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© Stoneridge Electronics LtdDD55468 Rev 01 1

Stoneridge Electronics Ltd

Tachograph Re-certificationTraining Course


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 Ltd DD55468 Rev 01 3

Day 1

9:00 Introduction, Health & Safety Information

9:05 Company Profile

9:10 Tachograph Introduction, Charts & Regulations

9:45 W,K & L and Calibration

10:00 Senders & Cables

10:10 Tea Break

10:20 Sealing and Plaques

10:50 Using the 8400 Tachograph

11:15 The MKII Tachograph Programmer

11:30 Using the MKII Programmer with the 8400 Tachograph

12:30 Lunch

13:00 Using the 2400 Tachograph

13:45 Using the MKII Programmer with the 2400 Tachograph

15:00 Tea Break

15:15 Questions?

15:30 Exam

16:45 Finish


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


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

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


Section 1.2

Company Profile


(1) – 50% Ownership

(2) – 20% Ownership

AlphabetStoneridge

Electronics GroupActuator/Sensor Products

Finance

StoneridgeWarren, OH, USA

Chihuahua,Mexico

Warren, OH Stoneridge Electronics- Stockholm, Sweden- Örebro, Sweden- Tallinn, Estonia- Dundee, Scotland, UK

Pollak Electronics- El Paso, TX- Juarez, Mexico

PST Electrônica JV(1)- Campinas, Brazil- Manaus, Brazil

Minda/Stoneridge JV(2)-Pune, India

Canton, MA

Juarez, Mexico

Cheltenham, England, UK

Pollak Actuators - Boston, MA

Hi-Stat - Lexington, OH

Hi-Stat Sensors- Sarasota, FL- Lexington, OH

Pollak Switch Products

Stoneridge Sales

China Representative Office

Monclova,Mexico


Stoneridge Electronics Locations

Sales & Support:

Stuttgart, Germany Frankfurt, GermanyNuremberg, Germany Madrid, SpainParis, FranceBayonne, France

Dundee, Scotland Örebro, Sweden Bromma, Sweden Tallinn, Estonia


UK – Design, Manufacture & Sales

• Dundee• 100+ employees• 7400 m²


Instrument Clusters

Tachographs

Multiplex Systems

Power Distribution Centre

ECU’s

Telematics Systems

Overview Stoneridge Electronics Products


Stoneridge Electronics Customers

Off RoadVCESame Deutz-FahrCase New Holland

BusScaniaVolvoEvoBusJonckheere PlaxtonIRISBus

TrucksScaniaVolvo Daimler ChryslerMANRenault DAF

AutomotiveRenaultFordEberspächer


Section 1.3

Tachograph Introduction, Charts & 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 – 1100 Tachograph

The first type of Tachograph introduced by Veeder-Root was in the 1970’s and was the 1100 series Mechanical Tachograph

This was similar in design to existing mechanical drive circular speedometers of that time

The 1100 Tachograph utilises a mechanical flexible rotating shaft drive cable that is connected between the gearbox rotating shaft output and the rear of the Tachograph driving the mechanical speed and distance measuring systems within the instrument

An electrical supply to the Tachograph is required, but only to power the clock and the lamps



The Electronic Tachograph was first introduced by Veeder-Root in the early 1980’s and was the 1200 series. This was superseded by the more advanced 1400 series Tachograph in early 1984

The exterior design was very similar to 1100 Mechanical Tachographs

The 1200/1400 Tachograph eliminates the need for a mechanical flexible rotating shaft gearbox drive cable and instead uses an electronic gearbox motion sensor and electric cable to connect to the gearbox output

Microprocessor technology was used for the internal speed and distance measuring systems within the instrument


Tachograph Introduction – 8300/8400 Tachographs

In 1987 the 8300 Tachograph was introduced and used a microcontroller to perform the basic measurement, calculation and control functions

The 8300 Tachograph was the first Veeder-root Tachograph to utilise the four 8-way Amp mini-timer rear connectors that have since become the industry standard

In 1991 the 8400 series Tachograph was introduced. It is visually and dimensionally identical to the 8300 Tachograph but uses more modern electronics

The 8400 has electronically programmable engine rev bands, overspeed, ignition-on-record and pulses-per-rev settings

The 8300 and 8400 Tachographs are automatic in terms of ‘drive’ recording



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 – SE5000 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

Pear hole charts are detailed below. There is 24 Hour time scales which are standard to all one-day charts, subsections for speed, 4th trace/events recording, activity mode, distance and centrefield

Centre Field

24 Hour MarkingsSpeed Trace

4th Stylus/Events

Activity Mode

Distance Trace


Charts – Pear Hole Charts – Reverse Side

Manual Entries

Chart and Tachograph EU Approval Numbers, Always check compatibility.

Additional Changes of Vehicle


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

Vehicles registered on or before 30th April 2006 can be fitted with either a Digital Tachograph or Analogue Tachograph at the customers request. Vehicles registered after this date must have a Digital Tachograph system fitted


Tachograph Regulations – VOSA

The Vehicle and Operator Services Agency, VOSA, was formed in 2003 following a merger of the Vehicle Inspectorate, VI, and the Traffic Area Network, TAN, divisor of the UK government Department for Transport, DFT

The aim of VOSA is to contribute to the improvement of road safety, environmental standards, and to the reduction of vehicle crime

VOSA are the government body responsible for enforcing all drivers’ hours and Tachograph legislation, including the fitment and calibration of Tachograph systems

The limits of accuracy for speed, distance and time, both visually and recorded, for Analogue Tachographs are summarised below and are as listed in Council Regulations (EEC) 3821/85 and in the VOSA Approved Tachograph Centre Manual


Tachograph Regulations – Tachograph Tolerances

The Bench Test tolerances at Initial or 6 Yearly Inspection, also for 2 Yearly inspection for Centres using non-roller test equipment

• Distance Travelled: ±1%, where that distance is at least 1km• Speed: ±3 km/h• Time: ±10 minutes per 7 days, or ±2 minutes per day if clock cannot

run for 7 days continuously

The tolerances for an Installed system at the initial calibration stage are,

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

The tolerances for an Installed Analogue Tachograph system that is In Use, including as part of the 2-Year or 6-Year inspections, 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 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 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 withinlegal tolerances

– 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 6 years


Tachograph Regulations – 2-Yearly Periodic 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


Section 1.4

W, K & L-Factors and Calibration Methods


Establishing the Vehicle W and L-Factor Calibration Parameters

In the U.K. all Tachograph centres, other than remote centres, are required by law to have an electronic test rig to obtain the W and L-factors

The electronic test rig 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

The Hartridge system, although having been designed in the 1970’s, is still the most commonly used rolling-road system in UK Approved Tachograph centres, working on a set measuring speed of 50 km/h


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

Console with MKII ProgrammerInfra-red Transducer

Distance Roller

Vehicle Support Roller

Bogie Rollers


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 stations 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 the 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


Section 1.5

Senders & Cables


Senders & Cables – 4-wire Non-Armoured Cables

4-wire Non-Armoured Cable

4-wire Armoured Cable From 1/1/96

Encrypted Sender Cable Round Pin


Senders & Cables – 8-Pulse Gearbox Sender

The initial 8-Pulse sender devices, 2155 and 2157, were developed by Kienzle. These sender devices had only one speed signal channel and were known as 3-wire 8-Pulse Senders. However with one speed signal channel, it was possible to tamper with the speed signal without detection

Thus it became necessary to develop an 8-Pulse sender that had a second complimentary speed signal channel that made tampering with the speed signal more detectable. These devices with two speed pulse channels are known as 3-wire 8-Pulse senders

Stoneridge 8-pulse senders use a Hall-effect IC that produces 8 impulses for each revolution of the gearbox driven shaft. Stoneridge Tachographs such as the 8400 and 2400 will record error modes if either of the input signals from the two speed signal channels is not present

An 8400 Tachograph will not work with a 3-wire sender although an electronic 3-wire to 4-wire converter can be used if a vehicle is fitted with an old style 3-wire 8-pulse sender


Senders & Cables – 8-Pulse Gearbox Sender

4-wire 3-wire

Pulses from Channel 1

1 Revolution of Sender Input Shaft



Senders & Cables – Proximity Gearbox Sender Devices

Proximity senders also utilise a Hall-effect IC to generate a speed pulse train to output to the Tachograph 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

Gearbox Tone-Wheel

Proximity Sender

Hall-Effect IC


Senders & Cables – KITAS1 Gearbox Encrypted Senders

Stoneridge KITAS1 Encrypted senders are also proximity devices and their construction is very similar to standard 4-wire proximity sender devices. KITAS1 Encrypted devices must only be used with Analogue Tachographs that are compatible with them e.g. 2400 series Tachograph

The main difference between an encrypted sender and a 4-wire proximity device is that the encrypted device has an encryption communication channel instead of the standard ‘complimentary’ channel that the 4-wire devices have. The encryption channel has encryption data embedded into the complimentary signal as shown


Encryption Signal



Section 1.6

Sealing & Plaques


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 and marked with the appropriate manufacturer symbol and a valid VOSA Approved Tachograph centre number, e.g. GBL 300

Red plastic seals must be embossed with your station number using sealing pliers 7955-255 equipped with anvils supplied by Stoneridge and marked with a valid Approved Tachograph centre number, e.g. GBL 300

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


Plaques – Different Types

Calibration Label with Coverlay 7955-111• Vehicle calibration details are recorded

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

2-Year check label 6955-579• Once the Tachograph system passes all

the 2-year tests, this label is affixed to the inside of the Tachograph. Coverlay for this label is 6955-562

Minor Work Label 6955-561• To be used on a Tachograph system that

is repaired under the Minor Work Procedure. Coverlay for this label, is 6955-562


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

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


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 Additional Requirement

If a Tachograph is fitted with armoured cable the following procedure must be carried out as a VOSA requirement:

Check the rear Sealing Shroud that is used to secure the power and signal cable plugs at the rear of the Tachograph - if no sealing label has been previously fitted, or if the fitted seal is no longer intact, conduct checks on the integrity of system and then seal, or re-seal, as follows

• Seal the rear shroud in the normal way using an embossed red seal• Take a K-factor label, 6953-266, and cross through the “Imp/km”

marking and enter the Tachograph Centre Seal Number as shown in Appendix I of the VOSA Approved Tachograph Centre Manual

• Affix the white K-factor label vertically so that it is affixed to both the side of the rear sealing shroud and the casing of the Tachograph. Ensure that label is ‘tucked’ over the lip to ensure a good seal

• Complete sealing process by covering the white K-factor label with a blue edged plastic adhesive overlay, 6953-267


Sealing for the 8400 Series Tachographs – Rear Sealing Shroud Additional Requirement

K-factor Label with Plastic Overlay Applied on top

GB (X)(XXX)

Imp/km

Cross ThroughCentre Number Must Be Entered

White K-factor Label


Sealing the 8400 Series Tachograph – Calibration Switch Cover

The DIL switches require sealing after calibration

Sealing must be carried out using a black plastic cover - a clear plastic cover MUST NOT be used

The cover is inserted into place and moved upwards. The red seal locks it into place. It is essential that the seal is inserted into the hole and fully pushed home

Similarly to the rear shroud, as a VOSA requirement, a K-factor label and protective overlay must be placed over the fitted calibration DIL switch cover 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 connectorsThere is no requirement 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 Data Plate Label

2400 Data Plate Label

K-factor Label With Plastic Overlay Applied on top of Label

6872

The 2400 Tachograph Data Plate Label is factory fitted and gives specification details of the Tachograph

When the Tachograph is calibrated, the exact K-factor in impulses per kilometre should be recorded on a K-factor label. The K-factor label should be fixed to the Data Plate Label in the space provided also as shown. The K-factor label recorded value must be protected by covering the completed label with the blue edged plastic adhesive overlay as described previously for an 8400 Tachograph


2400 Installation plaque

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


Documentation – Paperwork for Registration

When a vehicle has been calibrated, the Tachograph fitted, and the whole installation sealed, the appropriate paperwork for the installation has to be made out for record purposes. This paperwork 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


Documentation – Tachograph Record Sheet


Documentation – Tachograph Record Sheet Information

6-Yearly Calibration of a Vehicle (Mechanical & Analogue Systems)

• The date work was carried out

• The vehicle make

• The tyre size and manufacturer

• The sealing number of the Approved Tachograph Centre

• The calibration switches settings or the corrector box gears required where applicable

• The W-factor and the L-factor

• The vehicle registration number

• The customer's name and address

• The tyre pressures

• The serial number of the Tachograph relating to the named vehicle

• The signature of approved Tachograph technician who carried out work

• The name and address of the Approved Tachograph Centre where the work was carried out



2 Year Inspection on Mechanical and Analogue Systems• The vehicle registration number and vehicle make• The customer's name and address and date the work was carried out• The tyre pressures, size and manufacturer’s name• The serial number of the Tachograph relating to the named vehicle• The signature of approved Tachograph technician who carried out work• The name and address of the Approved Tachograph Centre where the

work was carried out• The effective circumference of the vehicle drive wheel tyres, L-factor,

as is currently recorded on the Tachograph installation plaque and as measured during the current 2-year inspection

• The renewal date for the next 2-year inspection. Note: this is usually 2-years exactly from the date of the current 2-year inspection but the date recorded must not come after the due date of the next 6-year inspection



Minor repairs to a Mechanical or Analogue Tachograph System

• The vehicle registration number

• The customer's name and address and date work was carried out

• The vehicle manufacturer

• The tyre size and manufacturer’s name

• The serial number of the Tachograph relating to the named vehicle

• The signature of approved Tachograph technician who carried out work

• The name and address of the Approved Tachograph Centre where work was carried out

• Brief details of the minor repair carried out


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 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 Vehicle and Operator Services Agency, VOSA, require that each Approved Tachograph centre generate record sheets for all Tachograph work carried out by that centre

The VOSA register of Tachograph Plaques Issued, form GV 212, is a detailed log of Tachograph work carried out. Individual vehicle details and details on the work carried out on that vehicle MUST be recorded on the GV 212 form. The form must be kept in a secure place for at least 6 years and be made available for inspection by VOSA officials. One of the following five categories should be assigned to each job logged

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


Documentation – Official Register of Plaques Issued GV 212


Documentation – Minor Work Procedure

Minor work applies only to vehicles that are submitted for repair with all seals intact on an analogue Tachograph system. Should any seal be broken then a full calibration and re-seal would be required

From July 2005 VOSA stated that replacement tachographs could not be fitted as minor work. When fitting a replacement Tachograph the full calibration procedure must be carried out

VOSA requires that a Tachograph record sheet must be completed for every minor repair

VOSA requires that all Tachograph work carried out should be included on the GV 212 form ‘Register of Tachograph Installation Plaques Issued’. Approved Tachograph Centres must record Minor repairs on the GV 212 form, so that proper records are kept

It is a VOSA REQUIREMENT that 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


Section 1.7

Using The 8400 Tachograph


The 8400 Tachograph – Front View

Lock

Crew Duty Knob Driver Duty Knob

Chart Detect/ Over-speed Warning Light

Clock

Clock Tell-Tale

Odometer

Speed Pointer


The 8400 Tachograph – Rear View

Rear Connectors –

‘A’ – Voltage, White

‘B’ – Vehicle Speed, Yellow

‘C’ – Engine Speed, Red

‘D’ – Auxiliary Signals, Brown


The 8400 Tachograph – Other Tachographs, SVDO-Kienzle 1318 & 1319 and Motometer EGK-100

Motometer EGK 100 (VOLVO)

SVDO-Kienzle 1319 (Mercedes)SVDO-Kienzle 1318


The 8400 Tachograph – Chart Fitting

Crew Chart Fitting Driver Chart Fitting

Co-Driver’s Chart

Chart Separation Plate

Driver’s Chart


The 8400 Tachograph – Power Connections

An AMP mini timer plug, 2714-265 and terminal 2714-270, are used with automotive insulated cable 1 mm2, to make up the appropriate power loom for an 8400 Tachograph as shown. For an 8300 Tachograph, the only difference would be that the Tachograph electronics are powered separately via the A4 connection

LAMPS

IGNITION

2714-265HOUSING NATURAL

AND2714-270, TABS

A-CONNECTOR


The 8400 Tachograph – Sender Connections

The connections for the standard yellow Amp mini-timer 4-wire Tachograph sender input connector are as listed in the table below. Pins 5 to 8 are not connected to the sender. A full description of all 8400 Tachograph rear connections is included in Appendix A of the 8400 section of the Training Manual

-Pin 8

-Pin 7

-Pin 6

-Pin 5

WhitePin 4 Complimentary Input

BluePin 3 Main channel input

Brown or RedPin 2 Negative supply to sender

Black Pin 1 Positive supply to sender

VR 8 PULSE SENDER (4-wire)SOCKET B


The 8300 & 8400 Tachographs – ADR Goods Vehicles Fitment

Extra care must be taken when installing or repairing Tachographs on this type of vehicle due to the dangers involved – a Technician must only work on an ADR goods vehicle Tachograph system if they are ADR certified

The 8300 Tachograph was designed to be intrinsically safe and carries BASEEFA approval for use in ADR goods vehicles when used in conjunction with an 8300 barrier device – check that the [EExib] label is attached before fitting an 8300 Tachograph

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

The 8300 and 8400 when used specifically with their own barrier device have 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


The 8300 & 8400 Tachographs – ADR Goods Vehicles Fitment

8300 and 8400 Tachographs MUST ONLY be fitted in an ADR Goods Vehicle if they are fitted in conjunction with a 8300 or 8400 barrier device respectively

An 8300 Tachograph must NEVER be used with an 8400 barrier device or any competitor barrier devices

An 8400 Tachograph must NEVER be used with an 8300 barrier device or any competitor barrier devices

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 8300 & 8400 Tachographs – Calibration Switches

8300 Bank1 DIL Switches 8400 Bank1 DIL Switches

The EU type approval numbers for the 8400 Tachograph are e11-20 for 125 km/h, e11-21 for 140 km/h and e11-24 for 180 km/h versions

The EU type approval numbers for the 8300 Tachograph are e11-18 for 125 km/h versions and e11-19 for 140 km/h versions


The 8400 Tachograph – 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 a 8400 Tachograph that is installed in a vehicle is as follows:

• Switch off the vehicle ignition and check that the clock indicator is turning

• Switch on ignition, switch on the vehicle sidelights and check that the Tachograph dial lights are illuminated

• Drive the vehicle onto a rolling-road and accelerate the vehicle on the rolling road rollers until the speed reading on the rolling road console 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 Tachograph speed returns tozero. If a rolling-road is not available the vehicle must be road tested to ensure the Tachograph responds to vehicle speed changes


Section 1.8

The Stoneridge MKII Tachograph Programmer


The MKII Programmer – Introduction and Overview

Socket C

LCD Display 2 x 16

Socket BSocket A

Socket D Socket E

Keypad



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

‘Delete’ key allows the deletion of an entered value

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

‘ON/OFF’ key is used for turning unit on and off



A MKII Tachograph Programmer can be used with all types of analogue electronic Tachographs

• Stoneridge 1400, 8300, 8400 and 2400

• Siemens-VDO Kienzle 1314, 1318, 1319 and 1324

• MotoMeter EGK-100


The MKII Programmer – Software Version and Upgrading

The MKII Programmer software version is displayed each time the unit is switched on. It can also be displayed via the Diagnostics Menu/ROM test. The software version must be 2.0 or greater for use with DigitalTachographs

A MKII Programmer’s software version can be upgraded using a PC running a dedicated Stoneridge installation program which is available on a Programmer specific Upgrade CD. The PC Serial Communications Port is connected to the Programmer, Socket D above via a Field DownloadCable, Part Number: 7780-953


The MKII Programmer – Programmer Functions

Listed below are the Functions available in the MKII programmer along with a brief description of the function and to which Tachograph types the function is applicable. Note: all Tachograph types if not specified

Tacho Select - this function allows the operator to specify the Tachograph type that is to be calibrated or tested by the Programmer, as described above

Pulser Select - 8300, 1400, 2400 and 1314 only. This function allows the operator to specify the pulser or sender type that is being used with the current Tachograph, as described above

Rolling Road Test - this function is used to determine the vehicle W-factor using a Hartridge or similar Rolling Road

Fixed Distance #1 Test - this function is used to determine the vehicle W-factor using the Physical method 20m track

Fixed Distance #2 Test - this function is used to determine the vehicle W-factor using the Physical method 20m track with a Flexi-Switch



Bench Test - this semi-automatic function assists a Workshop Technician when bench testing a Tachograph using a series of commands displayed on the screen

Speed Simulator Test - this function injects speed pulses into a Tachograph for the purpose of checking Tachograph speed indication, the overspeed warning, the stylus positions on chart or the speed limiter operation

RPM Pulse Test - 2400, 8400, 8300, 1318, EGK100, 4-stylus Tachographs only. This function is used to determine the “Pulse Per Engine Rev” from the “W” terminal on the alternator or a revs sender

Clock Test - this function checks the accuracy of a Tachograph clock. The function is automatic for the 2400, EGK100, and 1324 but uses an optional external clock-tester for all other analogue Tachographs



Tacho Control – 8400, 2400 and 1324 only. This function is used to force the Tachograph to enter either a “Self Test” or an “Extended Test” mode, to Reset the Tachograph memory to the “Default state” or to pair a Tachograph with a sender in the 2400 and 1324 only

Identify Tacho - 2400 and 1324 only. This function interrogates a Tachograph via its K-line connection and determines the System supplier, Manufacture date, Serial number, Hardware version, Software number, Software version and System name

Read/Erase DTCs - 2400 and 1324 only. This function enables the Diagnostic Trouble Codes (DTCs) stored in the Tachograph to be displayed on the Programmer and then erased in the Tachograph if required



Read all data / Modify data / Send all data – 2400, 1319, 1324 and EGK100 only. These functions interrogate the Tachograph via the K-line or serial data line. They allow a Workshop Technician to change various Tachograph settings in the programmer and then re-program the Tachograph with all the data set-up in the Programmer in a single operation

Program Tacho – 8400 only. This function can be used to select and modify various settings such as “Ignition On Recording” and “Overspeed Setting”

K-factor Test – 8400, 1319, 1318 and 1314 only. This function determines the K-factor currently set on a Tachograph

DIL calculate - 8400, 8300, 1400 and 1318 only. This function eliminates the need to look up DIL switch calibration tables


Section 1.9

Using The MKII Programmer With the 8400 Tachograph


Using the MKII with 8400 – Clock Test

A Tachograph clock test can be carried out on circular Tachographs such as the 8400 using an independent clock tester as shown. The tester must be connected to the programmer socket C only. There is no direct connection to the Tachograph

Initially set both the Tachograph duty knobs to Rest. Ensure that the Tachograph is powered with speed pointer at rest. When the clock test starts, hold the adapter against the Tachograph face. For the correct location, a regular clicking sound will be heard. Please note that the correct location is not necessarily near the clock face, as the Tester detects the clock motor. If the duty knobs are not at Rest or the speed pointer not at zero, the Tester may detect the chart motor instead of the clock motor. Also, the Tester must not be within 12 inches of a mains transformer


Using the MKII with 8400 – Clock Test

ERROR! No signalIn the case of loss of signal or inconsistent signal from the Tachograph (usually caused 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.

VR8400 MAIN MENU:CLOCK TEST

From the MAIN MENU select CLOCK TEST using the ← and → keys. Hold the clock-tester at the correct location on the Tachograph face (as described above). Press ENTER to start the test.


Using the MKII with 8400 – 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 switches at the appropriate times as indicated by the Programmer. The Programmer is connected to the 8400 using a Tachograph drive lead, 7780-981 similar to that shown below



Before performing the Bench Test it must be ensured that the UK Bench Test is selected via Diagnostics menu. We recommend prior to Bench Testing the Clock Test should be performed on the Tachograph

Connect drivelead to tacho

Check the Tachograph drive cable connection is made.

Check tachosettings

Check DIL switches 2,3 & 9 are ON with others OFF.

Select K-factor:8000 Pul/km?

Set the Tachograph to a K-factor of 8000 (remember to note the original setting first). Press ENTER.

Select the scale: 125 km/h ← →

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

VR8400 MAINMENU:BENCH TEST

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



Switch on atcorrect voltage

Set power supply voltage to the correct level for the Tachograph (12V or 24V)

Close thetachograph

Perform the task displayed. Press ENTER on completion.

Prepare andinsert 2 charts

Perform the task displayed. Press ENTER on completion. Note: For dual driver Tachographs, 2 charts have to be inserted. For a single driver, only 1 chart has to be inserted.

Check clock foraccuracy

The clock time should be adjusted if necessary.

Check bulbs areilluminated

Check both bulbs are lit.

Check clock isStepping OK

Make sure clock tell-tale is moving.



Driver=ActiveCrew=Active

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

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.


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.

Note odometerreading

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

Close thetachograph

Perform the task displayed. Press ENTER on completion.

Check clockto chart time

Make sure the FSD speed marking on the chart is within 5 minutes of the Tachograph time.



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.


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.



Recording dutyTime: 120 s

The unit will record Active (4) 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 unit will record Passive (1) duty for 2 minutes (the time will count down to zero). After that time an audible beep will be heard.

Driver=RestCrew=Rest

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


The unit will record Rest (2) 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.



Check chartrecordings

Remove the two charts and check the traces recorded (speed, duty and distance on driver chart and duty only on crew chart). Press ENTER.

VR8400 MAIN MENU:BENCH TEST

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

SWITCH OFFPOWER SUPPLY

Switch off the power to the Tachograph and disconnect the power cable.

Set K-exactfor vehicle

The DIL switches must be returned to the correct settings for the vehicle in which the Tachograph is to be fitted.

Note: carry out ‘sender disconnect’ and ‘power interrupt’ tests to complete the bench test


Using the MKII with 8400 – K-factor Test

This provides a simple way of determining the K-factor currently set on the Tachograph

The programmer is connected to the 8400 using a Jack-socket cable and a crocodile clip to the vehicle earth connection. The method of the test is 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 ← and → keys.


Using the MKII with 8400 – K-factor Test

ERROR! CHECKCONNECTIONS

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

Sending pulsesK = 8000

Step 3 will then repeat until the MENU 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 with 8400 – Programming the Tachograph

The MKII Programmer supports programming of 8400, 2400, 1319, 1324 and EGK-100 analogue Tachographs

It should be noted that in all cases that, once settings have been altered, the SEND ALL DATA command may be used to transfer all the information at the end. It is however possible, to send each individual setting after alteration by pressing the SEND key, although not with the 1319 and EGK-100

Care must be taken when using SEND ALL DATA that no parameters are accidentally overwritten with a wrong value which in extreme cases may cause the vehicle to malfunction. Using the SEND key to individually transmit parameters is more time consuming but is much safer in terms of accidentally overwriting a Tachograph parameter with a wrong value

The programmer is again connected to the 8400 using a Jack-socket cable and a crocodile clip to the vehicle earth connection. The method of the test is as follows


Using the MKII with 8400 – Programming the Tachograph

VR8400 MAIN MENU: PROGRAM TACHO

From the Main Menu select PROGRAMTACHO and press ENTER

VR8400 MAIN MENU:SEND ALL DATA

Select SEND ALL DATA from the MAIN MENU and press ENTER.

Overspeed:80 km/h

Overspeed - Press ENTER and a cursor will flash. Key in the required overspeed value and terminate the entry by pressing ENTER.

Ign On Record:OFF

Ignition On Record - Press ENTER and ←→ will appear on the display. Use the ← or →keys to select ON or OFF and press ENTER to terminate the selection.


Using the MKII with 8400 – Practical Exam

Carry out the 8400 practical exam as instructed



Section 1.10

Using the 2400 Tachograph


The 2400 Tachograph – Introduction

CANbus, Kline or D6

2400 Tachograph

Instrument Cluster



The 2400 Tachograph was introduced in 1999 and displays and records speed and distance in km/h and km and driver activity as per regulation 3821/85. The 2400 Tachograph is available as 12 and 24 Volt versions

The chart drawer is held in the locked closed position whilst a vehicle is moving. This can only be opened, in order to facilitate access for inserting or removing charts, with the vehicle stationary and ignition on

The 2400 Tachograph can be used by two drivers, and thus two sets of driver-specific controls are provided adjacent to the display. These comprise a duty push-button and three LEDs that indicate non-driving activity. Three further push-buttons are provided: the left-hand control is a Mode Change push-button, the centre control is an Advance push-button and the right-hand control is an Eject push-button

2400 Tachographs use pear-hole charts



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

The EU type approval numbers for the 2400 are e11-27 for 125 km/h, e11-26 for 140 km/h and e11-25 for 180 km/h 2400 versions respectively

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



The calibration of a 2400 Tachograph is achieved using a MKII programmer. A large K-factor range of 500-64255 pulses/km is achievable

The 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 can be displayed and are stored in the non-volatile memory

OEM specific CANBus versions are available for different vehicle manufacturer 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


The 2400 Tachograph – Front View ‘With-Display’ Version

Mode Change Button

Advance Button

Drawer Eject

Button

Driver Duty LEDs

Crew Duty LEDs


The 2400 Tachograph – Rear View

Rear Connectors –

‘C’ – Engine Speed, Red ‘A’ – Voltage, White

‘D’ – Auxiliary Signals, Brown ‘B’ – Vehicle Speed, Yellow

D C B A


Siemens VDO-Kienzle 1324


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 Push Buttons

The Mode Change push-button, which is identified by a circular white dot ●, is used to select whether the display indicates the odometer reading or the odometer trip reading, and to adjust the time

If a 2400 Tachograph has been configured to display engine Revs in RPM, then the mode change push-button will select between RPM, Odometer and Trip distance

The Advance push-button, which is identified by a white plus sign +, 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 2400 Tachograph – Eject Push Button

The Eject push-button, which is identified by the white legend ▲, is pressed to open the drawer. When the Eject push-button is pressed, a 3 mm radial line is drawn on the Driver chart between the Duty and Distance traces to record that the drawer is being opened, then the styli are withdrawn from the charts

While the styli are retracting, the LED mode changes to the automatic sequence indicating that the Tachograph is carrying out internal functions, in this case stylus retraction. Once the styli are fully retracted, the LED mode reverts back to the flashing sequence, indicating that the drawer can now be opened by the operator by pushing the drawer at the oval emboss next to the eject button


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 – 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 Tachograph drawer must be opened by pressing the Eject push-button

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

The LEDs will illuminate in turn, as described previously

Push the front of the drawer in the position shown – this will cause the drawer to unlatch and spring forward to the partly open position

DO NOT press on the display



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


The 2400 Tachograph – Chart Fitting – Co-driver

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 12 o’clock

With the face of the chart uppermost, insert the edge of the chart through the transverse slot between the front and rear chart platens, as shown. Then carefully locate the chart over the pear-shaped drive spindle such that the thin end of the pear-shaped hole in the centre of the chart is located first


The 2400 Tachograph – Chart Fitting – Driver

Fit driver chart under location

fingersLocate chart

over pips

Again rotate the chart table so that the thin end of the pear shaped drive spindle on the table is facing 12 o’clock

With the face of the chart uppermost, insert the edge of the chart such that its edge locates under the two location fingers at the rear of the chart table, as shown. Carefully locate the chart over the pear-shaped drive spindle such that the thin end of the pear-shaped hole in the centre of the chart is located first – make sure the chart is located over the pips on the spindle



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, the stylus movement is minimised, thus reducing the overall acoustic output of the 2400. This is known as the quiet running mode

If the following conditions are present• Driver duty (and if appropriate, crew duty) set to rest• Zero speed• Ignition off• Fourth trace OFF (i.e. no events and/or zero engine speed)

Then the speed rack will remain positioned at the zero speed mark. The duty rack will position itself in the duty rest position. The chart table will continue to rotate and this will cause a zero km/h speed trace and a driver duty rest trace to be drawn but NO distance trace will be recorded as shown below


The 2400 Tachograph – Chart Recording in Stationary Vehicle with Ignition 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


The 2400 Tachograph – Installation - 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 2400 Tachograph as shown


The 2400 Tachograph – Installation - Sender Connections

4-pulses per metrePin 8

V-pulse – ISOPin 7

V-pulse – customer specifiedPin 6

Dual-axle settingPin 5

Encrypted 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 Tachograph sender input connector are as listed in the table below. Pins 5 to 8 are not connected to the sender, but are used for output signals as described. A full description of all 2400 Tachograph rear connections is included as Appendix A of the 2400 section of the reference Training Manuals


The 2400 Tachograph – Removing the Tachograph

Four Removal

Holes

The 2400 Tachograph may be removed with the drawer open or closed. With the drawer closed, four small holes can be seen at the sides of the plastic front fascia, as shown. To remove the unit, a pair of Tachograph extraction tools, 6350-023, should be inserted into the two pairs of holes, with the tools perpendicular to the Tachograph. Once pushed in, both extraction tools should be pushed out sideways and then pulled at the same time. The tools will grip the unit and enable it to be pulled out


The 2400 Tachograph – Opening the Drawer Whilst Disconnected

Drawer Release Hole

In the event of a power disconnection or failure the 2400 drawer may only be opened - to access charts - after removing the unit from the dashboard to gain access to the release mechanism at the rear of the Tachograph

At the rear of a 2400 as shown, there is a small hole. If a Drawer-Eject tool (6450-131) is inserted and light pressure is applied to the fascia, the drawer will unlock and spring out. This method must only be used when there is no power present. Opening the drawer using this method, when the unit is powered, will result in damage to the Tachograph


The 2400 Tachograph – 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 a 2400 Tachograph that is installed in a vehicle is as follows:

• Switch on ignition, switch on the vehicle sidelights and check that the Tachograph display lights change from bright to dim and that theduty LEDs are on and that all driver duties can be selected

• Drive the vehicle onto a rolling-road and accelerate the vehicle on the rolling road rollers until the speed reading on the rolling road console is 50 km/h. Hold the speed at 50 km/h and check that the 2400 displays a speed of 50 km/h ±4 km/h. Decelerate the vehicle to a stop and check that the 2400 speed returns to zero. If a rolling-road is not available the vehicle must be road tested to ensure the 2400 responds to vehicle speed changes


The 2400 Tachograph – Input and Output Signals –Communication Interfaces - 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 the Tachograph chart and respond to signal levels in excess of 4V

• Rear Connector Pin D1 is used for the Event 1 Input• Rear Connector Pin D2 is used for the Event 2 Input

Engine Revs InputThe Revs 1 input signal is monitored by the processor and is used to determine engine speed. The input line is normally connected to the W-terminal of the alternator

The Revs 2 input signal is monitored by the processor and is used to determine engine speed

Engine speed can be measured by monitoring either the signal from revs sender, rear connector Pin C4, or from the W-terminal of the alternator rear connector Pin C3



V-Pulse Output - The V-Pulse output is a positive going signal that is triggered by each pulse from the speed/distance sender

• Rear Connector Pin B7 is used for the standard ISO V-Pulse Output Signal

• Pin B6 can be used as an alternative customer variant V-Pulse signal available in ISO or Open Collector formats

4-Pulses per Metre Output - The 4-PPM output is a string of positive pulses generated at a rate where 4 pulses correspond to one metre

• Rear Connector Pin B8 is used for the 4-Pulses Per Metre signal

Overspeed Output - The Overspeed Output is active when an overspeedcondition is detected

• Rear Connector Pin D5 is used for the Overspeed signal



Speedometer Output - The Speedometer output signal is a rectangular output waveform that is used to drive the vehicles’ speedometer so that it displays the correct speed. A speedometer output calibration factor must be programmed into the Tachograph in order for the correct speed to be displayed

• Rear Connector Pin D6 is used for the speedometer output signal,and it should be noted that for some 2400 customer types, this output would have been factory initialised as an open-collector output as opposed to the standard ISO configuration

General Warning Output - The General Warning Output allows options for Low-Speed, DTC Warnings or Chart Change Warnings, or the output may be disabled

• Rear Connector Pin D4 is used for the General Warning


Section 1.11

Using the MKII Programmer With the 2400 Tachograph


The MKII Programmer – 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 i.e. 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


The MKII Programmer – Sender Selection 2400

For 2400 series Tachographs, the sender type must be selected

With the Programmer 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

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 with the 2400 – Interfacing the MKII to the 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 below

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


Using the MKII with the 2400 – Interfacing the MKII to the Tachograph

Insert DIN Connector into MKII Programmer 8-Way DIN Socket

2400 6-way Programming Socket with sealed cover-clip removed


Using the MKII with the 2400 – Clock Test

A Tachograph clock test can be carried out on 2400 Tachograph using a direct MKII-Tachograph connection via 2400 calibration cable, 7780-936

ERROR! No signalIn the case of a lack of signal from the Tachograph (caused usually by a faulty cable connection to the Tachograph) 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 ‘Sending Data’ then ‘Testing Clock’ as shown

VR2400 MAIN MENU:CLOCK TEST

From the MAIN MENU select CLOCK TEST using the ← and → keys. Press ENTER to start the test.


Using the MKII with the 2400 – 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 Programmer. The programmer is connected to the 2400 using a Tachograph drive lead, 7780-981 similar to that shown below



Before performing the Bench Test it must be ensured that the UK Bench Test is selected via the Diagnostics menu. We recommend the 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 ← and → keys, and press ENTER.

VR2400 MAINMENU:BENCH TEST

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



Prepare andinsert 2 charts

Perform the task displayed. Press ENTER on completion. Note: For dual driver Tachographs, 2 charts have to be inserted. For a single driver, only 1 chart has to be inserted.

Auto Duty:Off ← →

Select whether the change of driver Duty is to be automatically or manually changed.Press Enter to accept current settings or the ← and → keys to change.



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.




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.


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.


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.




The unit 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 unit 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 unit 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 2400 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 – do not open the 2400 drawer until the clock colon is flashing to indicate the Tachograph is recording


Using the MKII with the 2400 – Control Menu Functions

For a 2400 Tachograph, this menu can be used to reset the Tachograph or to pair the Tachograph with a KITAS1 encrypted sender

The programmer is connected to the 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 with the 2400 – Control Menu Functions

Sending dataData transfer OK

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

Note: When paired to an encrypted sender, the 2400 Tachograph recognises only that sender. The signal from the sender becomes unique to that Tachograph.

CONTROL MENU: Reset tacho

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


Using the MKII with the 2400 – Programming the Tachograph

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

It should be noted that in all cases, once settings have been altered, the SEND ALL DATA command can be used to transfer all the information at the end. It is, however, possible to send each individual setting after alteration by pressing the SEND key

Care must be taken when using SEND ALL DATA that no parameters are accidentally overwritten with a wrong value which in extreme cases may cause a vehicle to malfunction. Using the SEND key to individually transmit parameters is more time consuming but is much safer in terms of accidentally overwriting a Tachograph parameter with a wrong value


Using the MKII with the 2400 – Programming the Tachograph, Reading Parameters

All interaction between a MKII Programmer and a 2400 Tachograph is controlled by the MKII Programmer

Initially the parameters must be read from the 2400 Tachograph and a copy transferred to the Programmer. The MKII ‘READ ALL DATA’ 2400 Main menu option is used to do this

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

2400 MAIN MENU

:READ ALL DATA


Using the MKII with the 2400 – Programming the Tachograph, Reading and Modifying Parameters

Press the Programmer ‘ENTER’ button to initiate the parameter data transfer from the 2400 Tachograph to the MKII Programmer. The Programmer will display the message shown while the data is being transferred and then a second message as shown once the parameter transfer is completed

Reading data

. . . . . . . .

Data transfer OK

Once the VU parameters have been ‘read’ into the Programmer they can then be modified individually


Using the MKII with the 2400 – Programming the Tachograph, Modifying and Sending Individual Parameters

The 2400 parameters can be modified 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 2400. 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 with the 2400 – Programming the Tachograph, Sending All Parameters & Checking Updated Parameters

The successful transmission of the parameters can be confirmed by ‘reading’ back the parameters from the Tachograph as described previously and then using the ‘modify’ function to check the new values have been programmed correctly

2400 MAIN MENU

:READ ALL DATA

2400 MAIN MENU

:MODIFY DATA


Using the MKII with the 2400 – Programming the Tachograph, Parameters that can be Modified

2400 Parameters which may be Programmed are:

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



K-factor – Press ‘ENTER’ and key in the new value. Press ‘ENTER’ again to confirm the value

Odometer – Press ‘ENTER’ and key in the new value. The last digit input is tenths, thus an odometer reading of 100.0 km should be input as 1000. Press ‘ENTER’ again to confirm the new value. Note: the value can be programmed above 1000 km ONLY ONCE

K-factor

:8000

Odometer

:000548.7



CANBus RPM – Press ENTER and use the ← and → keys to select ON or OFF. Press ENTER to confirm the selection

RPM Display – Press ENTER and use the ← and → keys to select ON or OFF. Press ENTER to confirm the selection

CANBus RPM

:Off ← →

RPM display

:Off ← →



Odo Leading Zeros – Press ENTER and use the ← and → keys to select ON or OFF. Press ENTER to confirm the selection

Overspeed flash – Press ENTER and use the ← and → keys to select ON or OFF. Press ENTER to confirm the selection

Odo leading 0s

:Off ← →

Overspeed flash

:Off ← →



DTCs Enabled – Press ENTER and use the ← and → keys to select ON or OFF to enable or disable DTC display. Press ENTER to confirm the selection Note: DTC recording in not affected by this parameter

Overspeed – Press ENTER and a cursor will flash. Key in the required over speed value and press ENTER

DTCs enabled

:Off ← →

Overspeed

:90 km/h



Current time – Press ENTER and a cursor will flash. Key in the current time and press ENTER. The time can also be set via the keys on the fascia of the 2400 Tachograph for non-RTC units

Current date – Press ENTER and a cursor will flash. Key in the current date and press ENTER. The date can also be set via the keys on the fascia of the 2400 Tachograph for non-RTC units

Current time

:10:35

Current date

:05/06/2007



Time offset – Press ENTER and use the up/down arrow keys to choose a time offset between +23:00 and –23:00 hours

Output shaft factor – This value should not be changed from the vehicle factory set value

Time offset

:+1:00

O/P shaft factor

:8.140



4th Chart Trace – Press ENTER and use the ← and → keys to select ON or OFF. Press ENTER to confirm the selection

CANBus enabled – Press ENTER and use the ← and → keys to select ON or OFF. Press ENTER to confirm the selection

4th chart trace

:Off ← →

CANBus enabled

:Off ← →



Speedo output factor – Press ENTER and a cursor will flash. Key in the required value and press ENTER to confirm the selection

D6 pin function – Press ENTER and use the ← and → keys to select OFF, Revs warning or Speedometer as required

Speedo OP factor

:4971

D6 pin function

:OFF ← →



Ignition on Record – Press ENTER and use the ← and → keys to select ON or OFF. Press ENTER to confirm the selection

Crew auto duty – Press ENTER and use the ← and → keys to select ON or OFF. Press ENTER to confirm the selection

Ign On Record

:OFF ← →

Crew auto duty

:OFF ← →



VIN – Press ENTER and key in the Vehicle Identification Number. This can be up to 17 characters long. Press ENTER to confirm the selection

Service Delay – Press ENTER and a cursor will flash. Key in the number of WEEKS left until the compulsory check (maximum 104 weeks) or next calibration of the Tachograph and press ENTER

VIN

:1234567890ABCDEFG

Service delay

:104 weeks



Install date – Press ENTER and a cursor will flash. Key in the date of installation for the Tachograph and press ENTER

Reset Heartbeat – Press ENTER and use the ← and → keys to select ON or OFF. Press ENTER to confirm the selectionNote: when set to ON the vehicle cluster presence is confirmed by the Tachograph

Install date

:05/06/2007

Reset Heartbeat

:OFF ← →



Pin D4 Function – Press ENTER and use the ← and → keys to select the Pin D4 function required. Press ENTER to confirm the selection from: Off, Dynafleet, Low Speed, Functions, DTC Warning and Chart Change

Pin D4 Function

:OFF ← →

Low speed Limit – Press ENTER and a cursor will flash. Key in the required low speed value and press ENTER

Low Speed Limit

:5 km/h


Using the MKII with 2400 – Practical Exam

Carry out the 2400 practical exam as instructed


Any Questions?