MLT-400i Installation Guide

V.4.4

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Notice

This installation guide is published and copyrighted by Fleet Management Solutions (FMS). All information and specifications in this document are subject to change without notice. Nothing in this document is intended to create additional or separate warranties or guarantees.

Installation Requirements

Fleet Management Solutions recommends that you contact a professional installation provider. Please contact FMS for an approved installation provider list or to arrangeinstallation training. All installations must be done by approved personnel to ensure warranty coverage. Damage caused by incorrect installation will void the warranty.

© 2009 Fleet Management Solutions, All Right Reserved.

2007 & 2008 Inc. 500 Honoree3426 Empresa DriveSuite 100San Luis Obispo, CA 93401 Tel: (800) 999-2169Fax: (805) 787-0509

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Contents

NoticeTechnical SpecificationsRecommended Equipment and SuppliesInstallation DocumentationAntenna InstallationTamper DeterrentPower Connections and I/OThree Wire ConnectionDe-InstallationSecuring the UnitValidate the InstallationTroubleshootingAppendix A – ANTIRO1 Antenna installationAppendix B – Installation Checklist

Technical Specifications

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What IsThe MLT-400i Module?

The MLT-400i module is acritical tool for providing integrated GPStracking

and satellite service that tracks your fleet and assets anywhere in the world.

Satellite-Based Fleet And Asset Location:

Can fit anywhere.The MLT-400i is amodem that fits into small areasas it detects vehicle

surroundings, including landmarks,geo-fencecrossings and boundaries, and

also has the capability to display vehicle diagnostics—such asproactive fault

code messagesand total idle time.

Fast data delivery.The device’squick and efficient data delivery system works from rugged

environments anywhere in the globe.

Optional in-cab messaging.The MLT-400i module provides an optional messagedisplay terminal for

two-way driver communication.

OBD-II diagnostics connection and analog/digital inputs.The diagnostics connection quickly collects vehicle data, such as idle time

and speeding. Analog and digital inputs enable additional vehicle data to

be grouped and processed.

Technical Specifications:

Power Source:

11Volts (min) - 30Volts (max)

Transmit Freq: 1610-1626 MHz

Receive Freq: 1610-1626 MHz

Power Consumption:

Transmit at 12V = 650mA(typical)

Standby at 12V = 120mA (typical)

Sleep at 12V < 1mA

Size:6.375x 6.375x 1.5 inches

(16.19 x 16.19 x 3.81 cm)

Weight: 25.6oz (725.7g)

Transmit Power: 2 watts

Operating Temperature:

-31° to +158°F

-35° to +70°C

Digital Inputs: 1 @0 - 30Volts

Analog Inputs:

3 @0 - 5Volts,10-bit A/D†

Digital Outputs:

2 @12Volts,75mA(max)

Transportation

Vibration Requirements:

Designed to meet or exceed

allSAE standards

Recommended Equipment and Supplies

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This installation manual covers the installation of the MLT-400i and MLT-400iO.

The MLT-400i/O includes a GPS receiver and a two-way satellite communications modem.

Options include: a built in onboard diagnostic interface (OBDII), an in cab Message Display Terminal (MDT), ignition disable relay (IGNDRA), and roadside emergency send button (REBIR01).

Recommended Equipment

Digital Volt/Ohm Meter (DVOM)

Soldering iron/solder

Wire strippers/cutters

Cordless Drill

Drill bits (step bit or Unibit, #36, 19/32”, etc.)

Flash light

Standard and Metric socket set

Screwdrivers (standard, Phillips, Hex, Torx)

Recommended Supplies

Electrical tape

Velcro

Silicon sealant

Tie-Wraps

Sheet metal screws

18 gauge wire

2 amp ATC fuse

Torque Seal (blue) for tamper deterrent

Installation Documentation

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Installation Documentation

Appendix B includes an Installation Checklist to capture required installation and systemvalidation information.

The checklist is designed to becompleted in two phases. Phase 1 is installation information. Phase 2 is system validation.

You will need to locate the Electronic Serial Number on the label located on the back of the unit. This identifies theVehicle Name(Asset Name) to themodem IMEI Serial Number(ESN):

Antenna Installation

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The MLT-400i antennas combine GPS and Iridium satellite antennas. The ANTIR01 is a permanent mount (see Appendix A for additional information); ANTIR02 is a suction cup window mount antenna. Proper installation is critical to achieve optimum performance.

Safety Considerations Some locations do not allow suction

mount antennas on the windshield.Check your local regulations

Determine the Best Location Locate the antenna for an

unobstructed view of the sky, avoid windscreens, ladder racks and other radio antennas (minimum radius of 2 feet is recommended)

Orient the antenna horizontally

Ensure that the antenna GPS cable connects to the MLT-400i GPS cableand the Iridium cable connects to the MLT-400i Iridium cable (they arecolor coded blue and blackrespectively)

Check antenna cable length will reach to desired location; antennas typically include 12 feet of cable

Coil and secure any loose or extra lengths of antenna cable, do not allow cables to kink

The antenna must be attached to the MLT-400i prior to attachingpower

Tamper Deterrent

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Tamper Deterrent – Torque SealFor customers wanting to create a visual tamper deterrent for the OBDII connector,Torque Seal may be used to create a visual seal. FMS does not endorse or warrantyTorque Seal.

Apply Torque Seal “across”desired connectors such asthe OBDII and antenna

Apply inspection torque seal if desired (see below)

Torque Seal may be purchased through Organic Product Company(http://www.opcompany.com)

Do Not apply Torque Seal insideany connector so as to interferewith electrical continuity

Power Connections

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Two versions of the MLT-400i are available (check the product label located on the back of the unit to determine which one you have): 1) the MLT-400iO is OBDII compatible; 2) thestandard MLT-400i uses a three-wire connection. Both are described below.

MLT-400iO OBDII Connection Ensure your vehicle is OBDII com-

patible, read the FMS OBDII “How to Determine Compatibility” availablefor download on Fleet Central fromAdmin|Support|UserGuides

Connect the right angle OBDII connector into the vehicle OBDII connector

The OBDII connector may be located behind a panel, check your vehicle documentation for the location

After installation validation, tie wrap the connectors together, if possible, and add a dot of inspection/torqueseal to detect tampering

If your vehicle is not OBDII compatible, you can still use themodem with the Three-WireConnection below. See inset belowon Using the MLT-400iO in Three-Wire Mode.

The Red, Green and Black wire fromthe Modem should not beconnected for OBDII installations.

Three Wire Connection

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added or replaced, it should be of the same type as originally supplied from the factory. The originalfuses supplied is one (2 Amp ATC BUSS fuse).

Use care when routing the power cable. Route the cables where they will be protected and usecommonly accepted install practices for aftermarket automotive electronic devices.

Using The MLT-400iO in Three-Wire Mode Disconnect the OBD-II connector and attach ignition and power wires, (see MLT-400i Three-Wire Connection

above for more details)

Contact FMS Technical Support to issue the Reset Configuration Command

If you are using a Message Display Terminal (MDT-PRO), you must also connect both the modem AND the MDT (using the white two pin connector) to the same power source in addition to performing the stepsabove.

MLT-400i Three-Wire Connection

The MLT-400i is shipped with one in-line 2-amp fuse attached to the power cable. This fuseshould be installed as close as possible to the primary 12 or 24 volt source connection. If thepower connection is more that 1-2 feet from the fuse an additional fuse must be added as close to the power connection as possible should a short occur in the wiring. If a fuse is

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Solder your connections (see Poke and Wrap next page)

Ensure that connections are mechanically sound and properly insulated Use high quality electrical tape or shrink tubing, cheap tape will unravel in hot weather,

making it a poor insulator

Never use “t-tap” connectors (poor quality mechanical type connection). Never “twist and tape”without soldering your connection

Black Wire – Ground

Connect to a ground wire in a harness or

Connect to a bolt in the vehicle chassis

Red Wire – Continuous Power

Attach the Red wire to the battery power or Connect, with the key Off, to a constant power of 9 to 24 volts DC. Use a voltmeter and ensure

that the voltage does not drop below 9 volts when starting the vehicle.

Green Wire – True Ignition

Attach the green wire to true ignition source of 9 to 30 volts DC.

Do not connect to accessory power

To determine true ignition:1. Select a wire.2. With the key OFF, use a voltmeter to measure the DC voltage is between 0-2 VDC.3. Turn the key ON and confirm the voltage is equal or greater than 11-13 VDC. The voltage

must not drop below 9 VDC when starting the vehicle.4. Turn the key OFF, confirm the voltage is now 0-2 VDC.

Three Wire Connection continued

Three wire Connection Poke & Wrap

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Poke and Wrap1. Expose approximately 1/2” of bare wire.

2. Use a fine point tool to separate the wire strands.

3. Insert the end of the bare wire from your electronic device.

4. Push the wire to one end of the loop in preparation for wrapping.

5. Wrap your wire with the existing automotive wire.

6. Solder your connection.

7. Using a piece of electrical tape, wrap the connection and½” of insulation on either side of the exposed wires.

8. Place a zip tie around the section where the bare wires are located under the electrical tape.

I/O Connections

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MLT-400i/400iO I/O Connection

Note: When installing the modem, leaving easy access to the serial cable will facilitate anycode updates.

If additional I/O connections are desired for analog/digital inputs or digital outputs, the wire harness is defined below.

MLT-400i Wire Harness DescriptionWire Color Use Operating Range

Red Constant Power Source. Not accessory power. 9-30VDCBlack Chassis Ground GroundGreen True Ignition 9-30VDCPurple Signal ground. Connect at analog sensor’s ground. GroundOrange Analog/Digital IN #0 0-5VDCBrown Analog/Digital IN #1 0-5VDCGrey Analog/Digital IN #2 0-5VDCBlue Digital IN #0 3-30VDCYellow Digital OUT #1 12VDC, 50maWhite Digital OUT #2 12VDC, 50ma

Notes: Cap off any Digital out sensors not being used. Ground any inputs not being used.

De-Installation Guidelines

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Uninstallation guidelines1. Uninstallation of OBD only requires disconnecting the OBDII connection and also

disconnecting both coaxial connectors for the antenna wires to the modem. (Do not cut cables from unit on OBD installations, cutting of cables will void warranty and render theunit irrepairable).

2. Uninstalling of 3 wire type installs is fairly straightforward. There are three wires that will need to be disconnected(green, red, black) along with the antenna wires as mentioned for OBD . Each of these connections should be severed towards the end of the wires as to preserve its length for possible future installations.

Securing the Unit / Validating the Installation

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1. Before securing the unit, typically under the dashboard, record the IMEI/Serial Number (ESN), Vehicle Name (Asset Name), Odometer and if available Engine Hours on the Installation Checklist in Appendix B.

2. Use tie-wraps to mount the unit securely to a stable bracket.

3. If possible orient the unit so the LED indicators are visible.

4. Do not place the unit near moving parts, or next to any of the vehicle’s pedals.

5. Loosely bundle any excess antenna cable, power wiring and unused I/O signals.

6. Leave easy access to the 9-pin serial cable which will allow for code updating.

Validating the InstallationTake the vehicle outside where the antenna has a clear view of the sky in all directions. Avoidlocations with metal overhangs, tall buildings and trees. Conduct installation verification afterthe vehicle has been running outside for at least 15 minutes.

Observe LED Lights

Power LED - Relates to GPSo Green Solid - GPS fix acquiredo Yellow Blinking - GPS Searchingo Red Blinking one per second - GPS hardware failure

Signal LED - Relates to Iridiumo Green Solid - Signal detected, modem is readyo Yellow Blinking - modem is initializingo Red Blinking - modem hardware failureo Off - No Iridium satellite detected / cable problem.

Validating the Installation continued

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Validate Communications with MDT

If you have a Message Display Terminal (MDT) installed, you can begin the validation process by going to the SystemStatus|Diagnostics Menu. The tests encompass the local connection between the MDT and MLT-400i, the Iridium signalstrength, the GPS satellite count, as well as ignition wiring (and type), and the optional Ignition Enable/Disable feature.

Validate Communications with Fleet Central

If you don’t have access to the FMS Fleet Central web application please call FMS Technical Support at (800) 999-2169, Monday through Friday, 6:00 am to 6:00 pm Pacific Time. Our friendly and knowledgeable support staff will take the ESN Number of your unit and will verify data transmission.

If you have access to the FMS Fleet Central web application (password and user id re- quired) log on at www.fmsgps.com. Run a “History Report” for the current date to see if the data from your unit has been transmitted. The first messages youshould see from your unit are these:o Host Synchronization: the message sent when it reboots and receives a GPS locko Ignition ON: the message sent when the vehicle is startedo Ignition OFF: the message sent when the vehicle is turned off

If you gave the unit 30 minutes to transmit the data and still don’t see the messages, it is possible the installation was not done properly (see Troubleshooting Section below).

o Verify the history information which should show correct location of your vehicleo Verify/set the time zone for the vehicleo Record validation information on the Installation Checklist in Appendix B

Troubleshooting

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A summary of various troubleshooting cases are presented below. The FMS Knowledge Baseis a searchable resource of information related to common questions. Login to Fleet Centralto access the Knowledge Base on the Admin|Support|Knowledge Base Screen.

Note: If the GPS and Iridium cables were swapped and then reconnected, you will need to wait at least 30 minutes for a first time GPS fix.

Case# Case Possible Cause Action

1 There are no Ignition On/Off messages

Green wire is not connected correctly

Verify that the Green Wire receives≥9VDC when starting vehicle.

2 There is no HostSynchronizationmessage

No GPS fix – GPS antenna does not function properly

Verify antenna installation.Verify no objects obstructing antenna’s view of sky.

3 There are no mes-sages at all

Antenna does not function properly or unit is not activated

Swap unit with a known good vehicle installation. Verify antenna installa-tion. Verify that the unit is activated.

4 No LED activity on MLT-400iO - OBDII

Blown fuse powering OBDII connector

The OBDII fuse typically powers thecigarette lighter also, check the fusew/VOM and replace as necessary

5 Power LED: No GPS fix Wait at least 30 minutes for first time

Troubleshooting continued

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Help

Yellow/blinking fix. Verify antenna installation. Verify no obstructing antenna’s view of sky.

6 Power LED: RedBlinking

GPS hardware failure

Call Technical Support.

7 Signal LED: Off

No Iridium satellite detected

Verify antenna installation. Verify no obstructing antenna’s view of sky.

8 Signal LED:Red Blinking

Iridium hardware failure

Call Technical Support.

Access Source Location

Online: Knowledge Base Admin|Support|Knowledge Base

FAQs Admin|Support|FAQs

Fleet Central User’s Guide Admin|Support|Fleet Central User’s Guide

Open a Support Ticket Admin|Support|Open Support Ticket

E-mail: - Contact FMS Technical Support at:(800) 999-2169

Phone: - Contact FMS Technical Support at: techsupport@fmsgps.com.

Mail: - Fleet Management Solutions 3426 Empresa Drive, Suite 100 San Luis Obispo, CA, USA 93401

Appendix A – ANTIR01 Antenna Installation

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Keep antenna at least two feet from all other antennas

Use hole template below as a drill guide. Check printed template is sized to 1.660” between holes as dimensioned on the template.

The connector located closest to the center is for the GPS cable (Blue), the connector located closest the end is for the Iridium cable (Black)

Verify the template size with the actual antenna in case any scaling issues have occurred during theprinting process.

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Appendix A – ANTIR01 Antenna Installation continued

Appendix B – Installation Checklist

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CUSTOMER & VEHICLE DETAILSDriver’s Name Vehicle Type

Driver’s ID Model & Year

Work Location/Facility VIN Number

Last 6 of Modem Serial Number Registration/Plate Number

Installation Vehicle Fleet #/Asset Name

Maintenance Vehicle Color

De-installation Current Odometer

Modem-Vehicle Connection Type OBDII 3-Wire Vehicle Fuel Type Petrol Diesel

SYSTEM VALIDATIONFirmware Version MDT Modem

GPS/RF Validated Via MDT Diagnostics FMS Tech Support

Seat Belt Digital Input Configured Yes No None Present

REBIR0 Configured Yes No None Present

Driver ID Configured Yes No None Present

NEWMONT VEHICLE FUNCTIONALITY VALIDATIONBefore After Before After

Head lights – dip Clock

Head lights – main Radio

Indicators – front left Interior roof lights

Indicators – front right Number plate lights

Indicators – back left Dashboard illumination

Indicators – back right Dashboard warning lights

Hazards Main beam tail light

Brake lights Indictor tail light

Spot/fog front Electric sunroof

Spot/fog back Roof lining

Reverse lights Electric side mirrors

Central locking Electric aerials

Upholstery Shifter Bezel

Remote start functionality OTHER

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Appendix B – Installation Checklist continued

NOTES/COMMENTS

START DECLARATIONI, the Customer/Contact agree with the indicators given in the vehicle check section before any work was started, and hereby give authority for the technician to attend to this vehicle.

Customer Signature …………………………………. Full Name(s) ………………………………………………Date ………………….

TECHNICIAN

Time Started …………………………………………. Time Ended ……………………………………….

Technician Signature …………………………………. Full Name(s) …………………………………………….. Date ………………….

END DECLARATIONI, the Customer/Contact agree with the indicators given in the vehicle check section after the installation as completed.

Customer Signature …………………………………. Full Name(s) …………………………………………….. Date ………………….