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© Stoneridge Electronics LtdDD55684 Rev 01

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Stoneridge Electronics Ltd

Combined Tachograph Re-certification

Training Course


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Stoneridge Electronics LtdCOPYRIGHT

This training course and all material used and issued throughout this course is the sole Copyright of Stoneridge Electronics Ltd.

The information contained in this document is the Property of Stoneridge Electronics Ltd. and should not be disclosed, reproduced in whole or in part, or used under any condition by anyone without the written authority of Stoneridge Electronics Ltd.

© Stoneridge Electronics LtdDD55684 Rev 01 3

Training Course Agenda

8:30 Introduction, Health & Safety Information

8:35 Company Profile

8:40 Tachograph Introduction, Charts, Smartcards & Regulations

9:10 W, K & L and Calibration Methods

9:20 Senders & Cables

9:35 Plaques, Sealing & Documentation

10:00 Tea Break

10:10 Analogue Tachographs

11:00 Using the Stoneridge MKII Tachograph Programmer

12:15 Lunch

12:45 Analogue Practical Exam

13:15 Digital Tachographs

14:00 Digital Tachograph Inspection Procedure

15:10 Tea Break

15:20 Questions?

15:30 Digital Practical Exam

16:00 Written Exam

16:45 Course Feedback

17:00 Course End


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Statement

This course has been written and created in conjunction with the VOSA published document

‘The Approved Tachograph Centre Manual’

Please consult your copy of the VOSA manual

This is a VOSA approved training course


5

Section 1.1

Health & Safety


Health & Safety

In the event of the fire alarm sounding, personnel should leave the building by the nearest practical exit, keeping traffic routes clear for emergency services, and gather at assembly point 6 at the front of the building

DO NOT STOP TO TAKE POSSESSIONS WITH YOU OR GO BACK FOR THEM

DO NOT RE-ENTER THE BUILDING UNTIL INSTRUCTED BY THE EVACUATION COORDINATOR OR HIS DEPUTY

Please ensure that mobile phones and all other electronic devices are switched off at all times

This is a no smoking facility. Smoking is only permitted in the designated area at the side of the facility

Lunch, Coffee & Tea are provided free of charge in the Canteen

Toilet Facilities are at the front end of the building


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Section 1.2

Company Profile


Stoneridge Electronics Locations

Sales & Support:Dundee, UKStuttgart, Frankfurt & Nuremberg, Germany Madrid, Spain & Rome, ItalyBayonne, France

Dundee, Scotland

Bromma, SwedenÖrebro, SwedenTallinn, Estonia

100+ employees7400 m²

Tachographs, Instrument Clusters, Multiplex Systems, Power Distribution, ECU’s, Telematics Systems


Stoneridge Electronics Customers

Off RoadVCESame Deutz-FahrCase New Holland

BusScaniaVolvoEvoBusJonckheere PlaxtonIRISBus

TrucksScaniaDAFDaimler ChryslerVolvoMANRenault HinoNissanIsuzuMitsubishi

PeugeotCitroenLandroverNissanVolkswagenLDV

Light VehiclesFordRenaultMazdaMercedes FiatHummer


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Section 1.3

Tachograph Introduction, Charts, Smartcards &

Regulations


Tachograph Introduction - Why is a Tachograph Required?

All EU member countries must adhere to EU legislation. It is a legal requirement to have a Tachograph chart fitted or Driver smartcard inserted, depending on vehicle Tachograph type, whilst driving a non-exempt vehicle

Under EU Tachograph legislation, all vehicles that are used for commercial purposes and have a maximum permissible weight of greater than 3.5 tonnes must have a Tachograph installed

Tachographs are required to be fitted to passenger carrying vehicles with more than 9 seats for all journeys. Note: an exemption is given to vehicles with between 10 and 17 seats exclusively for the non-commercial carriage of passengers

There are a number of examples of vehicles that are exempt to these rules as listed in the EU legislation e.g. vehicles with a maximum speed of not more than 40 km/h. The legislation also defines the specification that any type approved Tachograph must meet


Tachograph Introduction – Round Tachographs

1100 series Mechanical Tachograph – 1975

Uses a flexible rotating shaft drive cable between the gearbox rotating shaft output and rear of the Tachograph to drive the mechanical speed and distance measuring systems

Electrical supply powers the clock and the lamps

1400 series Electronic Tachograph – 1984

1400 eliminates mechanical drive cable and instead uses an electronic gearbox motion sensor and electric cable to connect to the gearbox output

Uses electronic speed and distance measuring systems

8400 series Electronic Tachograph – 1991

Programmable engine rev bands, overspeed, ignition-on-record and PPR settings

Uses industry standard four 8-way Amp mini-timer rear connectors

Automatic in terms of ‘drive’ recording


Tachograph Introduction – Radio-sized Analogue Tachograph

The 2400 series Veeder-root Tachograph was introduced in 1999

These tachographs fit inside a standard ISO7736 radio enclosure allowing for an integrated cluster in the vehicle

The 2400 can be driven from an 8-pulse sender but unlike older tachographs it can also accept speed pulses from an encrypted sender, KITAS 1. This device provides the Tachograph with a secure speed signal that cannot be tampered with without the tachograph sensing and memorising the event

The 2400 was designed to function under CANbus and/or K-line control

It also has a real time clock with a 10 year battery life


Tachograph Introduction – Radio-sized Digital Tachograph

The Digital Tachograph was introduced by Stoneridge in 2005 in the form of the SE5000

The SE5000 Digital Tachograph is designed to fit inside a standard ISO7736 radio enclosure

The SE5000 can only be driven from a gearbox motion sensor device known as an encrypted sender, KITAS 2

The SE5000 was designed to comply with EU regulation 1360/2002 and displays and records speed, distance and driver duties in a digital format recorded in internal memory and duties on a driver smartcard

The EU type approval number for the SE5000 Tachograph is e5 0002


Charts – Pear Hole Charts

The Front and Rear markings of pear-hole charts are detailed below. There are 24 Hour time scales which are standard to all one-day charts and subsections for speed, 4th trace/events recording, activity mode and distance and also a centrefield for recording driver and vehicle details

Centre Field

24 Hour Markings

Speed Trace

4th Stylus/Events

Activity Mode

Distance Trace

Manual Entries

Chart and Tachograph EU Approval Numbers. Always check compatibility

Additional Changes of Vehicle


The Workshop Smartcard

Red in colour, valid for one year, in UK expires 31st

March. Will not be re-issued if training certificate details held by VOSA are out of date

Workshop may only hold one card per technician

PIN issued to technician, card to workshop – card self-locks after 5 consecutive incorrect PIN entries

Card/PIN must NEVER be used by anyone other than the named technician on the card – card lost, or PIN forgotten, means new card and PIN

MUST be securely stored in safe when not in use and must NEVER leave the workshop premises

Lost workshop cards must IMMEDIATELY be reported to VOSA. Initially report loss to police to get crime incident number which can be quoted to VOSA when getting a replacement card

Allows for activation, calibration and data downloading


Other Digital Tachograph Smartcards

Driver Card White in colour, valid for 5 years

Personal to driver, 28 days driving activity capacity

Must report lost/faulty cards to DVLA within 7 days

Must take printouts whilst card lost/faulty – for up to 15 days

Must always have spare paper roll

Company CardYellow in colour

Valid for 5 years

Allows for locking of VU data

Allows for downloading of company-locked VU data

Control Card Blue in colour, valid for 2 years

Issued to enforcement authority/officer

Allows Read-Only access to all Tachograph data


Tachograph Regulations – Analogue Recording Equipment

In 1985 new EU Tachograph Recording Equipment legislation was issued in the form of Council Regulation (EEC) No. 3821/85. This legislation, which is commonly known as ‘Annex 1’ is the basis for all modern Analogue Tachographs that are currently available on the market e.g. 8400/2400 etc

Subsequently there were various amendments to the Annex 1 legislation in the form of Commission Regulations (EC) 3314/90, 3688/92, 2479/95 and 1056/97. These amendments are regarding,

• new chart marking requirements for equipment power disconnection and speed sensor signal failure

• the requirement for armoured speed sensor cable fitting• the introduction of speed sensor signal encryption• the fitting of armoured cable into small vehicles


Tachograph Regulations - Digital Recording Equipment

Original hours law rules published in EC No 3820/85

Annex 1B originally announced in Council Regulation EC No 2135/98

The final Annex 1B legislation was published in Commission Regulation EC No 1360/2002 published 5th August 2002

In April 2006, the Regulation (EC) 561/2006 was published and this stated that Digital Tachograph fitment was mandatory for all non-exempt new vehicles registered on or after 1st May 2006

Vehicles registered on or before 30th April 2006 can be fitted with either a Digital Tachograph or an Analogue Tachograph at the customers request


Tachograph Regulations – Tachograph Tolerances

The Tachograph limits of accuracy for speed, distance and time, both visually and recorded, are summarised below and are as listed in Council Regulations and in the VOSA Approved Tachograph Centre Manual

The Bench Test tolerances for an Analogue Tachograph at Initial or 6 Yearly Inspection, also for 2 Yearly Inspection for centres using non-roller test equipment are as follows,

• Distance Travelled: ±1%, where that distance is at least 1km• Speed: ±3 km/h• Time: ±2 minutes per day or ±10 minutes per week

The tolerances for a Bench Test of a Digital Tachograph VU at Initial or 2 Yearly Inspection are as follows,

• Distance Travelled: ±1%, where that distance is at least 1km• Speed: ±1 km/h• Time: Not Applicable


Tachograph Regulations – Tachograph Tolerances

The tolerances for an Installed Analogue system at the Initial calibration stage are as follows,

• Distance Travelled: ±2%, where that distance is at least 1km• Speed: ±4 km/h• Time: as Bench test

The tolerances for an Installed Digital Tachograph at the Initial or 2-Yearly Inspection calibration stage are as follows,

• Distance Travelled: ±2%, where that distance is at least 1km• Speed: ±2 km/h• Time: as Bench Test

The tolerances for an Installed Analogue or Digital Tachograph system that is In Use, i.e. when carrying out a post installation Vehicle-Tachograph speed-for-speed check, are as follows,

• Distance Travelled: ±4%, where that distance is at least 1km• Speed: ±6 km/h• Time: as Bench test


Tachograph Regulations – Installation / 6-Yearly Periodic Analogue Inspection Procedure

The full procedure is described in the VOSA Approved Tachograph Centre Manual – please consult for the full current up-to-date procedure

Prior to carrying out the procedure, any previously fitted charts must be removed and returned to the driver. The procedure is as follows:

• For a mechanical installation, any adaptor gearboxes must be stripped, cleaned and re-greased before continuing

• Check Legal Requirements for the installation– Manufacturers data label / EU type approval number– Check all Tachograph manufacturer seals are valid and intact– For vehicles registered on or after 01/01/1996, check Tachograph

can automatically record driving. Check Tachograph-vehicle motion sensor connection is made with armoured cable that is sealed at both ends – not required if a signal encryption type motion sensor is fitted



• Bench Test the Tachograph with the Tachograph removed from the vehicle using an approved method and equipment

– Check all displayed and recorded speeds and distances are withinthe legal tolerances listed previously

– Check all non-driving duty modes are displayed and recorded correctly

– Check clock for accuracy to within legal tolerances– For vehicles registered on or after 01/01/1996 check that power-

failure and sender disconnect conditions are detected and recorded

• Calibrate the Vehicle– Measure the characteristic coefficient of the vehicle (W-Factor in

imp/km or rev/km)– Measure the effective circumference of the drive wheel tyres

(L-Factor in mm)



• Set the Tachograph Constant (K) using an approved programming device or by adjusting DIL switches as appropriate

• Carry out a speed-for-speed check on the rolling road at a 50 km/h test speed

• Seal the Tachograph installation as per authority instructions

• Remove all existing plaques and fit a new installation plaque

• Complete documentation – GV 212 and Tachograph Record Sheet

• Retain Tachograph Test Charts and Tachograph Record Sheet for a minimum of 6 years


Tachograph Regulations – 2-Yearly Periodic Analogue Inspection Procedure

The full procedure is described in the VOSA Approved Tachograph Centre Manual – please consult for the full current up-to-date procedure

A 2-yearly inspection is due 2 years after the most recent calibration was carried out or 2 years since the last 2-yearly inspection was carried out unless a 6-yearly inspection is due. Note: a 6-yearly inspection must NEVER be delayed

Prior to carrying out the procedure, any previously fitted charts must be removed and returned to the driver. The procedure is as follows:

• Check Legal Requirements for installation– EU type approval number / Tachograph descriptive plaque valid– Check all Tachograph system seals are valid and intact



• Test the Tachograph using an approved method and equipment– Fit test charts– Check clock for accuracy to within legal tolerances– Check illumination– Check chart to clock time ±5 minutes maximum– Check all non-driving duty modes are recorded for 2 minutes and

displayed correctly– For vehicles registered on or after 01/01/1996 check that power-

failure and sender disconnect conditions are detected & recorded– Measure L-factor and check to within ±4% of L-factor recorded

previously on installation plaque– Using roller test equipment drive at 40 km/h and then 60km/h for

2 minutes each – check displayed speeds are within tolerances– Record odometer reading and distance travelled during test



• Remove test charts and check all recorded speeds and distances are within legal tolerances and duty mode traces are correct

• If installation meets all tolerances, remove all existing 2-yearly plaques and fit a new 2-yearly plaque & seal – unless it is a type that cannot be removed without destroying

• Complete documentation – GV 212 and Tachograph Record Sheet

• Retain Tachograph Test Charts and Tachograph Record Sheet for a minimum of 2 years

• If criteria not met, carry-out minor repair if possible e.g. external electrical connections, odometer, front bezel to complete the inspection

• If criteria not met and W and/or L out with VOSA tolerances, then a 6-yearly inspection including system recalibration must be carried out


Tachograph Regulations – Reasons for Digital Inspection

After any repair of the equipment. Replacement of the paper cassette does not constitute a repair of the VU

If the motion sensor seal is broken

After any alteration to the W or L factors

If the VU UTC clock time is inaccurate by more than 20 minutes

When it has been 2 years since the last inspection

If the VRN has changed


Tachograph Regulations – Digital Inspection Procedure

A visual inspection must be carried out to ensure that the unit has not been tampered with and no security breach attempts have been made. In cases of tampering see VOSA warning notice GV215 for further advice

The VU manufacturers' label must be checked, i.e. type approval mark e5 0002 etc

Check all system seals are intact

Bench Test the Digital Tachograph

The tyre size and actual circumference of the drive wheels must be checked

The presence and content of the current installation plaque must be checked – record any anomalies on the final Inspection Report


Tachograph Regulations – Digital Inspection Procedure

Check that the recording equipment functions correctly, including data storage on smartcards

Check the integrity of the Motion Sensor/VU connection using an independent cable connected directly from the sensor to the VU

Confirm that the unit operates to within maximum tolerances for both speed and distance and check that its UTC time is set correctly

A mandatory vehicle re-calibration must be carried out. Program the new VU calibration parameters and also ‘Next Calibration Date’ to 2 years on. Check all other programmable VU parameters are set correctly

A new installation plaque must be fitted after the inspection is completed and an inspection report/calibration certificate must be issued to the vehicle owner to confirm the inspection completion. Update the GV212 –2009 VOSA manual indicates that this must be in a VOSA accepted electronic format from 1st January 2010


Digital Inspection Procedure – 1381 Extra Requirements

The VDO 1381 Digital Tachograph has a 3.6V, ½-AA Lithium back-up battery that MUST be replaced every two years maximum, usually as part of the Digital Inspection. The back-up battery must first be exposed by breaking the red seal on the battery compartment rear cover as shown

The Tachograph MUST be powered through it’s rear ‘A’ socket as shown before the back-up battery is disconnected and replaced. Failure to do this will result in the Tachograph losing its internal memory settings and will cause the Tachograph to permanently malfunction

Remove seal, open compartment and expose back-up battery

1381 MUST remain powered whilst disconnecting battery

Connect replacement battery

Fit battery in compartment, close and re-seal to secure battery


Digital Inspection Procedure – 1381 Extra Requirements

The VDO 1381 has a type approval/security label inside its printer paper compartment. It must be ensured that the label is present and completely intact as part of a Digital Inspection procedure

It must also be ensured that the 1381 front security red-seal is intact and has not been tampered with or replaced, i.e. must be original VDO seal

If the 1381 Ignition Key On/Off parameter settings are updated solely, this change does not require a full VU inspection/calibration. However, as indicated in the 2009 VOSA manual ‘Minor Work to a Digital Tachograph’section, the GV212 must be updated with a manual entry marked ‘Minor Work’, although Minor Work plaque fitment is NOT required


Digital Inspection Procedure – SmarTach Extra Requirements

It must be ensured that the SmarTach type approval label is present and completely intact on the side of the unit as part of a Digital Inspection procedure

It must also be ensured that the three metallic strip seals, as seen from above the VU, and front-panel side red-strip seals are all present and intact

Type approval labelMetallic Strip Seal

Red Strip Seal


Tachograph Regulations – M1N1 Adaptor Digital Inspection Requirements

During the periodic inspection of a Digital Tachograph system, if an M1N1 adaptor is fitted, then as part of the Digital inspection procedure it must be confirmed that the,

• Adaptor carries the appropriate type approval marking, i.e. e11 0042

• Seals on the adaptor and its connections are intact

• Adaptor installation location is as indicated on the installation plaque

• Adaptor is installed as specified by the adaptor manufacturer

• Use of adaptor is authorised for the inspected vehicle type


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Section 1.4

W, K & L-Factors and Calibration Methods


Establishing the Vehicle W and L-Factor Calibration Parameters – Using a Stoneridge Rolling Road

Console with MKII Programmer

Infra-red Transducer Distance Roller

Vehicle Support Roller

Bogie Rollers

In the U.K. all Tachograph centres, except remote ones, are required by law to have an electronic test rig to obtain the W and L-factors. This takes the form of a Rolling Road combined with a Tachograph Calibration system

There are several types of system available. The Stoneridge Rolling Road and MKII programmer are shown below. This system calculates using a measured distance roller


Establishing the Vehicle W and L-Factor Calibration Parameters – Physical Method

Where an electronic Tachograph Calibration system is not fitted, e.g. in Ireland or remote centres in the U.K., or where the Tachograph calibration system has failed, or cannot be used on a specific vehicle, the ‘physical method’ must be used instead to determine the vehicle calibration parameters

The physical method for determining W-factor consists of measuring over a calibrated fixed distance of 20 metres, either the number of gearbox turns for a mechanical output system or the number of gearbox sender pulses for an electronic output system

The measured W-factor value can be easily multiplied by a factor of 50, for a 20m track, to provide the required “per kilometre” value

The L-factor can be determined by marking the ground and measuring thedistance travelled for five rotations of the drive wheel. The distance measured for five rotations of the driven wheel can then be divided by five to provide the vehicle L-factor value in mm

In the case of a failed calibration system, VOSA permission must be obtained before using the physical method


38

Section 1.5

Senders & Cables


Senders & Cables – 4-wire & Encrypted Cables

4-wire Non-Armoured Cable

4-wire Armoured Cable From 1/1/96

Encrypted Sender Cable Round Pin


Senders & Cables – 8-Pulse Rotary Gearbox Senders

4-wire 3-wire

Pulses from Channel 1

1 Revolution of Sender Input Shaft


4-wire only

3-wire & 4-wire


Senders & Cables – 4-Wire Proximity Gearbox Sender Devices

Proximity senders utilise a Hall-effect IC to generate a speed pulse train that is proportional to the speed of the vehicle. However unlike 8-pulse senders where the sender fits directly onto the gearbox drive shaft to count gearbox revolutions, the proximity devices generate a speed pulse for every tooth on the gearbox tone-wheel that passes the sender as shown. Like other 4-wire devices these always have flat connection pins

Gearbox Tone-Wheel

Proximity Sender

Hall-Effect IC


Senders & Cables – Encrypted Gearbox Senders

Encrypted senders are usually found in proximity form and these have a very similar construction to 4-wire proximity devices. KITAS1 Encrypted devices must only be used with compatible Analogue Tachographs e.g. 2400 series Tachograph. KITAS2 devices must only be used with Digital Tachographs. There is also a rotating-shaft type KITAS2 device available

The main difference between encrypted and non-encrypted devices is that the encrypted device has encryption data embedded into the complimentary signal as shown. Also, encrypted devices always have round connector pins


Encryption Signal


KITAS1 Proximity Senders

KITAS2 Proximity

KITAS2 Rotary


Senders & Cables – M1N1 Adaptor

For M1 and N1 vehicles requiring a Digital Tachograph that cannot be fitted with a Kitas2 sensor directly or via a Mechanical adaptor, the solution for these vehicles comes in the form of an M1N1 Adaptor

The M1N1 Adaptor legislation, Commission Regulation (EC) No 68/2009, came into force on 24th July 2009

A Type Approved Adaptor can only be installed in M1 or N1 class vehicles registered from 1st May 2006 to 31st December 2013 inclusive, where it is not mechanically possible to install any other type of existing approved motion sensor


Senders and Cables – Mechanical Adaptors

The solutions for some vehicles were found and approved in the form of mechanical adaptors, either an intermediate device fitted between a standard Kitas2 sensor and the gearbox or a mechanical adaptor that allows the sensor to be located in the differential housing

Example Stoneridge mechanical solutions are shown below, i.e. Hummer H2 and Ford Ranger / Mazda BT-50, 2007+

KITAS2 Sensor – Hummer H2

Stoneridge Adaptor – Hummer H2

Complete Unit – Ford/Mazda


45

Section 1.6

Plaques, Sealing & Documentation


Plaques – Different Types

Installation/Calibration Label with Coverlay• Vehicle calibration details are

recorded using a combined calibration & overlay label. Suitable for both mechanical & analogue Tachographs

2-Year Inspection Label• Once the Tachograph system

passes all the 2-year tests, this label should be fitted beside the current Installation label

Minor Work Label• To be used on a Tachograph

system that is repaired under the Minor Work Procedure


Plaques – Different Types

Calibration Label – Metallised Analogue and Digital Approved

• This plaque it is of a type that cannot be removed without damaging it

• Plaque must be fitted on or beside the VU and must be visible at all times

• Plaque must be generated automatically• For 6-year analogue and 2-year digital inspections

the new plaque must be fitted in place of old one

Information on the plaque must include,

• Name and address of approved technician or workshop

• W, K and L factors• Tyre size• VIN• Date of W & L factor determination


Plaques – Different Types – M1N1 Adaptor Requirements

For a Digital system installation that uses an M1N1 adaptor, a new style M1N1 adaptor Installation plaque must be fitted to the vehicle

The plaque must contain additional information to a standard Installation plaque as follows,

• Part of the vehicle where the M1N1 Adaptor is installed• Colour of cable between adaptor and part of vehicle providing impulses• Serial number of the embedded motion sensor of the Adaptor


Sealing Parts - Lead & Red Seals

To comply with the law, a Tachograph system must be sealed at all times

A lead seal is compressed around a loop of sealing wire using a pair of sealing pliers 7955-008. These pliers should be equipped with anvils supplied by Stoneridge that are marked with the appropriate manufacturer symbol and a valid VOSA Approved Tachograph Centre number, e.g. GBL…

Red plastic seals must be embossed using sealing pliers 7955-255 before fitting. The pliers are equipped with anvils supplied byStoneridge that are and marked with the appropriate valid Approved Tachograph Centre number, e.g. GBL…

The Tachograph seals required vary depending on the exact model but include a calibration switch cover, a programming socket cover, rear connector seals, jack plug seals and round plastic seals


How and Where to Seal an Electronic Tachograph System

Sealing the gearbox sender is mandatory for all Tachograph systems including adaptorsFor a non-encrypted system, the sender cable must also be sealed at both endsFor vehicles registered after 01/01/1996, and fitted with a non-encrypted system, the sender cable must be of an approved armoured typeFor an encrypted system, only the gearbox sender seal is required and non-armoured sender cable can be used for all encrypted systems

Gearbox

Wired Seal

Sensor Cable

Sensor Connector and Retaining Nut


Sealing for the 8400 Series Tachographs – Rear Sealing Shroud & Calibration Switch cover Additional Requirements

K-factor Label with Plastic Overlay Applied on topGB (X)

(XXX)

Imp/kmCross

ThroughCentre Number Must Be Entered

White K-factor Label

DIL Sealing must be carried out using a black plastic cover. DO NOT use a clear plastic cover

The DIL switches and Rear Shroud must be sealed after calibration. The red seal secures them into place when fully pushed home

As a VOSA requirement, modified K-factor labels and protective overlays must be placed over the fitted calibration DIL switch cover seam and the Rear Shroud seam as shown


Sealing Requirements for the 2400 Series Tachograph

All electrical connections are made at the rear of the 2400 Tachograph using industry standard AMP Mini-timer type connectorsNormally it is not required to fit a rear connector sealing shroud when the 2400 system is installed with an encrypted sender as part of the Tachograph systemFor non-encrypted sender types, a sealing shroud must be usedOnly the A and B sockets are sealed because only these have signal connections that require protection from tamperingThe shroud is then held in place by a red seal that has been embossed with the appropriate Approved Tachograph Centre number prior to fittingIt is a VOSA requirement that the rear shroud must also be secured with a completed K-factor label and protective overlay in the same manner as was described for the 8400 rear connector shroud


2400 Plaques and Programming Cover clip Sealing

After a 2400 Tachograph system has been installed or re-calibrated, an installation plaque should be completed with the usual details of Tachograph Centre name and address, W and L-factors, calibration date and Sealing Number of the Approved Centre. The label and a protective coverlay, 7955-111, must be positioned carefully on the front panel of the Tachograph

Installation Plaque and Protective Overlay are Applied Here

Cover clip fitted and red seal embossed with the Approved Centre number

K-factor label and plastic overlay applied on top of Data Label


Sealing a Digital VU System

Sealing the motion sensor to the gearbox is a necessity – an approved method must be usedNotes: 1. plastic gearbox sender sealing shrouds that are fitted by some vehicle manufacturers are not VOSA approved and are to be replaced by sealing wire and a soft-metal seal embossed with the workshop identification number2. the gearbox seal identification number must always match the centre details shown on the Tachograph Installation plaque

Any VU system presented with a broken seal must be re-sealed and re-calibrated but a report must also be prepared and made available to the relevant authorities as to why the seal was broken

The VU Installation plaque must be sealed unless it is of a type that cannot be removed without damaging it

All sealing of Digital Tachograph systems must be done by an approved Digital Tachograph workshop technician


Sealing a Digital VU System – SE5000 Rear Shroud

• Stoneridge SE5000 Rear Shroud – kit part number is 7800-006

• Stoneridge SE5000 Rear Shroud – Fitted and Sealed with Embossed Red Seal

If an output speed related signal is being used, i.e. B7, then an SE5000 Rear sealing shroud must be fitted as shown,


Documentation – Paperwork for Registration

When a vehicle has been calibrated, the Tachograph fitted, and the whole installation sealed, the appropriate paperwork for the installation must be made out. This consists of a Tachograph Record sheet, any test charts generated during the procedure and the updating of the official VOSA Register of Tachograph Plaques Issued, GV 212

The Tachograph Record sheet is traditionally in the form of a duplicate sheet. The top sheet is handed to the customer with all the calibration information and serves as a record of the calibration and sealing since the record contains the Approved Tachograph Centre number, which is marked on their seals. The duplicate copy, which is of a stiffer material, is retained by the Approved Tachograph Centre and has a slot cut into it to accommodate any test charts generated during the procedure so that the paperwork for that vehicle can be kept together. An example of the Stoneridge Tachograph Record sheet is shown below. VOSA require that each Approved Tachograph Centre generate record sheets for all Tachograph work carried out by that Centre


Documentation – Tachograph Record Sheet

Tachograph Centre DetailsSignature of Workshop

Technician

Customer / Vehicle Details

Calibration Details

2-Year Inspection

Details

Minor Work

Details


Documentation - Test charts

Any test charts that are used during a procedure to check a Tachograph installation should be retained by the Approved Tachograph Centre and kept with the Tachograph Record Sheet

Test charts should show all the appropriate speed and distance recordings and the work mode traces recorded in accordance with the legislation

Complete all centre-field areas

Chart must show power and sender disconnect for vehicles registered on or after January 1st

1996


Documentation – Official Register of Plaques Issued GV 212

The GV 212 is a detailed log of all of the Tachograph work carried out at the Tachograph Centre. The GV 212 must be kept in a secure place for at least 6 years. If an M1N1 adaptor has been fitted to the vehicle, the GV 212 entry must be annotated with “ADAPTOR” to indicate this

Minor work applies only to vehicles that are submitted for repair with all seals intact. Should any seal be broken then a full calibration and re-seal would be required. It is a VOSA REQUIREMENT that all procedures are fully understood and complied with. The Tachograph Centres’ authorisation will be at risk if their Technicians fail to make and keep these records

Assign One of Following categories to each job recorded

Initial Calibrations (I),Re-Calibrations (R),2 year Checks (2),Minor Repairs (M),6 Year Checks (6)


60

Section 1.7

Analogue Tachographs


The 8400 Tachograph – Front & Rear View and DIL Calibration Switches

Lock

Crew Duty Knob

Driver Duty Knob

Chart Detect/ Over-speed Warning Light

Clock

Clock Tell-Tale

Odometer

Speed Pointer

‘A’ – Voltage, White,‘B’ – Vehicle Speed, Yellow,‘C’ – Engine Speed, Red,‘D’ – Auxiliary Signals, Brown

8400 DIL Switches

EU type approval numbers:• e11-20 for 125 km/h versions• e11-21 for 140 km/h versions• e11-24 for 180 km/h versions

D C B A


The 8400 Tachograph – ADR Goods Vehicles Fitment

Extra care must be taken when installing or repairing Tachographs on this type of vehicle due to the dangers involved. Only ADR certified Technicians should work on the Tachograph system

The 8400 carries LCIE approval for use in ADR goods vehicles when used in conjunction with an 8400 barrier device – check the [EEXib] label is attached before fitting an 8400 Tachograph

The 8400 when used specifically with its own barrier device has approval to the [EEx ib] IIB standard. This standard allows for Tachograph fitment in vehicles carrying all flammable materials except hydrogen, acetylene, carbon disulphide and ethyl nitrate

An 8400 Tachograph must NEVER be used with any other barrier device type

When repairing a Tachograph/barrier system in an ADR goods vehicle, a faulty part may only be replaced by an identical replacement part. If an identical replacement part cannot be found, the whole Tachograph/barrier system should be removed and replaced by an equivalent approved Tachograph/barrier system


The 2400 Tachograph – Introduction

CANbus, Kline or D6

2400 Tachograph

Instrument Cluster



Speed and distance displayed and recorded in km/h and km. Driver activity as per regulation 3821/85. Available as 12 and 24 Volt versions

Electronically programmable large K-factor range of 500-64255 pulses/km

Duty LEDs are also used to indicate the presence of error conditions such as a missing chart

A battery-backed real-time clock is used to ensure the correct time is permanently available. Note: not all versions

Diagnostic Trouble Codes (DTC) are stored in the non-volatile memory

OEM specific CANBus versions are available for different vehicle types

Can be set-up to have a dedicated speedometer output for vehicles fitted with a separate electronic speedometer

2400 are NOT approved for use in ADR goods vehicles



All 2400 Tachographs are designed to perform the basic requirements of EC regulation, 3821/85, but also meet the regulations for power disconnect and gearbox sender failure as per amendments 3314/90, 3688/92 and 2479/95. The differences in operation due to these amendments are

• The Tachograph will record a full scale deflection on the chart after a power interrupt

• During a ‘sender disconnect’ condition the Tachograph speed indicator will indicate, and a chart record will be made of a 0 to 30 km/h sweep every few seconds

A 2400 must receive a speed signal from a electronic gearbox sender. 2400 Tachographs are programmable to accept signals from 3-wire, 4-wire, magnetic and also from encrypted Kitas1 senders

2400 Tachographs use pear-hole charts


The 2400 Tachograph – Front View and Rear Views

Mode Change Button

Advance Button

Drawer Eject

Button

Driver Duty LEDs

Crew Duty LEDs

EU type approval numbers:

• e11-27 for 125 km/h versions• e11-26 for 140 km/h versions• e11-25 for 180 km/h versions

D C B A

Drawer Release Hole – With power-removed, insert drawer-eject tool (6450-131) and apply light pressure to fascia to cause drawer to unlock and spring out

‘A’ – Voltage, White,‘B’ – Vehicle Speed, Yellow,‘C’ – Engine Speed, Red,‘D’ – Auxiliary Signals, Brown


The 2400 Tachograph – Display Modes

When the drawer is closed, two display modes are normally available by pressing the Mode change button (●)

NORMAL MODE TRIP MODE

The upper right hand area of the display alternatively indicates• the odometer – the total cumulative distance travelled in km• the trip reading – the total distance travelled, in km, since the trip

figure was last reset, up to a maximum of 9999.9km. Note: the trip distance is prefixed with the letters ‘Tr’

The lower right hand display area indicates the time in 24-hour clock format, with a colon separating hours and minutes. The colon flashes when the correct chart time has been found and indicates chart recording has started

The left-hand side shows the speed of the vehicle in km/h


The 2400 Tachograph – Driver-Duty Buttons

Two push buttons are provided for the current driver and the co-driver or crew, for initiating a period of recorded duty. The current driver is allocated the left hand ‘1’ button, while the crew is allocated the right hand ‘2’ button

The mode of duty for the Driver or the Crew is selected by the appropriate Duty push-button and displayed by LEDs immediately below. In order to change a mode of activity the Driver or Crew member will press their respective Duty push-button a number of times, until the LED indicating the required mode of duty is illuminated

The 2400 is fully automatic. This means that the driver duty status automatically reverts to ‘Drive’ whenever a vehicle moves, reflected by a Drive trace on the Driver 1 Chart, although the LED’s will continue to reflect the most recently selected mode for Driver 1. Similarly for the Crew, if the 2400 Tachograph ‘Crew Auto-Duty’ parameter is enabled, when a vehicle moves the Crew duty status recorded will automatically change from rest to available (1). This parameter can be enabled using a MKII programmer


The 2400 Tachographs – Mode Change, Advance and Eject Push Buttons

The Mode Change push-button, ●, is used to select whether the display indicates the odometer reading or the trip reading, or RPM if the 2400 has been configured to display engine Revs, and to adjust the time

The Advance push-button, +, is used to reset the trip value to zero – press and hold for 3 seconds in trip-mode, and to alter individual field settings of the time and date

The Eject push-button, ▲, is used to open the drawer. When pressed, a 3 mm radial line is drawn on the Driver chart, below the Duty trace, to record the drawer opening. The styli are withdrawn from the charts and the LEDs change to an automatic sequence indicating the stylus retraction. Once fully retracted, the LEDs revert back to a different flashing sequence, indicating that the drawer can now be opened by pushing the drawer at the oval emboss next to the eject button


The 2400 Tachograph – Adjusting the Time

The time setting actions for a 2400 Tachograph is dependant on whether or not the unit has an internal battery-backed real-time clock, RTC, fitted

For units with an RTC fitted, the master time and date for the Tachograph can only be set using a MKII Tachograph programmer, as described in the next section. The user controls can only be used to set a local time which is based on an offset value applied to the master RTC time

For units without an RTC fitted, the master time and date and the local time are always the same and they can be set using either a MKIIprogrammer or by using the user controls on the front of the Tachograph

Setting the clock with the user controls is described in the 2400 section of the reference training manuals


The 2400 Tachograph – Chart Fitting

Initially open the Tachograph. It is not possible to open the drawer when the vehicle is in motion or when the ignition is off, or if the power is removed

The LEDs will illuminate in turn, as described previously

Push the front of the drawer in the position shown - DO NOT press on the display. This will cause the drawer to unlatch and spring forward to the partly open position

The drawer can now be carefully pulled out to its fully extended position, as shown. The chart table, upon which the chart locates, is now exposed to facilitate easy insertion of the chart



Fit crew chart under chart table plate

Rotate the chart table so that the thin end of the pear shaped drive spindle on the table is facing up. With the crew chart face uppermost, insert the edge through the transverse slot between the front and rear chart platens. Carefully locate the chart over the pear-shaped drive spindle such that the thin end of the chart pear-shaped centre hole is located first

With the driver chart face uppermost, insert the edge such that it locates under the two location fingers at the rear of the chart table. Carefully locate the chart over the pear-shaped drive spindle such that the thin end of the chart pear-shaped centre hole is located first. Make sure the chart is located over the spindle pips

Fit driver chart under

location fingers

Locate charts

over pips



After the charts are inserted, close the drawer by pushing it forward only in the position as shown above until it is mechanically latched

For single driver operation no crew chart should be fitted into a 2400 Tachograph

The Tachograph will then carry out internal procedures to align the charts to correspond with the correct time and to deploy the styli

These procedures, which are automatic operations, are usually completed after a short time, typically 40 seconds, but may take up to 90 seconds in some cases. The Tachograph will only start recording when the colon in the clock begins flashing


The 2400 Tachograph – Chart Recording in Stationary Vehicle with Ignition Off

When a vehicle is stationary with ignition off, stylus movement is minimised, thus reducing the overall acoustic output of the 2400. This is known as the quiet running mode

To enter ‘quiet running’ mode, as shown, the following conditions must be present

• Driver/crew duty set to rest• Zero speed• Ignition off• Fourth trace OFF

If the vehicle moves, or the ignition is switched on, or the drawer is ejected, then the speed, duty and distance traces will revert to being recorded in the usual manner

Duty trace remains in

‘Rest’position

No distance trace

recorded

Speed trace remains at

0 km/h mark


8400 / 2400 Tachograph – Power Connections

LAMPS

IGNITION

2714-265HOUSING NATURAL

AND2714-270, TABS

A-CONNECTOR

An AMP mini timer plug, 2714-265 and terminals, 2714-270 are used with automotive insulated cable 1 mm2 to make up the appropriate power loom for an 8400/2400 Tachograph as shown. Full descriptions of all Tachograph rear connections are included as appendices of the reference training manuals


8400 / 2400 Tachograph – Sender Connections

4-pulses per metrePin 8

V-pulse – ISOPin 7

V-pulse – customer specified (2400 only)Pin 6

Dual-axle setting (2400 only)Pin 5

Encrypted (2400 only) or Complimentary InputPin 4

Main channel inputPin 3

Negative supply to senderPin 2

Positive supply to senderPin 1

FunctionSocket B

The connections for a standard 4-wire/encrypted Tachograph sender input connector are as listed in the table below. Pins 5 to 8 are not connected to the sender, but may be used for output signals as described. Note: both 8400 & 2400 if not specified. Full descriptions of all Tachograph rear connections are included as appendices of the reference training manuals


Analogue Tachographs – Checking the System Installation

It is a VOSA requirement to prove that the Tachograph installation is correct by carrying out a Tachograph test after the installation into the vehicle

The procedure for testing an Analogue Tachograph installed in a vehicle is as follows:

• Switch off ignition and check clock still running. Switch on ignition and the vehicle sidelights and check that the Tachograph displaylights are on (2400 changes from bright to dim). For 2400, check the duty LEDs are on and that all driver duties can be selected

• Drive the vehicle onto a rolling-road. Accelerate the vehicle on the rollers until the speed reading on the rolling road console/controller is 50 km/h. Hold the speed at 50 km/h and check that the Tachograph displays a speed of 50 km/h ±4 km/h. Decelerate the vehicle to a stop and check that the speed returns to zero. If a rolling-road is not available the vehicle must be road tested to ensure the Tachograph responds to vehicle speed changes


The 2400 Tachograph – Communication Interface - CANbus

CAN – Controller Area Network – a versatile vehicle communications system. It functions as an interface between the Tachograph and the vehicle instrument cluster. The CANbus capability of the 2400 must be disabled using the MKII Programmer when no CANbus is present in the vehicle

CANbus types supported by the 2400 are

• Daimler-Chrysler Renault

• MAN Volvo

• DAF Iveco

• Scania ISO

Typical parameters that can be transmitted through the CANbus network include:

• Speed, Time, Driver Duty, Distance Travelled


The 2400 Tachograph – Input and Output Signals

Events Inputs - these inputs are used to record events on a Tachograph chart. Two Events inputs are available on D1 and D2 respectively

V-Pulse Output - this signal is triggered by each pulse from the B3 sender input. B7 is used for the standard ISO signal. B6 can be used as an alternative customer variant ISO or Open Collector signal

4-Pulses per Metre Output - this is a string of positive pulses on B8, generated at a rate where 4 pulses correspond to one metre

Overspeed Output - this Output on D5 is active when an over-speed condition is detected

Speedometer Output - this output on D6 is used to drive the vehicles’speedometer. A ‘Speedo O/P’ calibration factor must be programmed into the Tachograph to enable the correct speedometer speed to be displayed. D6 may be an ISO or Open Collector output depending on instrument type

General Warning Output - this output on D4, if enabled, allows options for Low-Speed, DTC Warnings or Chart Change Warnings


Competitor Analogue Tachographs

Motometer EGK 100 (VOLVO)

VDO-Kienzle 1319 (Mercedes)

VDO-Kienzle 1318 VDO-Kienzle

1324


81

Section 1.8

Using the Stoneridge MKII Tachograph Programmer


Using the MKII – Introduction and Overview

Socket C

LCD Display 2 x 16

Socket B Socket A

Keypad

‘Delete’ key allows the deletion of an entered value

‘0..9’ keys are alpha-numeric for the entry of data strings

The MKII Programmer can be used with all electronic Tachographs

Menu options are navigated using the ‘left/right’ arrow keys

‘Enter’ key is used to select options or to terminate a parameter entry

‘Menu’ key is used to return to the main menu and abort the current menu item

‘Send’ key is used to transmit parameters to any connected Tachograph

Socket DSocket E


Using the MKII – Tachograph Type Selection

Before using the Programmer, the model of Tachograph to be interfaced with must be selected from the Main Menu. When the Programmer is switched on the first item displayed on the ‘MAIN MENU’ is ‘TACHO SELECT’. From elsewhere in the Main Menu press the ← or → keys until ‘TACHO SELECT’ is displayed

Press ENTER and the ‘TACHO TYPE’ menu will be displayed. Press ENTER again and then use the ← or → keys to select the appropriate Tachograph type e.g. Stoneridge VR2400. Press ENTER to make the selection and then MENU to return to the Main Menu

TACHO TYPE:2400 Series

VR2400 MAIN MENU:TACHO SELECT


Using the MKII – Interfacing to the 2400 Tachograph

Interfacing of the MKII Programmer to a 2400 Tachograph is done via the MKII 8-pin DIN connector and the 2400 6-way front calibration connector. Both connectors are keyed so that wrongly inserting them is not possible

The 2400 6-way connector is exposed by first opening the drawer and removing the sealed programming socket cover-clip as shown

For most tests, the programmer is connected to the 2400 using a 2400 calibration/programming cable ‘U’, part number 7780-936, as shown

Insert Connector into 8-Way DIN

Socket

2400 6-way Programming Socket with sealed cover-

clip removed

MKII-2400 Programming

Cable, 7780-936


Using the MKII – Sender Selection

For 2400 series Tachographs, the sender type must be selected

With the MKII at the ‘VR2400 MAIN MENU’ and displaying ‘PULSER SELECT’, connect a cable U between the programmers’ socket ‘C’ and the 2400 Tachograph 6-way D-shaped socket and then press ENTER to display the current sender type

SENDER TYPE:Encrypted ←→

VR2400 MAIN MENU:PULSER SELECT

Note: Use the ← or → keys to scroll through the options until the preferred sender type is displayed. Press ENTER and again to confirm the selection

The four choices available for sender type are

• Encrypted, 4-wire, 3-wire, Magnetic


Using the MKII – Clock Test

A clock test can be carried out on a Tachograph that has an electro-mechanical clock, e.g. 8400, 1318 or 1319, using an independent clock tester connected to socket C – there is no direct connection to the Tachograph. Both duty knobs must be set to ‘rest’ and the speed pointer must be at zero. Hold the adapter against the Tachograph face and adjust its position until a regular clicking sound is heard

For 2400, 1324 and EGK100 analogue Tachographs and for all digital Tachographs the clock test is carried out using a direct cable connection. For the 2400 a programming cable, 7780-936, is used

The MKII method for the clock test, as described below, is the same in all cases


Using the MKII – Clock Test Screens

ERROR! No signalIn the case of loss of signal or inconsistent signal from the Tachograph (usually a faulty cable connection or by movement of the clock-tester away from the clock motor), the programmer will display an error message.

Clock Accuracy+0.2s/day

After a short time the clock accuracy in seconds per day will be displayed.

Testing clockThe programmer will display the message ‘Testing clock’, and will make a regular clicking sound.

VR2400 MAIN MENU:CLOCK TEST

From the MAIN MENU select CLOCK TEST using the ← or → keys. Connect direct cable or hold the clock-tester on the Tachograph face (as indicated above). Press ENTER to start the test.


Using the MKII – Jack Socket K-factor Test

This test is used to determine the K-factor currently set on 8400 or 1318 Tachographs, and must be done prior to starting a bench test

The MKII is connected to the Tachograph using a jack socket cable and a crocodile clip to a vehicle earth. The method of the test is always the same as shown,

Sending pulsesK=8000 < >

After a few moments the programmer will beep, and then display the K-factor setting of the Tachograph. If the K-factor is different from the previous test, then the programmer will beep and display “<>“.

Sending PulsesPlease wait

Press ENTER. The programmer will send test pulses to the Tachograph.

VR8400 MAIN MENU:K-FACTOR TEST

From the MAIN MENU select K-FACTOR TEST using the ← or → keys.


Using the MKII – Jack-socket K-factor Test

ERROR! CHECKCONNECTIONS

Note: In the case of the message ERROR! CHECK CONNECTIONS being displayed, ensure that the cable earth connection is made correctly. Otherwise check the other connections.

Sending pulsesK = 8000

Step 3 will then repeat until the MENU button or ENTER button is pressed. Three repetitions are recommended. If a significantly different K-factor (>10 pulses/km difference) is displayed, this usually indicates a cable fault or bad connection. It may also be due to a faulty Tachograph.


Using the MKII – Programming a Tachograph, Reading Data

All interaction between a MKII and a Tachograph is controlled by the MKII. Initially the parameters must be read from the Tachograph and a copy transferred to the programmer. The MKII ‘READ ALL DATA’ main menu option is used to do this

The MKII menu screens should be scrolled through using the ‘Left’ or ‘Right’arrow buttons until the ‘READ ALL DATA’ option is shown

Press the programmer ‘ENTER’ button to initiate the parameter data transfer from the Tachograph to the MKII. The programmer will display the message shown whilst the data is being transferred and then a second message as shown once the parameter transfer is completed

2400 MAIN MENU

:READ ALL DATA

Reading data

. . . . . . . .

Data transfer OK


Using the MKII – Programming a Tachograph, Modifying and Sending Data

Once a copy of the VU parameters have been ‘read’ into the MKII they can then be modified individually using the programmer ‘MODIFY DATA’ main menu option. A full list of the ‘read’ parameters that can be modified is given below

2400 MAIN MENU

:MODIFY DATA

Once a parameter has been modified the new value can then be ‘sent’back to the Tachograph. The programmer ‘SEND’ key can be used to transmit individual parameters. The display will be as shown

Sending Data Sending Data

Data transfer OK


Using the MKII – Tachograph Programming Method

Using the method described above, the MKII can be used to program most types of programmable analogue and digital Tachographs. The method is the same regardless of type. Using the SEND key to individually transmit parameters is very safe in terms of accidentally overwriting a Tachograph parameter with a wrong value as only the parameter sent can change

It should be noted that sending individual parameters using the SEND key is not possible for 1319 & EGK100 analogue and SmarTach digital Tachographs. For these Tachograph types the SEND ALL DATA command must be used to transfer all the information at the same time. Also for SmarTachs a KITAS2 sender must be attached before sending data. When using SEND ALL DATA, it must be checked that no parameters are accidentally overwritten with a wrong value which in extreme cases may cause a vehicle to malfunction

In the case of programming a new Tachograph, under no circumstances must the data be read from an old Tachograph and then be sent to the new Tachograph using SEND ALL DATA. This method may result in bad data being sent to the new Tachograph causing it to malfunction also


Using the MKII – 2400 Parameters that can be Modified

K-FactorOdometer readingPulses per engine RevEngine Speed RecordingCANBus RPMRPM DisplayOdo leading 0sOverspeed flashDTCs enabledOverspeedCurrent time

Ign On RecordCrew Auto Duty7 day eject PINVINService DelayInstall dateReset HeartbeatAnalogue RevsPin D4 FunctionLow Speed LimitKline Speedo

Current DateTime OffsetOutput shaft factor4th chart traceCANBus enabledCustomer typeDual axleDual axle ratioSpeedo OP factorD6 pin functionSerial comms


Using the MKII – SE5000 Parameters that can be Modified

W-FactorK-FactorOdometerCurrent timeCurrent DateTime OffsetO/P shaft factorCANBus enabledSpeedo OP factorD6 pin functionVINService DelayInstall dateReset HeartbeatD4 Pin Function

Illumination OffRPM FactorCAN TerminationAdd. Event Rec.Eng. Speed Rec.VRESDVeh. Speed Rec.VRVSDD5 Pin FunctionCAN trip resetPre-OverspeedPre-next CalibMax. WarrantyWar. Valid TimeWarranty Time

Low Speed LimitL-FactorTyre SizeNext Calib DateVeh. Regis. NationVRNSpeed AuthorisedIllumination InputRevs Inp. C3/CANPreferred LanguageCANBus typeD7 Pin FunctionSerial Data OutBacklight SelectIllumination Lvl

No. writes WTActivation TimeRD Activ. StatusRD Card WritingRD CAN ConfigShow Remote DLCAN Wake upFilter pin B3D6 pin Config.C1 pin FunctionIgn. Activ. Change.Def.Key On/Off


Using the MKII – Bench Test

Before installation and during recalibration it is a legal requirement to carry out a Tachograph bench test with the Tachograph removed from the vehicle. This requires the unit to be run at different speeds for different periods of time and with different driver duty modes selected

The Tachograph Programmer provides a test signal simulating the pulser output which gives the required speed outputs for the required times. The only operator intervention is then to set the duty modes at the appropriate times as indicated by the MKII. The programmer is connected to the Tachograph using a drive lead, 7780-981, similar to that shown below


Using the MKII – Analogue Bench Test

Before performing a Bench Test it MUST be ensured that the ‘UK’ test is selected via the Diagnostics menu. It is also recommended that a Clock Test is performed on the Tachograph prior to Bench Testing

Select K-factor:8000 Pul/km?

Set the Tachograph to a K-factor of 8000 (remember to note the original setting first). Press ENTER.Note: for a 2400 it is easier to read in the current K-factor value prior to the bench test and then use this value.

Select the scale: 125 km/h ← →

Select the Tachograph scale (125, 140 or 180 km/h) using the ← or → keys, and press ENTER.

VR2400 MAINMENU:BENCH TEST

From the MAIN MENU select BENCH TEST using the ← or → keys, and press ENTER.



Prepare andinsert 2 charts

Perform the task displayed. Press ENTER on completion. Note: For dual driver Tachographs, 2 charts must be inserted. For single driver 2400s, only 1 chart is required.

Auto Duty:Off ← →

Select whether changing the driver duty is to be done automatically or manually.Press Enter to accept the current setting or the ← or → keys to change.

Driver=ActiveCrew=Active

Set the driver and crew duty to active (4). Press ENTER on completion.

Check backlightilluminated

Make sure the 2400 LCD display backlight is illuminated.Note: this task should be ignored for a ‘No-display’ version of the 2400.



Speed: 125 km/hTime: 10 s

The speed will now be maximum speed for the selected scale for 10 seconds and the time will count down to zero and then an audible beep will be heard.

Speed: 0 km/hTime: 10 s

The speed displayed will then go to 0km/h for 10 seconds (the time will count down to zero) and an audible beep will be heard again.

Speed: 40 km/hTime: 150s

The speed will now go to 40km/h and will be held for 2½ minutes (the time will count down to zero). At the end of the 2½ minute test there will be an audible beep.

Note odometerreading

Note the current odometer reading on the Tachograph. This will be required later to check the accuracy of the odometer. Press ENTER.




The speed will then go up to 80 km/h. After a further 2½ minutes (the time will count down to zero) there will again be an audible beep indicating the end of that test.


The speed will move up to 100 km/h for a further 3 minutes (the time will count down to zero). At the end of the time there will be a further beep and the speed will return to zero.

Driver=ActiveCrew=Active

Set the driver and crew duty to active (4). Press ENTER on completion.

Recording dutyTime: 120 s

The Tachograph will record active (4) duty for 2 minutes (the time will count down to zero). After that time an audible beep will be heard.



Check odometeradded 10 km

Compare the new odometer reading with that noted above - a difference of 10km is expected.

Driver=RestCrew=Rest

Set the driver and crew duty to rest (2). Press ENTER on completion.


The Tachograph will record rest (2) duty for 2 minutes (the time will count down to zero). After that time an audible beep will be heard.

Driver=PassiveCrew=Passive

Set the driver and crew duty to passive (1). Press ENTER on completion.


The Tachograph will record passive (1) duty for 2 minutes (the time will count down to zero). After that time an audible beep will be heard.



Check clockto chart time

Open the Tachograph and check that the time on the chart corresponds with the time indicated on the clock. Press ENTER on completion.

VR2400 MAIN MENU:BENCH TEST

Press the ENTER key to complete the test and return to the MAIN MENU.

Check chart rec.Set K for veh.

Remove the chart(s) and check the traces have been completed satisfactorily – speed, duty & distance traces on driver chart and duty trace on crew chart (if fitted). Press ENTER on completion.

Note: carry out ‘sender disconnect’ and ‘power interrupt’ tests to complete the bench test. Note: do not open a 2400 drawer until the clock colon is flashing to indicate the Tachograph is recording


Using the MKII – Control Menu Functions

For 2400 or 1324 Tachographs, this menu can be used to pair a Tachograph with a KITAS1 encrypted sender. For 2400s it can also be used to reset the Tachograph

The programmer is connected to a 2400 using a 2400 calibration cable, 7780-936. The method of the test is as shown

CONTROL MENU: Pair sender

From the CONTROL MENU make the required selection - using the ← or → keys to select Reset tacho or Pair sender. Press ENTER to confirm the selection.

VR2400 MAIN MENU:TACHO CONTROL

From the MAIN MENU select ‘TACHO CONTROL’ using the ← or → keys, and press ENTER.


Using the MKII – Control Menu Functions

Sending dataData transfer OK

In the case of ‘Pair sender’, press ENTER and the sender and Tachograph will pair automatically within 60 seconds.

Note: When paired to an encrypted sender, the Tachograph recognises only that sender. The signal from the sender becomes unique to the Tachograph that it is paired with.

CONTROL MENU: Reset tacho

In the case of ‘Reset tacho’, the programmer will cause the Tachograph to simulate a ‘Power Off/On’ condition.


104

Any Questions?


105

Section 2.1

Digital Tachographs


Digital Tachograph System

Motion SensorProvides the VU with speed signal pulses from a vehicles’ gearbox systemSpeed signal is encrypted to ensure integrity of signal. Any tampering will be detected and recordedPaired with VU at installation to work as a mutually inclusive pair

Driver SmartcardUsed when a vehicle is being driven to store driving data relating to the named driver on the card

Vehicle UnitISO7736 radio sized. Contains printer, display, user controls & two smartcard slotsInformation stored consists of vehicle parameters, driver duties, events & faults, speed and distance informationCan supply signals to other vehicle systems

Instrument ClusterRemote displayUsed to display speed and distance, using information passed from the VU


Description of Controls

Return Button

Driver Smartcard

Drawer

Confirm Button

Display Paper Cassette

Down Button

Driver Duty-Change / Smartcard

Eject Button

Up Button

Crew Duty-Change / Smartcard

Eject Button

Printer Paper Slot

Crew Smartcard

Drawer


User Control Buttons

Duty-Change / Eject Buttons‘1’ for driver, ‘2’ for crew‘short-press’ – duty change, ‘long-press’ - eject

Return ButtonIs used for returning to the driver display screens and for cancelling selections

Up/Down ButtonsScroll through menu options or increment/decrement displayed values

Confirm ButtonEnter main menu, confirm selectable options, acknowledge and clear warning messages


Universal Time Co-ordinated - UTC

ALL VUs operate using UTC as their master reference time – all driving event times stored, displayed or printed are UTC times

UTC replaced GMT in 1986 as the world standard for time

UTC does not change due to seasonal adjustment i.e. no concept of “Summer time”

Workshops MUST set VU master time to UTC

Local time is available to a VU user for display purposes only


Standard Driving Display

Top line relates to driver and shows from left side; current activity and duration, cumulative break time, and VU mode of operation

Bottom line relates to crew and shows from left side; current activity and duration, and the current local offset time in 24-hour format


Printouts

Drivers must take printouts ifTheir driver smartcard is lost, stolen or faulty – take at start and end of driving – or if they are mixing driving in vehicles fitted with digital Tachographs and chart based units

Printouts must be taken on approved paper – the paper rear shows approval number, e.g. e5 0002 for SE5000. Printouts and paper charts must be safely stored and be readily available for any enforcement checks

There are 6 legally required types of VU printout availableDaily driver activities from Card or from the VU,Warnings - events and faults from Card or from the VU,Technical data,Overspeed data

Note: Additional non-legal printouts available are: Daily Driver Activity for Card or VU in Local-time, D1/D2 events, Vehicle engine speed and Vehicle speed bands


VU Warnings - Events & Faults

A VU can detect a number of different types of Events and Faults conditions

The VU will warn a user of a detected event or fault condition by displaying an appropriate warning message

Messages can be acknowledged and cleared from the display by pressing the ‘Confirm’ button

A printout of any Events and Faults stored in a VU or on a smartcard can be obtained as required

There are 6 types of VU warning message


Workshop Approval

All workshops must have VOSA approval before they can work on digital Tachograph systems

Workshop technicians must be holders of valid in-date analogue and digital certificates or a combined certificate before they can work on digital Tachograph systems. In the UK, updated certificates must be faxed to VOSA. See VOSA ATC manual for further details

Workshops must have a Designated Manager responsible for Tachographs, in their absence a deputy must fill this role

Workshops must operate as a secure environment ensuring that all workshop cards are properly used and securely stored when not in use

VOSA approved equipment must be used for all digital Tachograph work


Pre-Installation of a Digital Tachograph System

It is essential that prior to fitment of an SE5000 VU the following items are checked,

The VU data label must show the correct Stoneridge VU type approval number, i.e. e5 0002

The tamper label must be intact

The Stoneridge hologram must be correct

The VU should have no evidence of physical damage or tampering


Installation of a Digital Tachograph System

Fitting the gearbox motion sensor and the sensor cable

Making the required power and signal connections

Mounting the VU

Pairing the VU and motion sensor. This will automatically occur as part of the activation process – all VUs will always auto-pair

Activating the VU, verify the activation symbol () disappears

Calibrating and programming of the VU system

Sealing the VU system

Completion and fitment of a VU installation plaque. Complete paperwork and update GV212. GV212 must be in VOSA accepted electronic format from 1st January 2010


A VU is delivered non-activated. Activation occurs automatically on first insertion of a valid PIN authenticated workshop card and must be done prior to the vehicle being put into service

Access to calibration functions is granted while non-activated, even when not in Calibration Mode

After activation, the VU is fully operational including recording functions

A Workshop card is required to program the VU calibration parameters

Programming should be carried out using a VOSA approved device such as the Stoneridge MKII Tachograph Programmer

The 1st calibration of the VU system must be within 2 weeks of installation or VRN allocation

Activating, Calibrating and Programming the VU for Use


Repair and Decommissioning of Vehicle Units

Due to the security requirements of Digital Tachograph systems there are no repairable parts in a Stoneridge VU

A VU case must never be opened as this would be a breach of Digital Tachograph security, making the unit invalid

Replacement of the paper cassette is permitted – this is NOT classed as a repair

Faulty VUs must be decommissioned using the method as follows –


Decommissioning Procedure

Remove the VU from the vehicle

Download the VU data memory contents

The downloaded data must be securely stored for at least 1 year

The workshop must inform the current vehicle owner in writing that they are holding data which belongs to the owner

After a written request, a copy of any company-locked decommissioned data can be exported to the data owner. Note: keep a copy of the written customer request

If download is not possible, a certificate must be issued and a copy of the certificate must be kept for 1 year


Data Download Process

Downloading is the copying of a partial or a complete set of data that is stored in VU memory or on a smartcard

All VU downloading when decommissioning must be done when the vehicle is stationary or the VU is removed from the vehicle

The actual download process is controlled by the download tool, with the VU automatically responding to download requests from the download tool, assuming the VU is in the calibration mode and the vehicle is not moving or the VU is removed from the vehicle

Downloading can be very easily achieved using the Stoneridge CITO Download Tool ‘Quick VU Download’ and ‘Quick Smartcard Download’Buttons


Workshop Download Tool - CITO

Sufficient Memory space for 20 full VU data downloads

Decommissioned data download from a VU is via RS232 communications interface, front 6-way connector

Data upload to PC via USB interface

PC CITO Software for legal data storage, printing reports and exporting data to owners


Competitor Digital VUs

VDO 1381 Vehicle Unit

Actia SmarTach Vehicle Unit


122


123

Section 2.2

Digital Tachograph Inspection Procedure


Tamperproof Label

Type Approval Label

Inspection Procedure – Security Checks

Installation Plaque

Sealing of the VU

Visually check the following items and ensure that the unit has not been tampered with. Check VU/sender connection integrity using an independent cable


Inspection Procedure – Workshop Card Insertion

All interaction between a MKII Programmer and a Stoneridge VU iscontrolled by the MKII

In the operational mode, the VU will only allow its internal parameters to be read by an external device

In the calibration mode of operation, i.e. VU has an authenticated Workshop card inserted, the VU will respond to bench test, speed simulator and parameter re-programming signals

A Workshop card that is inserted into a VU can be PIN code authenticated using the VU keypad. However an SE5000 can also be remotely authenticated using a Stoneridge MKII Programmer. Note: for VDO and Actia VUs the number of digits in the PIN code must be entered and accepted before the PIN code itself

Always set the clock on the MKII Programmer to UTC time


Inspection Procedure – Bench Test Card Authentication

Remove the VU from the vehicle

Take a technical printout from the VU

Insert a Workshop card into slot 2 and then slot 1. Verify the card can be authenticated in each slot by entering the PIN code through the keys on the VU front panel. Note: ‘Long Press’ the ‘Confirm’ button to authenticate the input PIN code


Inspection Procedure – Bench Test Card Authentication

For an activated VU, once the Workshop card PIN is authenticated, the VU display will be as shown. Bypass the manual entries option by selecting the option screens as shown

If card insertion is on a new day, select the “Begin country” as ‘United Kingdom’

Check the ‘calibration mode’ symbol is shown on the top right corner of the VU display to confirm the Workshop card has been authenticated


Inspection Procedure – MKII/VU Bench Test Connections

Interfacing of the MKII Tachograph Programmer to a VU is done via the programmer 8-pin DIN connector and the VU 6-way front calibration connector

Both connectors are keyed so that wrongly inserting them is not possible

The SE5000 VU 6-way connector is exposed by first removing the paper cassette

SE5000 VU Front 6-Way Calibration Connector

VDO-1381 VU Front 6-Way Calibration Connector

Actia SmarTach VU Front 6-Way Calibration Connector


Inspection Procedure – Bench Test Using MKII

Perform a 1000m Distance Test using a MKII programmer

Use a test speed of 50km/h for the current VU K-factor setting

Confirm the speed displayed on the VU is accurate to ±1km/h

Verify the VU odometer is accurate to ±1%


Inspection Procedure – Bench Test Using MKII

Execute the Bench Test program using a MKII programmer

Perform a speed test using the MKII programmer, checking the three speeds 40, 80 and 180km/h are all displayed on the VU to an accuracy of ±1km/h

Verify that each duty, in the order; work, rest and available, can be selected by the duty buttons on the VU. Check that the appropriate symbol is displayed on the VU for each duty selected. Record each duty for a minimum of one complete ‘VU’ minute


Inspection Procedure – Vehicle Calibration

The vehicle Tachograph parameters must be re-determined as a mandatory requirement

Usually this is done using a rolling road in exactly the same way as for analogue Tachograph vehicles

The actual circumference of the drive wheel tyres (‘L-factor’) must be measured and recorded

The characteristic co-efficient of the vehicle (‘W-factor’) must be measured and recorded

The drive wheel tyre size must be checked and recorded

Modification of the VU stored parameters using a Stoneridge MKIITachograph Programmer can then be carried out


Inspection Procedure – VU Parameter Update – Practical Exercise

Use a MKII programmer to ‘Read All Data’ from a Stoneridge VU

Use the ‘Modify Data’ function to update the W & K-factors to 4567 pul/km, the L-factor to 2345 mm and to program the ‘Next Calibration Date’appropriately

Update the VU with the modified parameters using the programmer individual parameter ‘SEND’ function

‘Read’ the VU parameters again with the MKII to confirm the VU parameter update has been successful

Remove the workshop card from the VU to close the calibration session

Take a technical data printout to confirm the VU parameter update


133

Section 2.2.1

Downloading Workshop Card Calibration Records


Downloading Workshop Card – CITO Upload

The CITO unit should initially be powered by pressing the ‘ON/OFF’ button – wait for the unit to initialise

The required workshop smartcard to be downloaded should be inserted into the CITO unit smartcard socket with the smartcard chip facing upwards


Downloading Workshop Card – CITO Upload

Reading data

. . . . . .

For downloading the entire smartcard data memory contents the ‘download-smartcard’ ‘Fast-Key’ should be pressed and the data download will then begin

Whilst the download process is continuing, the CITO unit will display a ‘Reading data’ message as shown

Once the download process is complete, the CITO unit will display a ‘Data transfer OK’ message as shown to confirm the download

Data transfer OK


Downloading Workshop Card – PC Upload

Insert USB Cable Connector into CITO USB Socket

Insert USB Cable Connector into PC USB Port

Insert USB Software key (Dongle) into PC USB Port. Note: when the Centre is not operating the software key must be securely stored in the Workshop floor safe



PC upload of data held in a CITO tool can be carried out by a PC running the CITO Workshop PC software

All interaction between the Stoneridge CITO tool and the PC is controlled by the PC with the CITO tool acting as a slave

The CITO tool will automatically respond to upload signals from a PC

For upload to be possible by a Workshop Technician, the PC CITO Workshop software must be operating in a password protected mode of operation for data security purposes, and the software key (dongle) must be present in the USB port

The CITO tool must be switched on or the data upload to the PC CITO Database will not be possible



The data upload USB cable must be connected between the CITO tool and the PC USB port as shown above

The CITO Workshop PC software must be ‘run’ on the PC by clicking on the CITO icon on the desktop

Initially the CITO login screen will be displayed on the PC

A valid User Name and password must then be input to access the CITO database, as shown over

The password is personal to each workshop technician and must not be given to other workshop personnel



If the correct password is input for a valid user name then the main menu will be displayed as shown below



To upload data from the CITO tool to the CITO PC database, the ‘Download Centre’ should be executed by clicking on the correct icon

Click ‘Next’ and the download wizard will automatically begin the data transfer to the PC database



The PC with then automatically communicate with the CITO tool and download the data. Once the data transfer is complete, the PC software then saves the data received to the PC CITO database

The data in the CITO tool will be automatically deleted once it is saved in the PC database


Uploading Data from a Stoneridge CITO Tool to a PC

Once the card data, as listed, has been saved to the database click ‘Finish’ to return to the CITO software main menu

Click ‘Sign Out’ to return to the log-in screen for security purposes


143

Section 2.2.2

CITO Installation Plaque Generation


CITO Installation Plaque Generation

From the main menu the ‘Report Centre’ option should be selected by clicking the appropriate icon

The screen will then be as shown and the required report option should be highlighted before selecting ‘Next’ to proceed


CITO Installation Plaque Generation – Vehicle Selection

Assuming the ‘Digital plaques not yet printed’ option was selected previously, the next stage is to select the vehicle for which the plaque is to be produced

The screen will be similar to below and the required vehicle option (VIN/VRN) should be highlighted before selecting ‘Next’ to proceed


CITO Installation Plaque Generation – Calibration Date Selection

Once the vehicle is selected, the next stage is to select the date for which the plaque is to be produced

The screen will then be similar to that shown and the required date option should be highlighted before selecting ‘Next’ to proceed


CITO Installation Plaque Generation – Plaque Printing

The installation plaque details to be printed will then be automatically created from the database stored information, and the screen will be as shown below

The ‘Print’ option should be selected to print the plaque and the ‘Finish’option selected to end the operation


148

Any Questions?

www.stoneridgeelectronics.infowww.SE5000.comE-mail: [email protected]: 01382 866400

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