Commercial Vehicle Workshop September 2021

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The trade magazine for servicing and repair professionals

COMMERCIAL

VEHICLE WORKSHOP SEPTEMBER 2021

GOING PAPERLESS The long-term benefits of switching to digital solutions in the workshop

Also in this issue…

Part five of Bosch’s ‘KTS Made ESI’ ■ Revisiting the Earned Recognition pilot ■ The importance of maximising space in the workshop ■ Win one of four giveaways this month ■

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CONTENTS

Volume 18

17

Issue 8

REGULARS 5

Viewpoint

13 Business & Training

6

News

46 MECHANEX Monthly

8

Tech Tips

48 What’s New?

SPECIAL REPORTS 14 Roadlink celebrates its 40th anniversary

BATTERIES 17 How workshops can protect against costly failures 18 Why retaining optimum levels on CVs has never been so important 20 Exploring the creation of Europe’s first AGM battery for commercial vehicles 22 Looking at which battery type is best for each vehicle application 24 The new technology helping to ease the strain of continuous usage

COMPLIANCE 27 Revisiting the Earned Recognition pilot 30 How investing in a roller brake tester can play a vital role in protecting your OCRS score

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32 Investigating the important new roles for intelligent tachographs 33 Satisfying your fleet compliance needs and the DVSA with just one system 34 How workshop equipment translates to scrutineering for the British Truck Racing Championship 36 Case study: How Grist Environmental stays ahead of the game on compliance

WORKSHOP MANAGEMENT 39 The benefits of bringing testing facilities all under one roof 40 Preventing health and safety risks by keeping workshops clean 42 Case study: Easing time pressure for one company’s move into London 44 The importance of using space efficiently in a workshop

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45 How to streamline orders and maximise savings

COMPETITIONS 47 Giveaways

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VIEWPOINT

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DRIVING CHANGE

Editor CIAN BRITTLE Group Editor KIERAN NEE Digital Manager KELLY NEWSTEAD Senior Account Manager ALEX DILLEIGH Group Manager ROBERT GILHAM Graphic Designer GEMMA WATSON Group Production Manager CAROL PADGETT 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 © 2021

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leets and workshops have a symbiotic relationship; one could not exist without the other, and developments in the former often have effects on the latter, and vice versa. As we continue to move on from the events of the past 18 months (and hope that this pandemic can be consigned to history), there is a lingering issue affecting fleets across the country. Therefore, it’s set to affect workshops moving forwards, unless action is taken quickly.

This issue was around before the pandemic – although not nearly as pronounced – but it has only got worse as lockdown after lockdown have been enforced across the country. The commercial vehicle driver shortage in the UK has long been predicted to hit catastrophic levels, and the pandemic served to push it into worrying territory.

Back in June, Richard Burnett, CEO of the Road Haulage Association (RHA), commented on the developments that had pushed the shortage to this point. He said: “The upturn in the economy since COVID-19 is increasing demand across supply chains and the reopening of non-essential retail outlets and parts of the hospitality sector is making the situation even worse.”

He added: “The pandemic also resulted in the loss of about 12 months of driver training and testing. The long-term ineffectiveness of apprenticeships for lorry drivers and the general hostility from authorities and Government is also unhelpful for recruiting and retaining drivers.” Fixing the ineffectiveness of apprenticeships extends far beyond just the driver shortage, something that commercial vehicle workshops will be all too familiar with, so long-term solutions are certainly required. However, we need answers now and we need them fast.

The initial response from the Government fell short in typical fashion, as drivers’ hours were extended in an attempt to ease the strain. While this was akin to attempting to heal a broken arm with a plaster, there remains a dire need for solutions. Vikki Woodfine, Head of Road Transport and Logistics at DWF, thinks that the long-term focus needs to be placed on the next generation, as driver shortages and an ageing driver population are not new issues. She explained: “A greater focus on investment in training and on making driving a more desirable career among younger drivers could be the solution. As could reducing the cost barriers of entering the profession for prospective drivers seeking to gain their licence.”

However, Peter Mansfield, Group Marketing Director at Trakm8, believes that the answer lies in the assets fleets already possess. He said: “We have seen time and time again how deploying a route optimisation platform can lead to more deliveries being made with the same assets, and help businesses get more out of their existing fleet.” So, while we wait for the next generation of drivers to come through in the future, this could certainly act as a feasible solution to ease short-term concerns.

Have a great month and enjoy the issue,

Cian B rittle Editor

8,459 From 1 July 2020 to 30 June 2021

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

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NEWS Conren celebrates half century Specialist manufacturer and installer of resin systems Conren has celebrated its 50th anniversary this month.

Founded back in 1971 to service the needs of the automotive industry with a range of epoxy resin floor coatings, Conren quickly established a reputation for quality, long-lasting protective systems and has developed into one of the UK’s foremost providers of surfacing solutions.

Conren has continued to develop and manufacture pioneering products by working closely with its clients to understand the needs of their specific environments.With the focus on hygiene and safety, this includes tailored finishes for floors such as antislip, anti-static, safety demarcation, high temperature resistance, and impact resistant surfacing.

Conren’s Managing Director, Ann Collins, explained: “It is such an achievement to reach the 50th year of trading. I think that is perhaps all so much more poignant after working throughout the COVID pandemic and facing the daily challenges during this unprecedented time. The fact that we were able to work safely and continue to supply our customers is down to the dedication of a fantastic team of people.

“Without our loyal customers, we would not have the success of 50 years’ trading and we are extremely grateful for their continued support. We do pride ourselves on the high level of repeat business we have with our contract installation service.”

She concluded: “The fundamental key to achieving success and reaching this 50-year anniversary is the Conren staff, past and present. For example, our longest currently serving employee (Contracts Manager Paul Stansbie) reached an impressive 40 years with the company in October 2020.

“This level of commitment shows how passionate we all are and how we put our customers’ needs at the forefront of our business ethos.”

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DVSA to recruit 40 additional driving examiners A campaign to recruit additional vocational driving examiners in England and Wales to help reduce the lorry driver shortage has been launched by the Driver and Vehicle Standards Agency (DVSA).

40 new vocational examiners will be recruited in total, made up of existing DVSA employees and external candidates.

The Government wrote to the UK haulage industry on 20th July outlining a package of measures to help address the lorry driver shortage. It acknowledged that increasing the availability of vocational driving tests is key to this issue.

DVSA continues to develop measures to maximise testing capacity, including consulting on plans to streamline the process for drivers to gain their HGV licence. The additional examiners will enable DVSA to offer more lorry driving test appointments.

It has already increased the number of vocational driving tests from 2,000 a week pre-pandemic to 3,000 by overtime and allocating additional employees into testing.

DVSA Chief Executive Loveday Ryder said: “We recognise the haulage industry keeps the wheels of our economy turning and have listened to its concerns about the current lorry driver shortage.

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“We have responded by doing all we can to support the industry in tackling this issue through increasing lorry driver testing.

“This includes our latest campaign to recruit more vocational examiners so we can maximise our lorry testing capacity.”

Roads Minister, Baroness Vere, said: “Our HGV drivers provide a vital service delivering food, medicine and other vital goods to where they’re needed. That’s why we’re committed to working with industry to address the shortage of drivers and have unveiled a package of robust measures.

“Increasing the DVSA’s testing capacity is a crucial part of this plan, and I’d encourage anyone with the right experience to apply for a role – helping keep our country moving.”

“It has increased the number of driving tests from 2,000 a week pre-pandemic to 3,000.”

HGV market in Q2 post-COVID boost New heavy goods vehicle (HGV) registrations increased by 128.7% in the second quarter of 2021, according to figures released by the Society of Motor Manufacturers and Traders (SMMT).

The increase saw some 9,493 units registered, up from 5,342 in COVIDimpacted 2020. Compared to the pre-pandemic five-year average, however, truck registrations fell -20.1% as

nationwide lockdown and business uncertainty continued to discourage greater investment in new equipment.

Mike Hawes, SMMT Chief Executive, commented: “While it’s good – if unsurprising – to see an increase in HGV registrations, these are still relatively low numbers compared to the rapid growth the sector enjoyed before the start of the pandemic.

“As operators continue to battle against acute driver shortages, the sector faces a longer term and more significant challenge as the Government proposes the complete decarbonisation of this sector by 2040.

“This would be an incredibly tough timeline when the technological solutions are unclear, with nearly all of the sector diesel-powered. The sector needs stability, certainty and support if it is to develop the technologies and make them commercially viable for our heaviest mobility challenges.”

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UK Government selects Leyland Trucks for electric truck trial Leyland Trucks is to participate in a project in which a total of 20 electric DAF trucks will be trialled to help UK operators make the transition to battery electric trucks.

A total of 20 DAF LF Electric 19-tonne rigids, together with the required charging infrastructure, will be fitted with data logging equipment and used to support the UK Government’s Department for Transport (DfT) efforts to encourage the use of battery electric vehicles in commercial transport.

An interactive website will inform future fleet operator buying decisions and help stimulate the sale of battery electric trucks.

To support operators in understanding the costs and considerations around the deployment of zero emission trucks, the DfT is adopting a proactive campaign to assist the road transport sector in its transition.

The project is part of the Government’s £20 million zero emission road freight trials.

The project is delivered using the SBRI (Small Business Research Initiative), which is a process that brings together government challenges and ideas from business to create innovative solutions.

Leyland Trucks will work with CENEX, the low carbon research consultancy, to create an interactive report and website using real-world data to assist public and

private fleet operators to better understand the strengths, challenges, and deployment options around zero emissions trucks.

Leyland Trucks manufactures the successful DAF LF series of distribution vehicles, including the LF Electric which recently entered production at its state-ofthe-art plant in Lancashire.

Leyland Trucks will be partnering several end-users in the public sector during the trial, including various NHS (National Health Service) operations around the country earmarked to trial eleven DAF LF Electric rigids. The remaining nine vehicles will go to a number of Local Authorities to support recycling and deliveries to schools. Bodywork will include ex-factory PACCAR box bodies and refrigerated bodywork from Gray & Adams.

The project is valued at £10 million and focuses on an end-to-end solution, covering vehicles, charging infrastructure, user training, repair and maintenance and total-cost-of-ownership. The project will provide operational insight across a variety of duty cycles.

“We’re delighted to have been selected to play such a key role in the initiative,” said Rob Lawton, Project Manager, at Leyland Trucks, “We’re proud to be leading the drive towards a cleaner, more sustainable future for the road transport industry. Our LF Electric and CF Electric vehicles offer the best solution for zero-emissions operation. The results from our NHS and Local Authority partners will support Leyland Truck’s extensive and longterm testing programmes to further strengthen our leading position in providing Battery Electric Vehicles.”

IVECO promotes benefits of natural gas IVECO launches projects to promote the benefits of natural gas and its key role in decarbonising transport.

IVECO has launched the IVECO Ambassador programme to give a voice to customers, enthusiasts, and partners who share the brand’s values on different themes, and recognise their actions in these areas. The company has started the programme with the Sustainability theme, aiming to raise the profile of natural gas and highlight the brand’s commitment to the environment.

With more than 45,000 natural gas vehicles sold, it is the European market leader and the first manufacturer to offer a natural gas-powered heavy-duty truck specifically designed for international long-haul missions.

The natural gas distribution network is developing fast, keeping pace with the growth in sales of natural gaspowered vehicles. This network can also be used to distribute biomethane, so that a dedicated infrastructure is not necessary to transition to bio-LNG. Currently it is supplied as a blend or under customers’ order. However, production volumes of biomethane are growing and this sustainable fuel is becoming increasingly available.

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TECH TIPS

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In the last part, we looked at Model Info which covered technical and service data, fuse and relay diagrams, and troubleshooting for the vehicle as a whole. System Info provides additional information for specific systems within the vehicle.

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nce the vehicle has been correctly selected, the list of available systems are shown. If you know which system you need to work on, select it from the list on the left and then, if required, select the specific system from the list on the right (Fig. 1). This will make the System Info button become live and you will be able to view the information which ESI Truck carries for that system. This could be a combination of: ■ ■ ■ ■

Wiring diagram Technical data Technical documents Troubleshooting by symptom

Just like with Model Info, the amount of information varies depending on the selected vehicle and, again, whenever you see this symbol (circled in red in Fig. 1), it means that the laptop, tablet, or PC which you are using ESI Truck on must be connected to the internet in order to view this information.

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Wiring diagram There could be options for which wiring diagram to view depending on the vehicle and system selected. Once the correct one is selected, the wiring diagram appears on screen (Fig. 2a). The list of components can be expanded and clicking on one of these will highlight it on the wiring diagram (Fig. 2b). Alternatively, you can search for the name of the component to quickly and easily find its position. The Symbols button can be used to view the key to all the different symbols used in the diagram (circled in red in Fig. 2b).

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Technical data

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The technical data is specific to each component in the chosen system. Clicking on one of the components listed (Fig. 3a) will show you an image of where to find the component on the vehicle and any additional information which is relevant to its function and, therefore, diagnosis (Fig. 3b). Under this heading, you might also find tightening torques or other key technical data for the system.

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Technical documents Technical documents will be specific to parts of the system selected (Fig. 4a). This could include general information about an aspect of the system or instructions relating to the calibration of a component as is shown in this example (Fig. 4b).

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Troubleshooting by symptom ESI Truck will provide a list of symptoms relevant to the system in question (Fig.5a) and this list can be searched to find the guided troubleshooting instructions to solve the problem (Fig.5b). These instructions can lead to secondary tests but all of this is explained in easy steps within ESI Truck (Fig. 5c).

In ‘Part 6’ of this series, we will look at the Common Tests function – just when you thought ESI Truck couldn’t possible have any more information in it, it does!

TO SEE ANY OF THE PREVIOUS PARTS OF THIS SERIES, CHECK OUT THE MAGAZINE ARCHIVE ON THE CVW WEBSITE, WWW.RDR.LINK/VAD001

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TECH TIPSS

REPLACE FLYWHEEL WHEN CHANGING CLUTCH The commercial vehicle experts at ZF Aftermarket explain why careful checking of the flywheel when changing the clutch is so important.

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n most commercial vehicle (CV) engines, the flywheel is a massive component. But despite its size, it can wear out: for example, on the starter gear ring or the friction surface. This is because the flywheel is tapered by only a few tenths of a millimetre in order to ensure smooth clutch engagement.

After a clutch change on a truck, if the clutch engage is still jerky and affects the starting behaviour, it may be because the flywheel is worn. Although this component is extremely durable and, therefore, not included in the usual clutch spare parts kits, even this massive component is subject to wear and tear over time.

The friction surface, for example, has a conicity that is barely visible to the naked eye. It is tapered by a few tenths of a millimetre so that the friction disc does not abruptly apply, but instead makes the startup process as smooth as possible.

However, this taper can wear out after long use. If this happens, the frictional connection is established without transition when the clutch is engaged, which leads to the inharmonious starting behaviour, as described above. Incidentally, this jerky behaviour is not only a comfort disadvantage, but can also result in consequential damage to the driveline.

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KEY POINTS ■ The starter pinion repeatedly meshes with the flywheel ring gear ring and causes abrasion ■ The taper of the friction surface can also wear after repeated use, leading to clutch vibration ■ Proactive replacement of the flywheel prevents expensive consequential damage In addition, another point on the flywheel that is subject to wear is the starter ring gear. The engine is likely to be started several thousand times during its service life meaning that the starter pinion meshes with the corresponding ring gear

frequently, wearing away the material.

This can result in starting problems.

Other criteria for assessing the condition of a single-mass flywheel are local thermal overloads or cracks in the contact surface.

The experts from the Aftermarket Division of ZF, the world's leading supplier of commercial vehicle driveline technology, therefore recommend that commercial vehicle workshops intensively inspect the vehicle's flywheel every time the clutch is changed.

It is recommended that the customer replace it at an early stage or at the same time as the clutch if there are any signs of wear. Replacing the component does not incur high additional costs, but can prevent expensive consequential damage.

ZF AFTERMARKET OFFERS AN EXTENSIVE PRODUCT RANGE OF FLYWHEELS FOR TRUCKS AND BUSES FROM VIRTUALLY ALL WELLKNOWN VEHICLE MANUFACTURERS UNDER ITS SACHS PRODUCT BRAND. TO SEE THIS FOR YOURSELF, WWW.RDR.LINK/VAD002

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BUSINESS & TRAINING

SPILL KITS:

USING THE RIGHT ONE Spills are commonplace in CV workshops, but are you equipped to deal with them? Spill kits play a crucial role in tackling potentially hazardous liquid spills and leaks. FirstMats gives an overview of the types available.

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hether you drive, maintain, repair, or own commercial vehicles, you’ll undoubtedly come into contact with different potentially dangerous liquids. Brake fluids, coolants, lubricants, oils, and fuels are all substances that – if allowed to leak into the environment – can be hazardous to health and the ecosystem.

In some cases (bulk fuel or oil storage, for example), spill kits are mandated through the Health and Safety Executive’s extensive COSHH (Control of Substances Hazardous to Health) regulations. In others, it’s simply best practice to have a spill kit handy to protect personnel, equipment, and your site. Whatever the reason, you need to know what kinds of spill kits are available, and make sure that you have the correct ones stocked and ready for use.

Spill kits explained

How many do you need?

Oil spill kits – Typically white in colour, oil and fuel spill kits include absorbent pads and rolls made from a hydrophobic material.

They actively repel water, while soaking up hydrocarbons (the fuel or oil). They’re especially useful in damp environments or where the spill has mixed with water.

Once you’ve worked out what kind of spill kit you want, you need to assess how many you need and in what size. Popular sizes are anywhere between 90 and 240 litres (based on absorbent capacity) and you need to base your choice on your specific needs.

Best practice for larger sites or those with multiple chemical storage or use areas is to spread out smaller kits, letting personnel tackle spills quickly and then source more absorbents from further afield as necessary.

Kits are also available in handy invehicle sizes – perfect for keeping in the cabs of your vehicles and tackling any leaks or spills that happen off-site. If in doubt, check with a health and safety expert to make sure you are meeting your obligation under the law and protecting your people, site, and the broader environment.

Universal spill kits – Easily identified by their lighter grey colour, universal spill kits are particularly versatile, and well-suited to sites that use a broad range of fluids. They are able to absorb water-based liquids like coolants and antifreeze, and are also very effective in tackling oil and fuel spills.

AdBlue spill kits – Supplied in easily recognisable blue containers, one of the more recent additions to the spill kit world is the AdBlue kit. These are designed for use against spills of diesel exhaust fluid (an aqueous urea solution), which is used to reduce harmful emissions from diesel engines. Other spill kits are not very effective in dealing with AdBlue, so if you store or use it, these dedicated kits are a must-have.

FOR MORE INFORMATION ON THE AVAILABLE SPILL KITS FROM FIRSTMATS, WWW.RDR.LINK/VAD003

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SPECIAL REPORT

40 YEARS

AND COUNTING

With its 40-year anniversary approaching, Keith Sedgley, Managing Director of Roadlink, explains how it came to offer such a wide range of CV braking, alongside its own well-established RI brand.

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oadlink’s market-leading exchange brake shoe programme provides customers with a choice of friction materials including DON, Textar, Ferodo, and its own high performance RF materials. All Roadlink ‘brake assured’ brake shoes are fully remanufactured in the UK in ISO 9001 and 14001 approved dedicated engineering facilities.

The same expertise and value for money are built into its huge and growing range of RI branded remanufactured exchange calipers. Also produced on site to the highest standards, Roadlink remanufactured brake calipers represent the widest range and the best quality available in today’s market, all at competitive prices – engineered to perform at least as well as the original.

Keith Sedgley explains: “With the demand for remanufactured braking products increasing year on year, we have been alarmed at the number of low-quality parts entering the trade. Roadlink’s continued investment in this area underlines our position as a quality supplier.”

Roadlink’s dedicated on-site remanufacturing facilities are some of the largest in the UK. Combining this with its highly skilled team and production processes approved to both ISO 9001 and

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14001 accreditations ensures any increased demand is met and product availability remains high.

Expanding its offering In addition to its expertise in CV braking and remanufacturing, Roadlink is distributor for OE quality AL-KO shock absorbers and, more recently, Weweler road springs.

Roadlink extended its offering to customers after becoming an official distributor of Weweler road springs, providing premium quality multi-leaf, and parabolic springs for the CV aftermarket, as well as U-Bolts and fittings. With an enviable OEM pedigree, Weweler road springs are state of the art, durable, reliable, and cost effective, and are used by leading axle, truck, trailer, and bus manufacturers the world over.

Roadlink holds over 230 references in stock at their central UK distribution centre with full technical support and access to a database of over 70,000 cross references.

“This is a major addition to the Roadlink product portfolio and fully complements our existing high-quality suspension offering. Weweler is a fantastic, well-known brand within the CV industry and customers are able to source the widest range of products, delivered next day,” comments Keith Sedgley.

Quality assured AL-KO shock absorbers also stocked at Roadlink’s UK distribution centre are quality approved and specified by some of the most demanding world-class OEMs such as Schmitz, Weweler, SAF Holland, Iveco, Renault, etc.

As the European leader in the manufacture of original equipment trailer shock absorbers AL-KO produces more than 3500 units per day and uses the same manufacturing processes, standards and rules for the aftermarket as they do for their growing number of original equipment business partners.

Combined with a massive three-year warranty this demonstrates why AL-KO is a European leader in the field of suspension.

With accreditations such as ISO9001, ISO14001, and ISO TS16949, strict process controls, and full traceability down to component level, they provide a solution that can be trusted for OE and aftermarket replacement alike. “50% of Europe’s air suspended trailer axles now have AL-KO shock absorbers fitted as original equipment,” claims Roadlink.

FOR MORE INFORMATION ON PRODUCTS IN THE ROADLINK WWW.RDR.LINK/VAD004 RANGE,

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BATTERIES

Battery replacements are costly and battery-related failures waste time, resources, and can affect a company’s profit and reputation. CTEK Training Manager Tony Zeal explains how commercial vehicle workshops can protect against this.

BE PROACTIVE, NOT REAC TIVE

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TEK estimates that as many as one in three commercial vehicles entering the workshop has a battery requiring attention, meaning it needs charging or replacing. Indeed, figures released by the RAC list battery related problems as the most common cause for RAC business call-outs.

could stop and restart in excess of 30 times.

The charge within the battery will become lower and lower, placing it at risk of sulphation or failure. It’s a myth that the alternator can bring the battery up to maximum capacity, and the short journeys often undertaken means that the alternator is working flat out all of the time, with no hope of even coming close to charging the battery.

Technological demands Whether it is a light commercial vehicle or a heavy goods vehicle, in-cab functions, including heating, cooling, refrigerator, and media system, as well as power for tools and equipment (tail lifts etc.), are supplied by either the starter or secondary service batteries. Batteries are working harder than ever before, so make sure you look after the beating heart of any commercial vehicle. By regularly charging and maintaining commercial vehicle batteries, you can extend battery life by up to three times.

Don’t rely on the alternator Commercial vehicles making frequent stops are more susceptible to battery failure. Every time the vehicle is started, amperage is drawn from each battery and, if the next stop is a short distance away, the alternator won’t have the time or capability to fully charge the battery. In one day, a commercial vehicle

It’s all about 12.4V Workshops need to ensure that batteries are kept above 12.4V at all times, to protect against the risk of sulphation – the biggest killer of vehicle batteries. This occurs when the battery charge drops below 12.4V and the electrolyte solution begins to break down, converting into lead sulphate crystals that coat the battery plates, reducing the battery’s ability to accept and hold a charge.

Balance is key One way to maintain batteries in a 24V series is to charge each 12V battery individually. The reason for this is that, over time, the two batteries become ‘out of balance’, with one battery at the front of the circuit absorbing all the loads placed on it, so the second battery has a slightly easier life. This leads to an imbalance between the two batteries, meaning they are not

performing well together.

The individual testing of each battery to establish a clear picture of battery health and the use of two 12V chargers (like the CTEK PRO25S) will restore battery balance and bring each battery back to its full capacity.

Battery management programme Testing a battery or charging a battery is still viewed as ‘fault finding'. If it’s only carried out when a fault is reported or the vehicle fails to start, then this is too late. A battery management programme will: ■ ■ ■ ■

Improve fleet reliability Reduce vehicle downtime Identify battery problems early Reduce battery failures and non-starts in cold weather ■ Reduce the number of batteries being replaced

FOR FURTHER INFORMATION ON THE COMPLETE RANGE OF CTEK CHARGERS AND ACCESSORIES FOR COMMERCIAL VEHICLES, WWW.RDR.LINK/VAD005

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BATTERIES

CHECK AND RECHARGE Banner Batteries’ Commercial CEO, Andreas Bawart, explains why retaining optimum battery levels on commercial vehicles has never been so important.

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ot only are CVs facing higher frequencies of short distribution trips, irregular driving profiles, stop-and-go traffic, and daily cold starts, they are additionally required to accommodate electrical consumables, such as seats and in-cab heating, which all serve to gradually reduce battery energy levels.

Compared to their counterparts in cars, truck batteries are discharged more frequently, so it is against this backdrop that they should be recharged externally at least twice annually. Should this not be the case, the open-circuit voltage in a 24V vehicle electrical system, which involves two 12V batteries connected in series, may fall from 25.44V to 24.60V or even lower, all with related negative consequences.

Therefore, in order to ensure that maximum voltage outputs are maintained – helping avoid starting problems and reducing the incidence of unplanned failures – Banner has devised a six-point plan of action.

Six degrees of reparation ■ Before charging, the electrolyte level should always be checked. If necessary, the battery should be topped up with desalinated or distilled water to the acid level mark, or 15mm above the upper edge of the plates. During charging, the battery screws may not remain open and it is best when they are screwed back in. This is not applicable to AGM batteries, however.

■ Obviously, inactive batteries are subject to discharge. Here, lead sulphate collects on the lead plates and hinders the current flow, resulting in a decline in both battery capacity and cold start performance. Therefore, devices such as the Banner Accucharger 10A/24V and the Accucharger PRO 25A should be used to keep the battery active and help prevent sulphation from occurring.

■ It is important to constantly monitor the battery’s charge level. The display

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provides up-to-date information regarding current power consumption and alarms the driver if, for example, the charge status is too low. This is particularly important in long-haul trucks, because they are not simply a means of transport, but instead often the workplace and home of the driver five days of the week.

■ Given that a drop in temperature from 20 to 18˚C, for example, roughly halves battery capacity in Ah, battery charge status should be subject to constant surveillance, and additional electrical consumers should be used in moderation, especially when the vehicle is not in use.

■ Furthermore, electrical consumers should be shut down when no longer required. As a result, when the engine is switched off, battery current will only be employed for a refrigerator, tablet, computer, or sound system.

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■ A suitable vehicle mode should always be employed once the engine is turned off and the parking mode actuated. This applies if the cab functions are not in use, but, should they be needed, a switch to the accommodation mode is necessary for as long as the cab functions are required. Afterwards, the parking mode can be reactivated. Additional cab functions are available via the accessory mode, but care should be taken that this is also only utilised for a limited period, in order that battery power is not fully exhausted.

Play it safe When recharging, Banner recommends deploying chargers in line with battery capacity and charge status. Banner’s Accucharger 24V 10A Recovery is ideal for batteries with up to 240 Ah that require frequent equalisation charging with open-circuit voltage of the individual batteries of >12.5V. The Banner Accucharger PRO 25A is recommended for batteries with up to 240 Ah for recharging with open-circuit voltage of the individual batteries of <12.5V. As far as the serial connections in a 24V vehicle electrical system are concerned, in which two 12V batteries are connected in line, Banner states that both batteries should be of identical type, approximately the same age, and have an equal charge status. In addition, the connecting cables must be dimensionally as short as possible.

“Compared to their counterparts in cars, truck batteries are discharged more frequently, so it is against this backdrop that they should be recharged externally at least twice annually.”

In the situation of a battery change, both batteries must always be substituted simultaneously, or at the very least the battery that is still functional should be removed, fully changed, and then reinstalled with the new battery.

If the recommendations above are not followed, during series connection, differing resistances in the individual batteries cause corresponding voltage splitting and, thus, asymmetric load during the charging and discharge phases. Should this actually prove to be unavoidable due to the varying temperatures on the batteries or 12V part loads, Banner advises the use of a charging equaliser, which distributes the charge voltage evenly amongst the batteries.

Furthermore, with regard to the charge voltage in any CV, it should always be noted that the individual voltage of each battery be checked. Ideal for this process is Banner’s handy BBT-DBA 12V Battery Tester, which should be used for the periodic inspection of the open-circuit voltage.

ADDITIONAL TIPS RELATING TO BANNER BATTERIES CAN BE FOUND IN BANNER’S TECHNICAL ADVICE MANUAL, WWW.RDR.LINK/VAD006

020_CVW_SEPT21_Layout 1 20/08/2021 16:08 Page 20

BATTERIES

MAKING THE

RIGHT CHOICE

Thorsten Werle (left) and Thilo Hofmann, Senior Specialist Technical Business Development at Clarios, discuss the ProMotive AGM’s optimised production methods, design, and requirements according to specifications and the desired functionality.

Clarios, the global market leader in advanced energy storage solutions, discusses how the VARTA ProMotive AGM battery was conceived in close collaboration with Europe’s leading commercial vehicle manufacturers.

T

hese days, conventional batteries have a hard time keeping up with the large amount of energy-draining electrical functions that modern trucks are equipped with. Trucks are on the road for longer which means more overnight stays in the cabin – with increased expectations regarding to comfort. Refrigerators, microwaves, coffee machines, and entertainment electronics lead to deeply discharged batteries after the rest periods.

On top of that , there is an increasing number of EU legislations to be met.

Advanced fuel saving technologies like coasting/sailing and passive boost are on the rise in order to reduce CO2 emissions and overall consumption.

Together with AdBlue tanks taking up additional space, this often makes an endof-frame installation close to the rear axle necessary, subjecting the battery to increased vibrations. High robustness and vibration resistance are therefore required.

20 CVW SEPTEMBER 2021

The manufacturer’s choice “Some of the biggest manufacturers, therefore, turned to us with a request to collaborate on the development of a solution. That’s how the VARTA ProMotive AGM came into being,” explains Thorsten Werle, Engineering Design Lead Heavy Duty at Clarios EMEA. VARTA is the market- and technologyleading brand in the field of commercial vehicle batteries. The ProMotive AGM combines the know-how from both product lines and draws on 20 years of experience in producing advanced AGM batteries With an Original Equipment (OE) market share of 65% in the European heavy duty battery business, VARTA is the manufacturer's choice when it comes to fitting the best battery technology available. The VARTA ProMotive AGM has passed both lab and road tests and fulfills all four key requirements to be labelled an original spare part:

■ Cold cranking power ■ Cycling performance and deep discharge capabilities ■ Vibration resistance ■ Charge acceptance “Long-term trials have confirmed that the VARTA ProMotive AGM lives up to the promises we made about it. Major manufacturers have approved the battery and are integrating the AGM as OE into their latest generation of heavy commercial vehicles,” comments Werle.

What is the VARTA ProMotive AGM? The VARTA ProMotive AGM is Europe’s first AGM battery for commercial vehicles.

AGM stands for Absorbent Glass Mat. The eponymous fleece absorbs the battery acid and increases cycle stability. This prevents loss of capacity due to acid stratification, the main cause of battery failure in modern trucks.

020_CVW_SEPT21_Layout 1 20/08/2021 16:09 Page 21

PAST

t t

TODAY

Battery requirements for modern The advantage is the battery trucks have changed significantly has a lifetime expectancy of two with more regulations, overnight years or longer. To reach a stays, and an overall increased comparable lifetime with a number of electrical consumers. regular battery would result in its Governmental drop of capacity down to 20%.

EURO I EURO VI -95% regulations Good for business Due to the special design of the Fleet managers of today expect VARTA ProMotive AGM, reliability from their vehicles, as however, up to 80% of the well as from their choice of spare specified capacity can be utilised parts. They put their trust in without significantly leading technologies and brands compromising cycle lifetime. It Approx.

Up to More overnight to ensure minimum risk of provides the ideal power supply 2 nights/week 5 nights/week stays downtime and constant for vehicles equipped with optimisation of their fleet’s total comfort and safety functions and costs of ownership (TCO). advanced fuel-saving features According to Werle, the such as coasting/sailing.

VARTA ProMotive AGM is AdBlue tanks and larger fuel More electrical providing a unique value now tanks are displacing batteries Basic Comfort/Efficiency devices and in the years to come. He towards the rear end of explains: "If you already have a commercial vehicles. In this lot of well-equipped trucks, it’s worth position, they have to be able to withstand VARTA FLEET PROGRAM upgrading them to our AGM battery. It increased vibrations in order to prevent gives drivers and fleet operators additional premature failure. The VARTA ProMotive The increasing complexity of modern security against battery failures, reduces AGM addresses this challenge with its trucks represents a major challenge for overall operating costs, and ensures rugged casing and special fixations. trucking companies. To ensure that satisfied customers for the truck Shorter driving times overall and an fleets are best equipped to cope with manufacturers. The VARTA ProMotive increased number of overnight stays make these, VARTA has not just developed a AGM is absolutely future-proof and still has the VARTA ProMotive AGM's enhanced reliable, future-ready product in the a lot of free capacity available for additional charge acceptance and larger number of form of the AGM battery, but also offers energy consumers." cycles an indispensable asset in modern the corresponding service with its logistics. With this combination of features, VARTA Fleet Program. This programme’s the VARTA ProMotive AGM ensures costTO FIND OUT MORE ABOUT THE main feature is that it offers fleet effective, safe, and comfortable driving. For VARTA FLEET PROGRAM, OR TO the first time, it is possible to take advantage managers direct contact to the SIGN UP FOR YOURSELF, of the full potential of commercial vehicles manufacturer. By registering free-ofWWW.RDR.LINK/VAD007 with an extended battery life. charge on the website, members will receive custom advice relating to their fleet, strategic purchase recommendations, support on battery management-related questions, analysis and optimisation options for battery performance, and a great deal more.

SEPTEMBER 2021 CVW 21

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BATTERIES

DO YOUR DUE DILIGENCE

C

ommercial vehicle fleets often consider changing their existing battery technology because of continued battery problems, rising costs, and increased penalties for delayed services. More often than not, the fault lies with the battery management process rather than the actual battery type.

The repeated advice that Rotronics gives is that changing the battery technology alone on your fleet is not going to resolve the problem if you continue to abuse the batteries and fail to look after them – you will simply keep having the same issues. The technology may not be letting you down; it is most likely to be the charging system, the usage, the application, or lack of maintenance.

In practice One of Rotronics’ customers is a southernbased emergency service fleet and they are currently using standard flooded maintained batteries. They approached Rotronics for help when their battery costs continued to escalate.

The workshop team at this organisation were struggling to stay on top of their battery maintenance and had been beguiled by batteries that were called ‘maintenance free’. But, ‘maintenance free’ is unfortunately a misnomer, as you still need to maintain them. Rotronics reminds customers that

22 CVW SEPTEMBER 2021

Ken Clark, Managing Director of Rotronics, looks at which battery type is best for each vehicle application, and the considerations or assessments to be made when changing battery type.

EFB and AGM batteries are more resilient to discharge cycles of the vehicle.

But, they are more costly, and if workshops do not change maintenance habits, they will not see the return on investment. Ken Clark has provided some top tips for workshops to follow, to try to make the best assessment of the batteries that are suitable for the fleet:

they shouldn’t assume that one battery fits all applications – this is not the case.

Emergency service drive cycles will vary – the loads, the routes, and engine offload will be different and the way they are maintained is different. If you don’t look after ‘maintenance free’ batteries specifically for their application, you will still have the same issues. Each type has beneficial characteristics over the traditional battery, but you will need specific management of each battery type.

Maintained batteries have benefits for high charging and discharging requirements. The electrolyte evaporates and then they are topped up and ready to go. The downside is that they need more hands-on maintenance compared to EFB or AGM battery technology.

■ If you introduce new battery types – be clear about what improvement you expect to see? You would hope to achieve better reliability and extended life performance

■ Identify if the problem is with your battery technology and application or if you don’t test and charge enough

■ Monitor and track the before and after if you are changing battery type ■ Although there is no topping up of electrolyte with EFB and AGM batteries, you will still have exactly the same testing and charging regime.

‘Maintenance free’ is the wrong title AGM batteries won’t explode or leak acid through abuse, but they can often expand if not cared for, because of thermal runaway, leading to defects and failure.

022_CVW_SEPT21_Layout 1 20/08/2021 16:11 Page 23

HOW CAN ROBIS HELP The Rotronics team has been using ROBIS with many CV customers; this is an online interactive dashboard for fleet and independent workshops. ROBIS is a problem-solving tool and helps establish the best solution.

Using ROBIS as the data and visual tool to monitor any new technology you are trying within your vehicle fleet, will give you real time evidence to establish whether the investment you are making is truly going to deliver the savings and reliability you expect to see, before fully committing to replacing your existing product.

ROBIS is a tool to provide maximum ROI and give visibility of the battery health of a fleet, identify any battery problems and show what improvements can be put in place, and improve internal practices by introducing battery management processes.

ROBIS is the basis from which improvements can be made.

The online interactive dashboard provides technicians with battery information which shows the health of batteries, to show the current state of health, the state of charge, how likely the batteries are to fail or have roadside defects, and the impact on fleet performance.

ROBIS provides impartial warranty proof and evidence for warranty claims. It is a tool to help you assess where your workshop is against the national average and helps you develop your own internal KPIs. Ken Clark says: “We describe ROBIS as a team member or technician, who will work in partnership with your team to help you achieve optimal battery performance. It also has responsibility for the road map that ensures your vehicles start first time, your vehicles reach their destination on time, you receive no late delivery fines, and you achieve positive warranty claims because of consistent battery management quality standards and workshop practices.”

FOR MORE INFORMATION ON ROTRONICS, PRODUCTS AVAILABLE, AND THE BATTERY MANAGEMENT PROGRAMMES, EMAIL INFO@ROTRONICSBMS.COM, CALL KEN CLARK ON 0121 514 0605, OR WWW.RDR.LINK/VAD008

024_CVW_SEPT21_Layout 1 20/08/2021 16:13 Page 24

BATTERIES

BUILT TO LAST With more and more long-distance commercial vehicle drivers operating on double or triple driver shift patterns, conventional batteries are struggling to cope with the demands of continuous use. John Bentley, Technical Sales Manager at Ecobat Battery Technologies, discusses the new technology helping to ease the strain.

A

lthough engine starting currents haven’t significantly changed over the years, the recent surge in electrical demands, combined with the need to support onboard facilities such as auxiliary heating systems, air conditioning, mobile phone chargers, and GPS devices, means that conventional vehicle batteries are failing.

The move towards drivers sleeping in their cabs, now commonplace while trucks are parked up overnight, is also having a huge impact as vehicles double up as hotel rooms with the battery becoming the sole source of power for cooking, heating, lighting, and charging tablets or laptops.

As a result, hauliers are experiencing a sharp rise in vehicle breakdowns with many operators and logistics companies picking up the cost of call outs and frequent battery replacements, along with the inconvenience of unnecessary down time.

Here to help To address the challenges of supporting the electrical demands of a modern-day fleet, more original equipment (OE) manufacturers, logistics companies and operators are switching to Odyssey, produced

by EnerSys, for their battery requirements.

Developed using next generation absorbed glass mat (AGM) technology, Odyssey batteries are capable of powering the heavy usage required for hotel loading as well as double/triple driver shift patterns, without compromising on the massive cranking power needed to start the engine, time and time again.

Engineered with specialist thin plate pure lead (TPPL) technology, which was

24 CVW SEPTEMBER 2021

first used in aerospace and the military, Odyssey has been powering professional vehicles and competition cars for 25 years.

Speaking of the advantages of switching to Odyssey, Director of Transportation for EMEA & APAC at EnerSys, Peter Hart, explains: “Reliability is key for haulage operators as the risk of battery failure can have a devastating impact.

“As well as the immediate disruption to delivery schedules and the inconvenience of goods arriving late, there is also the cost of breakdown recovery and potential damage to brand reputation to take into consideration, that’s in addition to lost productivity and revenue. We understand the challenges of powering the everincreasing electrical requirements of modern day commercial vehicles, so Odyssey AGM TPPL technology is a real game-changer for haulage operators who can’t afford to leave battery performance to chance.”

John Bentley, Technical Sales Manager at Ecobat Battery Technologies, welcomes the innovative AGM TPPL technology, which sets Odyssey apart. He comments: “The haulage industry is seeing a huge rise in battery failure with many conventional batteries failing in just six to eight months as they simply can’t cope with the increased power outputs required by today’s commercial vehicles.

“By comparison, Odyssey batteries are lasting an average of four years, so it really is a no brainer for haulage operators to invest in powering their fleet with this next generation battery technology.”

He continues: “Although engine starting currents haven’t changed over the years, it’s clear there’s a growing need for a new type of high performance alternative like Odyssey, which is optimised to meet the increasing electrical demands of the modern fleet.

“Odyssey batteries are incredibly reliable and a smart investment for haulage companies that need to keep their vehicles moving efficiently, as well as for the logistics companies that are servicing hauliers and having to stand the unnecessary costs of call outs and battery replacement.”

The sensible choice The innovative technology used in Odyssey batteries effectively provides the capability of two batteries in one, delivering the cranking power needed to start the engine, whilst also giving superb deep cycle capacity to support hotel loading and onboard facilities.

Conventional batteries are not optimised to handle the heavy electrical loads demanded by the rise in triple shifts and drivers using cabs as hotel rooms, which should be helping to improve business efficiency, but are actually leading to battery failure and higher numbers of breakdowns.

Providing twice the power and three times the life of conventional batteries, Odyssey batteries can provide a service life of up to 10 years, which make them the perfect power storage solution for the modern day fleet. In addition, as they are unaffected by extreme temperatures, they can be stored at room temperature for more than two years, without the need for charging or maintenance.

FOR MORE INFORMATION ON THE ODYSSEY BATTERY, WWW.RDR.LINK/VAD009

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CPN/CVW page grid_Layout 1 18/08/2021 10:22 Page 1

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COMPLIANCE

EXEMPL ARY PERFORMANCE Back in 2018, DVSA completed the pilot of its operator Earned Recognition scheme. We take a look at the initial process and why operators should still be looking to sign up.

E

arned Recognition is aimed at raising standard of compliance throughout commercial vehicle and bus and coach fleets. Some 30 private and public sector organisations took part in the pilot scheme, with fleet sizes ranging from two vehicles to over 3,500.

Earned Recognition is intended to reward what DVSA calls ‘exemplary operators’ from some of the burdens of enforcement. DVSA accepts that while Operator Compliance Risk Scoring (OCRS) has helped it identify the bad operators, it’s retrospective and doesn’t do enough to acknowledge and reward good operators.

Earned Recognition aims to change that and to help DVSA refocus its own resources on non-compliant operators.

What are the benefits?

Operators accepted on the Earned Recognition scheme are: ■ Less likely to have vehicles stopped at the roadside for inspections; ■ Less likely to have DVSA enforcement staff visit premises; ■ Have the DVSA Earned Recognition marque on their website and other publicity materials; ■ Be recognised as a DVSA-approved operator on a list on gov.uk; ■ Have direct access to a DVSA earned recognition business manager.

How much does it cost?

There’s no application fee to join or remain in the scheme. The main extra cost will be

the initial audit and a follow-up two-yearly audit after that. There may be some cost in upgrading or investing in DVSA-approved software systems.

What’s involved in the audit?

There are two sets of criteria – for trucks, and for bus and coach. The audit criteria depends on fleet size and number of operating centres. The audit is evidence based. Many of the processes and reporting will already be in place, thinks the DVSA – so it will be a case of proving that you are following those processes and that your systems can record and report the KPI data.

Criteria include O-licence compliance, transport management, vehicle standards and servicing, operations management, driver management including training and behaviour management and driver related policies. There’s an additional ADR management element for Hazchem operators and for PSV service performance criteria. Auditors can be chosen from a DVSA approved list.

the previous two years.

■ Operators must be able to meet the KPI standards.

■ The operator’s IT systems must be capable of monitoring the Key Performance Indicators (KPIs) set by DVSA.

Will DVSA have access to my data?

No, DVSA will not have access to individual operator’s IT systems and data.

Instead, Earned Recognition operators will submit monthly reports to demonstrate ongoing compliance with sets of KPIs -– there are two sets: one for vehicle maintenance and safety reporting, and one for driver’s hours compliance.

DVSA has a list of approved software suppliers for both sets of KPIs. Those companies have proven to DVSA that their software will produce the KPI reports in an acceptable format. Operators must use one of the approved systems – and those with older versions of approved systems should check that reports meet the earned recognition requirements.

What are the basic criteria?

■ Operators must have held an O-licence for a minimum of two years – one exception is if a business is acquired by another in which case the previous business’s history will be allowed.

■ All O-licences controlled by the legal entity must be included in the application.

DVSA wants a single feed of data.

■ There must have been no regulatory action by the Traffic Commissioners in

SEPTEMBER 2021 CVW 27

027_CVW_SEPT21_Layout 1 20/08/2021 16:15 Page 28

COMPLIANCE Maintenance KPIs Number 1 2

3 4

5

Measure Complete set of safety inspection records.

Safety inspection records are completed correctly, including all relevant sections and signed off as being roadworthy.

Safety inspections are completed within the stated frequency.

Driver defect reports where road safety related items have been reported are appropriately actioned.

Vehicle and trailer MOT initial pass rates.

KPI 100%

100% 100%

100% 95% (if you only have up to 20 vehicles in your fleet, the KPI is no more than one failure in 13 rolling measurement periods).

Driving activity KPIs Number

Measure

KPI (total number of infringements as a percentage of the total number of tachograph days).

1

Band 1

1.3%

An infringement recorded on the tachograph analysis that would attract a Band 1 fixed penalty.

2

Band 2

1.2%

An infringement recorded on the tachograph analysis that would attract a Band 2 fixed penalty 3

Band 3

0.8%

An infringement recorded on the tachograph analysis that would attract a Band 3 fixed penalty.

4

Band 4

0.7%

An infringement recorded on the

OPERATOR COMMENTS Construction

tachograph analysis that would attract a Band 4 fixed penalty.

5

Overall infringements

4%

– total number of infringements found.

6

Working time

4%

– any infringement identified under current legislation.

What if our fleet operates from multiple depots?

Multi-depot fleets can currently receive visits from DVSA at any site. Under Earned Recognition the operator (the ‘legal entity’) would have a single point of contact with DVSA for all their fleet and depots.

To establish the KPI criteria, DVSA used data from six million tachograph records and the maintenance compliance criteria from five companies in the pilot scheme.

If you report less than 25 tachograph days in a measurement period, the KPI will be no more than one offence in the period.

What KPIs are required?

What happens if we miss a KPI?

There are two sets of KPI: vehicle maintenance and driving activity, and they are reported to DVSA four-weeks in arrears, in a PDF document. Only non-compliant exceptions are reported to DVSA – it only wants to know when something has gone wrong for whatever reason, not when all vehicles and drivers are compliant.

Any KPI infringements are automatically reported in the monthly KPI reports.

28 CVW SEPTEMBER 2021

However, it is lightweight enforcement because DVSA expects Earned Recognition operators to be mainly compliant. Operators will get an alert when a KPI is missed, but not by enough to send a trigger to DVSA. Only when a Red Alert is triggered would an alert be sent to DVSA. Before that, missed KPI’s are reported under a traffic light system measured over three rolling periods and with tolerances of up to 2% built in.

DVSA expects operators to monitor these alerts and take action to prevent repetition.

For example, five yellow or amber triggers over three periods would result in a red alert trigger to DVSA. Even then, it wants to take a guidance approach and agree what actions should be taken within what timeframe.

Construction company Mick George says it is already saving many hours using r2c Online’s compliance platform and is now aiming for Earned Recognition status.

“Before r2c, we did everything the old fashioned way, it was all paper-based. The inspection sheets would arrive from the workshop by post and need sorting; often we couldn’t even read them,” comments Ian Rowe, Fleet Maintenance Manager.

“The r2c system is now used by the whole business; the transport office, our drivers and our workshop too. It’s made my life a whole lot easier as I have greater control over the fleet and there’s no longer any need to have filing cabinets stuffed full of paper. We now have improved driver behaviour because they like using r2c. We are more time

Type of alert

Level

When it’s triggered

Yellow

Minor

Missing a KPI by less than 1% point three times in three rolling periods.

Amber

Moderate

Missing a KPI by 1% point or more twice in three rolling periods.

Grey

Major

Missing a KPI by 2% points or more.

027_CVW_SEPT21_Layout 1 20/08/2021 16:16 Page 29

efficient as we’ve saved around 70 hours per week, and we’re much more accurate with our compliance.” Ian concluded: “I’d go digital for no reason other than Earned Recognition. It’s going to be here, it’s going to stay and I want to be on board with it.”

Waste management Waste management company Cawleys is also an early participant in Earned Recognition, using r2C software. Phil Gudgeon, Director of Waste Collection and Logistics at Cawleys, said: “Using the r2c platform enables us to manage our time better, with proactive maintenance and cost control. We have been accepted onto the Earned Recognition pilot, proving we are ultra-compliant and allowing us to keep our customers ahead of the curve, so we’re really happy with our results.”

Buses Bournemouth Transport, CT Plus and Reading Buses are representing the bus industry in the DVSA Earned Recognition pilot. Coach operators selected for the pilot are Lucketts Group, Barnes Coaches, Allenby Coach Hire and Stanley Travel.

“Having successfully deployed Freeway’s software to eliminate paper reporting we are already well down the digital path,” says Steve Perks, Group Engineering Director of HCT. “To report our performance and compliance to the DVSA digitally is a natural progression. With Freeway we already produce all our reports digitally and with the system now configured for Earned Recognition, the required DVSA reports will be generated completely automatically.”

“We welcome the DVSA initiative on digital reporting and we are pleased to be able to represent the London bus sector during the Earned Recognition pilot. When the scheme is rolled out there will be some important benefits for the bus and coach industry that will make managing compliance easier and more efficient” adds Perks.

John Bickerton, Head of Engineering and Innovation, Reading Buses. “We were pleased to have been selected as one of the pilot operators for the Earned Recognition scheme. Freeway is central to our workshop processes and our KPI reporting to DVSA flows straight out of this. It’s great recognition for ourselves and our suppliers at the highest level of our industry.”

FOR MORE INFORMATION ON EARNED RECOGNITION, WWW.RDR.LINK/VAD010

030_CVW_SEPT21_Layout 1 20/08/2021 16:18 Page 30

COMPLIANCE

TIME TO INVEST? Investing in a roller brake tester is a big commitment but it still costs substantially less than buying a new truck and it can play a vital role in protecting your OCRS score, says VL Test Systems.

A

nnual test failures are recorded in the roadworthiness section of a fleet’s Operator Compliance Risk Score file. Too many first-time failures can mean operators slip from green to amber or even amber to red. Using the test itself to discover if there are any roadworthiness faults that need fixing has therefore become a risky strategy and more operators are focused on achieving high first-time pass rates.

Brake performance failure remains a top cause of vehicles not achieving a first-time pass, so it is a sensible precaution to carry out a pre-test brake check. If you are an independent workshop, you will want reassurance that the OCRS score is not being adversely affected by low first-time pass rates when you submit vehicles for test. VL Test machines will give you a pass/fail print-out identical to the one you would receive at a DVSA station and you can show that to your customers.

Buyer’s tips

���

���

Consider the vehicles you will be testing – 3.5tonne vans? 44-tonne tractor units? All VLT machines are approved in standard format for Class IV, V, VI, VII, HGV and trailers.

An axle weighing system will help deliver predictable results. An axle load simulator is not required unless applying for ATF status. Ideally, a vehicle should be loaded to 65% of its GVW for a brake test, although most will probably pass the brake test at the point of wheel lock. If you are using your RBT for pre-MOT brake checks and relying on wheel lock to pass, remember that the same conditions may not be replicated on the RBT used at the test facility, which can result in an unexpected test failure, especially for those vehicles that are borderline. (All VLT RBTs will give a pass or fail in the vehicle as it is being presented).

��� Don’t under-specify. VLT builds to a minimum 16,000 to 20,000kg axle weight to ensure the equipment does not work continuously at the top of its capability.

Equipment which is used constantly at its maximum capacity puts extra stress on the machine which can result in unplanned breakdowns and higher service costs.

��� Ask whether the system stops the RBT rollers turning when it registers wheel lock during the brake test. Automated wheel lock recognition and stop helps prevent tyre damage.

���

���

Check the equipment meets DVSA specifications for RBTs used in either DVSA stations or at ATF test lanes. The roller width and diameter are particularly important criteria as this can affect results.

Opting for infrared or wireless connectivity between the hand control and the display console allows the tester to carry out the test from the vehicle – it speeds up testing and there’s no need for a second person.

30 CVW SEPTEMBER 2021

030_CVW_SEPT21_Layout 1 20/08/2021 16:19 Page 31

��� Check there is adequate space. The actual equipment needs a space approximately 4,000 by 1,000mm. For installation you will need a substantially level area in front and behind the RBT to accommodate the length of the longest vehicles you wish to test.

An inspection pit is only necessary if you have a full ATF lane, although it can be useful to have a pit in the locality of the RBT so that adjustments can be easily made.

��� Don’t forget the power supply and requirements. VLT machines work off a 63amp 3-phase Earth and Neutral supply and feature soft-start for less power consumption.

��� A play detector is only required for ATF lanes, but can be a useful diagnostic tool as it replicates wheel suspension, king pin movement by moving the wheel/tyre in different directions to show excessive movement.

쐅 Do consider buying the DVSA vehicle database even if you are not applying for ATF status. Presenting brake results in the DVSA format is beneficial for both independent and in-house workshops – any pass/fail printout will be identical to that at the official test and include all the officially required data such as front wheel allowance, lock allowances, trailer rules and so on. A standard RBT will test all items that the machine with the DVSA database tests, but it may not compute or present the results in the recognised format.

쐈 Do make sure the RBT computer has sufficient capacity to store all the data. A VLT machine will store the data in its own CPU (central processing unit) PC and can automatically download data to a PC. VLT recommends that the data is downloaded regularly so that test records are secured in case of unforeseen circumstances in the workshop, such as fire or flood.

쐉 Don’t forget to factor in routine maintenance and calibration. For ATF lanes, the minimum requirement is every six months, but regular service and maintenance can prevent costly breakdowns and time delays. VLT offers fully inclusive maintenance packages with servicing done by company engineers.

FOR MORE INFORMATION ON VL TEST SYSTEMS’ WWW.RDR.LINK/VAD011 ROLLER BRAKE TESTERS

032_CVW_SEPT21_Layout 1 20/08/2021 16:37 Page 32

COMPLIANCE

THE FUTURE IS NOW

Continental’s Gilles Mabire, Head of the Commercial Vehicles & Services Business Unit, and Dirk Gandras, Manager in Charge of Tachograph Development, discuss the important new roles for intelligent tachographs.

T

achographs have an important role to play as Continental’s nextgeneration intelligent tachograph will enable implementation of the guidelines set forth in the new legislation Mobility Package I. One of the most important changes will be the rules governing cabotage and posting of workers in the transport industry.

In addition to the tachograph’s existing functions, units installed in commercial vehicles will record border crossings through a link to a satellite positioning system. “We welcome the use of the DTCO for monitoring compliance with the guidelines for cabotage and posting of workers, and we think it is good that tachographs will soon be mandatory for vehicles with gross weights between 2.5 and 3.5 metric tons engaged in international transport,” says Gilles Mabire. “The Mobility Package I will ensure fair competition within the transport industry and promote better levels of safety. That is very good news.”

Greater importance of tachographs This decision is certain to increase the importance of smart tachographs because the Mobility Package requires them for achieving its transport policy goals.

Trustworthy data from commercial vehicles will be needed for this purpose. “We’re making an important contribution to society, and we’re proud of it,” says Mabire. “We’re also very confident that our tachographs will help policymakers deal with a number of other important problems in society.

Thanks to their ability to record clearly assigned data in a secure, trustworthy manner, they are a marvelous tool for this.”

Work on the next generation, the DTCO

4.1, has already begun at Continental’s renowned tachograph manufacturing centre in the Black Forest. “We’ve been following the work on the Mobility Package very closely and have already drawn up technical scenarios for recording border crossings,” comments Dirk Gandras. The previous tachograph generations will provide the technological foundation, and the current version DTCO 4.0 can already receive satellite signals.

Satellite communication The DTCO 4.1 will register border crossings by means of satellite positioning and record the locations where vehicles are loaded and unloaded. Authorities can use this data to check compliance with regulations, in particular those pertaining to market access (cabotage) and to posting of drivers. In fact, in addition to using GPS signals, it will be one of the first industrial applications to support Open Service Navigation Message Authentication (OSNMA) of signals from the Galileo system. The engineers of Dirk Gandras' team have already taken the Galileo signal into account constructing the present DTCO 4.0 generation.

FOR MORE INFORMATION ON CONTINENTAL VDO’S RANGE OF TACHOGRAPH SOLUTIONS, WWW.RDR.LINK/VAD012

32 CVW SEPTEMBER 2021

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TruTac explains how the new addition to its fleet compliance software has greatly improved vehicle management whilst simultaneously satisfying the DVSA.

TICKING ALL THE BOXES

T

ruFleet is TruTac’s latest addition to its TruControl cloud-based system.

TruFleet enables companies to plan, organise, and control all aspects of day-today fleet and O Licence management far more easily and with greater efficiency than ever before.

One such company to benefit from the new system is Bolton-based multi-temp specialist 3D International Haulage. It is a family-run business offering temperaturecontrolled, ambient, and high value deliveries for food manufacturers, retailers, and thirdparty distributors throughout the UK.

Two birds with one stone Senior Transport Manager Martin Rybka explains that the touch-button ability to review vehicle history, maintenance records, safety inspections, defect reporting, rectifications, and audit checks has not only reduced administration time, duplication, and human error, but has also made DVSA daily driver checks simpler and faster to carry out.

“We have 70 trucks on the TruTac system,” explains Martin. “Having all relevant driver, tachograph, and fleet information in one place means we can instantly check drivers’ hours, missing mileage, and infringements from anywhere, at any time.”

Martin recalls that, when the DVSA recently stopped one of 3D International’s vehicles and asked for details, the traffic office was able to send all relevant data in one go and immediately satisfy the vehicle

checking criteria. He adds: “Also, during a full audit a couple of years back, we were praised for our precise record keeping, [and our] accuracy and knowledge of compliance requirements. [It was] all made possible by using TruTac’s software products.”

Using TruFleet, Martin and his team can instantly see all planned maintenance events including inspections, MOTs, services, LOLER checks, and repairs.

Bespoke entries can be included, and all weekly calendar events viewed in detail on a single screen. Other reminders such as tax, insurance, and tachograph calibration dates can also be added to the calendar.

Furthermore, tyre and brake status are recorded along with details of each vehicle inspection and, for quick review, full safety inspection history is contained in report form and automatically filed in the system for future quick retrieval. It completely removes the need for manual wall planners and provides peace of mind with full alerting and reports.

Martin concludes: “The system fully integrates with our other TruTac compliance control products. Quite honestly, TruFleet is a life-saver. It saves time, organises the garage, keeps us focused and, above all, makes sure we remain compliant at all times.”

FOR MORE INFORMATION ON THE TRUFLEET SOFTWARE FROM TRUTAC, WWW.RDR.LINK/VAD013

ABOUT TRUFLEET TruFleet is fully compatible with TruTac’s modular suite of TruControl software and enables managers to switch seamlessly between tacho analysis, daily checks, and maintenance calendars, giving instant visibility and control over every vehicle and driver. The interactive system keeps daily checks, defects, and repair rectifications all in one place, along with all documentation and audit reports for future maintenance bookings. To streamline document management, TruFleet uploads and tags MOT certificates, safety inspection sheets, and contracts so that all garages can instantly assess individual vehicle requirements, while fleet managers can easily search for relevant documents and cross-refer each job with the garage which carried out the work.

SEPTEMBER 2021 CVW 33

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COMPLIANCE

RACING STRIPES MAHA UK’s dynamometers monitor performance levels, tuning, and diagnostic work for workshops across the country, but the company details how its extensive range of equipment goes the extra mile in the British Truck Racing Championship (BTRC).

S

ince the start of the 2019 season, MAHA UK has provided the BTRC with its ColumnLift RGA mobile column lifts to assist with the championship’s scrutineering. With the machines weighing in at more than five tonnes, the lifts, which are capable of lifting seven-and-a-half tonnes per column, are more than capable of doing the job.

BTRC Eligibility Scrutineers Terry Cox and Paul Garrett explain how the equipment was vital when inspecting the underside of the truck during race weekends. They comment: “These lifts are used for two specific reasons: the first is safety, so we can check the brake and fuel lines on the underside of the truck, as well as the suspension components and air lines.

“The second is so the eligibility scrutineer can check that the truck complies with the BTRC’s regulations; for example, the number of cross members that are not

34 CVW SEPTEMBER 2021

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always visible from the top of the vehicle, the prop shaft guard needs to be checked so it is the correct material and thickness, and the truck’s subframe, which has specific regulations, must be checked from both above and below the truck.

“The other added bonus is that while the truck is in the air, underside photographs can be taken, or eligibility seals can be attached easily.”

A strong relationship MAHA UK’s affiliation with truck racing began several years earlier following the acquaintance between Louis Tunmore, MAHA UK’s dynamometer expert and renowned motorsport enthusiast, and John Powell, owner and driver of JP Racing.

The Powell name is synonymous with the truck racing community, with John Powell Snr a pioneer of the sport back in the 1980s. Today, his sons are following in his footsteps and playing a significant role in the world of truck racing.

John drives a DAF in the class B category and boasts more than 25 years’ experience in commercial vehicle maintenance and

“The lifts [...] are capable of lifting seven-and-a-half tonnes per column, [so] are more than capable of doing the job.” repairs. He is also a committee member of the British Truck Racing Association (BTRA), working closely with the scrutineering team on some safety-related items and helps look after the day-to-day interests and well-being of BTRA members.

MAHA UK Managing Director, Neil Ebbs, says the relationship between MAHA and JP Racing has prospered for both parties

over the years. He explains: “We were first introduced to John through an existing customer with a truck dynamometer, as he was looking for suitable equipment to test some new fuel. Louis spent the day with John, putting the trucks through their paces, and the relationship blossomed from there.”

Neil reiterates that MAHA UK’s commitment to the BTRC, BTRA, and JP Racing, is a collaboration that “helps keep the MAHA UK name out there” in motor racing circles and presents excellent marketing and hospitality opportunities.

He adds: “John has been kind enough to lend us his racing truck for exhibitions, such as the CV Show, which always turns heads and encourages people to the stand. We’re also able to host hospitality for customers, which, with fans now allowed to attend race meetings, is something we’ll be looking to take advantage of.”

FOR MORE INFORMATION ON THE RANGE OF AVAILABLE PRODUCTS FROM MAHA UK, WWW.RDR.LINK/VAD014

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COMPLIANCE

CASE STUDY: KEEPING A RECORD Truckfile details how it has helped Grist Environmental stay ahead of the game with its compliance.

F

leet operators, and the workshop managers who look after them, know that compliance is key. More than just keeping vehicles safe and legal, this means ensuring that records are available to prove it.

As an operator that looks after the majority of its own vehicles in-house, Wiltshire-based waste management specialist Grist Environmental understands this issue from both sides. For both Transport Manager Paul Forth, and Workshop Manager Tony Little, Truckfile’s digital systems are the trusted tools relied on to ensure their operation is fully compliant.

History boys Founded in 1973 with a single vehicle, Grist Environmental has grown to become one of the leading waste management businesses in the Southwest, and also offers materials recycling, vehicle maintenance, end-of-life vehicle processing, event management, and agricultural cleaning services.

Today, the company employs over 160 people in and around its home town of Devizes, Wiltshire, and runs a growing fleet of over 70 trucks of various sizes and configurations. The line-up includes 44tonne artics, six- and eight-wheeled refuse collection vehicles, hook loaders, and skip loaders from 7.5 to 18 tonnes gvw.

As Tony Little recalls, before employing Truckfile, the task of keeping all

36 CVW SEPTEMBER 2021

No stone left unturned

maintenance records up to date using paper forms proved to be increasingly time-consuming.

He explains: “[Using paper forms] was set to get ever more onerous as the company’s fleet grew, with more vehicles being maintained in our own workshop rather than under service contracts with supplying dealers.

“A solution to make compliance management easier as well as more efficient was clearly required. The Truckfile system is so simple to use. I have a full overview, while our technicians can select jobs easily – which means job cards are always raised and accurately completed in a timely manner. As Workshop Manager, I can easily trace all vehicle or trailer maintenance and parts that have been fitted when reviewing a vehicle’s history.”

Drivers, too, have their part to play in the ‘chain of compliance’ – daily walk-around checks form a vital link in the trail of data that must be recorded. Paul Forth admits he initially had concerns that some of his team – with their background in an ‘old-school’ environment – might be reluctant to switch to a system of completing and recording checks electronically, but these fears were unfounded. He confirms: “Very soon, we were all wondering how we’d ever managed without it.”

Paul adds: “We asked several suppliers to bid for our business but, from the early stages, the Truckfile tender stood out clearly from the crowd. The key difference was that, while other packages were quite rigid and would have required us to adapt the way we work to fit the system’s design, with Truckfile it was the other way around.

“From the beginning, the Truckfile team were able to tailor their offering to our needs. We run a diverse fleet – trucks, their trailers, and body equipment, as well as various plant vehicles. We also have technicians working remotely at our five sites around Devizes, as well as in our purpose-built main workshop.”

036_CVW_SEPT21_Layout 1 20/08/2021 16:48 Page 37

“We wanted to keep on top of the ever-increasing requirements, and at the same time, reduce the time and hassle spent on administration.”

He continues: “Crucially, Truckfile works equally well for the different recording requirements of our various vehicle types, and for the team too. The fact that there is more than one way to input information is a big help – so a mobile technician looking after the plant at our satellite sites can carry a hand-held tablet device, on which he records everything he does as he goes about the job.

“Details are stored, and then automatically uploaded to our computer via mobile internet as soon as the device picks up a signal. The guys in the main workshop,

however, prefer to use a dedicated workstation terminal to record their jobs.

Both methods knit seamlessly together.

“We wanted to keep on top of the everincreasing requirements for compliance, and at the same time, reduce the time and hassle spent on administration. Truckfile has proved to be a winner on both counts.”

Paul concludes: “The ongoing support from the Truckfile team has been fantastic too – they don’t just sell you a system and then walk away. They were on hand throughout the installation phase to help us adapt to the change, but it didn’t end there.

“We’ve continued to refine our procedures and worked hand-in-hand with Truckfile personnel to create a set-up that does exactly what we want it to. Truckfile is the high-tech solution with a human face.”

FOR MORE INFORMATION ON THE SOLUTIONS AVAILABLE FROM TRUCKFILE, WWW.RDR.LINK/VAD015

ABOUT TRUCKFILE Truckfile is the brainchild of Magic Internet Technologies. Based in Redditch, Worcestershire, the company was formed in 2006 to create an innovative and user-friendly fleet and workshop management system for the commercial vehicle and transport sectors.

With well over 200,000 individual vehicle records stored for more than 24,000 users, Truckfile is the largest document store of its kind in the marketplace. Customers can access the system from any internet-connected device, with no need for additional investment in servers or extra hardware.

All documents are available around the clock and are securely protected against loss or damage.

When life changes we're life changing.

Life can throw the odd curved ball no matter what stage of life you're at: money worries, illness, mental health issues, social isolation. It can create a downward spiral for you and your family. It's why Ben's here. At these moments our support and care services can be life-changing. Ever since there's been an automotive industry Ben has been helping its people and their loved ones keep life on track. Together we’ll tackle the challenges that get in life’s way and make sure they don’t, for life.

Always here for you www.ben.org.uk Helpline 08081 311 333

Find plenty of advice, online chat and self-help tools on our website, or talk to us on the helpline, free and in complete confidence, Monday-Thursday 8am-8pm, Friday 8am–5pm

Here for the automotive industry

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WORKSHOP MANAGEMENT

South Wales fleet operator Owens Group has reorganised its workshop operations to bring ATF and tachograph calibration services onto a single site, making job flow management considerably easier. Here’s how the group went about it.

ALL UNDER ONE ROOF

I

n 1972, Owens Group began operations in Llanelli, South Wales. The fleet consisted of two small trucks used to carry furniture, kitchens and piano parts.

Warehousing facilities were added in 1995, as the company sought to diversify its operations. By 2002, it was working as a distributor for a leading UK supermarket and it also became a member of the Pallet Force network. The group now operates a fleet of 780 vehicles from 10 strategic locations across the UK.

The business issue Not only has the fleet grown to meet the needs of the business, but so have the workshop facilities. In 2006, Owens opened an on-site tachograph centre at its Lllanell headquarters, and in 2013, the company invested in its own Authorised Test Facility, at Llangennech, just off Junction 48 on the M4.

The introduction of new generation tachographs last year meant investment would be needed to upgrade calibration capabilities, and Owens took the decision to move the tachograph centre to the same site as the ATF centre, consolidating testing services at one location.

Digital solution A Continental BM14200 brake tester was installed as part of a 10m pit. The RBT can also be adapted for tachograph calibration.

To do this, all that is needed is a new sensor and a new middle roller on the brake tester to accommodate the tachograph option.

The tachograph calibration itself is carried out with a dedicated tablet that is easy to use and guides the technician seamlessly through the calibration process.

The tablet is paired wirelessly via a Bluetooth connection with the tachograph roller on the brake tester unit. Calibration times are reduced – the technician can check the crucial ‘W’ and ‘L’ factors on the vehicle in less than two minutes.

This approach has created a safe work space with no trailing cables across the workshop floor. It’s now a healthier

“The move has enabled Owens to offer a one-stop service.

Vehicles are off the road for a shorter time because all the work required can be done in a single workshop visit.”

working environment for technicians, too, with reduced emissions and noise – calibration can be done with the wheel speed at 3kph, so there is no need to run the vehicle engine.

Once the calibration of the tachograph has taken place, the information/results are then written on the workshop card, and the technician can create a calibration record sheet and plaque direct from the tablet.

The move has enabled Owens to offer a one-stop service. Vehicles are off the road for a shorter time because all the work required can be done in a single workshop visit – there is no need to pay a separate visit to a designated tachograph service centre for calibration, thereby avoiding additional downtime.

FOR MORE INFORMATION WWW.RDR.LINK/VAD016

SEPTEMBER 2021 CVW 39

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Daniel Took, Head of Professional Product Marketing at Kärcher UK, explores the process for keeping workshops clean and in good working order to prevent undesired health and safety risks.

A

messy workshop can quicky lead to an undesired health and safety risk with the potential for trips, slips, and ultimately injuries. To protect yourself and your colleagues, ensuring that the workshop is kept clean is imperative, especially when it comes to floors. To meet standards, weekly routines are ideal, although sometimes a daily or immediate clean can be required.

The amount and type of dirt on the workshop floors will determine the level of cleaning that is necessary. For example, Kärcher’s push sweepers are perfect for picking up loose dirt and debris scattered on the workshop floor on a daily basis; however, for a deeper clean and to target stubborn dirt, scrubber dryers are a particularly efficient and cost-effective solution. The machines can be operated either ride-on or walk behind and are great for surfaces from as small as 200m² in size.

The tools for the job

CLEAN

MACHINE

40 CVW SEPTEMBER 2021

Scrubber dryers use a series of brushes that scrub the floor as the machine passes over the surface, which loosens dirt that has worked its way into the floor. At the back of the machine, the squeegees collect the loosened dirt where it is then deposited in the dirty water tank to avoid contamination with the fresh-water tank. This process has the added benefit of leaving the floor dry after it has been cleaned, allowing you to quickly get back to the job at hand.

Heavily soiled flooring will require deep cleaning which can be achieved using an easy two-step method, which ensures that even the dirtiest workshop floors are returned to their former state. The first step involves the application of a high concentration (5-20%) detergent to the floor to break up the tough dirt particles, such as Kärcher’s FloorPro Intensive Deep Cleaner RM 752, which can be used in any of the scrubber dryers.

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WORKSHOP MANAGEMENT

The machine can then go over the surface with the scrubber whilst the solution reacts with the dirt. In the second step, the machine collects the dirt and grease loosened by the brushes and solution, where it is collected by the machine's squeegee and stored in the dirty tank.

For smaller spills, a general maintenance clean is an effective solution. This involves a one-step process using a cleaning solution of 0.5-3% prior to scrubbing the surface and collecting the loosened dirt.

Adjustable attachments can be added to scrubber dryers to improve the end result and to account for the different flooring types typically found in workshops. There are two main attachments to look out for: disc or roller scrubbing heads.

For smooth floors, such as laminated flooring, disc systems are effective.

However, most workshops contain structured floors for which roller systems are most effective. The roller systems contain fine bristles that can penetrate the surface of the floor whilst applying greater pressure and higher rotational speed to lift dirt from the surface. Additionally, the high

rotational speed (up to seven times greater than on disc systems) allows the brushes to clean themselves by propelling dirt away.

Stoneware tiles When cleaning stoneware tile flooring it is important to make use of a powerful mechanism and microfibre technology. This is because the micro-pore structure of the tiles attracts dirt resulting in them becoming grey and discoloured. With lots of fine pores to contend with, thicker bristles are unable to penetrate effectively.

The addition of a microfibre roller pad is ideal for stoneware tile cleaning as the strong contact pressure and high rotational speed of the microfibre rollers removes the dirt and immediately expels it from the microfibre material. This means the roller maintains the same efficiency throughout, restoring the tile to its original appearance.

polypropylene bristles. The bristles work to lift dirt off the surface, which, when combined with a powerful alkali-based gravel, are highly efficient in dislodging grease, oil and brake dust, and mineral soiling.

Cement screed Cement screed flooring can often be found in workshops and is usually exposed to the elements, coloured with an epoxy resin coating or is treated with a slip-resistant material. To clean these surfaces, a roller scrubber head is essential for getting into the gaps within the concrete where it has dried.

In the current climate, having a clean working area is not just a ‘nice-to-have’. A hygienic workshop not only protects the health and safety of those working within it, it also prolongs the life of the workspace and goes a long way to bolster a positive business reputation.

Ceramic tiles Other popular tiles found in workshops are “orange peel” ceramic tiles (typically reddish-brown in appearance) and these are best cleaned using roller brushes with

FOR MORE INFORMATION ON KÄRCHER’S CLEANING SOLUTIONS, WWW.RDR.LINK/VAD017

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COMPLIANCE

GOING

PAPERLESS When Abellio Bus entered the London bus market in 2009, the engineering team was under intense time pressure to implement a solution quickly. Dan Crumpton, Technical Sales Manager, explains how Freeway Fleet Systems covered all the bases.

W

ith the establishment of Abellio London (following the purchase of buses from National Express), Abellio entered the competitive bus market in London. “Having worked with Freeway Fleet Systems previously, Abellio opted to work with a supplier that they knew and trusted with a system that was already proven for managing the fleet and compliance,” explains Dan Crumpton.

From the outset Freeway provided a procurement, scheduling, workshop management, cost control, and accounts integration solution. Today, Freeway is used across Abellio’s six workshops that employ 220 workshop operatives. It is used to manage Abellio’s assets which include 853 buses, 115 ancillary vehicles, and 220 additional assets such as lifts and tools.

Abellio typically raise 40 job cards a day across the operation resulting in allocation of labour for 370 individual jobs and the issuing of 300 parts. To improve efficiency, Abellio started the process of moving to paperless working in late 2018 with the introduction of mobile devices and a total of 160 tablets

42 CVW SEPTEMBER 2021

are in use across 6 London workshops.

Technicians use tablets to manage their jobs and pick up jobs and are being deployed to replace paper recording wherever possible.

“Using the tablets in the workshop ensures staff follow a strict data entry process,” says Crumpton. “It takes longer, but everything is now complete and consistent and that saves a lot of time later, not only by eliminating keying in but also because everything is recorded properly in the first place – so we always have all the information we need at the click of a button.”

Streamlining the workshop For management, Freeway automatically generated reports provide high visibility of the engineering operations keeping management informed and a handy smartphone app is used to view and authorise purchase orders. Managing labour is also a key application area with inspectors able to analyse the performance of individual technicians, assessing data entry accuracy and frequency to track productivity and performance issues.

“With Freeway, we can see what people are doing and we can run audits very easily. We have much better visibility and improved accountability. As a result, we are more efficient, the levels of accuracy and compliance are improved; the result is a better quality of fleet maintenance,” Crumpton explains.

“Freeway enables us to have meaningful evidence-based conversations about reducing impacts to our service performance. Managers can manage their workshop remotely, which proved hugely important during COVID lockdowns. And technicians not only have greater visibility of problems arising and ongoing but they can pass work to each other without having to deal with physical documentation.”

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ABOUT ABELLIO Abellio Bus is part of the Abellio Group, a major transport operator in the UK, running bus services across London on behalf of Transport for London. The operator carries 150 million passengers per year employing 2,500 staff across six depots in Central, South, and West London.

Earned Recognition bonus Abellio has been accepted under the DVSA Earned Recognition scheme and Freeway plays a central role in managing compliance under the scheme; the system’s Earned Recognition Tracker ensures compliance criteria are properly managed.

“Earned Recognition is a key focus for us and Freeway’s software is playing a vital role here. In meeting the DVSA’s key performance indicators, everyone has confidence that we are correctly inspecting and repairing. We also feel it gives us a competitive edge with Transport for London (TfL) when tendering for new work,” Crumpton comments.

Freeway is also used for managing parts and stores stock control. The software has been used to improve the management of parts and materials ensuring accurate tracking and cost recording to enable benchmarking contracts and vehicle types as well as building whole life cost models.

In other developments, Abellio has installed large display monitors in the workshops to eliminate paper 24hr sheets with a real-time rolling display showing jobs and their live status. Future plans also include integration with Zenobe, the provider of charging and battery storage solutions for electric powered vehicles, and integration with Trapeze, Abellio’s operations system.

Beyond Abellio’s London bus operations, the company also delivers rail replacement services across the UK and also operates the Greater Anglia, Scotrail, East Midlands Railway, West Midlands Trains and Merseyrail services.

FOR MORE INFORMATION ON FREEWAY FLEET SYSTEMS’ WORKSHOP MANAGEMENT SOLUTIONS, OR ANY OF ITS OTHER PRODUCTS, WWW.RDR.LINK/VAD018

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WORKSHOP MANAGEMENT

MA XIMISING SPACE An important aspect of managing your workshop efficiently is ensuring that you are maximising the space available to you. Stertil-Koni details how it assisted one company that wanted to expand its operations.

A

s an accredited distributor for the extensive range of Stertil-Koni heavy-duty vehicle lifting equipment, Autocraft Equipment has supplied a 25-tonne capacity 4-post lift to A R Haddy & Son. A R Haddy & Son has recently commenced the process of updating and enlarging its vehicle workshop which is based at the company’s site in Saltash, Cornwall. As a crucial element of this project, and following positive recommendations, Autocraft Equipment was commissioned to supply and install the Stertil-Koni vehicle lift, type ST4250.

The ST4250 was specifically designed to ensure safe and reliable operation within the heavy-duty vehicle sector and incorporates a number of unique features including a very low drive-on height and the complete absence of crossbeams. Consequently, the lift offers almost unlimited flexibility by ensuring unrestricted access for personnel and equipment such as axle stands and transmission jacks.

A flexible solution The adjustable spacing between the lift’s two platforms ensures the ideal width to suit the broadest range of vehicles. This, in turn, ensures maximum space utilisation within the busiest of workshops.

Electronic control of the lift’s hydraulic system ensures a smooth lifting and lowering cycle which is vital when vehicles to be raised have an extremely uneven load distribution. Other innovative features include a programmable lifting height, impact-resistant LED lighting that switches on and off automatically just above floor level plus an audible warning signal to help prevent technicians’ feet becoming trapped.

44 CVW SEPTEMBER 2021

ABOUT A R HADDY & SON With a legacy dating back to the First World War, A R Haddy & Son is a family-run haulage company, based in Southeast Cornwall, specialising in freight transport by road. The company operates a fleet of six-wheeler, eightwheeler, and articulated lorries to transport an extensive range of loads including aggregates, agricultural lime, sea sand, road planings, and tarmac, plus all types of plant machinery and equipment to any accessible sites throughout the Southwest.

The Stertil-Koni 4-Post ST4250 is extremely easy to operate using a control panel featuring hold-to-run low voltage push buttons. Also, the lift’s control system utilises a numerical onboard self-diagnostic programme that provides technicians with constant information on the system’s status.

Offering a maximum lifting height of 1900mm in an impressive 77 seconds, the lift is one of the world’s fastest in its class.

During lifting and lowering operations, total safety is assured by an integral

patented mechanical locking system that operates complete independently of the lifting system. Relying on gravity alone, this mechanical locking system is permanently enabled to guarantee the highest possible safety standards.

Each cylinder incorporated within the ST4250 is fitted with an oil flow control valve that is enabled throughout the lifting process.

Furthermore, an integrated over-pressure valve is fitted as standard to prevent all lifting columns from becoming overloaded.

“We’ve worked closely with the team at A R Haddy & Son during the fitting out of the upgraded workshop at Saltash,” says Doug Bingley, Sales Manager at Autocraft Equipment. “As a long-standing distributor of Stertil-Koni heavy lifting products, we knew that the 4-Post ST4250 would provide top performance and reliability in the customer’s demanding industry.”

FOR MORE INFORMATION ON THE ST4250 FROM STERTIL-KONI, WWW.RDR.LINK/VAD019

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©Visual Generation/AdobeStock

TAKING

STOCK

When operating a commercial vehicle bodyshop, margins are tight and time is of the essence for each job. Graham O’Neill, CEO of ACIS, explains how to streamline orders and maximise savings.

I

t is important that businesses not only look for savings in the time spent on jobs, but also the money spent on the products that are required. The savings can be achieved through conversations around where the products are being used and who is using them. In the past, this information was not available; however, with the advancement of technology it is now easily accessible.

ACIS’s Ascribe system provides full visibility of a business, which enables managers to speak to the technicians on the floor and ask why certain consumables are being used more by technician A than technician B, for example. It can also allow businesses to understand if any of their technicians require training on specific processes, which then promotes a conversation with their distributor (ACIS), who can talk to a manufacturer partner and arrange some training. An example of this is an abrasive disc, which is now being used multiple times before it is changed, when it may have only been used once previously.

From a monetary aspect, most businesses have a rough idea as to what their cost per sold hour is but (with margins being tight), if the cost per job goes up, the profitability goes down. So, having the ability to see figures first hand, in real time, ensures that senior management can catch issues early, find out what the problem is, and put in place steps to fix it.

Another saving is through acquiring knowledge; this is because, as a business, ACIS works with several partners that have years of experience in the industry. So, when Ascribe is installed, there is the ability to put in core stock, which is agreed with the business and tailored to its individual needs.

Streamlining the process When it comes to streamlining a bodyshop’s ordering process, the traditional way was for a distributor to go in and visit the site to take an order or the bodyshop parts manager walking through checking stock and then placing an order.

This was a labour-intensive process and there was no traceability on the stock, especially when it came to bodyshop consumables (who was using them, where were they going, and what jobs were they being used on).

This lack of traceability would lead to businesses holding (and using) more stock than is required. Whereas for paints, businesses can see exactly where each penny is going with the help of smart scales. However, with the advancement of technology, the Ascribe system has changed this. It has been designed to allocate products to a technician, department, or job number easily, and it knows when the items are at their minimum level so it can automatically reorder them to the agreed level.

This then leads to the bodyshop slowly reducing its overall stock holding because it can easily see how much it is using. This also means the business becomes leaner both from a stock and financial point of view because it has moved away from the traditional method: ordering a certain amount of product each month, potentially resulting in not being able to use all of it, before reordering the same amount the following month, causing dead stock to be sat on the shelves.

TO WATCH A VIDEO EXPLAINING THE ASCRIBE SYSTEM FROM ACIS IN MORE DETAIL, WWW.RDR.LINK/VAD020

SEPTEMBER 2021 CVW 45

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PROFESSIONAL MOTOR MECHANIC

MECHANEX

THE REGIONAL TRADESHOW FOR AUTO REPAIR PROFESSIONALS

BACK AND BETTER THAN EVER IN 2021!

The UK’s only regional tradeshow dedicated to garage businesses is back again in 2021, with a fresh approach and a host of exciting new content.

2021 SHOW DETAILS Sandown Park, Esher, Surrey KT10 9AJ, 9th & 10th November It’s an unmissable opportunity to attend FREE seminars, sample the latest products on the market, and take advantage of exclusive show special offers.

So, why not bring the full workforce along and make a day of it?

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GIVEAWAYS

ARE YOU FEELING LUCK Y? FOR YOUR CHANCE TO WIN THESE GIVEAWAYS, GO TO WWW.RDR.LINK/VAD021

1 SENSORMASTER DRA08

3 VEHICLE SANITISERS

DRAKEFIELD

VALEO

The Drakefield SensorMaster DRA08 is a handheld EBS/ABS sensor and exciter ring tester, for use on trucks, trailers, buses, and coaches.

Conventional wisdom has it that problems with EBS/ABS systems fitted to trucks, trailers, and buses are best diagnosed via the vehicle's Electronic Control Unit (also known as the ECU).

However, since 80% of all EBS/ABS problems are sensor related, by connecting to the sensor socket on each wheel (which is what the SensorMaster DRA08 does) rather than the ECU, you are, in effect, taking the quickest and most direct route, by going straight to the heart of the problem.

Lightweight and portable, the product comes supplied with a 1.6m high quality cable, a sturdy carry case, short introductory printed manual, and a single 9V battery.

Designed with ease of use in mind, the SensorMaster DRA08 takes minutes to set-up, and, once connected, undertakes a complete test cycle of the six most common causes of EBS/ABS faults, at the touch of a button, in just 15 seconds.

CVW is giving one lucky reader the chance to get their hands on a Drakefield Sensor Master DR08!

Valeo ClimSpray has an automatic effect: once sprayed in the cabin, it disinfects the interior in 15 minutes flat. The product has the dual advantage of not only preventing the spread of infectious microbes at the source, but also releasing a pleasant fragrance. It is suitable for use on both plastic and rubber, and it does not leave any traces or stains behind. Valeo ClimSpray has the ability to neutralise viruses (including coronaviruses), bacteria, and fungi.

10 T-SHIRTS & BASEBALL CAPS CASTROL CLASSIC OILS Presented in high-quality cotton, the T-shirt is a workshop-friendly inverted version of Castrol’s pure white tee.

Equally at home with jeans, it features a bold, screen-printed graphic that is designed to be as hardwearing as the shirt itself. Also on offer is the popular, one-size-fits-all baseball cap, embroidered with the company’s familiar post-war logo, and presented in its distinctive green, white, and red colourway.

There are 10 of each available to CVW readers.

10 INTERIOR CLEANER & SANITISERS AUTOGLYM The all-purpose spray cleaner from Autoglym is quick and highly efficient at removing stubborn stains from all washable interior surfaces. But, more than that, its use removes all concerns over cross-contamination as vehicles are moved within workshop premises. It does this by including powerful agents that kill 99.99% of harmful micro-organisms, including enveloped viruses such as coronavirus, influenza, severe acute respiratory syndrome (SARS), and swine flu (H1N1), leaving nothing but a fresh, cologne-like scent in the process.

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WHAT’S NEW?

BOSCH AGM BATTERY Nowadays, modern commercial vehicles used in long-distance traffic are equipped with numerous comfort and hoteling functions, which has improved the labour conditions of commercial drivers.

To make sure these features are reliably supplied with enough power, even in the case of stationary operation, the Bosch range of commercial-vehicle batteries has now been complemented by the new and powerful TA AGM 12-volt starter battery.

EMINOX DIESEL PARTICULATE FILTERS Eminox has expanded its aftermarket range of accredited diesel particulate filters (DPFs). DPFs are a key component in ensuring Euro VI emissions compliance, enabling operators to meet regulations within the growing number of Clean Air Zones (CAZs) across the UK, including London’s Ultra Low Emission Zone (ULEZ) and Greater Manchester’s planned CAZ. DPFs trap carcinogenic particles from exhaust gases, but faulty or blocked filters risk non-compliance with emissions standards and internal damage, as well as increased engine loads and higher fuel consumption.

Storied history Built on 42 years of experience of designing and manufacturing exhaust aftertreatment systems, Eminox’s range of independently certified, high quality DPFs provide a cost-effective, typeapproved alternative to potentially high cost OEM parts, enabling operators to keep their fleets on the road while reducing expenditure. Each DPF comes with a complete fitting kit and includes a two-year unlimited mileage warranty.

Meeting all standards Manufactured in the UK, the direct-fit DPFs comply with ISO and TS quality standards.

Eminox’s factory, processes, tooling and quality are all independently certified to meet the tight tolerances of the OEM products its DPFs replace and achieve the internationally recognised IATF 16949:2016 standard. They have (EU) No.582/2011 European Type Approval certification. Eminox’s comprehensive range of Aftermarket filters are approved for use in the majority of Euro VI vehicles on UK roads today, and are available for an ever-increasing range of vehicle manufacturers, including DAF, Iveco, MAN, Mercedes, Renault, Scania and Volvo.

GO TO WWW.RDR.LINK/VAD022

48 CVW SEPTEMBER 2021

Up for the challenge Bosch TA AGM reliably supplies a large number of electrical consumers installed at commercial vehicles during stationary operation. This includes features such as, a parking cooler, parking heater, microwave, or TV. As a result, this reduces breakdowns and, thus, unnecessary downtimes.

The new TA AGM truck battery featuring AGM technology was specifically developed for demanding applications in longdistance traffic. AGM stands for Absorbent Glass Mat. At this technology, the acid is completely absorbed by micro-fibre glass mats. It makes the new battery absolutely leakproof and maintenance-free.

Multiple applications Thanks to its high vibration resistance, it can also be installed at the back of the truck. At a depth of discharge of up to 80%, TA AGM features a deep-cycle resistance six times higher than conventional lead-acid batteries. This reduces the number of breakdowns caused by cyclic loads. Featuring a cold start performance of 1 200 A (CCA) and a capacity of 210 Ah, it reliably supplies enough energy for safe cold starting and all comfort and hoteling functions.

The micro-cycle stability closely linked to AGM technology, means it is also suitable for functions such as start/stop systems and sailing or coasting – without engine support. By means of the most powerful TA AGM battery, Bosch complements its existing range of commercial-vehicle batteries – comprising EFB batteries and conventional lead-acid batteries – by a new and reliable premium product featuring original-equipment quality.

GO TO WWW.RDR.LINK/VAD023

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NISSENS AIR CONDITIONING RANGE The complete Nissens AC programme includes the key system components workshops need, developed and manufactured according to marketrecognised, genuine Nissens quality standards. The portfolio of more than 3,000 parts, which includes compressors, condensers, interior blowers, evaporators, receiver-driers, fans, and thermal expansion valves (TXV), caters for in excess of 15,000 OE part numbers, so provides workshops with a highly competitive offering. In addition, the majority of the company’s AC parts are also ‘First Fit’ products, which means the technician gets everything that is needed for their correct installation, within the product box.

Alongside its premium quality components, Nissens has a reputation for its technical support, which it provides to installers through a variety of forms from print to online, including technical training, self-learning modules and technical tips, as well as detailed installation and troubleshooting guides.

GO TO WWW.RDR.LINK/VAD024

HELLA LED REAR LAMP HELLA has launched a full-LED modular rear lamp for 24-volt truck and trailer applications. The patented HELLA LED light curtain, which creates the tail light of the full-LED rear lamp, can now, for the first time, be customised. Graphic structures such as dots, stripes, and shapes can be marked out for this purpose.

With an installation space of only 55.5 millimetres in depth, the full-LED rear lamp has technical features that make it fit for the future. Thanks to mechanical interfaces for sensor technology, ultrasonic sensors can be connected on both sides, for example, in order to implement a parking assistant.

In addition, the control for the flashing side marker lamps, the direction indicator failure control and the load simulation designed to monitor the stop and direction indicator lights, are all integrated into the system. This eliminates the need for additional control units, a fact which significantly reduces the amount of wiring required and ultimately saves costs.

GO TO WWW.RDR.LINK/VAD025

SEALEY AUTOMATIC BATTERY CHARGERS Sealey’s automatic battery chargers are available in three different output charges: 8A, 12A and 16A, and these Fully Automatic 7-stage Battery Chargers are specifically designed for charging a variety of GEL, AGM, lead acid, and calcium batteries with auto chemistry selection.

They are designed to automatically select and charge 6, 12, or 24V batteries, depending on the battery connected.

Zero-volt battery charging enables the recovery and charging of a completely discharged battery (providing any load is removed from the rechargeable battery).

All three Premier Battery Chargers feature an intuitive LED screen that displays illuminated charging stages, volts & amps output and battery capacity. They also feature a compact design with unique retractable hanging hook, and a cable management system that allows the clips to be stored neatly away whilst not in use.

They are also fitted with reverse polarity, short circuit, over temperature and overcharging protection. Better yet, all three of these come with a five-year guarantee.

GO TO WWW.RDR.LINK/VAD027

SNICKERS WORKWEAR BASELAYERS ‘Climate Control’ clothing from Snickers Workwear delivers exceptional comfort and performance. There’s a range of garments that use socially and environmentally responsible fibre technology, such as 100% recycled polyester, as well as others available in high-tech breathable fabrics. For consistent comfort, the seamless designs are also available in 37.5 ventilating technology for efficient body moisture transport, as well as odour-reducing merino wool to suit different types of work, whatever the weather conditions.

These cutting-edge AllroundWork, FLEXIWork, and LITEwork designs and fabrics will keep you cool, warm, and dry when you need to be. All the garments are made from quick drying, lightweight fabrics that come with special ventilation features to control and regulate the heat from your body. All in all, Snickers Workwear Baselayer clothing will give you the kind of fresh working comfort you wouldn’t have thought possible.

GO TO WWW.RDR.LINK/VAD026

SEPTEMBER 2021 CVW 49

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ADVERTISEMENT INDEX

Banner Batteries .............................................. (page 23)

Jack Sealey Ltd ................................................ (page 11)

Ben .................................................................... (page 38)

MAHA UK .......................................................... (page 29)

Checkpoint Safety .................................. (bound outsert)

Mannol .............................................................. (page 41)

Clarios .............................................................. (page 16)

Merridale Ltd .................................................... (page 43)

CTEK ................................................................ (page 19)

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

Conren Ltd ........................................................ (page 43)

Robert Bosch Ltd .............................................. (page 4)

CVW Online ...................................... (inside back cover)

Sampa UK & Ireland Ltd .................................. (page 12)

Dayco Europe .................................................. (page 15)

Schaeffler (UK) Ltd ............................................ (page 25)

Eminox Ltd ........................................................ (page 26)

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

Energizer Group Ltd .......................................... (page 31)

TotalKare Heavy Duty Workshops ................ (back cover)

Haldex .............................................................. (page 25)

Tungsram .......................................................... (page 35)

Induction International ...................................... (page 37)

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