Commercial Vehicle Workshop September 2025

COMMERCIAL VEHICLE WORKSH OP

LET’S GET TECHNICAL

Step-by-step guide to fitting timing and auxiliary belts on a 2.0 L EcoBlue diesel (2016 Ford Transit)

TRUCKTASTIC RACING

Spend the day with CVW at Convoy in the Park

Also in thi s issue...

■ How an oil switch can cut diesel use, downtime, and ensure compliance

■ Using hydrogen to power fuel cells could the best way to drastically reduce air pollution

■ Teamwork makes the dreamwork in cutting battery failures

REGULA RS

BATTERIES & LIGHTING

31 With more than a third of light commercial vehicles failing their MOTs ‘and half of these being down to lighting’, OSRAM is reinforcing its message around quality bulbs.

33 Everything you need to know about commercial vehicle battery ‘check and recharge’ ritual from Banner Batteries.

36 Confronted with increasing battery failures from high electrical demand, a national haulier partnered with Fleet Components and Ecobat Battery. Together, they developed a durable solution that sharply reduced return rates.

38 Modern commercial vehicles need stable power during maintenance. GYS battery support units ensure consistent voltage for diagnostics, programming, and ADAS calibration, preventing costly damage.

Labcraft launches the Orizon FLEX, a R10 approved flexible strip light.

With a proven track record in passenger cars, Mann+Hummel is expanding its expertise to become a preferred partner for commercial vehicles.

Different filters each play different and important roles in modern commercial vehicles. Hifi Filters is here to break it down for us.

45 The use of hydrogen to power fuel cells could be one of the best ways of drastically reducing air pollution when it comes to heavy vehicles, explains UFI Filters.

BODY REPAIRS & REFINISHING

49 The latest products in body shop repairs from PowerTEC, including a mobile door remover and a gluepulling kit.

50 Find out the importance of good quality tools and abrasives for reducing downtime from Steve Smith, national sales manager collision repair at Mirka UK.

VIE WPOINT

Editor

FREYA COLEMAN

cvw@hamerville.co.uk

Group Editor

KIERAN NEE

Digital Manager

KELLY NEWSTEAD

Digital Assistant

LYDIA PROCTER

Advertising Sales Manager

MATTHEW BOASE

Group Manager

ROBERT GILHAM

Graphic Designer

ADEEL QADRI

Group Production Manager

CAROL PADGETT

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Copyright © 2025

8,249

THE HEART OF THE INDUSTRY

Irecently ventured up north to visit a couple of garages (garage profiles to come!), and it was a brilliant reminder of why we do the work we do on Commercial Vehicle Workshop. Not to hit you with two sentimental viewpoints in a row, but it struck me again that it’s the mechanics who really keep this industry moving.

Take Lewis, a young man from Newark who has dreamed of working in the automotive trade. Long before college, he was spending his Saturdays in the workshop, later completing a Level 1 course while gaining hands-on experience with his employer, PW Motors. By all accounts, he was already living the life of an apprentice.

“Progress isn’t about quick wins, it’s about persistence.”

Yet when it came to progressing, the system nearly shut the door on him. His GCSE results didn’t meet the threshold, and without an Education Health and Care Plan there was no flexibility. What followed was months of calls, emails and meetings with colleges, government departments and charities — all just to secure a place. At one point, he was even told to consider plastering or bricklaying instead.

Thankfully, the story has a happy ending. Thanks to the determination of Diana at PW Motors, Lewis will start his Level 3 apprenticeship this September. But it shouldn’t take hundreds of hours of advocacy to prove that a passionate, determined young person deserves a chance.

And perhaps that’s the point: progress isn’t about quick wins, it’s about persistence.

That theme carried through when we visited AJ Fleetcare in Leeds. Alan told us how, ten years ago, his son pushed him to do more — to keep learning, keep training and to see the business through the customer’s eyes. At first, the changes were exhausting: every new course meant more ideas, more late nights, more hard work. But over time, that commitment became culture.

The reward? After years of near-misses, AJ Fleetcare won the Motor Ombudsman’s Star Award last year — not bought but earned through customer votes and independent judges.

As Alan put it: “It showed that going the extra mile really does pay off.”

Freya Coleman

Editor

CVW NEWS

NEWSIN BRIEF

■ Delphi Academy invests in hydrogen training. This is with the addition of a hydrogen-powered Toyota Mirai to its fleet of training vehicles, giving technicians handson experience with real-world fuel cell systems.

■ Additives brand celebrates 30th anniversary. Founded in 1995, Cataclean was developed in response to growing concerns about vehicle emissions, beginning with a mission to clean catalytic converters without removal and evolving into an 8-in-1 fuel and exhaust system cleaner.

■ Birmingham City University wins funding. Researchers at Birmingham City University have been awarded nearly £50,000 to develop AIpowered strategies that will make the UK’s transport systems both greener and more resilient to the impacts of climate change.

■ MAHA’s loyal employee Matthew Wood praised accordingly. MAHA UK has paid tribute to one of its longest-serving service engineers by rewarding his 25 years of service with a golf package, gift card and commemorative plaque.

HGV Driver recruitment needs a jump-start

The government’s employment data shows unemployment is at its highest level since June 2021 and has increased to 4.7 per cent in the three months to May. The announcement comes as Logistics UK publishes the findings of its latest Skills and Employment Update and calls for a coordinated effort to address recruitment and retention in the logistics sector.

Logistics UK’s Skills and Employment Update analyses data from the first quarter of the year and identifies pressing concerns regarding HGV drivers, where the average age is 48 years old and more than half of the profession are over 50. In addition to demographic pressures, the report shows that transport operators are

also facing significant difficulties in recruiting HGV drivers, with 14.5 per cent experiencing severe or very severe issues.

“An ageing workforce and inability to recruit is a recipe for potential disaster in the future unless action is taken now,” says Bethany Windsor, head of skills policy at Logistics UK. “The situation is being made more difficult by recent government decisions to devolve effective initiatives at a time when a long-term national approach to recruitment and retention would be more appropriate.” Ms Windsor cites the government’s decision to discontinue centralised funding for the HGV Skills Bootcamp programme as “a case in point”.

News in Quotes: Road safety proposals

Statement from the Association of Fleet Professionals on the new Government road safety proposals.

"Our view is that most fleets will welcome the mooted reduction of the drink-drive limit, which would presumably make it effectively impossible to legally consume any amount of alcohol and get behind the wheel.

"Fleet managers know that even at the current legal limit, the risk of having an accident is massively increased. A decrease in the limit would remove the dangerous grey area

where some drivers will have one or two drinks and try to count units, assuming they will avoid prosecution if breathalysed.

"In terms of over-70s, there are relatively few fleet drivers who fall into this age range but there are some, especially employed on a casual basis for the occasional driving job. Many remain good drivers but there is an element of risk because of declining eyesight, and any new law introducing a sight test would make it easier for fleets to enforce sensible measures in this area."

Date for the diary: RTX Scotland

•When: 19-20 November 2025

•Where: SEC, Glasgow – providing easy access by public transport and car

•Cost: Free for all visitors

Registration is officially now open for RTX Scotland 2025, the all-new tradeshow dedicated to the commercial vehicle and road transport sector north of the border.

It has been developed by the organisers of the original Road Transport Expo held each summer at NAEC Stoneleigh in Warwickshire. This latest edition will follow the same ‘all about the truck’ format, tailored specifically to the needs and

Put to the electric test

Parcel delivery firm DPD has completed a successful test of the Terberg YT203-EV electric tug with the fully electric yard tractor put through its paces by a number of its drivers at its Oldbury hub.

DPD run a fleet of over 50 tugs to perform all trailer movements across its five centralised sorting hubs in Oldbury, Smethwick and Hinckley. The company is keen to understand how the electric vehicle could help as part of the move to a more sustainable HGV fleet in the longer term.

The model on test was fitted with 2 x 78kw batteries and comprehensive regenerative braking. Universal charging

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challenges of fleet operators in Scotland.

The show has already attracted strong backing from across the industry and visitors will be able to explore vehicle models from leading marques including DAF, Daimler UK, Isuzu, Iveco, MAN, Renault Trucks, Terberg and Volvo.

You will also discover a 5,000ft² indoor showcase of the latest trailers, bodybuilders, tyres, telematics, safety

systems and fleet services, featuring major manufacturers like Binotto, Boweld, Brigade Electronics, MAHA, Michelin, MV Commercials, Palfinger, Schmitz Cargobull, Totalkare, Thompsons and Whale Tankers, to name but a few.

With engaging stand hospitality and a relaxed, friendly environment, RTX Scotland is designed to help hauliers do business and make new connections.

means the YT203-EV can be charged at standard DC charging stations. Taking real life data from customer’s own vehicles

Terberg DTS are able to give a visualisation of how the YT203-EV can work over a 24hour period using opportune charging.

CVW NEWS

New London depot

Independent truck workshop chain Sapphire Vehicle Services is bringing its 24/7 back-up to operators in South London.

Sapphire's new Charlton workshop offers a full range of inspection, maintenance and repair services for trucks and vans of all makes, around the clock. The purpose-built site is already staffed by a team of four but, says regional manager Patrick McGlynn, the plan is to add more as soon as possible.

Sapphire boasts a network of 19 workshops across England and Scotland which together look after close to 30,000 vehicles, for a client list that includes some of the biggest fleets in the supermarket sector. The company is also an acknowledged leader in the fastgrowing electric vehicle field.

The new Charlton site, at Riverside, just upstream of the Thames Barrier, sits next to a distribution centre operated by one of Sapphire's customers but is open to all comers.

We have lift off!

Manchester Airport has upgraded its ground support equipment maintenance with the installation of two new Stertil-Koni SK2055EFA 2Post FreedomLifts, helping technicians work faster, safer, and with greater flexibility.

Replacing older 2-post models, the new lifts were selected for their proven reliability, ease of use, and versatility, key

factors in supporting the airport’s busy operational demands.

Each lift offers a lifting capacity of 5,500kg, ideal for handling a wide variety of vehicles including tow tractors and other specialist GSE vehicles. Thanks to the FreedomLift’s double-telescopic arms and hinged elbow joints, technicians can securely position vehicles of varying sizes, ensuring safe and efficient lifting every time.

Clutch care essentials TECH TIPS

Diesel Technic’s UK parts specialist Lee Harris shares practical inspection and fitting tips to help commercial vehicle technicians avoid common clutch pitfalls and maximise reliability on the road.

Clutch-related failures are a common source of downtime in commercial vehicles but with the right practices and attention to detail, many issues are entirely preventable. For technicians working across truck, bus, and coach fleets, ensuring the correct installation and ongoing reliability of clutch systems is vital to keeping vehicles on the road and out of the workshop for avoidable rework.

Diesel Technic aims to support workshops with over 900 clutch-related products under the DT spare parts brand. Our range covers discs, covers, flywheels and kits for leading marques including DAF, MAN, Mercedes-Benz, Volvo, and more.

Key components and wear indicators

The clutch disc, pressure plate (cover), and flywheel operate in close unison to manage torque transfer during gear changes. The disc’s torsional dampers are designed to absorb drivetrain vibrations, but excessive wear or heat can lead to embedded dampers, distorted contact patterns, or material breakdown, all of which are clear signs that replacement is due.

A blue discolouration on the flywheel is a classic sign of thermal overload and should prompt further inspection. Dimensional checks are advised to ensure continued compatibility, especially if reusing the component, and manufacturers' torque specs and bolt guidance must always be followed.

Installation tips

In workshop conditions where time pressures are real, it's tempting to cut corners—but improper fitting can lead to premature failures or misdiagnosis down the line. When removing the clutch cover, bolts must be released in a crosswise sequence to relieve spring pressure evenly. This prevents distortion and helps preserve the contact surface integrity.

Reinstallation should follow a strict torque and sequence process. Use centring sleeves to position the flywheel, apply the manufacturer’s torque spec—including angle tightening where expansion bolts are used—and mark bolt heads to ensure uniform alignment.

A centring pin is essential when positioning the clutch disc to avoid misalignment. Once two mounting bolts are used to fix the pressure plate to the flywheel, remaining bolts should again be tightened in a cross pattern and to spec. Before final torqueing, check that the clutch disc is properly seated as misalignment at this stage is one of the most common fitting issues, often leading to gearbox interference or poor engagement.

Inspection and diagnostics

Professionals will know that even a small oversight can compromise clutch performance. Always examine the release mechanism for grease leaks, damaged components, or wear. Overuse or contamination can present as sluggish operation, noise, or poor release characteristics.

Be cautious with lubrication and only apply grease where the OEM specifically advises it. Excess grease can cause clutch drag or erratic function. Likewise, don’t overlook contact surface flatness. A warped pressure plate or incorrectly seated flywheel can result in uneven engagement, judder, or rapid wear.

And crucially, remember to carry out any necessary parameter resets using diagnostic tools following clutch replacement. Failing to do so may affect the vehicle’s electronic control systems and performance.

Fit it right, first time

Busy workshops need reliability, not comebacks. Correct clutch installation and early fault detection are key to reducing downtime and building customer trust. Whether supporting fleet vehicles, buses, or local authority assets, following best practice makes all the difference.

Diesel Technic provides a comprehensive range of quality-assured parts along with technical support for workshops across the UK.

KNOW YOUR PARTS

SCR Systems

Febi shares everything you need to know about SCR systems.

Diesel engines of heavy-duty vehicles contribute excess oxides of nitrogen NOx and their related health problems in almost all regions. The mitigation of environmental pollutants like NOx from the diesel engine exhaust is a secondary NOx removal technique by aftertreatment. Selective catalytic reduction (SCR) is the latest technology adopted by many automobile manufacturers to mitigate NOx, wherein ammonia NH3 is used as a reducing agent.

SCR systems in modern vehicles are operated with a solution of 32.5 per cent synthetic urea and 67.5 per cent demineralised water, known under the brand name of AdBlue. The trademarks for AdBlue are held by the German association of the Automotive Industry (VDA). It is not a hazardous substance as it is biodegradable, non-toxic, colourless and water soluble.

Combined with SCR catalytic converter, the Diesel exhaust fluid AdBlue converts nitrogen oxides NOx emitted by the diesel engine into nitrogen N2 and water vapor H2O, non-

polluting components already present in the atmosphere:

AdBlue is injected by the dosage module into the exhaust pipe upstream of the SCR catalyst.

Under the effect of heat, urea decomposes into ammonia NH3

By chemical reaction with ammonia in the SCR catalyst, nitrogen oxides from the engine are converted into nitrogen N2 (a harmless gas, the main component of the air we breathe) and water H2O.

Keep SCR systems running

Every SCR system is equipped with an urea filter, also known as AdBlue filter. It ensures that no impurities enter the metering unit with the AdBlue liquid to guarantee a long service life of the sensitive SCR system components. The fineness and change intervals are comparable to those of a diesel fuel filter. Some AdBlue filters are equipped

with compensating elements. These flexible elements avoid damage to the system and the filter by reducing the free volume in the housing and absorbing pressure forces when the urea water solution expands at temperatures below freezing.

Some AdBlue filters are equipped with compensating elements. These flexible elements avoid damage to the system and the filter by reducing the free volume in the housing and absorbing pressure forces when the urea water solution expands at temperatures below freezing.

Timely maintenance avoids problems

If the urea filter is clogged by impurities or the SCR system no longer functions due to neglected maintenance or damaged components, the engine control unit

switches to an emergency program. Engine speed and power will be reduced depending on vehicle type. If the fault in the system is not rectified, the drive to the closest garage will happen at walking speed in the worst case.

Only completion of the required maintenance/repair of the SCR system by a specialist workshop will make it possible to end the emergency program.

Benefits of febi urea filters at a glance:

● More than 20 Urea filters and highest coverage of 97 per cent for the European Big 7 and further Asian vehicles in the IAM.

● Patented compensation elements prevent damage due to freezing.

● High filter capacity to protect the sensitive SCR system, for long replacement intervals and low downtimes.

● Dynamically growing product range for SCR components.

Further SCR system components

Another evitable component of the SCR system are NOx sensors. They monitor the function and effectiveness of the SCR system by measuring the nitrogen and oxygen concentration in the exhaust

gas. The data from the NOx sensors is also used to calculate the amount of AdBlue required for an optimal reduction process.

NOx sensors have a limited lifetime.

Due to ageing as a result of oxidation of the electrolyte material Zirconium Dioxide in the sensor, the reliability of the measurements decreases over the time. Also, the extreme temperature changes will shorten the lifetime due to the extremely porous and hard ceramic material and its temperature sensitivity.

As a result the driver receives an error message after a certain time when the measures getting more and more implausible. The lifetime depends on many factors so it is not predictable at all.

In addition to NOx sensors, AdBlue fluid and the corresponding filters, febi also offers many other spare parts for SCR systems, such as tank caps, metering modules and exhaust gas temperature sensors.

Rely on tested OE matching quality replacement parts from febi. The febi brand is part of the bilstein group, the umbrella organisation for several other strong brands.

Brake pad replacement BEST PRACTICE TIPS

Frasle Mobility braking specialist, Juratek, is warning technicians and garages against the outdated practice of using copper grease when fitting replacement brake pads.

While copper grease was once widely used to reduce brake squeal, modern brake pads –including the entire Juratek range – come equipped with premium anti-noise shims or coatings specifically designed to prevent noise and vibration. In fact, the application of copper grease can increase brake noise, reduce component lifespan and interfere with modern vehicle systems, warns the specialist.

“Modern braking systems are more complex and electronically integrated than ever before,” says Matt Leeming, head of product management for Frasle Mobility in

the UK. “Using copper grease is not only unnecessary but potentially damaging –particularly to ABS and EPS systems, where conductivity from the copper can cause serious interference.”

Juratek’s premium anti-noise shims are tested rigorously to SAE2521 standards, the benchmark developed by OEMs to alleviate braking noise. These tests are conducted in anechoic chambers using full vehicle corner assemblies, ensuring realworld relevance and reliability.

Other risks of using copper grease on brake pads include degradation of rubber

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seals, potentially leading to fluid leaks or even brake failure, and pad sticking, preventing proper sliding within the caliper.

Copper grease does still have its place to prevent seizing or corrosion elsewhere on the vehicle, however, on non-braking contact points when fitting replacement pads, it is better to use ceramic or silicone-based lubricants that are designed for use with modern braking systems, advises Juratek.

A/C Components KNOW YOUR PARTS

Valeo emphasises the importance of A/C compressors and condensers in vehicle air conditioning systems.

As temperatures rise, the demand for reliable vehicle air conditioning increases. Understanding the role of key A/C components—the compressor and condenser—is essential in ensuring you have access to the right parts for effective repairs and maintenance. The compressor is responsible for circulating refrigerant through the air conditioning system. It compresses low-pressure refrigerant gas into a high-pressure, high-temperature state before sending it to the condenser. If the compressor fails, the entire A/C system loses its ability to cool, leading to discomfort for the driver and potential damage to other components. The condenser works like a radiator, cooling down the hightemperature refrigerant gas and converting it into a liquid state. It plays a crucial role in regulating the system’s temperature and overall efficiency. If the condenser is

clogged or leaking, it can lead to overheating, poor cooling performance, and increased strain on the compressor.

Common issues and its impact on performance

● Compressor failures can result from refrigerant leaks, contamination, or lack of lubrication. Symptoms include unusual noises, reduced cooling, or complete system failure.

● Condenser malfunctions often caused by debris buildup, corrosion, or leaks. Signs include overheating, weak airflow, or reduced cooling efficiency.

● Refrigerant cycle disruptions: If either component is compromised, the entire A/C system becomes inefficient, leading to increased energy consumption and potential vehicle overheating.

Regular maintenance of compressors and condensers is essential to:

● Ensure A/C efficiency – Well-maintained components improve cooling performance and fuel efficiency.

● Prevent costly repairs – Early detection of wear and leaks helps avoid major system failures.

● Extend component lifespan – Keeping the system clean and well-lubricated reduces strain on the AC system. By using Valeo A/C compressors and condensers, workshops can use with the best-in-class components that enhance vehicle performance and reliability— ensuring a seamless and profitable A/C season.

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HOW TO

Belt replacement guide

A helpful step-by-step guide from Dayco of the correct fitting process for the timing and auxiliary belts on the 2.0-litre EcoBlue diesel engine, in the popular Ford Transit from 2016.

As well as being a leading supplier of original equipment (OE) components to vehicle manufacturers across Europe, Dayco is also the OE supplier of the timing and auxiliary drive systems used for the EcoBlue engine. This means it is in a

strong position to share its knowledge with professional technicians, to help them to undertake and complete belt replacement work efficiently and successfully.

In its latest video, which complements others covering the Ford 1.0-litre EcoBoost,

PSA 1.2-litre PureTech and Jeep 2.0-litre JTD, as well as the friction wheel used for the Mini 1.4 and 1.6-litre petrol engines, technicians are first reminded that before they start the job, they not only need the Dayco replacement kits, they will also need a new timing belt cover and vehicle sump (supplied by a Ford dealer), as well as the correct installation tools.

The removal begins

The best way to get to the wet belt system is to remove the driver side front headlight and the front right wheel. Then the action really begins as first the removal process, which includes several useful tips to make things easier, such as cutting both the auxiliary and oil pump belts, as not only can neither be reused, but it also makes their removal simple and quick.

During this stage and once everything has been removed, the video highlights several important steps that need to be actioned to either help technicians understand any potential underlying issues,

or to pave the way for the simplest possible replacement. These include examining the condition of the belts and related components for damage or wear and to replace them if there is any doubt, as well as to thoroughly clean the system and remove all sealant residue etc.

Although all Dayco wet belts now benefit from a new compound that is resistant to oil contamination, diesel fuel contaminating the oil is not uncommon with this engine and that can have a

particularly adverse impact on older belts, as well as many aftermarket replacements, which obviously has consequences for the entire drive system. In fact, in extreme cases, this can cause material to dislodge from the belt surface, further affecting the oil and potentially causing problems such as blocking the oil pump strainer. So, checking the oil pump pick up and strainer for debris is essential, as is their replacement if there is any evidence of wear or damage

The timing belt tensioner, which, in contrast to most, is a slipper, rather than a wheel, must be replaced. However, it must be positioned correctly, with its location tab in the corresponding recess, before the bolt is tightened and the pin retaining the spring, removed (after the new belt is fitted).

Fitting the belts

When it comes to fitting the two replacement wet belts – the timing belt from Dayco kit KBIO07 and oil pump belt (Dayco part number 941121) – there are again useful best practice steps to follow. The first is to smear oil on the back of the timing belt once it is fitted, which will lubricate the contact point between the belt and the tensioner when the engine is being turned over by hand to check the timing is correct, as well as on its initial start-up, once the replacement is complete.

The second is to feed the oil pump belt up from the bottom of the engine, rather than trying to thread it down from the top.

Although it should be second nature for technicians to follow the VMs installation processes, tightening sequences and torque settings, the video emphasises the importance of these procedures as it demonstrates how the new sealant should be applied, including around the holes on both the oil sump and the timing belt cover, during their reassembly.

When it comes to the auxiliary belt, which is elastic, so must always be replaced (Dayco part number 6PK1410S), to ensure is not damaged while being fitted, the correct installation tool must be used. In addition, to ensure that the auxiliary drive system works perfectly, it is also recommended that a new auxiliary belt tensioner is fitted.

Alongside the information presented through this new video, Dayco naturally recommends technicians refer to a reputable source of service and repair data, such as that supplied by Autodata or HaynesPro, for the full repair instructions, as well as for specified tightening sequences and torque values.

ALL IN ALIGNMENT

City Lifting, a leading crane and specialist lifting services hire company, has seen significant cost savings and improved workshop efficiency since the introduction of a Josam Laser AM wheel alignment system, supplied by the workshop equipment provider, AES UK.

City Lifting, based in Purfleet, operates a large and diverse fleet of mobile cranes and trucks, many of which feature complex multi-axle configurations—some with up to 8 axles. Previously reliant on external contractors for wheel alignment, the company faced growing costs, scheduling delays, and unnecessary tyre wear due to misalignment and vehicles being dispatched before alignment could be completed.

“We were spending a lot on contractor alignments, and when timing didn’t line up, we’d end up sending out vehicles before they could be aligned properly,” says Simon Sanderson, workshop manager at City Lifting. “That sometimes meant we’d ruin tyres that can cost around £1,600 each. We knew we needed to take control of the process.”

AES UK provided an on-site demonstration of the Josam Laser AM, an

analogue laser-based wheel alignment and chassis measurement system designed specifically for heavy-duty commercial vehicles.

The alignment system works by projecting precise laser beams from mounted brackets on each axle to measure toe and camber angles. Technicians can then compare the readings against manufacturer specifications and make accurate adjustments quickly.

Investment time!

After seeing the system in action, City Lifting immediately decided to invest. AES UK then delivered the equipment and conducted on-site training for the company’s technicians.

“We saw an immediate improvement,” says Simon, “and the ability to carry out alignments in-house has led to major savings on tyres alone, even before factoring in the cost of using external contractors. Significant savings were evident from the start and we estimate the system paid for itself in about 6 months.”

Also reports Simon, with correctly aligned axles, tyre wear has dropped dramatically, and fuel efficiency has improved thanks to reduced rolling resistance - operational gains which have

had a direct and favourable impact on the business’s bottom line.

Moreover, says the company, driver feedback has been overwhelmingly positive, with operators reporting that the cranes now “drive like a dream,” with noticeably improved handling and stability.

“Our decision to invest in the Josam wheel alignment system,” adds Simon Sanderson, “is a good example of how bringing key services in-house, and using the right equipment from experts such as AES UK, delivers both cost savings and performance improvements across the board.”

Simon also praised AES UK for their outstanding customer service and support throughout the process. “The service from AES UK was second to none,” he says. “From the initial demonstration to the delivery, setup and training, they were professional, knowledgeable, and completely supportive every step of the way. It gave us total confidence in the investment.”

CVW DOES CONVOY IN THE PARK

We were lucky enough to be invited by febi to spend the day at Convoy in the Park.

Iwasn’t sure what to expect when I stepped into Donington Park on 10th August but I certainly wasn’t disappointed.

Watching the trucks hurtle downhill at what I was told was an eye-watering 100 mph, I couldn’t help wondering how they didn’t just topple over in the bends. Ben from the febi team explained that the weight is concentrated low down, with the engines beneath the driver, so the cab

simply sits on top. It was fascinating and a little mindboggling.

After a thrilling race with only a touch of argy-bargy, we wandered back to the paddocks where I discovered the unsung heroes of truck racing: the drivers who reverse these giant HGVs into place with pinpoint precision.

As we walked, the air was thick with a scent like burnt clutch which, I learned, was actually the brakes. Thanks to the incredible speeds, the trucks use watercooled braking systems to keep

temperatures under control. Ben told me they have to replace the brake discs after every race weekend, which shows the immense strain these machines endure.

Racing recap

Convoy in the Park at Donington featured three British Truck Racing Championship (BTRC) rounds and two International Truck Prix races. BTRC wins went to David Smith, Ryan Smith, and Michael Oliver, while Jamie Anderson and Simon Reid won the International races.

In the first BTRC race, pole-sitter David Smith won, with Jake Evans leading Division 2. Ryan Smith retired. Race four saw Ryan Smith climb from sixth to victory, with Evans again winning Division 2. The final race used a reversed grid; Michael Oliver led from fourth to win, and Sami Ojanen took the Division 2 win.

OIL TRAINED UP!

CVW hears about Castrol expanding its training opportunities in the commercial vehicle sector, helping workshops boost knowledge on its products.

In a competitive and fast-evolving commercial vehicle market, workshops and distributors need more than just quality products, they need the knowledge and skills to sell, support and service them effectively. Recognising this, Castrol has significantly expanded its portfolio of training opportunities, offering tailored courses designed to help sales teams, service managers and mechanics improve leadership capabilities, enhance sales skills and boost familiarity with Castrol products.

Now available via the easy-to-use Learning Campus, in both online and faceto-face formats, a wide range of modules are available. From technical tutorials for

technicians and workshop managers, to video sessions for sales agents and front-ofhouse staff to improve customer service and facilitate upselling, the training is structured to deliver value for workshops.

Additionally, Castrol knows that every workshop has unique requirements and therefore facilitated courses that can be customised to meet the specific requirements of individual workshop teams. This is through providing tailored online webinars and face-to-face training sessions, with each course delivered by Castrol’s pan-European team of Technical Service Specialists who deliver training aligned with the specific needs of personnel at individual customer sites.

Castrol has continued to expand the number and scope of expert training courses to provide distributor and workshop partners with the knowledge and skills necessary to build capabilities and boost personal growth. The commercial vehicle market is changing at speed, and participants can be assured of expert guidance from a partner they can trust.

With a sharpened focus on both technical skill and commercial impact, Castrol’s enhanced training offer presents an opportunity for CV workshops to stay ahead not only through the product, but also through their staff.

Fuel efficiency saves money

Proven in real-world fleet tests, Witham Group’s Super HD FE 5W-30 delivers a 1.31 per cent fuel economy boost over 10W-40, slashing diesel use, cutting maintenance downtime, and keeping fleets compliant, all from a simple oil switch.

Earlier this year, Witham Group launched the new Super HD FE 5W-30, updated with the latest specifications for Daimler and Volvo commercial fleets. Thanks to research from the additive company Chevron Oronite, testing has now proved that fuel economy is definitively improved using this product in heavy duty engines as opposed to traditionally recommended 10W-40 viscosity oil.

The recently published report concluded that in comparable tests, fuel economy improved by 1.31 per cent. Fleet sizes of commercial vehicles of course vary in size but based on this increase and the following assumptions: 150,000 km average truck annual mileage, 11.5 mpg average truck fuel consumption and £1.10 Price of diesel per litre.

Each truck would use 37,950 litres of fuel at a cost of £41,934. Applying the improvement in fuel efficiency of 1.31 per cent, the same truck would use a reduced

37,459 litres of fuel – at a cost of £41,392 (491 litres less) saving £542 per truck. For commercial vehicle business owners with the following example size of fleet, there are the real cash savings potentially made, just by switching to this lower viscosity engine lubricant.

Potential savings achieved

For a 20-vehicle fleet, savings would be 10,840 pa, £27,100 pa for a 50-vehicle fleet, £54,200 pa for a 100-vehicle fleet and £65,040 pa for a 120-vehicle fleet. These savings are per year, so over a 3-year period, the saving from the oil switch would potentially be £195,120 for the largest vehicle fleet example.

Witham Group are big advocates of using the latest technology of low viscosity engine oils and suggest that a commercial lorry fleet owner should be looking at engine oil as a strategic tool, not just a maintenance item, because engine oil directly impacts fuel costs, vehicle uptime,

engine life, and total cost of ownership. Here's a breakdown of why it matters:

Fuel economy = major operating cost

Fuel is typically the largest variable cost in fleet operations. The right engine oil, especially low-viscosity, fuel-efficient formulations, can reduce fuel consumption by 1–3 per cent, saving thousands of pounds a year. For fleets burning thousands of litres per vehicle per month, this adds up to significant savings annually.

Engine protection = less downtime

High-quality engine oils reduce wear, prevent sludge, and extend engine life. This results in fewer breakdowns and lower maintenance costs, keeping trucks on the road and delivering goods.

Longer oil drain intervals = fewer service tops

Modern synthetic oils with advanced additives maintain their properties longer.

With proper monitoring (e.g., oil analysis), oil drain intervals can often be safely extended, reducing workshop labour, service downtime, parts and filter costs.

Environmental and regulatory compliance

Emission regulations (Euro VI, etc.) are stricter than ever and OEMs require specific oil types to keep aftertreatment systems (DPF, EGR, SCR) working effectively. The right oil helps maintain compliance and avoid fines or warranty issues.

Supports warranty and OEM recommendations

Using OEM-approved engine oils ensures warranty protection, optimal performance from modern engine technologies and reduced risk of engine damage from incorrect oil types.

Improved total cost of ownership

Engine oil affects more than just the engine: Better combustion = cleaner engine = fewer repairs and lower friction = less energy wasted = better performance. Smart oil selection is a small investment that delivers big returns over the life of a lorry. Fuel-efficient, low-emission fleet operations appeal to customers and partners. Oil choices contribute to lower CO₂ emissions, supporting sustainability reporting and ESG targets.

How does low viscosity oil actually help save on fuel economy?

1. Reduced internal friction

● Lower viscosity means the oil flows more easily through the engine.

● This reduces hydrodynamic drag between moving engine parts, such as pistons and crankshafts.

● Less resistance = less energy needed = better fuel economy.

2. Faster lubrication at startup

● Low-viscosity oils flow quickly at cold temperatures (e.g., during morning starts).

● This reduces engine wear and improves efficiency during the critical startup period.

3. Optimised for modern engines

● New-generation commercial engines are built with tighter tolerances and advanced technologies like turbocharging and variable valve timing.

● These engines are designed to take advantage of low-viscosity oils to reduce pumping losses and improve combustion efficiency.

4. Compliance with emissions and fuel standards

● OEMs (like Cummins, Daimler, Volvo)

often recommend low-viscosity oils to meet EPA, Euro VI, or GHG Phase 2/3 fuel economy targets.

● Using OEM-approved low-viscosity oils supports warranty compliance and environmental goals.

Witham Group’s MD Nigel Bottom said: For commercial fleet operators, fuel is one of the biggest line items in the budget. By simply switching to a high-performance, low-viscosity engine oil, fleets can see fuel savings of thousands of pounds a year, depending on duty cycle and operating conditions, without changing a single route, vehicle, or driver.

But it’s not just about fuel. These advanced lubricants are engineered to reduce engine wear, protect emissions systems, and enable longer oil drain intervals, which means fewer service stops and less downtime. In total, you're looking at a lower total cost of ownership and improved vehicle reliability.

We are proud that our engine oils and other lubricants are thoroughly tested in real-world fleet conditions and approved by major OEMs. For fleet owners under pressure to reduce costs while meeting tough emissions targets, the right engine oil is a low-risk, high-impact decision that delivers both immediate and longterm ROI.”

Sapphire Vehicle Services is using Truckfile workshop management software to cut paperwork, boost efficiency and to win new business too.

A SOFTWARE HELPING HAND

Sapphire is introducing Truckfile across its national network of independent, all-makes workshops and is using the system’s benefits as part of its pitch to potential customers.

“It’s a win-win situation for us,” said Sapphire Group Commercial Director Grant Tadman.

“We’re always looking for ways to work with like-minded partners to add simplicity to the way we operate. Using Truckfile makes life smoother for our technicians and managers, because the recording of work completed is so quick and easy – that in turn means we can pass on cost and time savings to our customers, which is something we consistently strive to do.

“But there’s another two-way benefit too,” he continued. “We can now include Truckfile as part of our offering to new customers. If any operator signs up to a maintenance agreement with Sapphire, they can have access to Truckfile as part of the package. That’s an attractive proposal for the customer and a great selling tool for our business.”

Truckfile’s systems allow all records to be created and updated in real time by technicians as they complete each job, using computer terminals, hand-held tablets – or, in the latest development, even voiceactivated software. Details are securely stored and easily retrieved. Nothing is ever mislaid, everything is automatically filed in

the right place and is always accessible with a few keystrokes.

“Our technicians have adapted to the system very quickly,” said Mr Tadman. “The hand-held tablets are very intuitive, and they can also use the same equipment to take and attach photographs if necessary. The process makes the crucial task of ensuring compliance for us and our customers very straightforward.

“Truckfile is a great aid for me, and our depot managers, too. It gives a comprehensive picture of what’s going on at each of our 19 sites across the UK.

Managers can easily keep tabs on every job going through their workshop and find any specific detail on any particular vehicle quickly, without having to leave their desks. All the information our customers need for their own records is securely stored and made easily accessible for them, which allows us to help them operate at maximum efficiency.

“We’ve been rolling out introduction of the system across our network over the last 12 months and will achieve full coverage soon. We’re confident this be a significant benefit to our teams and the operators who use our services, and we’re already to talking to potential new customers about the advantages this partnership of Sapphire and Truckfile can bring to the table.”

STAY PLANNING TO REDUCE DOWNTIME

Unplanned downtime is one of the most costly and disruptive issues facing commercial vehicle operators today. From missed deliveries to rising repair costs, the impact of downtime can be felt across the entire fleet. But AI-powered vision systems now help tackle a key root cause: risky driver behaviour. Real-time road intelligence enables fleets to shift from reactive maintenance to proactive protection, enhancing vehicle health and longevity.

Netradyne’s Driver•i, powered by computing and AI-driven vision systems, captures and analyses 100 per cent of drive time in real-time. By analysing the feed from both road-facing and driver-facing cameras, it delivers behavioural insights when they matter most, visibility into vehicle strain, and driver coaching tools.

Given the stringent operational standards and competitive pressures within the UK, Driver•i offers fleets the proactive intelligence needed not only to comply but to thrive, helping ensure vehicles are driven consistently, maintained efficiently, and kept on the road longer.

Cost of driving habits

Every vehicle’s lifespan is shaped not just by how far it travels, but how it’s driven. Harsh braking, sharp cornering, aggressive acceleration, and frequent

lane changes may seem minor, but over time, these behaviours accelerate wear on tyres, brakes, and suspension systems. They are not just safety concerns, but maintenance multipliers.

Driver•i intervenes with real-time audio alerts, flagging risky actions as they happen and allowing drivers to adjust in the moment. Fleet managers receive incident data with full video context, helping them pinpoint patterns and coach accordingly.

Real-time insight

Fleets using Driver•i have seen marked improvements in both safety outcomes and asset longevity. In one example, a fleet customer implemented Driver•i to improve visibility and coaching. The company captured 7x more risk events than its legacy system and reported a measurable improvement in driver behaviour and vehicle handling. With 87 per cent of drive time classified as riskfree, they were able to reduce unnecessary vehicle strain, improve operational uptime, and support more informed maintenance decisions.

By continuously monitoring how vehicles are handled on the road, Driver•i supports more dynamic maintenance planning. Instead of relying solely on odometer-based schedules, workshop teams can prioritise inspections and services based on real-world data.

Empowering drivers, protecting fleets

While some telematics tools focus on faultfinding, Driver•i is designed around constructive engagement. By actively recognising and rewarding proactive, defensive driving habits—such as maintaining a safe following distance, the culture shifts from compliance to collaboration, giving drivers the tools to perform at their best while protecting fleet assets.

For workshops and fleet managers, this results in more predictable maintenance needs, reduced workload volatility, and vehicles that come in with fewer surprises.

Maintenance and beyond

As fleets face mounting pressure to reduce costs, improve uptime, and extend vehicle lifespans, AI-powered road safety system is emerging as a foundational tool for achieving these goals. Platforms like Driver•i are no longer just safety solutions; they’re strategic maintenance assets.

By embedding real-time visibility and behaviour insight into daily operations, fleets gain the foresight to act before faults emerge, the flexibility to adjust servicing schedules with confidence, and the resilience to operate smarter, longer, and more safely.

We see a future where downtime is predictably minimised through intelligent, AI-driven technology, powered by proactive rather than reactive responses.

LIGHTING THE WAY

According to Select Leasing, the DVSA has revealed via a Freedom of Information request that “around 36 per cent of light commercial vehicles failed their initial test in a 12-month period between 2023 and 2024”. It also revealed that “of the nearly 890,000 vans that failed the MOT test, 47 per cent of these failures were due to problems with ‘lamps, reflectors or electrical equipment’.”

With a majority of LCVs being used for professional reasons, it’s concerning that nearly half failed on such a safety critical component, as lights are. This is especially important at the moment, as lights are being used more often due to the winter months that we are currently moving towards.

With more than 110 years in the automotive sector, renowned lighting specialist, Osram, is reinforcing why choosing and fitting original equipment (OE) quality bulbs will ensure driver safety on the road.

Range of bulbs

The company has a vast range of bulbs to suit LCVs and one that should be considered is OSRAM’s ORIGINAL Line 12V, which is an OEM quality product that is tried and trusted by vehicle manufacturers across Europe and therefore covers a wide array of applications for both headlight and auxiliary applications.

There is also the upgrade option in Osram’s Night Breaker 220, which is its

After a Freedom of Information request from Select Leasing, the aftermarket found out that more than a third of light commercial vehicles failed their MOTs, with half of these fails due to lighting. Therefore, leading lighting specialist, OSRAM, is reinforcing its message around quality in bulbs.

standard, providing more light and improved visibility, which can help drivers react to road conditions more quickly. The Night Breaker 220 is available in H4, H7 and H11 ECE types with a new gold cap.

Therefore, LCV drivers can have complete confidence that when they buy and fit this range of bulbs, they are getting a premium quality offering with an extra-long lifespan, optimised light intensity and vibration resistance from OSRAM, the leading original equipment lighting manufacturer.

HOW TO PLANAHEAD

Banner Batteries recommends commercial vehicle battery ‘check and recharge’ ritual. CVW finds out more.

“Retaining optimum battery power levels on commercial vehicles has never been more important”, states Banner BDM, Russell Shea. Indeed, not 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.

As Russ adds: “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:

1

● 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 15 mm 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.

2

● 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

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

● 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.

Recharging and battery replacement

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.

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.

As Russ states: “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 HD1+ Battery Tester, which should be used for the periodic inspection of the open-circuit voltage.

Faced with rising battery failures caused by high electrical demand, a national haulier turned to Fleet Components and Ecobat Battery. Their collaborative approach delivered a lasting

BATTERY BREAKDOWN AVERTED

As Ecobat Battery, dealing with the effects that increasingly high electrical demands have on the batteries fitted to the country’s commercial vehicle fleets, is a major problem and a significant unwanted cost to operators, as it is causing many batteries to fail prematurely.

This is precisely the issue that was encountered by a major national haulier, and one of CV parts factor and IFA member, Fleet Components’ valued, long term customers.

Fleet Components has an exceptional reputation for both the quality of the parts it supplies and the level of service it provides, so it came as an unwelcome surprise to find that when its customer went through its fleet’s replacement cycle, it began to experience an increasing incidence of early life battery failure.

As an approved supplier to the IFA, with an excellent working relationship with Fleet Components, Ecobat Battery was recommended as the go to company to help find a resolution to the issue, so there followed a technical investigation carried out by Chris Jones and Scott Barker, in conjunction with Fleet Components, to look at the problems and discover a solution.

Finding the problem

“After analysing the problems and following consultation with the customer, it became evident that a large number of the vehicles in the fleet had extremely high levels of electrical demand due to their reliance on numerous power consuming

functions,” explained Fleet Components’ Iain Allenden. “These include parking cooler/heaters and, when cabs double-up as hotel rooms overnight, the battery is also the sole source of power for cooking, lighting and TVs, as well as for charging tablets or laptops etc.

“At the conclusion of the joint exercise, the Exide PowerPRO EF2353 was the battery selected to help resolve the issues, due to its combination of capabilities and its original equipment pedigree, making it a cost-effective solution,”

Ecobat Battery’s Scott Barker added: “As an Ecobat Battery customer, we carry out ongoing staff training to help the Fleet Components team keep fully up to date with battery testing processes, and to question why batteries fail etc. So, by combining this knowledge with the experience we have within the Ecobat Battery team, having identified the customer’s initial problem, we were able to work together to find a suitable solution, which is a fantastic example of practical cooperation and mutual benefit.”

Another major dividend for Fleet Components, as it would be to any CV factor, is that since the switch, the battery return rate has dropped to just over 0.5 per cent, an impressive result that has been replicated by Fleetwheel Cardiff, another satisfied Ecobat Battery customer.

This example of customer consultation is not an uncommon occurrence for Ecobat Battery, as it is widely recognised for its extensive power storage related expertise, across the many industries the company serves. What it proves however, is that despite being a relatively big business, it is still able to respond to the specific needs of its customers to ensure the most suitable solution to a given problem, or set of challenges, is found.

This is made possible because Ecobat Battery has built its reputation by providing its customers with a level of service that reaches far beyond just battery sales. Although, as has been demonstrated, its additional services include practical advice as to which is the most suitable battery solution, they also embrace identifying the correct charging regime for each application, and providing flexible aftersales service packages that maximise battery life and optimise returns on their customer’s investment, as examples.

BATTERY SUPPORT

Modern commercial vehicles are increasingly reliant on electronics, with systems such as ECUs, ADAS, and onboard data systems drawing significant current during maintenance. Electronic servicing procedures often take place with the ignition on but engine off, placing the electrical load on the vehicle’s battery. Without a battery support unit, the battery can quickly become overloaded, increasing the risk of voltage drops, system instability, or even ECU damage.

What is battery support unit?

A battery support unit is a powerful workshop tool that takes over the power supply of the vehicle, ensuring stable voltage throughout. Depending on the current draw from the vehicle, which can fluctuate significantly during diagnostics or programming, the support unit will instantly match that demand, removing the battery from the equation entirely.

The consequences of unstable voltage can be high-risk during software updates or ECU reprogramming. An unstable power supply can corrupt data or permanently

Modern commercial vehicles depend on complex electronics that demand a stable power supply during maintenance. A battery support unit safeguards against voltage drops, system instability, and costly ECU damage by delivering consistent power during diagnostics, programming, and ADAS calibration, argues GYS.

damage the ECU, a costly mistake that can result in extensive rework, vehicle downtime, and in the worst case the need for a complete ECU replacement, which is an extremely costly process. Additionally, the majority of fleet vehicles are now equipped with ADAS, requiring precise sensor calibration, particularly after a collision, which can affect radar and camera positioning. During the repair process, maintaining stable voltage is critical. A voltage dip can interrupt the calibration process and lead to incorrect sensor alignment. This not only wastes technician time but also risks compromising the effectiveness of safetycritical systems like emergency braking or lane assist, increasing the risk of accidents, liability, and non-compliance.

An example

Designed specifically for modern diagnostics, the GYSFlash Pro range from GYS provides up to 100A of current at both 12V and 24V, maintaining consistent voltage

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even when the vehicle’s systems draw sudden electrical loads. With dedicated modes for charging, diagnostics, testing, and showroom use, they adapt to a wide range of workshop tasks.

Crucially, the GYSFlash Pro range also features connected (CNT) software, enabling full traceability of every charging and support session. This feature is particularly valuable in fleet and commercial settings, where recordkeeping, accountability, and service history tracking are essential for quality control and compliance.

A BIT OF LIGHT READING

Labcraft has launched the Orizon FLEX – a R10-approved flexible strip light. CVW finds out more.

Unlike many off-the-shelf LED strips, the Orizon FLEX has been purpose-designed for the automotive sector, addressing common failure points of traditional lighting solutions. It features built-in constant-current regulation, reverse polarity protection, and transient voltage suppression, which add up to ensure consistent performance across voltage ranges (12V and 24V systems), protect against electrical surges, and guarantee longevity under demanding operating conditions.

The strip delivers a powerful 500 lumens per metre from just 5W/m, with a cool white colour temperature of 7,000K–8,000K. The innovative circuit layout features a full control circuit every 250mm and ensures uniform light output along the full length of the strip, eliminating the dimming effect often seen in longer LED installations.

Built for adaptability and reliability, the all-new strip features a flexible, low-profile design (13x5mm) and is easy to mount on vehicle surfaces using high-strength 3M automotive adhesive tape. Its highly flexible structure allows it to contour around curves or fit within narrow recesses and cabinets – such as those on fire engines or mobile workshops.

Protected to the IP69K standard, the strip resists high-pressure jet washes, and is built to withstand harsh environments.

Suitable for internal or external applications, the Orizon FLEX is ideal for a wide range of vehicle types, including trailers and refrigerated trailers, emergency vehicles, box and luton vans, rigid trucks and specialist utility and service vehicles

Manufacturers can fully integrate the Orizon FLEX into a TruckLite plug-and-play harness system, offering a streamlined installation with auxiliary and mandatory lighting . The product has already been adopted by leading manufacturers, including specialists in refrigerated and emergency vehicles, where lighting performance and resilience are paramount. R10.06 EMC certification means it is cleared for use on vehicles across the UK and Europe.

Labcraft’s commitment to quality is further reinforced by its three-year manufacturer’s warranty, and all lights are designed and tested at the company’s ISO9001/14001-accredited production facility.

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FILTER THROUGH THE RANGE

AMann-Filter has become synonymous with quality and reliability. However, to some it is seen primarily as a car product and whilst car filtration is a huge part of the company’s portfolio, Mann+Hummel has been supplying all major commercial vehicle OEMs with large

vehicle use being heavy-duty (extreme temperatures, long operating hours and service invervals, plus being operated on busy motorways and roads surrounded by highly polluted ambient air), filters naturally work incredible hard. Using a trusted, quality filter is paramount to

themselves as a go-to choice for commercial vehicles.

protecting the high-cost of a commercial vehicle. Below are some examples and characteristics of the Mann-Filter CV range.

Filter ‘media’

Often referred to as filter ‘paper’, and the most expensive part of the filter (and where lower price and quality items reduce cost). With engine specific specification (no onespec-fits-all), and formulated to work with the latest technology oils, the media can be cellulose, mixed-fibre or fully synthetic, but always to OE specification. For air filters, the media is flame-retardant, avoiding engine fires from stray cigarettes or similar, thus is also a safety item.

Oil filters

With high temperatures and volume of oil, coupled with long operating times, a reliable oil filter is key. With features such as pressure-resistant and anti-corrosion coated spin-on filters with high-quality silicon non-

return valves, plus Teflon-coated bypass valves, filter integrity is a given.

Additional benefits like integrated filter removal devices on some cannisters aid the removal of high-torque filter housings, and the use of long-life sealing rings also prevent leakages. Oil filter inserts also have pressed and stamped support casings rather than wire mesh, aiding structural integrity.

Fuel filters

With ever-increasing regulations on emissions, CV engines are also pumping out more and more power from less and less fuel. With fuel injection systems thus growing finer and finer, water in the fuel is now a major concern with corrosion of these fine parts. With patented filter designs incorporating 3-stage filtration of both contaminant and water, and multilayer multigrade filter media, the fuel system is fully protected.

Cabin filters

With interior air quality now a hot topic since Covid, CV operators are not overlooked, especially as the vehicle is often

surrounded by increased airborne contaminant from motorway driving (tire and roadside debris particles, exhaust emissions/harmful gases, and of course pollen). With the 3-tier cabin filter range from MANN-FILTER, certain applications also benefit from the biofunctional FreciousPlus cabin filter with added antiallergen impregnation, preventing particulate matter, nitrogen oxide, allergens, moulds and bacteria from entering the cabin.

Additional OE Quality filters

With coolant filters, transmission oil filters, urea filters for the AdBlue emissions system, fuel pre-filters with the PreLine range, and also sometimes centrifugal oil filters used to pre-clean the oil and assist the main filter, the complete range is available –all in OE Quality.

A last word on brakes….and safety!

The air dryer filter or Air Dryer Cartridge as it is sometimes known (ADC) is critical to the filtering of the compressed air in the braking system and ultimately the safe and

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reliable braking function. Given the weight, power and load a commercial vehicle has to cope with, there can be no shortcut on braking safety.

As the world’s largest manufacturer of air dryer filters (over 100 million air dryer cartridges produced to date!) for both OEM’s and Aftermarket, the MANNFILTER range of ADC’s is the go-to for reliable filtration of the braking system. With a recently expanded range now with a 4-tier offering, every type of CV application is covered. The ADC range is identifiable from the colours of the cannister and is summarised as follows: -

White (basic) – long-distance operation with reduced braking requirements, i.e. haulage and some coaches

Black (standard) – longer service life than the basic version, faster drying and regeneration of the drying agent, also for reduced braking applications where better performance is required.

Silver (advanced) – improved protection over the black ADC with better protection against corrosion and icing and a longer service life, for higher braking requirements such as distribution transport/delivery, construction vehicles and some agriculture applications.

Gold (premium) – longest service interval (up to 3 years) with optimum performance in all categories, the best performer in the range. Intended for short distances where braking requirements are highest, i.e. refuse and street cleaning vehicles, heavier-duty transport.

The air dryer then is also a critical part of the servicing of commercial vehicles, and any cost-cutting by using a lower cost and quality item is potentially hazardous.

Mann-Filter for commercial vehicles is a go-to choice for genuine OE quality, without compromise, produced by one of the leading suppliers of original equipment filtration via Mann+Hummel, with the group producing 32 filters a second and with over 80 locations worldwide, expertise is guaranteed.

Mann-filter for cars? Yes, but also for all your commercial vehicle needs.

Each filter in modern commercial vehicles has a specific role in protecting its systems, and each are important. Hifi Filter takes CVW through its solutions that address the real-world needs of CV professionals

ALL FILTERED UP

The technical management of commercial and heavy-duty vehicles depends on a range of interconnected variables: parts quality, preventive maintenance, operating costs, and environmental compliance. In this context, filters play a discreet but essential role. Their impact goes far beyond trapping impurities. They influence engine longevity, vehicle performance, service intervals, and overall fleet availability.

To support these technical demands on a daily basis, Hifi Filter, a specialist in filtration for over 40 years, offers tailored solutions that address the real-world needs of professionals, whatever the system or operating environment.

A Filter for every need

A modern truck or commercial vehicle contains around ten filters, spread across engine, hydraulic, pneumatic, and emission control systems. Each has a specific role in protecting components, ensuring reliable operation, and meeting environmental standards.

Here are the main types of filters:

● Engine air filter: protects the engine by blocking harmful dust particles.

● Oil filter: removes metallic debris from mechanical wear, preserving internal components.

● Fuel filter: traps solid contaminants and water present in diesel or gasoline.

● Hydraulic filter: protects pumps, cylinders, and valves from fluid-borne contaminants.

● Cabin air filter: protects the driver by improving air quality in the cab and reducing exposure to fine dust, allergens, or harmful gases.

● Compressed air filter (desiccant): removes moisture and particles from pneumatic brake systems to prevent corrosion, freezing, or failures.

● AdBlue (DEF) filter: protects the SCR system from crystallized impurities, ensuring effective NOx emission reduction.

● Crankcase ventilation filter: retains oil and contaminants in blow-by gases, reducing overall emissions.

● Coolant filter: keeps the coolant clean and stabilizes fluid additives. These filters are critical to the smooth functioning of industrial vehicles. Their diversity reflects the growing technical complexity of systems, where contaminant control has become integral to system design.

Filtration protection

Filter quality has a direct impact on vehicle reliability and component lifespan. A poorly designed, unsuitable, or damaged filter may become partially or completely ineffective, allowing contaminants to circulate within critical systems.

This can result in:

● Premature wear of internal components.

● Decreased vehicle

performance (loss of power, increased fuel consumption, pressure drops).

● Recurring failures due to chronic fluid contamination.

● Deterioration of cabin air quality and/or poor exhaust gas management, increasing exposure of operators and the surrounding environment to pollutants (fine particles, NOx, irritant gases). When such issues become recurrent, they directly affect operations: unscheduled downtime, logistical delays, urgent maintenance needs, and increased service costs.

In this context, it is essential to use filters designed to deliver consistent protection under real operating conditions. They must withstand mechanical and thermal stress, while maintaining filtration efficiency throughout their service life.

Hifi Filter is said to meet these needs with a catalog of over 70,000 references, compatible with the majority of commercial vehicles and heavy-duty brands.

Manufactured to high standards, our filters offer performance equivalent to OEM parts and are backed by the legal warranty plus the Hifi Filter quality commitment.

Best practices

Following the maintenance intervals recommended by vehicle manufacturers is the first step to ensuring system reliability. These guidelines are based on each circuit’s specifications — such as tolerance thresholds and retention capacity — and assume normal operating conditions.

However, field conditions vary. Vehicles used on dusty worksites, in stop-start cycles, or exposed to temperature extremes may require more frequent filter changes. Maintenance decisions should be based on tangible indicators: clogging sensors, pressure differential readings, or visual inspections.

Adapting service intervals to actual usage, while respecting safety margins set by manufacturers, helps optimise performance and reduce the risk of unexpected failures.

Efficiency in service of maintenance

Hifi Filter's mission is to support professionals in their daily filtration needs, with solutions that are reliable, accessible, and tailored to real-world applications.

With more than 70,000 references for all types of vehicles and equipment, we offer a centralized range that helps reduce the number of suppliers, streamline sourcing, and simplify stock management.

It’s strength lies in being a single partner for all your filtration needs, 30,000 stocked references, available for rapid global delivery, practical tools like its e-catalogue and custom application tracking to help you quickly identify the right filters and anticipate replenishment and its team of technical experts, available to support your challenges and provide informed guidance

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POWERING ON AHEAD

UFI Filters explains why the use of hydrogen to power fuel cells is thought to be one of the best ways of drastically reducing air pollution when it comes to heavy vehicles, large tonnages and long distances.

Hydrogen has proved to be a valuable solution for the decarbonisation of transport, with this source of power attracting a great deal of attention both in the PNRR (Italy’s National Plan for Recovery and Resilience) and in the REPowerEU European energy plan.

UFI Filters began analysing the possible future scenarios related to the various different forms of power back in 2017. As part of this, the company started to look into the new challenges connected to the use of hydrogen in fuel cells and the issues relating to filtration. Studies focused particularly on the air filter fuel cell cathode, an element that plays a strategic and fundamental role in purifying the air fed into the system. This filtered air operates as a combustive agent within the cell, with the oxygen present reacting with hydrogen through an electrochemical process that is capable of producing electricity.

The context

Filtering the air has never been so important. Before arriving at the compressor and then being delivered to

the cell, the air fed into the system must be efficiently filtered, not only to remove particulate matter, but also to get rid of harmful gases such as SOx, NOx, H S, CO, O3 and NH3, along with VOCs (Volatile Organic Compounds), such as benzene and toluene. These gases, which are harmful to the fuel cell, are generally anthropogenic compounds that are derived from human activities (products of traditional combustion and those derived from oil); the air concentration of these varies in accordance with the geographical context.

Air filtration in fuel cells plays an even more important role than it does in traditional endothermic engines with regard to engine air filtration. Why? A number of studies conducted over the years have demonstrated that even extremely low quantities of gaseous particles (we are not just talking about PPM – parts per million, but even PPB – parts per billion) can dramatically reduce the performance and life of a cell. This is due to several

factors, including the contamination of the catalyst, which is decisive – this is what triggers the reaction necessary to convert

hydrogen and oxygen into electrical energy and water.

The catalyst, a fundamental component of the fuel cell, effectively consists of costly platinum (or other precious metals). The presence of impurities can compromise its performance and functionality with irreversible effects and can lead to progressive deterioration over time that affects the life of the cell. In the

air circuit, the compressor is also a key element; this part is very sensitive to solid air contaminants, which can compromise its performance.

The cells use ambient air that supplies the oxygen necessary to trigger the electrochemical reaction with the hydrogen. But air, as we know, is not the same everywhere, and its characteristics depend on a host of factors such as

temperature, altitude, local pollution, etc. As such, the quality of this air, and where it will be used in the vehicle, must therefore be taken into account when developing a cathode air filter, because an effective solution in one region will not necessarily work in another.

The UFI Filters solution

Super Adsorber is the brand that identifies cathode air filtration systems developed by UFI Filters. The company’s cathode air filter, designed for OE applications with fuel cells, has a dual function (solid particulate filtration and absorption of gaseous contaminants) and features a double layer, with the two layers contained within a single box; the shape and positioning of which inside the vehicle varies in accordance with the requirements of the OEM.

This configuration enables each layer of the air cathode filter to be specialised or customised in accordance with a given vehicle, the region in which it will be used, and/or the distance to be travelled and the expected useful life of the filter, thus guaranteeing optimal performance.

The first layer works as a physical barrier; i.e., it separates solid particles, and is similar in structure to that used in engine air filtration systems for internal

combustion vehicles. It is made using synthetic media that is distinguished by the fact that it has a different matrix and thickness compared to traditional filters, providing different accumulation characteristics and low system load losses. It works to capture all types of dust, including extremely fine particles, as well as salt particles.

Indeed, salt, which is used in winter to defrost roads and is present in coastal areas, is harmful to the fuel cell. The positioning of the first layer – upstream of the second layer – is strategic, as it serves to protect the activated carbon present in the second layer, which is very sensitive to the presence of particulates that limit its capacity to absorb gases.

The second layer, meanwhile, serves a chemical function; removing gaseous contaminants by adsorption. It is made from filtering media with a non-woven matrix (non-woven fabric), which blends various types of active carbon. Thanks to the experience of UFI Filters in the production of filter materials, the activated carbons used for this specific application are not those employed traditionally; rather, these have been modified via specific heat treatments and chemical reactions with inorganic salts.

In this way, in addition to having different physical hole sizes (as a result of the surface treatment), the activated carbons acquire the ability to absorb the gases, coupling with these via chemical bonds of various kinds. Accordingly, UFI Filters can offer the customer a diverse range of options for the same filter for a given application; in this instance, the different activated carbon mixes are the element that varies, enabling the different regions where the vehicle will be sold to be taken into account.

The thing that sets UFI Filters apart in terms of the innovative cathode air filter solutions it offers is the company’s consolidated expertise in filtering media, which is researched and produced in-house.

This knowledge lies both in the materials used for the filtering media and in the application of different geometries, as well as in the way the filters themselves are machined in order to improve the performance of the product. Pleating is an example of this: the performance offered by a pleated filter is closely linked to how the pleats themselves are created. At UFI Filters, a highly specialised department is dedicated to researching and finding the optimal parameters, which are then

passed on to the various global plants of the company, to ensure that the same high levels of performance are achieved across the board.

For some applications, in addition to the two layers, UFI Filters also offers preseparation elements for the preliminary treatment of air. In very dusty regions, for example, this can contain large quantities of solid particulate matter, which must be removed before it reaches the cathode air filter.

First series applications

UFI has taken another important step forward in the provision of technologies for fuel cell applications. The UFI super adsorber cathode air filter has already been chosen for China's first, series-produced hydrogen fuel cell car in 2023, the Changan Deep Blue SL03.

Furthermore, a number of functional UFI Filters prototypes, intended for global OEM applications in trucks, buses, light commercial vehicles and passenger cars, are already being tested in various regions of the world, with the materials for these close to being finalised.

OPENING NEW DOORS

CVW takes a look at a couple new products from Power-TEC: a mobile door remover/installer and a glue-pulling kit.

Power‑TEC has recently added a new mobile door remover/installer suitable for larger SUV and van doors (part number 91879). This mobile trolley is designed to streamline the removal and installation of heavy vehicle doors. By enabling a single technician to handle doors safely and precisely, these new trolleys eliminate the traditional two‑person lift, reduce workshop downtime and safeguard expensive paint finishes.

Maxi door remover/installer

A heavy‑duty, fully mobile trolley engineered for van and car doors up to 60 kg, the Maxi model offers maximum reach and precision:

● Max lifting capacity: 60 kg

● Door height range: 700 – 2600 mm

● Lift height: 200 – 900 mm

● Stable base and high lift: Ideal for both cars and light commercials

● Precision adjustment: Fine‑tune door panel alignment for pillar fixing

● Rubber supports: Protect fresh paintwork from scratches

● Mobility: Smooth castor wheels for effortless positioning

By cradling the door on soft‑rubber pads and allowing micro‑adjustments at height, the Maxi trolley empowers one technician to remove or refit even the heaviest of doors in seconds, cutting labour costs and workshop congestion.

Adhesion pro GP system

Introducing Power-TEC’s Adhesion Pro GP (part number 92748) — a comprehensive,

high-quality kit that brings together the very latest in hot and cold glue-pulling technology. Designed with the busy bodyshop technician and mobile PDR professional in mind, this 187-piece kit is neatly housed in a robust, compact 4drawer cart — complete with precision-cut foam inlays to keep everything secure, protected, and ready for action.

For those demanding even more pulling performance, this new package is also available paired with Power-TEC’s renowned Pulling Tower — capable of delivering up to 550kg of traction force, anchored anywhere in the workshop using a clever vulcanised rubber pad and compressed air suction system. No bolts, no drilling — just pure pulling power. The Adhesion Pro GP System with Pulling Tower is available as part number 92739.

Key Features:

● 187-piece PDR hot and cold glue dent pulling kit – Everything you need in one heavy-duty lockable cart.

● Cart dimensions: 700 x 290 x 710mm | Maximum load capacity: 80kg.

● Organised 4-drawer layout with foam inlays – Keeps tools safe and easy to find.

● Top shelf tools include: Cold-glue PDR kit, mini scraper chisel, T-Bar puller, razor blades, telescopic body hammer.

● Middle shelf: Dent puller kits with multiple pad options.

● Drawer 1: Digital infrared thermometer and butane hot air blow gun.

● Drawer 2: Blue multipads and assorted puller pads.

● Drawer 3: Solvent spray, glue sticks.

● Drawer 4: Use for sundries & consumables.

● Lower storage: PDR reflector board, 18V cordless glue gun (100W).

● Side storage: Bridge puller (460mm).

TRAINING, TOOLS & ABRASIVES

In the fast paced and constantly evolving CV sector, there are three things that technicians in the workshop require to conduct the work: training, tools and abrasives. Training is important as it provides users with knowledge and skills. For the abrasives and tools, it is paramount that they are versatile, as no job or surface is the same, and that they last a long time as any downtime to change tools or abrasives leads to an increase in key-to–key times, which is detrimental to businesses.

When working on commercial vehicles, technicians often face the challenge of

prepping large surface areas, which means tools are in use for extended periods. This prolonged use can lead to fatigue and discomfort. To address this, our technical team has taken the insights of the tool usage in the sector back to the R&D team, and what has happened is that the R&D team has prioritised user comfort in the tool design process. This has led to Mirka’s portfolio of products being filled with a wide-ranging selection of lightweight, ergonomically designed tools that are perfectly balanced and easy to handle. These features significantly reduce strain on joints and

Steve Smith, national sales manager collision repair, Mirka UK, emphasises the importance of good quality tools and abrasives to help reduce downtime.

muscles, helping operators stay comfortable and productive throughout the day. We have not just stopped at ergonomics; the R&D team has also focused on reducing tool vibration levels. By tackling vibration exposure head-on, Mirka is not only improving day-to-day user experience but also safeguarding operators from the hidden health risks that can build up over time from HAVS. Alongside this, we also stand by the build quality of tools through an extended warranty that means any issues with the tools can easily and quickly be fixed, so there is minimal downtime.

On to abrasives

Moving on from the tools to abrasives, there was time when cheap abrasives were bought to save money. However, what we are now seeing is a shift from cheaper to premium abrasives, which takes businesses away from the slippery slope that is ‘buy cheap buy twice’. While cheaper options

may initially save money, this short-term saving is quickly wiped out when the user has to purchase the same product again very quickly down the line. In comparison, premium products are built to last and will provide the same end product or service, whether it is being used for the first time or the hundredth time.

The CV sector is constantly evolving and this is leading to a concerted push to upskill the workforce and add new strings to their bow. At Mirka, we see our training as a full circle offering for the customer because once a comprehensive evaluation has been carried out, an action plan is agreed and implemented, and all training is documented and followed up with regular review meetings to monitor progress.

You may think why does Mirka need to go through all these different phases? And the answer is simple. It enables our experienced technical team to customise the programmes we undertake with customers based on their needs and requirements. This, in turn, ensures the business can reap the benefits of the training in the short, medium and long term.

All trained up

With training, it is also important to think about the future of the industry which is why our ATA accredited technical team also trains apprentices. This is carried out to

ensure the new kids on the block have access to knowledge and skills that will aid in their growth and development in the industry. Alongside this, we also conduct something we like to call ‘Train the Trainer’. This programme has been designed so that Mirka’s technical team trains a member of a bodyshop so that they can then train new starters on specific Mirka tools and processes and also carry out refreshers for any staff that need it.

Dust extraction

We know that the CV sector works on large areas and large amounts of dust are generated during the sanding process. Laboratory tests reveal that without proper dust extraction, airborne dust levels can exceed 200 grams per kilogram of sanded material, while dust settling on surrounding surfaces can reach nearly 800 grams per kilogram. To combat the dust, businesses are considering extraction systems to combat the dust particles and investing in systems to allow them to work in a dust-free way. The investment in a suitable mobile extraction

system is not a short-term injection of the business’ cash, it should be viewed as a longterm commitment, so that it can provide an effective solution for a cleaner workspace.

This means that businesses, no matter their size, have a dust-free environment and control of the sanding process and allows for multiple work phases to be undertaken in the same room, delivering efficiency both for the business and in terms of tool usage. In addition, it takes away issues that drive up costs that need to be passed on to customers, such as valeting costs and reworks, while reducing key–to–key times, so vehicles are back on the road more quickly and more jobs can come through the workshop. These savings ensure the customer is happy and means the shop has the financial ability to invest those savings back into the business, whether that is in the form of training, tools or both.

Overall, in the commercial vehicle sector, quality tooling and abrasives are more than consumables, they are productivity partners. With a focus on ergonomic design, low vibration levels, exceptional durability, and ongoing support, Mirka is helping CV businesses raise the bar on quality, safety, and performance. Because when the job demands the best, it pays to invest in products and services that do exactly what is required.

LIFTING EQUIPMENT GYS

GYS has recently expanded its wide range of lifting equipment for commercial vehicles with the Multitool Truck. The Multitool Truck is only 1.3m deep and 1.8m tall, yet boasts a rated maximum working load of 200kg (440lbs) – more than enough grunt for any lifting needs in the workshop environment. Not only is it mighty and ergonomic, but easily manoeuvrable too. On four wheels and with an adjustable main arm and legs for reliable stability, GYS’ latest solution makes getting to those hard-to-reach areas much easier. Included with your Multitool Truck are several handy accessories to add further functionality and remove the need for having multiple tools for the job, some of which include:

● A lifting hook for: brake discs and callipers, hubs and batteries.

● A lifting fork for: wheels and tyres.

A self-braking, manually cranked winch system provides the crucial safety to ensure ease of use and ultimate control when lifting and moving heavy loads. Up to 200kg can simply be lifted between 1 – 80cm from the ground, and at up to a 90-degree vertical angle, giving you a full range of adjustability for any heavy-duty situation. The Multitool Truck strictly conforms to all relevant build and safety standards, guaranteeing compatibility across all areas of the HGV world.

WANT TO FIND OUT MORE?

WWW.RDR.LINK/VBX031 GOTO

ENGINE AIR FILTER UFI FILTERS

UFI has announced the Aftermarket availability of UFICoreT, the range of high-tech engine air filters for truck, earthmoving and agricultural applications. The new UFICoreTM Aftermarket range, which is expected to be steadily expanded, currently includes 11 part numbers in the catalogue, covering around 500 applications. It aims to provide an excellent solution as a replacement for existing systems, offering the same protection as OE filters against harmful contaminants. Tested according to the ISO 5011 standard, UFICoreTM filters achieve up to 99.99 per cent filtration efficiency due to their unique design and high-quality filter media. The design features of UFICoreTM deliver a higher filtered air treatment capacity with a lower pressure drop. The filtration media’s structure consists of a system of both closed and open channels, incorporating a wavy groove design that directs the air flow into the side of the filter housing, which, being closed at the end, diverts air to the adjacent channel. In this way, clean air reaches the engine intake system while minimising velocity and pressure losses. This specific technology makes it possible to reduce the size of the filter by up to 40 per cent compared to traditional solutions based on pleated filter media, thus limiting its weight and facilitating its installation.

WANT TO KNOW MORE?

WWW.RDR.LINK/VBX032 GOTO

STAINLESS STEEL SECURITY BEZAL VAN GUARD

In response to the continued rise in van and tool thefts across the UK Van Guard Accessories, has announced the launch of a brand-new security bezel designed specifically for the Ford Transit Custom 2023 on. Manufactured from high-grade stainless steel and incorporating a built-in anti-drill plate, the new bezel is engineered to replace the original plastic bezel and fit securely over the original manufacturer's door lock, providing an additional layer of protection The bezel is the latest addition to a comprehensive range of vehicle security products produced at the company’s Devon facility.

WANT TO KNOW MORE?

WWW.RDR.LINK/VBX033 GOTO

NEW TYRE SIZE BANDVULC

Bandvulc, the UK’s leading manufacturer of retread tyres for commercial vehicles, is pleased to unveil a new size for its fifth-generation Wastemaster tyre. Initially launched in 2021, the product is now available in 315/70 dimensions with a high load rating – catering specifically to operators using vehicles operating in urban waste collection and recycling centre environments. It was developed, tested, and produced at ContiLifeCycle’s Ivybridge factory in Devon, which produces Bandvulc and ContiRe hot retread tyres. The Wastemaster 5 integrates Bandvulc’s sidewall technology, providing an extra protective layer of rubber compound along the mid to lower sidewall. This tapered band helps guard against sidewall scrubbing, reduces damage, and helps extend the tyre’s service life. In addition, the tread design on the Wastemaster 5 includes wide zigzag grooves to effectively clear mud and water, stone ejection features, stepped tread blocks, and deep pocket sipes for optimal traction and grip in adverse conditions.

WANT TO KNOW MORE? WWW.RDR.LINK/VBX034

TOOL PROMOTION SEALEY

The latest Tool Promotion from Sealey features more than 200 new products and over 1,400 incredible deals. You will find a selection of new lighting from Sealey on page 146, including the LED100PTR Telescopic Flexi Rechargeable Magnetic Pick-Up Tool Light and the LED142 Rechargeable Flexible Under-Bonnet Light. Furthermore, the new VSWB30 Walnut Blaster features a largecapacity drum and built-in filter to safely clean carbon deposits. The natural polishing properties of walnut media provide thorough cleaning of intake ports and valves without causing damage, while also avoiding the corrosion associated with chemical cleaners.

WIN!

One lucky winner will receive a heavyduty 160 bar pressure washer with a powerful 2200W motor, designed for extensive domestic and light commercial use. The prize package, valued at over £700 (list price), contains a comprehensive kit of cleaning equipment, including a mechanic’s detailing utility seat, a snow foam sprayer with snow foam, and TFR detergent. Enter online today for an opportunity to take home the ultimate detailing bundle.

WHAT'S NEW?

WORKSHOP TOOL TROLLEY LASER TOOLS

This 4-Drawer Workshop Tool Trolley is purpose-built for technicians who need reliable, mobile storage to streamline workflow around the service bay. Designed to bring tools, parts, and equipment right to the job, the trolley features a lockable top tray and four smooth-sliding drawers for secure, organised tool storage. Underneath, an open lower tray offers ample room for bulkier items, while a side-mounted horizontal slotted storage section keeps frequently used screwdrivers, etc, within easy reach. With a maximum load capacity of 300kg, the trolley is constructed from tough 0.8–2.0mm gauge steel and finished in a durable Laser-blue powder coating. The drawers are lined with EVA foam for tool protection and noise reduction, and the lid is supported by gas struts for smooth opening and closing. Heavy-duty 5 inch castor wheels (two fixed, two swivel with brakes) ensure the trolley stays put when needed and moves easily when it’s time to shift.

Key Features:

● Overall dimensions: 865(w) x 447(d) x 962(h)mm.

Max load: 300kg.

● 2x top drawers: 315 x 370 x 75mm

● 1x middle drawer: 655 x 370 x 70mm

● 1x bottom drawer: 655 x 370 x 100mm (drawer load capacity: 35kg each).

● Top tray: 767 x 410 x 100mm

● Bottom tray: 767 x 410 x 75mm

● Features: Powder-coated finish, EVA drawer liners, side storage slots, air-sprung lid, 5” castor wheels (2 fixed, 2 swivel with brake).

● Trolley weight: 44kg.

WANT TO FIND OUT MORE?

WWW.RDR.LINK/VBX036 GOTO

DIAGNOSTICS PLATFORM ZF AFTERMARKET

This new diagnostics platform combines the power of two advanced tools – ZF MultiScan and ZF Scan – claiming to allow technicians to accurately read and repair over 35,000 different systems across a wide range of vehicle brands, including trucks, trailers and buses. ZF [pro]Diagnostics contains features like secure gateway access to protected vehicle systems, remote diagnostics, and flexible subscription options.

The platform ensures compatibility with all major diagnostic protocols, such as Diagnostics over Internet Protocol (DoIP) and CAN FD, to facilitate fast, stable and secure data transfer. ZF MultiScan offers multi-brand diagnostics, supporting tens of thousands of vehicle models across various categories, including light commercial vehicles, trucks, trailers and buses.

ZF Scan also features a quick Vehicle Health Scan to capture ECU and DTC data efficiently and positions workshops to meet new secure vehicle access regulations seamlessly.

WANT TO KNOW MORE?

WWW.RDR.LINK/VBX037 GOTO

PLIERS KNIPEX

Knipex has added a new version to its TwinGrip® lineup. Designed for gripping, loosening or tightening screws with worn heads or threads, especially in tight spaces, the compact 150 mm model is now available with Comfort Grip handles.

The TwinGrip 82 02 150 packs a lot into a small tool, combining front and side gripping action with a tough box joint, quick push-button adjustment and a slimline head that’s built for tight spaces, and it’s now available with the brand’s new three-component comfort grip handles. It also has a large front and side gripping capacity for diameters and width across flats 3 to 16 mm and reliable, frontal gripping of flat workpieces up to 6 mm thanks to the three-point system. The pinch-stop protects fingers and, at just 278 g and 150mm long, these small, slim pliers let you work quickly and easily even in confined installation spaces.

WANT TO FIND OUT MORE?

WWW.RDR.LINK/VBX038 GOTO

CYLINDER HEADS

IMEXPART

Imexpart has issued a comprehensive array of IMEX-branded cylinder heads in its latest new-to range release, with popular van, pick-up and car engines from Ford, Volkswagen, Peugeot, Iveco , Nissan and Renault catered for.

The new-to-range expansion includes 21 cylinder heads, which covers a large number of vehicles including the Ford Transit, Iveco Daily, Mercedes-Benz Sprinter and many more. Part number FOR277687 caters for the Ford Ecoblue 2.0 engine from 2015 onwards, while FOR1740189 is for the Ford Ranger’s TDCI engine used between 2011 and 2015. Also covering Ford vehicles is FOR7166C032BA, used for the Ford Durtorq Transit 2.4 TDCI, as well as the Land Rover Defender 2.4 TD from 2007 to 2016.

Moving over to Iveco, part number 005504384837 is intended for the Daily 3.0 JTD, with 005504378075 catering for the Iveco Daily 2.3 from 2002 to 2014. For the Iveco Daily from 2016 onwards, the range offers up part number 0055802114243, while the Daily 2.3 from 2014 onwards gets part number 0055802227765.Looking towards Mercedes-Benz, part number 006151 010 32 20 is compatible with both the C-Class from 2008 to 2014 and the Sprinter van from 2006 to 2016.

WANT TO KNOW MORE?

WWW.RDR.LINK/VBX039 GOTO

WINDSCREEN WASHER PIPE REPAIR KIT

CONNECT WORKSHOP CONSUMABLES

Broken washer pipes and clogged valves are a common headache for technicians and DIY enthusiasts alike. Connect Workshop Consumables solves the problem with its Windscreen Washer Pipe Repair Kit (part number 36757) — a single, workshop ready box containing everything you need to repair windscreen, headlamp, and rear window washer pipes in minutes.

By replacing degraded hoses and stuck one ‑ way valves, you’ll eliminate leaks, blockages, and airlocks. The kit’s clear PVC tubing lets you visually confirm fluid flow (or spot new blockages) during installation and future diagnostics—saving both time and repeat visits.

What’s Inside the Kit?

•5× 3/16 (4.7 mm) 90° elbow joints.

•5× Straight connectors.

•5× T Piece splitters.

•2× One‑way check valves.

•4 m of clear PVC hose (4.8 mm ID).

•Mini hose cutter for clean, square cuts every time.

WANT TO KNOW MORE?

WWW.RDR.LINK/VBX040 GOTO

3 1 4

SUMMER’S TOPFIVE

business tips, it’s a great source of information right at your fingertips. If you’re not already convinced, this month, CVW takes a look back at the most popular articles on the website from the past month.

1 INDUSTRY BENCHMARK SET

Designed to raise standards and drive confidence across the unregulated commercial vehicle maintenance sector, government and industry has launched the Maintenance Provision Rating Scheme (MPRS). Logstics UK explains more in this top article.

WWW.RDR.LINK/ VBM041

2 BE PREPARED

Next up, CVW was recently given an exclusive guided tour of TIP Group’s Trailer Refurbishment Centre in Stoke-on-Trent. Inside, read all about the process, the environmental benefits and the cost benefits.

WWW.RDR.LINK/ VBM042

3

EMERGING ADAS TRENDS

In this next popular online article, Repairify’s director Martin Brown looks at some commercial vehicle ADAS trends, including the move from passive systems to active and the use of AI and driver facing cameras.

WWW.RDR.LINK/ VBM045 2

WWW.RDR.LINK/ VBM043

5

4 STAYING COMPLIANT

Want to find out how MAHA UK, Manchetts and Premier Pits collaborated on new ATF lane for Manchetts Group’s Sleaford depot –featuring a rising roller brake tester? Then look no further than this next popular online article.

WWW.RDR.LINK/ VBM044

5 BISH BASH BOSCH

Rounding off this month’s list of popular online article is Bosch sharing everything you need to know about the ESI [tronic] workshop software with Knorr-Bremse Diagnostics Add-On.

Here is a useful summary of all the adverts that appear in this issue of Commercial Vehicle Workshop. Each is listed with its page number and a direct URL that will get you straight to the relevant online information.

Automotive Equipment Services ..............................(page 16)

www.rdr.link/VBX100

Banner Batteries (page 39) www.rdr.link/VBX101

Ben (page 52)

www.rdr.link/VBX102

Contitech Power Transmission Group (page 17) www.rdr.link/VBX103

Esprit (page 25) www.rdr.link/VBX104

Febi (page 4) www.rdr.link/VBX105

Febi ..........................................................................(page 9) www.rdr.link/VBX106

Gates ......................................................................(page 11) www.rdr.link/VBX107

ISN Europe Ltd (page 44) www.rdr.link/VBX108

Liftmaster Ltd (page 6)

www.rdr.link/VBX109

Machine Mart (page 29) www.rdr.link/VBX110

MAHA UK (page 13)

www.rdr.link/VBX111

Mann+Hummel (UK) Ltd ..........................................(page 20) www.rdr.link/VBX112

Mechanex

(page 55) www.rdr.link/VBX113

Merridale Ltd (page 48) www.rdr.link/VBX114

Mirka (UK) Ltd (page 48) www.rdr.link/VBX115

Osram (page 37) www.rdr.link/VBX116

Premier Pits (page 37) www.rdr.link/VBX117

Road Transport Expo ..............................................(page 32) www.rdr.link/VBX118

Stertil UK Ltd ............................................................(page 2) www.rdr.link/VBX119

Totalkare (page 25) www.rdr.link/VBX120

Totalkare (page 60 outside back cover) www.rdr.link/VBX121

UFI Filters (page 42) www.rdr.link/VBX122

Varta Batteries (page 35) www.rdr.link/VBX123

KEEP UPT O D AT E WIT H CVW