How to Install and Remove a standard Teletrac Transceiver. April 27 2010 Draft: 001.fc.4_10.doc Introduction. This document is comprised of two independent sections. The first section addressed all the relevant steps required to perform an installation of a Teletrac transceiver. The second section addresses the removal of a Teletrac product and the vehicle care necessary once the equipment is removed.
Overview The purpose of this document is to provide the installer with instructions on how to install the TM2 with TBT and accessories; Inputs and Outputs. The installation of the system into the vehicle is the most important component of the system. It is very important to test the system and all its features at the end of the installation. Kit Components TM2 Combo WEDGE antenna Speaker TBT Button Main Power cable for TM2 Wiring harness 16 pin plug to wire the Inputs and Outputs and connect the speaker 3 relay assemblies Pre-Installation Vehicle Inspection Ensure that all major electrical and mechanical components are in working order ; o Headlamps o Air conditioner o Dome lights o Turn signals o Radio o Windshield wipers o Start vehicle engine if possible Installing a TM2 with MDT 1. Unit placement a) All equipment and wiring must be installed in a manner that will conceal its location. b) NEVER install on the driver side, place it behind the radio or passenger side. c) Installation must be on a dry surface that is free from moisture and heat. d) Installation location should be minimally exposed to dust and unnecessary vibration. e) It is always best to mount the unit to a flat surface; it should not be mounted on curves, dips or humps since this can degrade the security of the unit. f) Mount the unit to the chassis of the vehicle utilizing the mounting tabs. Always secure the unit with four (4) screws. g) Always check behind the place where any screws will penetrate to make sure you are not going to drill into a fuel or brake line, wiring harness, etc. h) If the unit cannot be secured on a flat surface, there are slits on the back of the VLU where wire ties can be used to secure the unit. i) Never mount the unit to the existing factory harness because vibration may cause an electrical short. Teletrac, Inc Transceiver Installation and Removal Guide. Page 1
j) Mount the unit so it will not cause any physical interference with the normal operation of movable equipment in the vehicle such as seats, pedals, hinges, air conditioning vents, etc. k) Never Zip tie to AIR HOSES Unapproved Locations: In a Truck bed In the Engine Compartment Behind the Seat Under the Seat Any place with extreme heat such as exhaust systems or heater cores Away from any sources of RFI such as the vehicle computer and alarm Under the dashboard on the driver side 2. Main Connections a) All connections MUST be soldered (preferred) or crimped with the proper crimping tool. Wrap and Tape, Scotch-Loc, or T-Tap connections may not be used when installing this system. Must use Teletrac supplied b) Zip tie excess wire slack c) Zip tie around the fuse holder to prevent tampering d) Hook-up wiring must be 20 AWG minimum. Use Teletrac provided cable. e) The Power input (red wire) MUST be connected to a constant (un-switched) +12 VDC supply. f) The Ignition input (white wire) MUST be connected to the vehicle ignition or another appropriate key operated line. g) The voltage on the line you are connecting to must not drop to zero while the engine is started (Cranking). h) It is mandatory to connect the Power connections are safer if they are done at the vehicle s ignition switch or the power inputs of the fuse or breaker panel. CAUTION: Never make a connection to a powered wire if it is not known what that wire controls. Ground Locate a strong spot in the metal near the transceiver to connect the ground lead. A good mechanical connection of the ground lead is vital, since a bad connection may cause the transceiver to locate poorly and behave erratically. Scrape away any paint or coating on Teletrac, Inc Transceiver Installation and Removal Guide Page 2
the metal where the ground will be attached, and then use a star washer between the metal and the ground terminal. Vehicles with aluminium and fibreglass bodies require special handling. Oxidation and electrolysis create problems with aluminium bodies, and fibreglass does not conduct current. In these cases, run the lead to the battery and connect it to the negative side. Never use the existing factory wires attached to ground; this could cause interference or noise. It is noted that the VLU performance will be seriously degraded. Ignition Wire Attach one end of fuse holder to the Ignition run source that will rest at ground while ignition is off (verify with suitable Multi-meter). Recommended locations are behind the ignition cylinder or behind fuse box. Always connect the ignition lead to the switched ignition power source at an acceptable ignition source, no matter what type of installation is being done. The ignition lead determines when an ignition message is sent or stored, and/or wakes the unit. Connect this wire to a good source for ignition, usually at the key-switch. To test for ignition, use a multi-meter to find a wire that has +12volts while the engine is being cranked and turns off when the key is turned off. 3. Tamper-Proofing the Installation a) Teletrac requires Installers to use techniques/materials to tamper-proof the unit and its main connections, including the Main Power, Ignition and Ground connections, and the two antenna connections. b) Teletrac supplies Installers with Anti-Tampering Compound to be applied to all connections at the transceiver and fuse holders. c) One cable tie should be used around each fuse holder in order to prevent fuse removal by un-authorized people. Teletrac, Inc Transceiver Installation and Removal Guide Page 3
Installing the Antenna The Teletrac antenna is a dual antenna. The antenna module and the GPRS antenna are fitted inside the single wedge type enclosure. Place the antenna on a flat section of the windshield Always attach the antenna on the passenger side lower corner. The coax for the antennas must be run behind the panels and in pillars. Suitable Locations for the MDT The first consideration when installing and MDT is safety. It is important that the MDT be placed near the driver in order to allow the driver to keep his/her eyes on the road. Teletrac does not recommend using the MDT while driving. Place the MDT within easy reach of the driver. Avoid the top of the dashboard. It is illegal in some states and if any holes are drilled they can not be easily repaired. Avoid angles where too much glare will be a problem. Teletrac, Inc Transceiver Installation and Removal Guide Page 4
Connecting Inputs and Outputs The TM2 features a set of analog inputs and outputs. There are two inputs in the TM2, these require specific polarity to trigger; Input 1 is negative, Input 2 is Positive. These inputs can take ground signals from sensors, switches. Inputs are level triggered and can be. There are two outputs; these are both negative and rated to 200 ma. These outputs are designed to operate in conjunction with a relay. A relay is an electromechanical switch that can be activated by the TM2 in order to switch on/off major vehicle circuits. a) Installing Honking Horn feature The Horn Honk uses the YELLOW wire in the harness. Wiring the relay; Relay s BLACK wire to TM2 s YELLOW wire. Relay s WHITE wire to Battery 12 VDC. Relay YELLOW wire to GROUND or 12 VDC depending of required trigger in truck Relay Blue HORN WIRE in truck. -Remove the RED wire NOT NEEDED b) Installing SCR (Starter Control Relay) The SCR uses the output BLUE in the harness. The way to wire the relay is; Relay s BLACK wire to TM2 s BLUE wire. Relay s WHITE wire to Ignition. Red to Starter Wire Blue to Starter wire. -Remove the YELLOW wire NOT NEEDED- Normally Closed Teletrac, Inc Transceiver Installation and Removal Guide Page 5
c) Installing PTO INPUT The PTO uses the GRAY INPUT in the harness. * If the truck switches negative when PTO goes active, simply wire directly into the circuit. If the truck switches positive wire a relay this way for a negative output; Relay s WHITE wire to Truck positive PTO WIRE. Relay s BLACK wire to GROUND. Relay s BLUE wire to solid GROUND Relay s Yellow wire to Gray/Black in TM2 harness. -Remove the RED wire, it is not needed- Sample relay schematics. Following are the wiring diagrams for the inputs for the PRISM TM. You would use these relays if you want to connect the ignition to an input. For a PRISM TM, you can configure 2 messages to be sent for 1 input, one for when it goes high and one for when it goes low. Teletrac, Inc Transceiver Installation and Removal Guide Page 6
Teletrac, Inc Transceiver Installation and Removal Guide Page 7
Overview Transceiver Removal. The purpose of this document is to provide the installer with instructions on how to de-install and remove the TM2 and accessories; Inputs and Outputs. The correct de-installation of the system from the vehicle is important to avoid damage to the vehicle or the Teletrac equipment. If looking for a quick removal, simply remove the transceiver, all other components could safely be left in the vehicle without any measurable degradation. If leaving the wiring in the vehicle, be sure to follow step 4 on PTO disconnection. Vehicle Components to be retrieved TM2 Transceiver (Required). 1 relay assembly (PTO Interface) (optional). Combo WEDGE antenna (optional) Main Power cable for TM2 (optional) Wiring harness 16 pin plug to wire. (optional) 2 fuse holders (optional). Power cabling (optional). PTO Wiring gray cable- (optional). *Only the transceiver and the relay assembly will be reused* The antenna and cable harnesses are not necessary for a reinstallation. These can be left in the vehicle is so desired, the PTO must be disconnected. ------------------------------------------------------------------------------------ Performing the work. 1. Vehicle Inspection Ensure that all major electrical and mechanical components are in working order ; o Headlamps o Air conditioner o Dome lights o Turn signals o Radio o Windshield wipers o Start vehicle engine if possible Teletrac, Inc Transceiver Installation and Removal Guide Page 8
Removing a TM2 2. Unit Placement 1) All equipment and wiring has been hidden under the dash. 2) The unit has been placed behind the radio area or passenger side. 3) Carefully remove the screws that secure the transceiver to the truck. 2.1 Main Power Connections First step is locating the 2 fuse holders and removing the fuses. This will ensure that no harm can be caused when the rest of the cables are cut and disconnected. The fuse holders will always be connected to a loom under the steering column or in the main fuse panel. CAUTION: Never cut or disconnect to a wire if it is not known what that wire controls. Ground Locate the black wire and unscrew the terminal using a Phillips screwdriver #2. The black wire can be simply cut using wire cutters. Ignition Wire The ignition connection is usually made behind the ignition switch, behind the ignition cylinder or behind fuse box. The ignition connection will be soldered, and rather that cutting it off it is best to leave the fuse holder in place and cut off the white wire and remove the 5 AMP fuse. 3. Removing the Antenna The Teletrac antenna is a dual antenna. The antenna module and the GPRS antenna are fitted inside the single wedge type enclosure. Carefully insert a spatula between the antenna and flat section of the windshield Teletrac, Inc Transceiver Installation and Removal Guide Page 9
Be very careful when prying against the glass as the adhesive tape is very strong and the glass can break. Gently pull the antenna coax from behind the panels and pillars. 4. Disconnecting the Input PTO Removal One input of the Teletrac transceiver has been connected to the PTO circuit of the truck in order to detect pump activation. A wire has been extended from the Relay assembly to a point in the truck where the PTO activation is being detected. It is important that the PTO connection be cut and the sensor cable removed. This is done by following the GRAY 4 conductor jacketed Teletrac cable and cutting off the GREEN Wire at its connecting point into the PTO circuit of the truck. Then insulate the truck cable and remove the gray jacketed cable. In most cases the PTO connection is in the dash and the disconnection is simple. In some tank trucks the PTO connection was done by the driver s seat or at the back of the truck. In these cases once removing the cable connection, be sure to properly tape and insulate the point were the GREEN cable is being removed. Adequate cable protection is very important when the cables are outside the cab of the truck. Use high quality electrical tape and 2 cable ties to ensure that the tape does not come off. Sample relay schematics. Teletrac, Inc Transceiver Installation and Removal Guide Page 10
Following are the wiring diagrams for the inputs for the PRISM TM. You would use these relays if you want to connect the ignition to an input. For a PRISM TM, you can configure 2 messages to be sent for 1 input, one for when it goes high and one for when it goes low. Teletrac, Inc Transceiver Installation and Removal Guide Page 11