DD55468 Rev01 Analog Tacho Recert Training

Stoneridge Electronics Ltd
Tachograph Re-certification Training Course
Stoneridge Electronics Ltd DD55468 Rev 01
Stoneridge Electronics Ltd COPYRIGHT

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.
Day 1
9:00 9:05 9:10 9:45 10:00 10:10 10:20 10:50 Introduction, Health & Safety Information Company Profile 11:15 11:30 12:30 13:00 13:45 15:00 15:15 15:30 16:45 The MKII Tachograph Programmer Using the MKII Programmer with the 8400 Tachograph Lunch Using the 2400 Tachograph Using the MKII Programmer with the 2400 Tachograph Tea Break Questions? Exam Finish
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Tachograph Introduction, Charts & Regulations W,K & L and Calibration Senders & Cables Tea Break Sealing and Plaques Using the 8400 Tachograph
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
Stoneridge
Warren, OH, USA
Stoneridge Sales
Finance
Alphabet
Warren, OH Chihuahua, Mexico Monclova, Mexico
Stoneridge Electronics Group

Stoneridge Electronics - Stockholm, Sweden - rebro, Sweden - Tallinn, Estonia - Dundee, Scotland, UK Pollak Electronics - El Paso, TX - Juarez, Mexico PST Electrnica JV(1) - Campinas, Brazil - Manaus, Brazil Minda/Stoneridge JV(2) -Pune, India
Pollak Switch Products

Canton, MA Juarez, Mexico Cheltenham, England, UK
Actuator/Sensor Products
Pollak Actuators - Boston, MA Hi-Stat - Lexington, OH Hi-Stat Sensors - Sarasota, FL - Lexington, OH
(1) (2)
50% Ownership 20% Ownership
China Representative Office
Stoneridge Electronics Locations
Dundee, Scotland
rebro, Sweden
Bromma, Sweden
Tallinn, Estonia Sales & Support: Stuttgart, Germany Frankfurt, Germany Nuremberg, Germany Madrid, Spain Paris, France Bayonne, France
UK Design, Manufacture & Sales
Dundee 100+ employees 7400 m
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Overview Stoneridge Electronics Products

Instrument Clusters Tachographs Multiplex Systems Power Distribution Centre ECUs Telematics Systems
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Stoneridge Electronics Customers
Trucks Scania Volvo Daimler Chrysler MAN Renault DAF
Bus Scania Volvo EvoBus Jonckheere Plaxton IRISBus
Off Road VCE Same Deutz-Fahr Case New Holland
Automotive Renault Ford Eberspcher

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Section 1.3 Tachograph Introduction, Charts & Regulations
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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
Stoneridge Electronics Ltd DD55468 Rev 01 14
Tachograph Introduction 1100 Tachograph

The first type of Tachograph introduced by Veeder-Root was in the 1970s 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
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The Electronic Tachograph was first introduced by Veeder-Root in the early 1980s 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
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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 minitimer 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-onrecord 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
24 Hour Markings Speed Trace 4th Stylus/Events Activity Mode Distance Trace Centre Field
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Charts Pear Hole Charts Reverse Side
Manual Entries
Chart and Tachograph EU Approval Numbers, Always check compatibility.
Additional Changes of Vehicle
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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
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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 Distance Travelled: 2%, where that distance is at least 1km Speed: 4 km/h Time: as Bench test
The tolerances for an Installed system at the initial calibration stage are,
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 within legal 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 powerfailure 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
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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
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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 powerfailure 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
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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
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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 1970s, is still the most commonly used rolling-road system in UK Approved Tachograph centres, working on a set measuring speed of 50 km/h
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Establishing the Vehicle W and L-Factor Calibration Parameters Using a Stoneridge Rolling Road
Distance Roller Infra-red Transducer Bogie Rollers Console with MKII Programmer
Vehicle Support Roller Stoneridge Electronics Ltd DD55468 Rev 01
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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 the distance 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
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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
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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

1 Revolution of Sender Input Shaft
Pulses from Channel 1
4-wire
3-wire
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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
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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
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Section 1.6 Sealing & Plaques
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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 6955562
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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
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How and Where to Seal an Electronic Tachograph System

Sealing the gearbox sender is mandatory for all Tachograph systems including adaptors For a non-encrypted system, the sender cable must also be sealed at both ends For vehicles registered after 01/01/1996, and fitted with a non-encrypted system, the sender cable must be of an approved armoured type For an encrypted system, only the gearbox sender seal is required and nonarmoured sender cable can be used for all encrypted systems
Wired Seal
Sensor Cable Gearbox Sensor Connector and Retaining Nut
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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
White K-factor Label
GB (X) (XXX) Imp/km
Centre Number Must Be Entered
Cross Through
K-factor Label with Plastic Overlay Applied on top
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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
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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 connectors There 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 system For non-encrypted sender types, a sealing shroud must be used Only the A and B sockets are sealed because only these have signal connections that require protection from tampering The shroud is then held in place by a red seal that has been embossed with the appropriate Approved Tachograph Centre number prior to fitting It 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
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2400 Data Plate Label

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 Data Plate Label
K-factor Label With Plastic Overlay Applied on top of Label
6872
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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
Cover clip fitted and red seal embossed with the Approved Centre number
K-factor label and plastic overlay applied on top of Data Label
Installation Plaque and Protective Overlay are Applied Here
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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
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Documentation Tachograph Record Sheet
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Documentation Tachograph Record Sheet Information

6-Yearly Calibration of a Vehicle (Mechanical & Analogue Systems) 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 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
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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 manufacturers 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
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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 manufacturers 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
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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
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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
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The 8400 Tachograph Front View

Lock
Clock Tell-Tale Speed Pointer Clock Chart Detect/ Over-speed Warning Light
Odometer
Crew Duty Knob
Driver Duty Knob
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The 8400 Tachograph Rear View
Rear Connectors A Voltage, White B Vehicle Speed, Yellow C Engine Speed, Red D Auxiliary Signals, Brown
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The 8400 Tachograph Other Tachographs, SVDO-Kienzle 1318 & 1319 and Motometer EGK-100
SVDO-Kienzle 1318
SVDO-Kienzle 1319 (Mercedes)
Motometer EGK 100 (VOLVO)
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The 8400 Tachograph Chart Fitting

Crew Chart Fitting
Co-Drivers Chart Drivers Chart
Driver Chart Fitting
Chart Separation Plate
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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
A-CONNECTOR 2714-265 HOUSING NATURAL AND 2714-270, TABS
LAMPS IGNITION
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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
SOCKET B Pin 1 Positive supply to sender Pin 2 Negative supply to sender Pin 3 Main channel input Pin 4 Complimentary Input Pin 5 Pin 6 Pin 7 Pin 8 VR 8 PULSE SENDER (4-wire) Black Brown or Red Blue White Stoneridge Electronics Ltd DD55468 Rev 01
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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
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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
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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 to zero. 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
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The MKII Programmer Introduction and Overview

Socket C Socket B Socket A
LCD Display 2 x 16
Keypad
Socket D Stoneridge Electronics Ltd DD55468 Rev 01
Socket E
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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
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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
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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 Digital Tachographs A MKII Programmers 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 Download Cable, Part Number: 7780-953
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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
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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
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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
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Section 1.9 Using The MKII Programmer With the 8400 Tachograph
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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
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Using the MKII with 8400 Clock Test

From the MAIN MENU select CLOCK VR8400 MAIN MENU TEST using the and keys. Hold the :CLOCK TEST clock-tester at the correct location on the Tachograph face (as described above). Press ENTER to start the test. The Programmer will display the message Testing clock Testing clock, and will make a regular clicking sound. After a short time the clock accuracy in Clock Accuracy seconds per day will be displayed. +0.2s/day In the case of loss of signal or inconsistent ERROR! No signal signal from the Tachograph (usually caused by movement of the clock-tester away from the clock motor), the Programmer will display an error message.
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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
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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
From the MAIN MENU select BENCH TEST using the and keys, and press ENTER. Select the Tachograph scale (125, 140 or 180 km/h) using the and keys, and press ENTER. Set the Tachograph to a K-factor of 8000 (remember to note the original setting first). Press ENTER. Check DIL switches 2,3 & 9 are ON with others OFF. Check the Tachograph drive cable connection is made. VR8400 MAINMENU :BENCH TEST Select the scale : 125 km/h Select K-factor :8000 Pul/km? Check tacho settings Connect drive lead to tacho
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Set power supply voltage to the correct level for the Tachograph (12V or 24V) Make sure clock tell-tale is moving. Check both bulbs are lit. The clock time should be adjusted if necessary. 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. Perform the task displayed. Press ENTER on completion. Switch on at correct voltage Check clock is Stepping OK Check bulbs are illuminated Check clock for accuracy Prepare and insert 2 charts
Close the tachograph

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Set the driver and crew duty to active (4). Press ENTER on completion. 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. Make sure the FSD speed marking on the chart is within 5 minutes of the Tachograph time. Perform the task displayed. Press ENTER on completion. Note the current odometer reading on the Tachograph. This will be required later to check the accuracy of the odometer. Press ENTER. Driver=Active Crew=Active Speed: 125 km/h Time: 10 s
Speed: 0 km/h Time: 10 s Check clock to chart time Close the tachograph Note odometer reading
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The speed will now go to 40km/h and will be held for 2 minutes (the time will count down to zero). At the end of the 2 minute test there will be an audible beep. The speed will then go up to 80 km/h. After a further 2 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. Set the driver and crew duty to active (4). Press ENTER on completion. Speed: 40 km/h Time: 150s
Speed: 80 km/h Time: 150s
Driver=Active Crew=Active
The unit will record Active (4) duty for 2 minutes Recording duty (the time will count down to zero). After that Time: 120 s time an audible beep will be heard.

Set the driver and crew duty to passive (1). Press ENTER on completion. Driver=Passive Crew=Passive
The unit will record Passive (1) duty for 2 Recording duty minutes (the time will count down to zero). After Time: 120 s that time an audible beep will be heard. 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. Compare the new odometer reading with that noted above - a difference of 10km is expected. Driver=Rest Crew=Rest Recording duty Time: 120 s
Check odometer added 10 km
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Note: carry out sender disconnect and power interrupt tests to complete the bench test
Remove the two charts and check the traces recorded (speed, duty and distance on driver chart and duty only on crew chart). Press ENTER. The DIL switches must be returned to the correct settings for the vehicle in which the Tachograph is to be fitted. Switch off the power to the Tachograph and disconnect the power cable. Press the ENTER key to complete the test and return to the MAIN MENU. Check chart recordings
Set K-exact for vehicle
SWITCH OFF POWER SUPPLY VR8400 MAIN MENU :BENCH TEST
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Using the MKII with 8400 K-factor Test

This provides a simple way of determining the Kfactor 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
From the MAIN MENU select K-FACTOR VR8400 MAIN MENU :K-FACTOR TEST TEST using the and keys. Press ENTER. The programmer will send test Sending Pulses pulses to the Tachograph. Please wait After a few moments the Programmer will Sending pulses beep, and then display the K-factor setting of K=8000 < > the Tachograph. If the K-factor is different from the previous test, then the Programmer will beep and display <>.
Using the MKII with 8400 K-factor Test
Step 3 will then repeat until the MENU or Sending pulses K = 8000 ENTER button is pressed. Three repetitions are recommended. If a significantly different Kfactor (>10 pulses/km difference) is displayed, this usually indicates a cable fault or bad connection. It may also be due to a faulty Tachograph. 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. ERROR! CHECK CONNECTIONS
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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
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Using the MKII with 8400 Programming the Tachograph

From the Main Menu select PROGRAM VR8400 MAIN MENU TACHO and press ENTER : PROGRAM TACHO Ign On Record Ignition On Record - Press ENTER and will appear on the display. Use the or :OFF keys to select ON or OFF and press ENTER to terminate the selection. Overspeed - Press ENTER and a cursor will Overspeed flash. Key in the required overspeed value :80 km/h and terminate the entry by pressing ENTER. Select SEND ALL DATA from the MAIN MENU and press ENTER. VR8400 MAIN MENU :SEND ALL DATA
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Using the MKII with 8400 Practical Exam

Carry out the 8400 practical exam as instructed
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Section 1.10 Using the 2400 Tachograph
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The 2400 Tachograph Introduction
2400 Tachograph
CANbus, Kline or D6
Instrument Cluster
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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, e1126 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
Driver Duty LEDs
Mode Change Button
Advance Button
Drawer Eject Button
Crew Duty LEDs

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The 2400 Tachograph Rear View

D C B A
Rear Connectors C Engine Speed, Red D Auxiliary Signals, Brown A Voltage, White B Vehicle Speed, Yellow
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Siemens VDO-Kienzle 1324
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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 LEDs 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 pushbutton 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
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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
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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 MKII programmer 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
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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
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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
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The 2400 Tachograph Chart Fitting Co-driver

Rotate the chart table so that the thin end of the pear shaped drive spindle on the table is facing 12 oclock 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
Fit crew chart under chart table plate
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The 2400 Tachograph Chart Fitting Driver

Again rotate the chart table so that the thin end of the pear shaped drive spindle on the table is facing 12 oclock 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 Fit driver chart under location fingers
Locate chart over pips
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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
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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
Duty trace remains in Rest position
No distance trace recorded
Speed trace remains at 0 km/h mark 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
The 2400 Tachograph Installation - Power Connections

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
A-CONNECTOR 2714-265 HOUSING NATURAL AND 2714-270, TABS
LAMPS IGNITION
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The 2400 Tachograph Installation - Sender Connections

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
Socket B Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Function Positive supply to sender Negative supply to sender Main channel input Encrypted or Complimentary Input Dual-axle setting V-pulse customer specified V-pulse ISO 4-pulses per metre
The 2400 Tachograph Removing the Tachograph

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
Four Removal Holes
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The 2400 Tachograph Opening the Drawer Whilst Disconnected

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
Drawer Release Hole
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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 the duty 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 rollingroad 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 MAN DAF Scania Renault Volvo Iveco 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 Input The Revs 1 input signal is monitored by the processor and is used to determine engine speed. The input line is normally connected to the Wterminal 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
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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 overspeed condition 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
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Section 1.11 Using the MKII Programmer With the 2400 Tachograph
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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
VR2400 MAIN MENU :TACHO SELECT
TACHO TYPE :2400 Series
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The MKII Programmer Sender Selection 2400

For 2400 series Tachographs, the sender type must be selected VR2400 MAIN MENU :PULSER SELECT
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
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
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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
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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
From the MAIN MENU select CLOCK TEST VR2400 MAIN MENU using the and keys. Press ENTER to :CLOCK TEST start the test. The Programmer will display the message Testing clock Sending Data then Testing Clock as shown After a short time the clock accuracy in Clock Accuracy seconds per day will be displayed. +0.2s/day In the case of a lack of signal from the ERROR! No signal Tachograph (caused usually by a faulty cable connection to the Tachograph) the programmer will display an error message.
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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
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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
From the MAIN MENU select BENCH TEST using the and keys, and press ENTER. Select the Tachograph scale (125, 140 or 180 km/h) using the and keys, and press ENTER. 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. VR2400 MAINMENU :BENCH TEST Select the scale : 125 km/h Select K-factor :8000 Pul/km?
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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. Make sure the 2400 LCD display backlight is illuminated. Note: this task should be ignored for a Nodisplay version of the 2400. 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. Set the driver and crew duty to active (4). Press ENTER on completion. Auto Duty :Off
Check backlight illuminated
Prepare and insert 2 charts
Driver=Active Crew=Active
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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 the current odometer reading on the Tachograph. This will be required later to check the accuracy of the odometer. Press ENTER. The speed will now go to 40km/h and will be held for 2 minutes (the time will count down to zero). At the end of the 2 minute test there will be an audible beep. Speed: 125 km/h Time: 10 s
Speed: 0 km/h Time: 10 s
Note odometer reading
135

The speed will then go up to 80 km/h. After a further 2 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. Set the driver and crew duty to active (4). Press ENTER on completion. 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. Speed: 80 km/h Time: 150s
Driver=Active Crew=Active Recording duty Time: 120 s
136

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. 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. Compare the new odometer reading with that noted above - a difference of 10km is expected. Driver=Passive Crew=Passive Recording duty Time: 120 s
Driver=Rest Crew=Rest Recording duty Time: 120 s
Check odometer added 10 km
137

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
Open the 2400 Tachograph and check that the time on the chart corresponds with the time indicated on the clock. Press ENTER on completion. Check clock to chart time
Remove the chart(s) and check the traces Check chart rec. have been completed satisfactorily speed, Set K for veh. duty & distance traces on driver chart and duty trace on crew chart (if fitted). Press ENTER on completion. Press the ENTER key to complete the test and return to the MAIN MENU. VR2400 MAIN MENU :BENCH TEST
138
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
From the MAIN MENU select TACHO VR2400 MAIN MENU CONTROL using the or keys, and :TACHO CONTROL press ENTER. From the CONTROL MENU make the CONTROL MENU required selection - using the or keys : Pair sender to select Reset tacho or Pair sender. Press ENTER to confirm the selection.
139
Using the MKII with the 2400 Control Menu Functions

In the case of Reset tacho, the programmer will cause the Tachograph to simulate a Power Off/On Condition. 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
Sending data Data transfer OK
140
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
141
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
142
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
143
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

144
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
145
Using the MKII with the 2400 Programming the Tachograph, Parameters that can be Modified
2400 Parameters which may be Programmed are: K-Factor Odometer reading Pulses per engine Rev Engine Speed Recording CANBus RPM RPM Display Odo leading 0s Overspeed flash DTCs enabled Overspeed Current time Current Date Time Offset Output shaft factor 4th chart trace CANBus enabled Customer type Dual axle Dual axle ratio Speedo OP factor D6 pin function Serial comms Ign On Record Crew Auto Duty 7 day eject PIN VIN Service Delay Install date Reset Heartbeat Analogue Revs Pin D4 Function Low Speed Limit Kline Speedo
146
K-factor Press ENTER and key in the new value. Press ENTER again to confirm the value
K-factor :8000
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
Odometer :000548.7
147
CANBus RPM Press ENTER and use the and keys to select ON or OFF. Press ENTER to confirm the selection
CANBus RPM :Off
RPM Display Press ENTER and use the and keys to select ON or OFF. Press ENTER to confirm the selection
RPM display :Off
148
Odo Leading Zeros Press ENTER and use the and keys to select ON or OFF. Press ENTER to confirm the selection
Odo leading 0s :Off
Overspeed flash Press ENTER and use the and keys to select ON or OFF. Press ENTER to confirm the selection
Overspeed flash :Off
149
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
DTCs enabled :Off
Overspeed Press ENTER and a cursor will flash. Key in the required over speed value and press ENTER
Overspeed :90 km/h
150
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 time :10:35

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 date :05/06/2007
151
Time offset Press ENTER and use the up/down arrow keys to choose a time offset between +23:00 and 23:00 hours
Time offset :+1:00
Output shaft factor This value should not be changed from the vehicle factory set value
O/P shaft factor :8.140
152
4th Chart Trace Press ENTER and use the and keys to select ON or OFF. Press ENTER to confirm the selection
4th chart trace :Off
CANBus enabled Press ENTER and use the and keys to select ON or OFF. Press ENTER to confirm the selection
CANBus enabled :Off
153
Speedo output factor Press ENTER and a cursor will flash. Key in the required value and press ENTER to confirm the selection
Speedo OP factor :4971
D6 pin function Press ENTER and use the and keys to select OFF, Revs warning or Speedometer as required
D6 pin function :OFF
154
Ignition on Record 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 Press ENTER and use the and keys to select ON or OFF. Press ENTER to confirm the selection
Crew auto duty :OFF
155
VIN Press ENTER and key in the Vehicle Identification Number. This can be up to 17 characters long. Press ENTER to confirm the selection
VIN
:1234567890ABCDEFG
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
Service delay :104 weeks

156
Install date Press ENTER and a cursor will flash. Key in the date of installation for the Tachograph and press ENTER
Install date :05/06/2007

Reset Heartbeat Press ENTER and use the and keys to select ON or OFF. Press ENTER to confirm the selection Note: when set to ON the vehicle cluster presence is confirmed by the Tachograph
Reset Heartbeat :OFF
157
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

158
Using the MKII with 2400 Practical Exam

Carry out the 2400 practical exam as instructed
159
Any Questions?
160

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Stoneridge Electronics Ltd

Tachograph Re-certification Training Course

Stoneridge Electronics Ltd DD55468 Rev 01

Stoneridge Electronics Ltd COPYRIGHT

Stoneridge Electronics Ltd DD55468 Rev 01

Stoneridge Electronics Ltd DD55468 Rev 01

Stoneridge Electronics Ltd DD55468 Rev 01

Section 1.1 Health & Safety

Stoneridge Electronics Ltd DD55468 Rev 01

Health & Safety

Section 1.2 Company Profile

Stoneridge Electronics Ltd DD55468 Rev 01

Stoneridge Electronics Group

Pollak Switch Products

50% Ownership 20% Ownership

China Representative Office

Stoneridge Electronics Ltd DD55468 Rev 01

Stoneridge Electronics Locations

Stoneridge Electronics Ltd DD55468 Rev 01

UK Design, Manufacture & Sales

Dundee 100+ employees 7400 m

Stoneridge Electronics Ltd DD55468 Rev 01

Overview Stoneridge Electronics Products

Stoneridge Electronics Ltd DD55468 Rev 01

Stoneridge Electronics Customers

Trucks Scania Volvo Daimler Chrysler MAN Renault DAF

Bus Scania Volvo EvoBus Jonckheere Plaxton IRISBus

Off Road VCE Same Deutz-Fahr Case New Holland

Automotive Renault Ford Eberspcher

Section 1.3 Tachograph Introduction, Charts & Regulations

Stoneridge Electronics Ltd DD55468 Rev 01

Tachograph Introduction - Why is a Tachograph Required?

Tachograph Introduction 1100 Tachograph

Tachograph Introduction 1400 Tachograph

Tachograph Introduction 8300/8400 Tachographs

Tachograph Introduction 2400 Tachograph

Tachograph Introduction SE5000 Digital Tachograph

Charts Pear Hole Charts

Stoneridge Electronics Ltd DD55468 Rev 01

Charts Pear Hole Charts Reverse Side

Chart and Tachograph EU Approval Numbers, Always check compatibility.

Additional Changes of Vehicle

Stoneridge Electronics Ltd DD55468 Rev 01

Tachograph Regulations Analogue Recording Equipment

Tachograph Regulations VOSA

Stoneridge Electronics Ltd DD55468 Rev 01

Tachograph Regulations Tachograph Tolerances

Tachograph Regulations Installation / 6-Yearly Periodic Inspection Procedure

Tachograph Regulations Installation / 6-Yearly Periodic Inspection Procedure

Tachograph Regulations Installation / 6-Yearly Periodic Inspection Procedure

Tachograph Regulations 2-Yearly Periodic Inspection Procedure

Stoneridge Electronics Ltd DD55468 Rev 01

Tachograph Regulations 2-Yearly Periodic Inspection Procedure

Tachograph Regulations 2-Yearly Periodic Inspection Procedure

Section 1.4 W, K & L-Factors and Calibration Methods

Stoneridge Electronics Ltd DD55468 Rev 01

Establishing the Vehicle W and L-Factor Calibration Parameters

Stoneridge Electronics Ltd DD55468 Rev 01