CONVERSIONS MADE EASY:

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1 Issue 1/2016 HELLA technology in the truck garage HIGHLIGHTS BEFORE TRAILER WITH NEW LED GLOW THANKS TO EASYCONN Conversion to modern LED technology also offers many advantages in the field of commercial vehicles. (Page 02) NEW ARRIVAL FOR LED LIGHT BARS The LED Light Bar 470 offers the same advantages as the 350 version, but has 16 instead of 12 high performance LEDs. (Page 05) AFTER CONVERSIONS MADE EASY: TRAILER WITH NEW LED GLOW THANKS TO EASYCONN Conversion to modern LED technology also offers many advantages in the field of commercial vehicles. These include an improved light pattern and therefore better vehicle recognition compared to standard halogen lamps. IAA NKW 2016 Under the heading Driven by ideas, the IAA-NKW will take place in Hanover from September 22-29, 2016 and HELLA will be there as well, presenting numerous innovations. (Page 06) In the medium term, savings can be achieved through lower operating, maintenance and repair costs. Thanks to the flexible HELLA EasyConn wiring and lighting system, especially trailer lighting can be converted quickly, in a few steps and therefore at a relatively low cost. Fleet operators also benefit from the LED advantages for the larger the vehicle pool, the higher the running costs through required maintenance. Costs which can in part be significantly reduced by replacing old halogen lights with new, highly efficient LED lamps. The lower downtimes and therefore the higher availability of the converted m

2 1 2 3 HELLA TECHNOLOGY Continued from page 01: EDITORIAL trailers additionally allow more efficient fleet management. Our illustrated instructions show how the conversion can be carried out in a few steps: Driven by ideas. This is the motto for this year's IAA-NKW in Hanover, where Hella will be exhibiting again. A principle which we can fully support for HELLA uses new, innovative developments to provide important stimuli for supplying the market with fresh ideas. This makes us one of the drivers in the field of commercial vehicles, ensuring the technological progress which is crucial on the path to industry 4.0. One of these innovations is the Ultra Beam LED Gen II, which is a classic example of a powerful, reliable and energy-efficient work light featuring 4,000 lumen measured light output and a multifacet reflector. Or the robust Light bar auxiliary headlamp range, which is perfect for mounting on truck cabs with its especially flat design. But changing to LED technology also benefits the drivers. It allows trailers to be seen more easily by other road users, improving safety. In addition, the LED lighting provides optimised illumination in the loading and manoeuvring area and therefore increased working comfort. But how can this conversion be carried out on EasyConn trailers? And which lamps can be replaced with the corresponding LED variants? As an example for you, we have equipped an EasyConn trailer with existing halogen lighting with new HELLA LED lamps. An old rear light (1) can be replaced with a modern hybrid rear light (2) with little effort. Drill the required holes using a drilling template (3) and renew the painting on the lamp carrier plate if necessary (4). Then attach the clearance light (5), followed by the rear light (6). Tighten the screws with a torque spanner (7). Then mount the licence plate light (8) and the reversing light (9). All that remains now is preparing and connecting the cables (10). And the trailer is ready with a new glow. The two figures on page 01 impressively illustrate the improved light pattern through the use of LED lighting The new edition of our Truck Journal reports on these two highlight products, among others. In addition to this, you will also find informative magazine articles from the world of commercial vehicles, to provide you with some entertaining reading. We hope you enjoy reading it. Your HELLA team LED LIGHT FAILURE MONITOR Due to the low energy consumption (watt) of LED lights, which are distinctly different from a bulb version, operation on different traction vehicles may require adaptation of the periphery for the bulb failure monitor. As checking of the direction indicator is required by law, we recommend operating these lamps only in conjunction with the HELLA indicator control unit, Part No. 5DS

3 BEHR HELLA SERVICE EXPANDS ITS RANGE WATER PUMPS FOR COMMERCIAL VEHICLES Water pumps are among the most important components of water-cooled combustion engines in commercial vehicles, as they play a crucial part in efficiently preventing overheating of the engine, therefore avoiding extended vehicle downtimes. Although there are different types of water pumps, the function is always the same: the heat generated by the engine has to be dissipated into the ambient air through the coolant. In the cooling circuit, the water pump ensures in close cooperation with a thermostat that the coolant stays in motion to create the circulation required for the heat exchange. This ensures that the optimum operating temperature of the engine is reached quickly and maintained reliably. The pump is usually driven mechanically with V-belts, V-ribbed belts or toothed belts via a pulley, so it is normally always in operation. Finally, a little extra advice: always ensure to use the correct coolant approved for your vehicle. For a low-quality coolant, in the worst case even just water, can easily lead to corrosion, which even the best water pump cannot counteract resulting in annoying defects. Regular checks of the entire cooling system will help to prevent this. Actually, good water pumps are mostly maintenance-free and designed to last for the service life of the engine. Due to the high permanent load, however, defects can still occur, especially for components with a high mechanical load, such as bearings and pulleys, but also through porous seals and the ensuing coolant losses. It is even more important, then, to choose good quality water pumps and the high-quality components from Behr Hella Service. The thermal management experts have comprehensively expanded their range of water pumps and water pump kits. Around 100 commercial vehicle water pumps are now available for all common vehicle makes in tried-and-tested Behr Hella Service quality. More information about the Behr Hella Service range can be found at and in the catalogue Thermal Management Commercial Vehicles/Transporters. MAXIMUM ATTENTION THROUGH FLASHING WARNING SIGNAL ROTA LED AND KL 7000 LED Beacons are not only required during rescue operations, but also whenever a special warning is required to alert people to hazardous situations. This also applies to the field of commercial vehicles. The HELLA beacons Rota LED and KL 7000 LED with flashing signal are the first choice for this. Whether hazardous goods transports, manoeuvring with heavy trucks or extra-wide or extra-long special transports: trucks and trailers also regularly need beacons when it comes to efficiently warning other road users against possible hazards. ROTA LED The main aspect of this is to attract maximum attention, as this is the only way to identify hazardous situations in time and to reliably avoid them. Beacons therefore make a substantial contribution to road safety and accident prevention. But not all beacons are the same. The market offers models with different lighting technologies such as halogen, xenon or LED, rotating or flashing signals and with different brightness levels. The combination of a flashing signal, which offers optimum warning efficiency, particularly in darkness, and the durable, energy-efficient LED technology with high light output is ideal for the commercial vehicle sector. The Rota LED and KL 7000 LED from HELLA have both properties. The Rota LED features high efficiency with low power consumption, a flat, compact design and a rotating or flashing LED light function without moving parts. Because of the shock-absorbing rubber foot, it boasts a high resilience against vibration and is therefore particularly suited for challenging applications. The flat, compact design and the impact-resistant polycarbonate dome offer efficient impact protection. Three different attachment variants guarantee a solution for every application. The KL 7000 LED is a flat beacon which is available with a rotating or flashing light function and features a particularly well thought-out thermal management. The heat from the LED is dissipated through heat-conducting materials and the special arrangement of the components which increases their service life. An innovative electronics concept makes a lighting function without moving parts possible. The impact and dirtresistant dome ensures an optimum warning effect at all times, even under tough conditions. KL 7000 LED 03

4 AN UNDERESTIMATED DANGER? ACCIDENTS CAUSED BY TRUCK TYRES IN POOR CONDITION They turn for thousands of miles every year, have to resist potholes and poor road conditions as well as climate fluctuations and external influences such as salt, grit and sand. In addition to this, they are often subject to great strain from heavy loads. We are talking about truck tyres, one of the most important yet most underestimated vehicle parts in the commercial vehicle sector. Unfortunately, news about truck accidents on highways are rather frequent. Most of the time, these are not too serious and at most result in miles of backed up traffic due to the recovery operation. But sometimes, the damage is not limited to high costs for the vehicles involved, but injuries occur, often serious or even fatal. The search for the cause of the accident then often comes to the conclusion burst truck tyre. Damaged truck tyres, even if they do not cause an accident directly, are also the cause of loose tyre parts, such as peeled-off casings, which are often found in the middle of a highway, where they can cause accidents, for example when a car cannot swerve to avoid them and runs over them at high speed. The reasons for these types of tyre damage are manifold: low tyre pressure, for example, can quickly result in damage. The tyres heat up and can wear prematurely because the rubber becomes cracked and brittle. As little as 0.4 bar less tyre pressure reduces the service life by around 30 %; at 0.6 bar this number already goes up to 45 %. tyre age, even if the profile is still sufficiently deep. Reduced wet grip properties in particular are a risk that should not be underestimated. Another reason for this is advanced material ageing in combination with environmental factors such as heat, humidity, UV radiation, etc., which can result in the rubber compound becoming brittle, hard and cracked. The original positive tyre properties then cease to exist. According to current recommendations, tyres should be replaced after six years at the latest, regardless of the remaining profile depth, which has to be at least 1.6 mm in most European countries. It is easy to find out how old the mounted tyres are please refer to the info box below. Whether tyre pressure, tyre age or profile depth: the condition of truck tyres can be checked regularly with only a few steps, to effectively reduce the number of tyre failures and the associated accidents. Take part in this for safety's sake! This can be remedied on trucks and on cars by regularly checking the tyre pressure, ideally during each fuel stop. The individual target values can be found in the respective vehicle documents in each case. An automatic tyre pressure monitoring system (TPMS) integrated into the vehicle is even more reliable, though. For newly registered cars, this became mandatory throughout the EU in November The EU Commission does not yet see any cause for action for trucks, though, so only few trucks are currently equipped with this feature. Yet the market has long been offering fully developed systems from different manufacturers, some of which are also suitable for retrofitting. These TPMS provide timely information about loss of tyre pressure and increased temperatures, effectively helping to prevent consequential damage. Here it is up to the fleet operators in particular to equip their vehicles accordingly in the future. In addition to insufficient tyre pressure, excessively old tyres are another frequent reason for wear and therefore also a potential accident risk. Studies have shown that safety decreases significantly with increasing Easily determined: tyre age The production date of each tyre can be found on the tyre flank after the letters DOT. It is usually positioned in an oval. According to ECE regulations, all tyres in Europe have to have a DOT number. It indicates the week of manufacture of the tyre. This enables users to calculate the age of the tyre. The tyres should be replaced after six years at the latest always remember to replace all tyres on the same axle at the same time. 04

5 A TRUE EVOLUTION: ULTRA BEAM LED GEN II Strong, stronger, Ultra Beam LED Gen II: HELLA has further optimised the LED variant of this already powerful work light. The Ultra Beam LED Gen II now produces a powerful 4,000 lumen light output and can even replace xenon headlights without problems. This is in addition to the known advantages of LED technology: lower power consumption of only 56 watt, durability, maintenance-free design and a light colour that is similar to daylight, preventing fatigue and therefore allowing comfortable working even at night, for example when manoeuvring and loading. With a specially developed multi-facetted reflector, the light from the LEDs is perfectly distributed and delivers homogenous illumination. With different lenses, this work light can be used for close-range and long-range illumination. Clever overheating protection through cooling fins and the integrated temperature sensor protect the work light against overheating, ensuring the long service life of the LEDs, which is 30 times that of a xenon lamp. Part numbers: 1GA close-range illumination 1GA long-range illumination NEW ARRIVALS FOR LED AUXILIARY HEADLAMPS: LIGHT BAR 350 AND 470 In the last edition of Truck Journal, we already reported on the Light Bar 350 in detail. The flat, elongated HELLA auxiliary headlamp in a compact light bar design now has a new companion: the Light Bar 470 has the same advantages as its little brother, but is equipped with 16 instead of 12 high performance LEDs. This exceeds the already strong light output of the Light Bar 350 again the Light Bar 470 has a range of over 400 m, providing excellent road illumination with a low power consumption of only 35 watt. As the Light Bar 350, the Light Bar 470 is available in two versions with different reference values: with reference index 25 for wide illumination and with reference index 37.5 for long-range illumination of the road. This provides maximum flexibility. Mounting of the Light Bar 470 is particularly easy thanks to the universal bracket. It can be mounted on surfaces with any gradient, upright or hanging. NOW ALSO WITH A BLACK BASE: K-LED 2.0 BEACON Whether heavy goods transports, manoeuvring work or extra-wide loads: truck journeys often involve situations where other road users have to be warned of hazards. The main aspect of this is to attract maximum attention. The HELLA K-LED 2.0 with a yellow dome is particularly suitable for this purpose. The beacon, which is now also available with a black base, is equipped with a brightness sensor which allows it to automatically light up 2.3 times more brightly during the day than at night, ensuring the best possible warning effect at all times. It is also the first HELLA beacon where you can switch between rotating or flashing warning signals by pressing a switch or by programming. Due to durable LED technology with 20 high-power LEDs, the light is maintenancefree, energy-efficient and therefore very cost-effective in terms of upkeep ideal for continuous operation. When combined with the LEDs, the special reflector provides ideal luminous efficiency in any situation. The omission of moving parts, the impact-resistant dome and a special housing coating mean that the K-LED 2.0 easily resists even stronger vibrations and chemicals such as salt and lye. And, thanks to the IP 67 protection rating, the light is perfectly protected from moisture and can even easily withstand brief immersion. Three different fixing options and the flat design offer the required freedom for mounting. The K-LED 2.0 is a true all-rounder! Part number: 2XD Beacon, yellow with black base 05

6 DRIVEN BY IDEAS. IAA-NKW 2016 IN HANOVER From September 22-29, 2016, the industry will be meeting in Hanover at the 66th IAA Commercial Vehicles This year, the biennial world leading trade fair for mobility, transport and logistics will be held under the motto Driven by ideas. This approach will also be picked up by the redesigned key visual of the trade fair, which shows transporters, trucks and buses as networked, innovative and futuristic looking vehicles. This is meant to express that commercial vehicles will be providing even more important impulses within the industry 4.0 in future, in a growing world economy with continuous digitisation. Of course HELLA will be exhibiting again this year as well, presenting numerous new developments and product highlights in hall 12, true to the company slogan Technology with Vision. Among the products presented will be new variants of the LED hybrid rear lamp for trailers as well as a newly developed side marker light with integrated indicator function. In addition to this, visitors can expect numerous other innovations which will be exclusively presented to the public at this trade fair for the first time. So it will definitely be worth visiting our stand! The HELLA trade fair team is always happy to provide help and advice and is already looking forward to your visit and exciting discussions. NEW: LED side marker light. Presented at the IAA in Hanover from September 22-29, ST INTERNATIONAL ADAC TRUCK GRAND PRIX MOTORSPORT IN XXL At the ADAC Truck Grand Prix, the annual industry meeting at the Nürburgring, the action is not only on but also off the track. Of course HELLA participated again this year. Whenever the ADAC announces the Truck Grand Prix at the Nürburgring, the greats in the industry do not think twice. Whether popular country music stars, highly decorated top racing drivers or ambitious technology professionals: all the big names come together at the Ring. HELLA is always right in the middle of this truckers' paradise, offering plenty of infotainment to visitors directly in the paddock. In addition to the latest products and technical developments, this naturally also included exciting technical discussions with the HELLA experts who are always happy to provide help and advice. And there was also plenty of actual racing atmosphere at the Truck Grand Prix: that was ensured by high-caliber truck racers such as ex-champion Jochen Hahn and top female racer Ellen Lohr, who competed in their MAN trucks against renowned colleagues from Germany and abroad during the FIA European Truck Racing Championship. In addition to the powerful MAN racers, the speedy trucks from Freightliner, Iveco and Mercedes-Benz also took part. In addition to the main race, various supporting races provided excitement and great entertainment. The supporting program was also very respectable: visitors experienced an entertaining mixture of action events and shows. And of course there was the evening festival, which once again lasted well into the night and provided a great party atmosphere with show acts like Tom Astor and Megaband. More information on the event can be found at and 06

7 STRONG LIGHTS FOR HARD WORK: UNIMOG LED CONVERSION For municipal and special purpose vehicles which are also used at night, optimum lighting is a crucial factor for successful and safe working. The perfect prerequisites for this can be created through targeted conversion or updating to LED technology. It is commonly known that LED technology offers many advantages: in addition to clearly improved road and work area illumination, this also includes cost savings through high energy efficiency and a long service life. Advantages which are also useful for municipal and special purpose vehicles these are often operated in the daytime as well as at night and often confronted with adverse ambient conditions which require powerful, reliable and durable lighting. It is precisely these reasons which often make a conversion of existing vehicles from halogen to LED technology worthwhile. HELLA and Bauhof Online, the information portal for municipal decision makers, have taken this opportunity to equip a Mercedes-Benz Unimog snowplow (1) accordingly, demonstrating the possibilities this can offer. First a K-LED 2.0 (2) was installed. In addition to the flat design and the impact-resistant dome, the primary features of this beacon are the automatic change between two brightness levels and the choice of rotating or flashing warning signal. This ensures an optimum warning effect at any time of day or night, regardless of the weather. Learn more about the K-LED 2.0 in our detailed article on page 05. Furthermore, the existing auxiliary halogen headlamps were replaced with two new C140 LED (3). This innovative combination headlamp for the first time unites all lighting functions (low beam, high beam, direction indicator and position light) in LED technology in one single light. In our conversion example, the headlamp functions as an auxiliary headlamp and as a replacement for the main headlamp, for example when the existing main headlamps are covered by the snowplow. More information can be found in the product box below. C140 LED The C140 LED is the world's first combination headlamp in 100 % LED technology, offering users many advantages. The super-flat Light Bar 350 (4) is also used. This has already been described in detail in the previous edition of our journal and is now complemented by the Light Bar 470. More information on this can be found on page 05. The robust auxiliary headlamp provides extra illumination, which is mainly required for nighttime use and in adverse weather conditions. Mounting is simple and requires only a few steps (5). After successful conversion (6) to LED technology, the Unimog shines brighter than ever before (7). Visibility for other road users (8) as well as road and ambient illumination (9) are greatly improved for extra safety and work comfort. The most important benefits at a glance: Low beam, high beam, indicator and position light (implemented as LED light guide) in LED technology Excellent light distribution through free-form reflector Overheating protection through specially developed thermal concept with temperature sensors Particularly vibration-resistant and impact-resistant thanks to heavy duty bracket and hardened plastic cover lens Maintenance-free through completely enclosed system 07

8 HELLA KGaA Hueck & Co. Rixbecker Straße Lippstadt, Germany Tel.: Fax: Internet: VERY PROMISING HELPERS DRIVER ASSISTANCE SYSTEMS PROVIDE INCREASED SAFETY Modern driver assistance systems are becoming increasingly important in the field of commercial vehicles. As varied as the different systems may be, the objective is always the same: improving the safety of the vehicles and therefore the drivers by avoiding accidents. HELLA Limited Unit 6 Appletree Industrial Estate Chipping Warden Banbury, Oxon OX17 1LL England, UK Tel.: (01295) Fax: hella.sales@hella.com Website: HELLA KGaA Hueck & Co., Lippstadt J01162/07.16 Subject to technical and price modifications The development of ever new, even more powerful assistance systems brings many advantages: the drivers' task is made easier, driving comfort is improved and last but not least safety for all road users is enhanced. The most commonly used systems are speed control systems, brake assist systems, electronic stability controls, reversing systems, lane keeping or lane change assist systems, tyre pressure control systems (also see the article on page 04) or voice control. The safety benefits confirmed through various studies have also lead to certain assistance systems now being mandatory for trucks in Europe: the installation of electronic vehicle speed control systems (EVSC), for example, better known as ESP or ESC, already became mandatory for all new vehicles of existing types (passenger cars, buses, trucks and trailers) on November 1, Lane departure warning systems (LDWS) as well as advanced emergency braking systems (AEBS) have been mandatory for new commercial vehicles over 3.5 t since November 1, One should not forget, however, that any assistance system can only ever be a support for truckers. They do not release the drivers from complying with their stipulated drivers' hours and applying the required concentration in traffic in the interest of all road users for the path to completely autonomous trucks is still very long, even if developments in this field have gained momentum in recent years. Particularly the networking and interaction of different autonomous assistance systems, e.g. via the CAN bus, offer many promising approaches for the future. TARGETED USE AND ROUTE OPTIMISATION GPS USE IN LOGISTICS The use of GPS navigation systems in passenger cars has become a matter of course for many drivers today. Not only do the useful helpers provide guidance to a destination on the fastest or most direct route, they also help drivers with finding their way in unknown territory. However, GPS applications are highly useful not only in private vehicles, but also in the commercial field. They can optimise routes for logistics and reduce journey times as well as providing a cost saving benefit. The best known feature is certainly the option of reacting to changes in the flow of traffic dynamically thanks to the GPS, avoiding roadworks and congestions, for example. The drivers can have information about suitable alternative routes displayed very quickly. This can avoid or at least reduce delays on the route to the destination in good time. In Germany alone, the annual abstract costs through traffic delays are estimated at over 30 billion euro, with an upward trend. Particularly in the fast paced field of logistics, unexpected idle times always involve a financial aspect as well. Targeted use of GPS systems and the resulting time savings can at least minimise costs due to traffic congestions. So-called route auditing (also referred to as breadcrumbing ), on the other hand, does not necessarily look at a specific destination but rather at individual waypoints and their analysis. GPS devices with this feature store various track points on the driven route, marking out a path of breadcrumbs. This allows companies to document all planned and unplanned stops along the vehicle route and to later on analyse any delays. This provides optimisation of routes in the medium term and even identification of unauthorised journeys outside of regular routes. Transport companies who want to make their journeys as efficient as possible can use the data from the GPS devices to calculate the speeds in all route sections and adapt the planned stops along the route accordingly, allowing for more efficient route planning. HELLA ONLINE Contact HELLA directly: either via LinkedIn or YouTube HELLA is active in a number of social networks. GPS WHAT IS THE EXACT DEFINITION? The Global Positioning System (GPS) is a satellite-based navigation network which uses satellites which are in constant 24h motion, orbiting the earth. The satellites were placed by the US ministry of defence and then released for civilian use in the 1980s. Using signals from at least three satellites, the position can be determined with an accuracy of approximately 10 meters using a special GPS receiver. GPS works regardless of the weather, at any time, and its use is free of charge. GPS receivers, however, require a mostly clear view of the sky for determining the position, otherwise reception is affected or even impossible. A similar European competing system called Galileo is currently being established. Unlike the American equivalent, this system will be under civilian authority. Facebook YouTube Online