VDO Commercal Product Catalogue

VDO Commercial
Product Catalogue
Handling a complex world.
Index
Product Description
Page Numbers
Electronic Tachograph MTCO 1390
Page 1
Tachograph Charts
Page 2
Tachographs Brackets
Page 3
Tachograph Speed Sensor - Electronic Tachograph
Page 4
Tachograph Speed Sensor
Page 5
Tachograph Interface - Signal Interfaces & Power Converters
Page 6
Tachograph Angle Drives
Page 7
Tachograph Adaptor Boxes
Page 8
Tachograph TCO Power Supply Leads
Page 9
Sealing Cover For Electrical Connections
Page 10
Accessories for Tachographs
Page 11
Tachograph TCO Drive Cables and Cable Parts
Page 12 - 15
Connecting Pieces, Adapters & Extensions
Page 16 - 17
Various Connecting Nuts, Left Hand / Right Hand Threads for Adapter Boxes
Page 17
Connecting Pieces, Adapters & Extensions
Page 18
Service Diagnostic Systems
Page 19
Sealing / Cable Making Tools
Page 20
Analysis Equipment
Page 21
EDM 1404 - Electronic Diesel Consumption Measuring System
Page 22
MTCO 1390 - Modular Tachograph Electronic
Page 23
MTCO 1390 - Installation Sealing Accessories
Page 24
CANLink Signal Adapter
Page 25
The Tachograph Chart
Page 26
Road Speed Recording
Page 27
Example of Economical/ Uneconomical Stop-Start Driving
Page 28
Assessment of Stop-Start Driving Techniques
Page 29
Engine Speed Recordings
Page 30-31
Engine Warm-Up
Page 32
Labouring/ Lugging
Page 33
Accident Analysis
Page 34
Commercial Target Market
Page 35- 36
Transport Terminology
Page 37- 38
Tachograph
Non-EC Tachograph, Electronic, Compact Design
(diameter of casing 140 mm, mounting depth 99 mm)
Part Number
Model
Version
Measuring Range
Voltage
1318-020000000103
1318-02
1-day
125 kph
12 V
1318-020000000121
1318-02
1-day
125 kph
24 V
Non-EC Tachograph, Electronic, Compact Design

(diameter of casing 140 mm, mounting depth 99 mm)
Part Number
Model
Version
Measuring Range
Voltage
1318-060000000103
1318-06
8-day
125 kph
12 V
1318-060000000121
1318-06
8-day
125 kph
24 V
Measuring Range
Voltage
Non-EC Tachograph, Electronic

With additional engine recording
Part Number
Model
Version
1318-040000000713
1318-04
1-day
1318-040000000733
1318-04
1-day
125kph
3300rpm
125kph
3300rpm
12 V
24 V
Tachograph Charts
24 Hour Road Speed Only
Part Number
Range
TCO
Spec. Number
1900-01120000
125 km/h
15/2
125-24-21*
1900-01140000
160 km/h
15/2
160-24
1900-51150000
180 km/h
MTCO
180-24
* also suitable for TCO 1318-02
24 Hour Road Speed / Engine RPM

Part Number
Range
TCO
Spec. Number
1900-21120408
125 - 3300
1318-04
125-3300/24/21*
1900-21120435
125 - 3300
1310-07
26 hours
1900-01120075
125km/h
MTCO
26 hours
* also suitable for TCO 1318-25 & 1318-04
8 X 24 Hour Road Speed Only

Part Number
Range
TCO
Spec. Number
1900-08120000
125 km/h
1318-06
125-8-24/21
1900-08140000
160 km/h
15/6
160-8-24
8 X 24 Hour Road Speed Engine RPM

Part Number
Range
TCO
Spec. Number
1900-28120401
125-3300
1310-07
80-3300/8X24
Part Number
Range
Mini
Spec. Number
1900-03140000
160 km/h
24 hour
160-24
1900-05140000
160 km/h
8X24 hour 160-8x24
Mini
Tachograph Brackets
Metal Holder
Part Number
Version
A721055
Straight
A721060
90 Degree Angle (Short)
A721050
90 Degree Angle (Long)
A721045
70 Degree Angle (Long)
Other versions available on request.
Spacer
Part Number
Depth
Version
A721035
16mm
Metal
A721040
30mm
Metal
Rubber Ring 140 mm

Part Number
Version
89 512 006
Rubber

Electronic Tachograph
Hall Generator
For conversion of rotational movements of the speedometer output into
electric pulses.
Operating Voltage: 8 - 16 volts
8 rectangular pulses per revolution
Connection:
Cable side: 3-wire panel connector bayonet joint
Gearbox side: thread, slotted catch 3mm
Part Number:
Version
Thread
340-214/002/001B
1310 Series
M22 X 1.5
Operating Voltage: 6.5 - 16 volts

Connection:
Part Number:
Version
Thread
2155-01000000
Female
1310 Series
M22 X 1.5
2155-02000000
Male
1310 Series
M22 X 1.5
Hall Generator with Continuous Shaft (without Holder)

For applications where an additional mechanical drive is needed.
Connection:
Cable side: 3-wire panel connector bayonet and
additional screw neck M22 X 1.5; tongue catch 3 X 7 mm
Gearbox side: connecting nut M22 X 1.5 left and
M22 X 1.5; slotted tongue 3 mm.
Part Number:
Version
Thread
2157-03000000
1310 Series
M22 X 1.5
Sender Unit Cable for Road Speed

Three-wire connection. Tachograph side: plug-type connection. Sender
unit side: bayonet joint. When using the road speed sender unit cable for
engine speed, special attention is to be paid to the pin assignment (wiring
scheme on tachograph casing).
Part Number:
Version
A Spec 731
1310 - Plug Kit Impulse Transmitter
A Spec 737
1318 - Plug Kit Impulse Transmitter

Hall Generator
For conversion of rotational movements of the speedometer output into
inverted electrical double pulses.
Operating Voltage: 6.5 - 16 volts
Connection:
Version
Part Number:
Thread
2159-01000000
Female 1318 Series + MTCO 1390
M22 X 1.5
2159-02000000
Male
1318 Series + MTCO 1390
M22 X 1.5
Integrated Pulse Generators

The pulse generator integrated in the gearbox converts the revolutions of a
pulse or gear wheel into inverted electrical pulses.
Connection:
Gearbox side: thread M 18 x 1.5
Part Number:
Version
Length
2159-50004101
19.8 mm
2159-50004201
90.0 mm
2159-50004501
35.0 mm
2159-50004401
63.2mm
2195-50004301
25.0mm
Sender Unit Cable for Road Speed

Connection:
4-wire
Tachograph side : plug-type connection (yellow)
Sender unit side : bayonet joint
Part Number:
Version
Length
2159.80 01 0500
1318 + MTCO 1390
5000 mm
Tachograph Interface
Signal Interfaces & Power Converters
Pictures are simular to products.
Current Limiter 24V

1314.90020000
Pulse Duplicator TCO 1318-25

1403044
1.Inductive Interface with Harness 12/24V

411 Spec 100
Interface Harness
411 099
Interface without Harness
411 100 A
2.Impulse Doubler
X10-415-000-009
Pulse Distributor 3 Outputs

2156-50140100
Tachograph Angle Drives

Mechanical Tachograph
Angle Drives
Connection to rpm takeoff: M22 X 1.5 union nut and 3 X 10 mm slotted hole.
Connection to measuring instrument: M22 X 1.5 male thread and
3 X 6 mm tongue tip.
Part Number
Ratio
Sense of Rotation
Installation
210.033/041/001
1:1
Non-Reversing
Right-Hand
210.033/041/002
1:1
Reversing
Right-Hand
Angle Joint
For direct connection to the tachograph (can be mounted in all directions,
transmission 1:1) composed of: Casing with gear shaft, counter gear, adjusting
disk, curved washer and mounting parts.
Part Number
Angle
Sense of Rotation
1308-90010100
Right Hand
90 Degree
Non-Reversing
1308-90010200
Left Hand
90 Degree
Non-Reversing
Angle Drive
Cable side:
Gearbox Side:
Screw neck M22 X 1.5; tongue catch 3 X 8 mm

Connection screw nut M22 X 1.5 left and M22 X 1.5;
Slotted catch 3 mm.
Part Number
Sense of Rotation
Ratio
214.043/011/001
Non-Reversing
1:1
214.043/011/002
Reversing
1:1
Tachograph Adapter Boxes

Adapter Gearbox with Second Output
(without connection unit)
For adaption to the characteristic coefficient of the vehicle for simultaneous
connection of two devices, constant sense of rotation.
Tachograph side : 2 Screw necks M22 X 1.5; tongue catch 3 X 8 mm.
Gearbox side : Screw neck M22 X 1.5 left; slotted catch 3 mm.
Part Number
Ratio
A752038
Adaptor Gearbox
0.501:1
A752062
Adaptor Gearbox
0.608:1
A752065
Adaptor Gearbox
0.621:1
A752070
Adaptor Gearbox
0.638:1
A752098
Adaptor Gearbox
0.787:1
A752100
Adaptor Gearbox
0.800:1
A752115
Adaptor Gearbox
0.903:1
A752130
Adaptor Gearbox
1.002:1
A752160
Adaptor Gearbox
1.294:1
Adapter Box Kit

Part Number
A852601
Holder for Adapter Gearbox

Part Number
Version
A721010
Metal
Connecting Nuts Dual Left Hand Right Hand

Part Number
Left Hand
Right Hand
1040-1200-003-001
M22 X 1.5 mm
M22 X 1.5 mm
A872025
M22 X 1.5 mm
7/8" 18 Ns
Blank Nut (Dust nut)

Part Number
992 198 001 (Plastic)
1403036 (Rubber)
Lead Seal
Part Number: 1305.0006.011.000
Seal Cup
Part Number: 1305.0006.010.000
Tachograph TCO
Power Supply Leads
TCO 15
Description:
Part Number:
TCO 15 (Complete)
A 729035
Housing 4 way
Z 863101
TCO 1310
Description:
Part Number:
TCO 1310 (Complete)
A 729045
Housing 6 way
Z 863102
Electric Terminal
Z 863016
Housing 8 way
Z 863103
TCO 1318
Description:
Part Number:
TCO 1318 (Complete)
1318.90100100
Housing Clear Colour
HS 53.6600.081
Housing Yellow
HS 53.6600.082
Housing Red
HS 53.6600.083
Housing Brown
HS 53.6600.084
Electric Terminal
HW 032260
Sealing Covers for

Electrical Connections
Electronic 1310 Series
Part Number : 1309.901107.01
Electronic 1318 Series

Part Number : 1318.9002.5200
Coding Switch Cover 1318 Series

Part Number : 1318.9002.1301
Illumination Bulbs
Description
Part Number
12 V Old Type
4 124 222
24 V Old Type
4 124 242
Illumination Bulbs
10
Description
Part Number
12 V New Type
Z 860035
24 V New Type
Z 860040
Accessories for
Tachographs
Lock with Key TCO 15, 1310 Series
Part Number : 1311-0111-073-050 (TCO 15 + 1310 Series)
1318.9999.027.000 (1318 Series)
Standard Tachograph Key

Part Number : 1305.9002.2901
Special Key 41.5 mm

Part Number : X11.140/000/039
Special Key 47.0 mm

Part Number : 1311.90 13 047 03
Chart Clip 26 Hours

Part Number : 1999-0913-001-000
Lock Nut TCO 8 Day Charts

Part Number : 1308.0111.028.000
Knife TCO 8 Day

Part Number : 1305.0002.020.000
Sealing Wire
Part Number : Z 817001 (1 Kg Roll)
Red Seal
Part Number : 1311.0111.132.010
Sealer Retainer - Odometer 1310 Series
Sealer Retainer - Cover Plate 1310 Series

Part Number : 1311.0111.131.000
11
Tachograph TCO
Drive and Cable Parts
Complete Cables
Tachograph side: Bayonet joint, catch 2.6 mm
Gearbox side : Thread M22 X 1.5, slotted catch 3 mm.
Part Number:
Length
2401 117 011 20
2 meter
2401 117 011 25
2.5 meter
2401 117 011 30
3 meter
2401 117 011 35
3.5 meter
2401 117 011 40
4 meter
2401 117 011 45
4.5 meter
2401 117 011 50
5 meter
Half Made Cables

Tachograph side:
Gearbox side : Thread M22 X 1.5, slotted catch 3 mm.
Part Number:
Length
2401 000 011 20
2 meter
2401 000 011 30
3 meter
2401 000 011 35
3.5 meter
2401 000 011 40
4 meter
2401 000 011 45
4.5 meter
2401 000 011 50
5 meter
Cable Kits (Part Kits)
12
Part Number:
Description:
2401 011
TCO Cable Gearbox end
2401 117
TCO Cable TCO side
2401 094
TCO Cable Intermediate
Tachograph Standard Drive Cable

for Mechanical Tachograph
Tachograph Connection
Bayonet Nut
Nut - 81 110 005

Spring - 19 146 068
Nylon Bush - 88 212 026
Outer Casing 9 mm - 13 030 A
Flex Drive 4 mm - 12 220 A
Cable Sleeve - 16 663 029

Male Drive 2.6 mm - 111 039 025
Hexagon Nut
M22 X 1.5
Nut - 61 006 005

Female Drive - 111 039 024
Nylon Bush - 88 212 026
Cable Sleeve - 16 663 029
Gearbox Connection
13
Tachograph TCO
Drive and Cable Parts
Inner Flex Drive 4 mm
Part Number : 12 220A
Outer Casing 9 mm
6.0
Part Number : 13 030A
33
1.5
13
11
6
End Piece Male Standard

4.1
17.5
Part Number : 111 039 025
26
End Piece Female Standard
10.5
4.1
11
10
35.5
13
10.5
11
1.5
10
Nylon Bush
11.3
6.4
4.5
4.1
End Piece Intermediate
Spring for Bajonett Nut

14
Cable parts for

Standard Tachograph Cables
44
10.9
9.3
Intermediate Sleeve
15
19.8
15
47
18.5
9.3
10.9
11.5
18.5
Standard Sleeve
47
9.3
10.9
Sleeve for M18 X 1.5 Nut
10
26
M22 X 1.5
13.4
11
Right Hand Nut M22 X 1.5 mm

14
26
M22 X 1.5
17.3
11
Left Hand Nut M22 X 1.5 mm

14
20
31
14
Bajonett Nut Instrument Connection

30
15
18
17
15
Connecting Pieces,
Adapters & Extensions
M22 X 1.5
M22 X 1.5
56
X11.200/001/023
X11.200/002/032
58
M22 X 1.5
M22 X 1.5
96
X11.200/001/021
X11.200/002/030
2.6 mm
23
M22 X 1.5
6.4
98
37
1040-1300-009-001
51
33
1040-1200-074-001
2.6 mm
4.75 mm
M22 X 1.5
34.5
A872 337
33
2.6 mm
2.6 mm
M18 X 1.5
26
993 318 002

32
1040-1300-007-00
16
4.75 mm
2.6 mm
M22 X 1.5
38
Connecting Pieces,
50
Flexible Drive
Part Number : On Request
22
22
6.2
5.2
10.94
3
1.52
11
26.5
Flag drive (Kienzle)

1040-12-00-11-03 4,7 x 26
1040-12-00011120 5,0 x 26
Various Connecting Nuts,

Left Hand / Right Hand Threads for Adaptor Boxes
M22 X 1.5 (Left)
20
Standard
Part Number : 1040-1200-003-001
M22 X 1.5
M22 X 1.5 (Left)
20
7/8 - 18 NS
Part Number : A872025
7/8" - 18
17
Connecting Pieces,
Part Number : A872 211
4.8
3.8
26
6.2
4.7
26
6.7
5.2
33
36
7.5
26
2.6
Part Number : 1040-1200-005-19
Part Number : 1040-1200-005-20
26
6.5
26
28
Part Number : 1040-1200-005-21
2.6
36
2.6
2.6
45
34
18
Service Diagnostic Systems

Stationary Test Computer STC 1601.25
Part Number: 1601.25 006 010
The STC 1601.25 is a very sophisticated device to test tachographs. It is
multi functional, easy to handle, with integrated power supply. It is the
multi-purpose comprehensive test centre for efficient diagnostic of both
mechanically and electronically driven tachographs. The STC is available in
Standard and Automatic versions.
MTCO 1390 Mobile Tester / Programmer

Part Number: 1602-04015000
For MTCO 1390 and 1324 calibration testing and programming
Hand-Test Computer HTC 1602-19

Part Number: 1403008
For 1310 Seies tachograph callibration the Hand-Test computer is the
economic a minimum equipment. It allows measuring of the basic vales
W and K on a measuring track. The HTC is also suitable for checking
complete installations for automatic speed control (RSL).
19
Sealing / Cable
Making Tools
Cable Hand Crimper
Part Number: 1999-1013-000-100
(Including dies for Standard Tachograph Cable)

Dies only (Std TCO Cable) : 1999-1013-002-100
Dies only (Std Automotive Cable) : 1999-1013-006-100
Sealing Pliers
Part Number: 1999-1213-002-980 (No insert)
Insert for above x2 1999-1213-002-980
Drive Cable Printing Press with Universal Die

Part Number: 1999-2410-002-000 (on request only)
20
Analysis Equipment
Chart Analyser with Magnifier and Illumination

Part Number
Version
1612-50500 100
With analysing disk
Measuring Microscope for Chart Analyser

Part Number
On request.
Analysing Disk
Part Number
1602-03040 000
21
EDM 1404
Electronic Diesel Consumption Measuring System

Part Number
Description
Option 1
1404-01-07-01-00
Full installation Kit 12/24 volt

Consists of:
Electronic Flow Meter
Compact Display
Mounting Kit for Display
Mounting Set for Flow Meter
Installation Instructions
Option 2
Parts required for OBC application
1404-01-01-00-00
1. Flow Meter
1404-01-06-01-00
2. Flow Meter Mounting Set
1040-01-09-00-00
Gas seperator - Cummins PT inj.
1404-01-04-01-00
Compact Display
1404-01-01-00-00
Flow Meter
1404-01-06-01-00
Flow Meter Mounting Set
A731012
Speed Impulse Generator
TBA
Portable EDM on Request
It is necessary to install a voltage converter if the flowmeter is used without a

display on a 24 volt system.
22
MTCO 1390
Modular Tachograph Electronic

Part Number
Description
One day recording models

1390-102110011005
125 km/h 12V 1 Day
1390-105112100005
125 km/h 24V 1 Day
1390-112110011005
180 km/h 12V 1 Day
1390-102120011005
125 km/h 3300Rpm 12V 1 Day
1390-10512210005
125 km/h 3300Rpm 24V 1 Day

Eight day recording models
1390-202140011005
125 km/h 12V 8 Day
1390-205142100005
125 km/h 24V 8 Day
1390-212140011005
180 km/h 12V 8 Day
1390-202130011005
125 km/h 3300Rpm 12V 8 Day
1390-205132100005
125 km/h 3300Rpm 24V 8 Day
X39-140-000-009
Installation Console
Additional Notes
a) All above models have a fixed drawer (Easy Modification for Lower Drawer
Application)
b) Green Display Illumination (Keys are not illuminated)
c) All Models will operate with Standard Speed Sensor (8 Pulse Square Wave
Signal)
d) RPM Signal taken from W Terminal of the Alternator
e) Operates with existing Diagram charts
23
MTCO 1390
Installation Sealing Accessories
Part Number
Description
1324-90010005
Mounting Frame for fitment into the radio compartment
X39-140-000-009
Installation Console for fitment on or under the dashboard
1322-84-602-02
Sealing Cover (Program Socket)
KN07-0139-047
Screw for above Cover
1322-50-003-00
Rubber Cap
1324-90020200
Sealing Cover Electric Connection
1311-0111-132-010
Red Seals
1318-90-10-01-00
Power Loom
HS53-6600-082
Housing 8 Pin Yellow
HS53-6600-083
Housing 8 Pin Red
HS53-6600-084
Housing 8 Pin Brown
Hw032260
Terminal for Housing

Recommended Speed Sender
A731012
8 Pulse Hall Effect (In-line)
A731002
8 Pulse Hall Effect (Male)
A872013
M22 Dual Nut for above
A-Spec-731
Electric Plug Kit for A731002
24
CANLink Interface
CANlink Signal Adapter

Part Number
Description
X10-140-401-002
CANlink Adapter
Mercedes Benz - Actros
Ateyo - Axor
X39-140-400-010
Cable - CANlink for above
X10-140-401-006
CANlink Adapter
MANTJA - DAF
IVECO - Scania
X39-140-400-003
Cable - CANlink for above
25
The Tachograph Chart

Sapphire Tipped
Rec. Stylus
Pressure Sensitive Wax

Black Paper
Backing Paper
Fig. 10
The chart is the most essential part of the Tachograph System. It consists of recording layer of pressuresensitive wax and black backing paper. The recordings are made with sapphire-tipped styli i.e. Without
marking fluid. The styli compress the recording layer which becomes visible (Fig. 10). The recordings
cannot be altered without damaging the recording surface.
Time Scale Speed

Time Scale
Driving and Stopped Times
Distance Travelled
Fig. 11
The clock mechanism in the tachograph rotates the chart(s) at a uniform rate so that the recordings are
made in relation to time. All charts are 124mm in diameter. The most common recording range is
0-125km/h (Fig. 11).
26
Base Line
Fig.12
When the vehicle is stationary, the speed recording stylus will record a line parallel to the time scales
on the chart. When the vehicle accelerates, the recording will move up to whatever speed the vehicle
is traveling at that moment. The recording can then be read against the speed scale on the chart to
determine at what speed the vehicle was traveling. When the vehicle slows down, the recording also
drops with the speed of the vehicle. When the vehicle stops, the recording will return to its zero km/p
position and will remain in that position for the amount of time that the vehicle is stationary. This
stationary line is called the BASE LINE. (Fig.12).
To be able to read the speed recording against the speed scale, the Base Line must be recorded just
touching the top of the lower time scale. If it is recorded above or below this position, the amount that
is away from its correct position must be added to, or subtracted from, the speed recording to
determine correct speeds.
Stationary
Driving
Driving
Fig.13
Driving and Stopped Time Recording
When a vehicle is moving, the time stylus shows this on the chart as a curved wide band and when
stationary, a thin curved line. (Fig. 13).
27
Example of Economical/ Uneconomical

Stop - Start Driving
Uneconomic
Economic
38.8
25.6
40
47.1
43.2
Journey Time in Minutes
25
27
Maximum Speed km/h
85
55
Manner of Driving
Fuel Consumption I/100km
Extra Consumption %
Average km/h
B
Sharp
Harsh Acce
leration
raking
Fig.20
Fig.21

If stop-start recordings take the form of needle-shaped peaks above
50km/h, then the vehicle was harshly accelerated and sharply braked
immediately thereafter. Fig. 20 shows typical uneconomical driving
where the driver harshly accelerates the vehicle until road/ traffic
conditions force him to brake sharply (Fig. 21). In suburban areas or on
major arterial routes, there are longer distances between stops. Hence,
uneconomical driving will also be shown as round-topped recordings
above the speed limit.
28
Constant
Speed
Acce
lerat
ion
g ng
in k i
ow ra
Sl ut b
o
th
wi
Braking
Fig. 22
Fig. 23

Economical stop-start driving entails gradual acceleration to an economical speed, which is
then maintained. Before the next stop, the vehicle is coated in gear as long as possible and
is then braked gradually to a stop (Figs. 22 & 23).
Fig. 22
Fig. 23

Economical open road driving entails traveling at a uniform speed within the companys or
legal speed limit (whenever is the lower). All fluctuations in speed must be gradual and
there must be no sharp peaks or sharply fluctuating speeds (Fig. 24). Sharply fluctuating
speeds indicate that the vehicle was driven too fast for the prevailing road, load and/or
traffic conditions. Speeds must always be adjusted to these conditions. High speeds on
the open road can increase fuel consumption by as much as 50%, tyre wear by 20% and
the vehicles overall maintenance costs without decreasing the journey time significantly
(Fig. 25).
29
Engine Speed Recordings
1 - Day Models
Engine speed is recorded on the reverse side of a doublesided chart (Fig. 58) by a recording stylus which is fitted
into the door of the road/ engine speed tachograph.
These recordings must be read in an anticlockwise
direction. The engine speed scale that is printed on the
chart is in 500 r/min steps up to 3300 r/min.
Fig.58
8 - Day Models
With these tachographs, the engine speed is recorded
on the same side of the chart as the road speed and
distance recordings (Fig. 59).
This recording replaces the driving and stopped time
recording on the TCO 15/6. The engine speed scale rises
in 500 r/min graduations for the TCO 15/7 - 3300.
Fig.59
30
Analysis of Engine
Speed Recordings
Only diesel-engined vehicles that are supplied with or have provision for an engine speed take-off
can be fitted with road/ engine speed tachographs. Engine speed recordings, together with road
speed recordings, provide a complete picture of driving economy and efficiency.
However, before engine speed recordings can be analysed, the following data must be at hand: - Manufacturers maximum permissible engine speed;
- Companys maximum permissible engine speed if it is lower that the manufacturers;
- Engine speed that produces maximum torque;
- Whether or not the engine is turbo charged
This data can be readily supplied by the vehicle manufacturer or supplier. Once the analyst has this
information, he can then analyse the recordings for the following: -
Engine Warm-up (Cold Start)
1-Day Chart
Correct
Fig.60
31
1-Day Chart
Incorrect
Fig.61
Engine Warm-up (Cold Start)

When a vehicle had been standing over night, some or all of the air pressure in the brake system (if
the vehicle is fitted with air brakes) will br lost. Also, some of the lubricating oil in the engine will
have drained to the sump. Therefore, when a diesel engine is started after an overnight stop, its
speed should not exceed 1000 r/min until oil pressure has built up to normal. The engine should then
be idled until the air pressure has build up sufficiently for the air brakes. This should not take more
than 3 or 4 minutes if the air system is in good condition (Figs. 60 & 61).
Gear change Over revving

Over revving on a gear change normally occurs when a driver does not know the maximum permissible
engine speed of the vehicle or changes into the wrong gear. Even though an engine may be governed,
if the driver changes down too soon, the engine will over rev. Over revving not only wastes fuel but
also results in premature engine failure.
Continuous Over revving

There are two types of continuous over revving. One is where the speed of the engine is constantly in
excess of its maximum limit. The other is where, due to lack of vehicle control on a downhill or as a
result of speeding, the speed of the engine gradually builds up above its maximum limit and
eventually returns to within the limit as speed drops or an upchange id made. This type of over revving
is very serious (Fig. 62 & 63).
1-Day Chart
8-Day Chart
Gear change
Over revving
Continuous
Over revving
Max Speed
2300r/min
Fig.62
32
Max Speed
2500r/min
Fig.63
Labouring/ Lugging
An engine is said to be laboring (lugging or under revving) when it is being run below the engine
speed, which produces maximum torque. However, most modern engines can be lugged down to
200 r/min below maximum torque without any damage being done. Prolonged laboring can be seen
on the chart when the speed of the engine drops for a few minutes below maximum torque and the
corresponding road speed is more than 20 mk/h, this indicates that the driver is using too high a gear.
Laboring wastes fuel and causes damage to the engine and transmission. (Figs. 64 & 65).
1-Day Chart
8-Day Chart
Fig.64
Fig.65
Engine Idling
A diesel engine should not be idled for more than 5 minutes at any one time. Engine idling wastes fuel
(up to 12 liters per hour) and prolonged idling can severely damage the engine (Figs. 66 & 67).
1-Day Chart
8-Day Chart
Fig.66
Fig.67
33
Accident Analysis
The Kienzle Tachograph is a highly sophisticated and accurate speed recording instrument. With the
aid of specially built Stereoscopic Microscopes (Fig. 50) that are fitted with Chart Tables which revolve
at 86 400 seconds for 1-day charts and 93 600 seconds for 8-day charts, together with an adjustable
Guide Line of 3 microns (1 micron = 1 millionth of a meter) cut into a window, the recordings on a Control
Instruments or Kienzle Tachograph Chart can be measured to an accuracy on 1km/h, 1 second in time
and 1 meter of travel.
The microscopic analysis method developed by Kienzle has resulted in Control Instruments Analyses
being accepted as invaluable evidence by all South African Courts up to and including the Appelate
Division of the Supreme Court which is the highest Court in the Land.
The Control Instruments organization pioneered Accident Analysis in South Africa over 30 years ago.
The Control Instruments Accident Analysis Section was the first such department to be established
outside Europe. The Control Instruments Analysis Section is ONLY Analysis Section in Africa, which is
equipped to the E.E.C. Standards.
The Control Instruments Analysts are the most experienced and best trained outside of Europe. This
service, supplied by accredited experts, is available to Control Instruments / Kienzle users.
34
Installation
Accessories
Sealing Equipment
Tachograph/ Diagram Charts

and Diagnostic System
Gearbox Adaptor
Angle Drive
Flexible Drive Cables
Diesel Consumption
Measuring System
Speed Sensor
35
Road Speed
Limiter
Signal Interfacing
Power Converter
CANLink Interface
Fleets
Defense Forces
Body/ Coach Builders
Food Manufacturing Industry
Vehicle Franchise Dealers
Chemical Manufacturing Industry
Construction Companies
Clothing Manufacturing Industry
Special Vehicle Manufactures
Mining
Engineering Companies
Forestry
Fork Lift Agents
Off Road Vehicles
Transport Companies
Plant Hire Equipment
Municipalities
Locomotive Manufacturers
Provincial Authorities
36
CAB Configurations
Normal Control
The cab is so located that the driver is situated behind the engine and front wheels (e.g. Motor car
with bonnet).
Forward Control
A cab where the driver is situated either in front of, above or alongside the engine, and ahead of the
front wheels (e.g. Flat fronted trucks).
Semi-Forward Control
A cab where the driver is situated alongside the rear portion of the engine and above the front wheels.
Driveline Configurations
4x2
4x4
6x2
6x4
6x6
Two axles one of which is driven.

Similar to 4 x 2 but with both front and rear axles driven
Three axle vehicle with one axle driven.
Three axle vehicle with two axle driven.
Three axle vehicle with all three axle driven.
Rigid Body Types
Platform body
Dropside body
Enclosed body
Tanker body
- A flat platform with a headboard only.

- A platform body with hinged sides and end which drop down to facilitate loading.
- A body where the load is fully enclosed.
- A body designed to contained liquids, granules or powder.
Trailer Types
Single axle trailer - A semi-trailer with one axle.

Tandem axle trailer - A semi-trailer with two axles forming a bogie.
Tri-axle trailer
- A semi-trailer with three axles forming a bogie.
Drawbar trailer
- An independent load carrying trailer designed to be towed by another vehicle or
a semi- trailer.
Rear Axles
Single speed
Two speed
Overall ratio
Tag axle
Differential
Diff lock
Brakes
Exhaust brake
Retarder
- A gear set with one reduction ratio.

- A gear set giving the driver a choice of two rear axle ratios. It effectively doubles
the number of ratios available from the gearbox.
- The ratio of engine r/min to driving wheel r/min.
- A load carrying axle that is not driven.
- (Diff) A device fitted in the driving axle to permit one wheel to turn faster than the
other when turning corners.
- A device for locking the differential to ensure that both wheels are turned at the
same speed.
- A brake using the engine as a compressor by shutting off the fuel completely and
closing a valve in the exhaust pipe thus making the engine pump a dead end.
- A brake fitted in the driveline operated by a magnetic field or hydraulic pressure.
Other Equipment
Turbo charger
- A pump driven by the exhaust gasses which forces air under pressure into the
Inter-cooler
Power take-off
cylinders thus providing better fuel consumption and more power.

- Air from the turbo charger is cooled by a separate radiator making it more dense
before going into the cylinders. Gives better fuel consumption and more power.
- A device to transmit engine power to ancillary equipment mounted on the vehicle.
37
Transmissions
Gear ratio
- The number of teeth on the driving gear divided by the number

of teeth on the driven gear.
Crash box
- A gearbox in which ratios are changed by sliding different gears in and out of
mesh with each other.
Constant mesh
- A gearbox with all gears in mesh at all times. Changes are made by locking or
unlocking one of the gears on its shaft.
Synchromesh
- A gearbox incorporating a mechanical device to match the gear speeds when

changing gears.
Splitter box
- A means of doubling the overall gear ratios available by the use of a two speed
close ratio gearbox fitted behind the main gearbox.
Pre-select
- A gearbox in which a gear can be selected before it is required and brought into
operation when needed by operating a pedal.
Geared Road Speed
Maximum geared road speed is calculated with this formula Engine r/min x 60.
Gearbox ratio x diff ratio x tyre r/km =km/h.
Legal Definitions
Adapter dolly
- A semi-trailer with one or more axles, designed or adapted to be attached between

the truck-tractor and semi-trailer and not to carry any load other than imposed by
the semi-trailer.
Bus-train
- A bus consisting of two sections connected to form a unit, can swivel on a

horizontal plane at the connection between both sections, designed to convey
at least 100 passengers and has a continuous passage way throughout the entire
length.
Converter dolly
- A trailer which has one or more axles and when in combination with a semi-trailer
converts the semi-trailer into a trailer.
Goods vehicle
- A motor vehicle other than a motor cycle, motor tricycle, motor quadru cycle,
motor car, mini-bus or designed or adapted to convey goods on a public road and
includes a track-tractor, mobile crane and breakdown vehicle.
Mini-bus
- A motor vehicle designed to convey more than 9 but not more than 16 persons
including the driver.
Motor car
- A motor designed to carry not more than 9 persons including the driver.
Public road
- Any road declared or recognised as a public road under any law, and includes any
road, street or thoroughfare or any other place (whether a thoroughfare or not) to
which the public or any section of the public has the right of access.
38

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Electronic Tachograph MTCO 1390

Tachograph Speed Sensor - Electronic Tachograph

Tachograph Speed Sensor

Tachograph Interface - Signal Interfaces & Power Converters

Tachograph Angle Drives

Tachograph Adaptor Boxes

Tachograph TCO Power Supply Leads

Sealing Cover For Electrical Connections

Accessories for Tachographs

Tachograph TCO Drive Cables and Cable Parts

Connecting Pieces, Adapters & Extensions

Connecting Pieces, Adapters & Extensions

Service Diagnostic Systems

Sealing / Cable Making Tools

EDM 1404 - Electronic Diesel Consumption Measuring System

MTCO 1390 - Modular Tachograph Electronic

MTCO 1390 - Installation Sealing Accessories

CANLink Signal Adapter

The Tachograph Chart

Road Speed Recording

Example of Economical/ Uneconomical Stop-Start Driving

Assessment of Stop-Start Driving Techniques

Engine Speed Recordings

Commercial Target Market

Handling a complex world.

Non-EC Tachograph, Electronic, Compact Design

Non-EC Tachograph, Electronic

Handling a complex world.

* also suitable for TCO 1318-02

24 Hour Road Speed / Engine RPM

* also suitable for TCO 1318-25 & 1318-04

8 X 24 Hour Road Speed Only

8 X 24 Hour Road Speed Engine RPM

8X24 hour 160-8x24

Handling a complex world.

90 Degree Angle (Short)

90 Degree Angle (Long)

70 Degree Angle (Long)

Other versions available on request.

Rubber Ring 140 mm

Handling a complex world.

Tachograph Speed Sensor

Operating Voltage: 6.5 - 16 volts

Hall Generator with Continuous Shaft (without Holder)

Sender Unit Cable for Road Speed

1310 - Plug Kit Impulse Transmitter

1318 - Plug Kit Impulse Transmitter

Handling a complex world.

Tachograph Speed Sensor

Female 1318 Series + MTCO 1390

1318 Series + MTCO 1390

Integrated Pulse Generators

1318 Series + MTCO 1390

1318 Series + MTCO 1390

1318 Series + MTCO 1390

1318 Series + MTCO 1390

1318 Series + MTCO 1390

Sender Unit Cable for Road Speed

1318 + MTCO 1390

Handling a complex world.

Current Limiter 24V

Pulse Duplicator TCO 1318-25