the aa ltd aa recovery division installation documentation...

The AA Recovery - Company Confidential

The AA Ltd

AA Recovery Division

Installation Documentation

MAN TGL 2013 with Boniface

Body

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The AA Recovery – Company Confidential

Overview The Recovery division of The AA Ltd require Trakm8 to provide a telematics solution that will monitor, collate and stream data including: • CANbus data – Can high and low connection to FMS gateway for recording excessive RPM, throttle and fuel usage • PTO usage – input zero used to monitor when the flat bed is operational • In cab driver feedback – Audio and visual feedback via a 15 LED driver display • Tachograph driver ID and working state changes – K-line connection to pin D8 on back of tacho • GPS tracking – location, speed and idling data This document has been produced to provide instructions on how this equipment is to be installed, power take offs equipment locations and any interfaces have been pre-approved by The AA Ltd and under no circumstances should they be deviated from without written permission

Please note that you are not insured to drive / move The AA Ltd vehicle during the installation process

Ensure the ignition remains switched OFF at all times during the installation

As a safety precaution do not fit the fuses until after all connections have been made and you are ready to power

up the unit

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The purpose of this document is to provide a guide and specification for the installation of the TrakM8 T8 telematics unit and Driver Feedback Display This instruction is specific to the AA Recovery 2013 MAN TGL vehicle models only.

Purpose Of Document


Trakm8 Install 2013 MAN TGL

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Hardware required for MAN TGL:

• T8P0005 - Trakm8 T8 Unit

• CAB 571 - Premium Wiring Loom

• ANT100 - GPS Antenna

• CAB 771 - CAN Extension Cable MAN Truck (CANbus high/low pins attached)

• DFD000 - Driver Feedback Display

• TAC100 - Brown 8 Way Tacho Plug and crimp pin

• AA O2 SIM to be supplied separately from existing T6 stock

Consumables required:

• Good quality double sided tape (i.e. 3M)

• Various sized cable ties

• Solder

• Insulation tape

• Selection of fuses

Hardware for 2013 MAN TGL Install


CAB771

DFD000

TAC100

T8P0005

ANT100

CAB571

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The key points under the front grille are: CAN high and low Connection at FMS Gateway Connect 2 ends of spare blue wire together on Boniface 8 core cable Permanent, ignition and earth feeds are all taken from fuse boards behind rack containing the KSM module CAB771 CAN extension cable is secured to existing vehicle wiring looms and fed through into vehicle cabin

Overview – Under Front Grille

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The key points behind the passenger dash panel are:

GPS Antenna location is on top of ECU rack with cable fed behind and down to T8 unit on the bottom shelf

P.T.O pick up is taken from the 3-pin plug next to the ECU rack

Main T8 unit location is in the (empty) bottom shelf of ECU rack

Main power, ignition, earth, CAN and tacho wires are all fed through to the passenger foot well from under the bonnet

Overview – Passenger side of cabin



The key points are:

Utilise spare blue wire from Boniface 8 core cable running to back of control panel

Connect Boniface spare blue wire to pin D8 on the back of the Siemens VDO Tachograph using TAC100 kit

Driver Feedback Display secured to dash on left side of steering wheel. Ensure display is fitted as low as is possible and that it is not obscuring the drivers view at all

Overview - Driver Side of Cabin



Lift the front grille and locate the 2 “no steam clean” panels on the right Remove these 2 and the panel directly below Remove the 2 torx 20 screws and drop the down the rack containing the KSM module to reveal the 2 fuse blocks behind (If not installed carry out fitment as per Nationwide instructions) Both the positive and ignition feeds for the T8 are taken from the top of the 6 fuse block on the right hand side Positive Connect the T8 loom red positive wire to the 3rd fuse in from the left side, using a female spade connector Ignition Connect the T8 loom blue ignition wire to the 4th fuse in from the left side using a female spade connector

Installation Power Pickup Points


PERMANENT IGNITION

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1

2

3

The earth/negative feed for the T8 is taken from the bottom of the 4 fuse block on the left hand side Connect the T8 loom black earth/negative wire to the 1st fuse on the right hand side of the block, using a female spade connector

This will require a 3 amp fuse to be fitted after all connections have been made

Earth/Negative Connection

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Earth

The FMS gateway is accessed from under the front grille of the vehicle Locate the “no steam clean” panel on the left hand side Remove this and also the panel directly below (Torx 20 screws) You will see a number of plugs within this unit, the one that you need is on the second row from the top on the right-hand side column The connector you need is the white 18 pin plug with a twisted pair of wires in pins 17 (Orange wire) and 18 (brown wire with orange trace)

N.B. There is a resistor between the ends of the twisted pair of wires that must NOT be removed

FMS Gateway Connection



Remove the crimps on the end of the CAB771 CANbus extension cable as they are not required for this installation Solder one end of the CAB 771 cable to the CANbus wires on the plug at the front of the vehicle (as below) CAN High • FMS Gateway PIN 17= Orange wire • CAB771 CAN Extension Cable = Green CAN Low • FMS Gateway Pin 18 = Orange wire with

brown trace • CAB771 CAN Extension Cable = Blue

Wrap the soldered wires securely with electrical insulation tape Run the cable across to the other side (using the instructions on the next page)




Do not remove resistor

CAN High

CAN Low

The CAB771 extension cable then needs running downwards to follow the existing vehicle wiring loom and then out at the bottom. Remove the rubber grommet and feed the cab771 through out of the unit and then behind the existing vehicle looms Run the CANbus extension cable along the 50mm bar that runs across the front of the vehicle cab, to the cover that the existing vehicle loom runs through. Secure with cable ties as you go along Remove the rubber gromit on the right hand side and feed the cable through into the unit Secure with a cable tie and then pass into the passenger side foot well.



Remove grommet + feed cable through

Remove grommet + feed cable into unit

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Secure CAB771 with cable ties

Pass cable through into passenger foot well

Solder the remaining ends of the CAB771 loom to the CAN wires on the T8 loom as follows: CAN High CAB771 CAN Extension Cable = Green Wire on Trakm8 loom = Green with White trace CAN Low • CAB771 CAN Extension Cable = Blue • Wire on Trakm8 loom = Blue with White

trace

Wrap the soldered wires with electrical insulation tape




CAN High CAN Low

To connect to the tacho utilise the spare blue wire in the Boniface 8 core cable. It runs from the back of the Boniface unit in the cabin, to behind the passenger foot well under the front grille The spare blue wire will also require connecting together near the FMS gateway Locate the blue wire behind the KSM module rack. Cut to the same length as the CAB771 CAN extension cable and secure together using insulation tape Solder this end of the wire to the white wire with a black trace on the T8 main loom (K-Line) and wrap with insulation tape Coil up the spare white Boniface wire and secure using insulation tape At the FMS gateway locate the 2 connected ends of the Boniface 8-core cable Solder the unconnected ends of the blue wires together and wrap with insulation tape

Tachograph Connection



Right Side - Front Grille

Left Side - Front Grille

Use a trim tool to remove the panels above the Boniface unit and tacho for access Remove the Boniface unit and locate the spare blue wire in the 8 core cable Remove the Tacho using standard car stereo keys and locate the empty D socket on the back of the unit Connect the TAC100 crimp terminal to a length of the blue wire cut from the other end of the cable Ensure there is enough length to reach from the Boniface unit to the tacho Solder to the spare blue wire in the 8 core cable and wrap with insulation tape Connect the crimp terminal to pin 8 on the TAC100 brown plug Feed around behind the overhead dash to the back of the tacho and locate into socket D Refit the Tacho, Boniface unit and the 2 panels above

Tachograph Connection



Boniface control Unit

Tachograph unit

The PTO pick up is taken from a 3-pin white plug situated next to the ECU rack behind the passenger dash It is easily identified as 2 white 3-pin plugs with a diode inbetween The top plug has only 2 pins populated with blue wires and the 3rd unpopulated pin is to be utilised for the PTO pick up Use a multi-meter to test and verify a voltage change is measured when operated Connect the purple wire (Input 0) on the T8 main loom to the unpopulated pin on the top white plug After these connections have been made loom any excess cable with cable ties to keep tidy

PTO Connection



The GPS antenna is positioned behind the passenger side dash, on top of the ECU rack that is alongside the air vent The cable should be run down the back of the ECU rack to the bottom shelf where the unit will be located The GPS antenna must be adhered to a suitable location, ensuring it is NOT mounted beneath or in very close proximity to electrically conductive materials, such as metal, certain types of plastic, metallised film or laminate windscreens The antenna is magnetic but additional security should be provided with a good quality double sided tape (such as 3M) Connect the antenna to the T8 unit and tighten using an 8mm open ended spanner.

GPS Antenna Location



The display is mounted on the dash as low as is possible above the radiator fan switch Use a trim tool to remove the panel from around the radiator switches and also the 2 switch panels below. Feed the cable behind the dash and through to the ECU rack on the passenger side Connect the display 9 way D connector to the 9 way D connector on the main T8 loom and tighten the thumb screws Solder the red display wire to the red permanent wire on the T8 Loom. Then solder the black display wire to the black negative/earth wire on the T8 main loom Connect the display to the bracket and then tighten the bracket arm at the correct angle, being careful not to over tighten Thoroughly clean the surface with the alcohol wipe supplied and then adhere the bracket to the dash with the adhesive pad

Driver Feedback Display location



Wire Colour

Description Notes

Red Vehicle Supply Positive (+ve)

Connect to the T8 permanent Positive supply via a 3 Amp fuse

Black Vehicle Supply

Negative (-ve) Connect to the T8 permanent Negative supply. Vehicle Ground.

Once all connections have been made connect the main 25-Way D connector to the T8 unit and tighten the thumb screws Fit the fuses as follows: Permanent = 3 amp Ignition = 1 amp Negative/Earth = 3 amp You are now required to follow the commissioning process on page 20 before securing the unit in place Once commissioned secure the T8 unit to the bottom shelf of the ECU rack, using good quality double sided sticky tape and cable ties Ensure there is no movement at all once secured in place

Main Unit Location




Commissioning

Before contacting Trakm8 to commission the unit start the engine. When the unit has powered up confirm that 3 green trills (GPRS), 3 green flashes (GPS) and constant yellow trills (FMS) have been observed. Finally operate the PTO to generate an event To speed up the process please have the following information available for the Trakm8 commissioning team: • Unit imei (this is the 15 digit serial number across the Trakm8 unit) • Vehicle registration • Odometer reading You will be asked to observe the Driver Feedback Display whilst the engine is idling. This is to confirm the LEDs run through the GREEN-AMBER-RED status in the correct order You will also be instructed to change the driver states on the tacho to confirm connectivity To do this ensure you can see the following screen on the tacho: When Trakm8 have finished commissioning the unit and confirmed location, CANbus data, PTO switching high/low, Tacho state changes and idling, you will be issued with a unique commissioning code (CC) which you will need to take note of



Press button 1 to change the state icons in the bottom left of the screen as follows:


Completion of Installation

Once you have received your CC code from the Trakm8 commissioning team you can secure the T8 in place To do this follow the instructions on page 19 All excess cable is to be neatly coiled and then secured using insulation tape and cable ties The vehicle can now be rebuilt checking all panels are fitted correctly and that all waterproof seals are in place Please ensure that the vehicle is left in a clean and tidy manner with all cable tie ends and cable snips removed from the vehicle

A vehicle post installation check should now be completed to check vehicle functions



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