in a small boat and purchases a fox, a chicken, and a bag of corn.

When the farmer returns to his boat to cross the river again and go home, he realises that he has a dilemma.

Win

The farmer can only take one item in his small boat at a time, or it will sink. He can’t leave the fox alone with the chicken because the fox will eat the chicken. He can’t leave the chicken alone with the corn because the chicken with eat the corn. How does the farmer successfully get all three items across the river?

Text ‘ALIGN CVW’…followed by the answer and your email address to 66777 (standard text costs apply).

Alternatively, email your answer to info@steertrak.co.uk. All answers to be submitted by 10/12/2020. T&Cs apply.

If you send the two relationships in, you can be in with a chance of winning an Amazon Echo Dot! ANSWER:

CAN YOU GUESS THE FILM?

✘

ANSWER:

Win

FIND THE STEERTRAK TRUCK We’ve hidden the Steertrak truck somewhere within this issue of CVW. Find it and email info@steertrak.co.uk, with the page number it’s located on, to be in with a chance of winning some Steertrak goodies.

Contact Steertrak today on 01684 276900, or visit www.steertrak.co.uk ANSWER TO CAN YOU GUESS THE FILM: Rambo

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WHAT’S NEW?

NEXA AUTOCOLOR TURBO VISION TINT RANGE

PCL BUYER’S GUIDE CATALOGUE PCL has released its latest product catalogue. Featuring an easy-to-read breakdown of the company’s product range, the newly designed catalogue also includes ‘how to’ sections, providing readers with guides for finding the right equipment and using it safely and effectively. Segments include couplings and adaptors, hoses and fittings, tyre inflation equipment, nitrogen equipment, workshop equipment, and air tools.

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SNICKERS HI-VIS PROTECTIVE WEAR AND POLARTEC JACKETS AND FLEECES A comprehensive selection of ergonomically designed base-, mid- and top-layer hi-vis clothes has been released

by Snickers, as an extended part of its protective wear. The products within the range are certified as appropriate for different risks at work to ensure comfort, health, and workforce-wellbeing. The hivis range includes waterproof and windproof AllroundWork hi-vis jackets that provide protection in low-light, highrisk environments.

The Turbo Vision Metallic Colour Palette is a range of 43 individual colours based on P651-9006 Aluminium Ready Mix and existing Turbo Vision Direct Gloss tinters.

The Turbo Vision Metallic Colour Palette is made up by tinting P651-9006 with up to 10% of the current Turbo Vision tinters.

It is a state-of-the-art chromatic colour tool. It is designed to act as a tool for customers who have a low complexity of colours and as an aide to conversions. The tool consists of 94 10x15cm flexible painted panels in a branded case, which can be either wall mounted or placed on a desk. Finally, the P600-9405 Bright Orange Tint is a limited-use tinter, made to provide enhanced colour matching capability in the bright orange colour area.

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ATLAS COPCO OIL-INJECTED G90-250 RANGE Atlas Copco has launched the remodelled, oil-injected G90-250 range (125 to 335 horsepower). The remodelled range features a more compact design and offers an increase in flow rates of up to 5% over the previous generation. The engines also feature a ‘cool air zone’ that lowers the energy needed to efficiently compress air.

The G range provides customers the option of either a fixed-speed design or the advanced, variable speed drive design. Air-cooled and water-cooled options are available, along with a range of auxiliary options designed to ensure the compressor performs well within each user’s environment. Users can also connect to and monitor the compressor 24x7 via its built-in SMARTLINK capability.

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48 CVW OCTOBER 2020

Snickers has also added Polartec stretch jackets to its offering, which deliver a tight, body-hugging fit with efficient moisture transportation and durable shape retention plus great freedom of movement. There are also long johns to match. The AllroundWork fleeces and bodywarmers are packed warmth and comfort to keep your body warm or comfortably cool when you most need it.

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LASER TOOLS HGV WHEEL BEARING LOCK NUT TOOL This wheel bearing lock nut tool (part number 7818) is heavy-duty and adjustable, specifically designed and sized for HGV use. The tool can be used to remove and replace wheel bearing retaining nuts (lock nuts), castellated retaining nuts, threaded bearing housing caps, and grease caps. It can cater to multiple sizes and shapes, including octagonal and hexagonal fittings, groove nuts and capstan nuts with round or square peg locating holes. Six sets of locating pins are supplied: 6mm, 8mm and 10mm round and square pegs.

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TRIBO BRAKE FRICTION PRODUCTS Tribo brake friction products are now available in the UK. Tribo is a well-established Ukrainian based manufacturer of friction materials for various industries and is an OEM supplier to truck and bus companies around the world, including MAZ, BelAZ and MTZ. Cannock-based Chamber Engineering has been appointed as the sole distributor of Tribo CV friction products in the UK. It will supply customers direct from the factory, which Tribo says will deliver significant cost savings.

The CV brake pads are certified to ECE R90 and ISO 26865 quality standards and have been designed to deliver over 100,000km service life with low disc deterioration. The design includes a steel plate resistant to deformation and corrosion, with an underlayer to improve the bond between the friction material and the plate, which protects the pad from overheating.

There is a metal mesh that gives a five-fold increase in the strength between the plate and the friction material to eliminate the risk of shearing. The pad material is manufactured so there is an even distribution of copper and brass particles. Special chamfers and slots help bedding and reduce dust formation. Manufacturing is to ISO 9001:201 5 and ISO 14001:201 to ensure consistent quality.

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ADVERTISEMENT INDEX Bowmonk Limited .................................................. (page 45)

Mechanex .............................................................. (page 43)

Boydell & Jacks .................................................... (page 49)

Merridale Limited .................................................. (page 45)

Clarios...................................................... (inside front cover)

Mirka (UK) Limited ................................................ (page 34)

Continental Automotive Trading Limited .............. (page 45)

Morris Lubricants .............................................. (back cover)

Energizer Group Limited ........................................ (page 33)

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

Ferdinand Bilstein UK Limited .............................. (page 12)

Robert Bosch Limited .............................................. (page 9)

Induction International .......................................... (page 38)

Rotronics .............................................................. (page 24)

Jack Sealey Limited .............................................. (page 21)

Schaeffler (UK) Limited .......................................... (page 19)

Juratek Limited ...................................... (inside back cover)

Stertil UK Ltd Inform Marketing Limited ................ (page 16)

Knorr Bremse Truck Services ................................ (page 33)

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

Liftmaster Limited .................................................. (page 42)

Truckfile ................................................................ (page 29)

Maha UK ................................................................ (page 34)

Vision Techniques .................................................. (page 23)

Mann & Hummel UK Limited .................................. (page 4)

Volvo Group UK Ltd/Road Crew .......................... (page 38)

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50 CVW OCTOBER 2020

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MAXIMISE THE EFFICIENCY AND LIFETIME OF YOUR VEHICLES WITH VERSIMAX ENGINE OILS • World-Class OEM-approved lubricants • Suitable for previous and current generation diesel engines • Provides maximum rationalisation potential in mixed fleets

For our latest brochure, please call 01743 232 200

www.morrislubricants.co.uk