Eroad Installation Manual 2012 V1.3

EROAD New Zealand Installation Manual
Elocate
EhuboLite
Ehubo
Tubo
Driver ID
© EROAD 2012 – form 001071A Commercial In Confidence Page 1 of 74

Contents
1 Overview ......................................................................................................................................... 5
1.1 Audience ................................................................................................................................. 5
2 Administration.................................................................................................................................. 6
2.1 Installer Website ...................................................................................................................... 6
2.2 The Installation Process .......................................................................................................... 6
2.2.1 Installation and Accessory Planners ............................................................................... 7
2.2.1.1 Accessory Planner ................................................................................................................................ 7
2.2.1.2 Installation Planner ................................................................................................................................ 8
2.2.2 Installation Documentation .............................................................................................. 9
2.2.2.1 Photographs .......................................................................................................................................... 9
2.2.2.2 Installation Certificate .......................................................................................................................... 10
2.2.2.3 Installation Instructions ........................................................................................................................ 11
2.2.2.4 Calibration of the Vehicle .................................................................................................................... 11
2.2.2.5 RUCHO Information Sheet .................................................................................................................. 12
.............................................................................................................................................................................. 12
2.2.2.6 Swap-Out Process .............................................................................................................................. 13
.............................................................................................................................................................................. 13
2.3 Warranties ............................................................................................................................. 14
2.4 Charge-Out Rates ................................................................................................................. 14
2.5 Submission of Invoices ......................................................................................................... 14
2.5.1 Installations - Invoicing .................................................................................................. 14
2.5.2 Remedial Work - Invoicing ............................................................................................ 15
2.6 Remedial and Returns Process ............................................................................................ 15
Request for remedial work can come from several different sources: .......................................... 15
2.6.1 Remedial Work .............................................................................................................. 15
2.6.2 Ebox Return Process (see Flow Diagram 2.6.3) ........................................................... 15
2.6.3 Ebox Return Flow Diagram ........................................................................................... 16
2.6.4 Faulty Accessories Return ............................................................................................ 17
...................................................................................................................................................... 17
3 Health and Safety .......................................................................................................................... 18
4 Technical Background ................................................................................................................... 18
4.1 Brief description of GPS system ........................................................................................... 18
4.2 GPS Antenna basics ............................................................................................................. 19
4.2.1 Wire Size and Current Capacity .................................................................................... 20
4.3 Speed Sensors ...................................................................................................................... 22
4.3.1 Inductive (variable reluctance) sensors......................................................................... 22
4.3.2 Speedometer Cable-Driven Sensors ............................................................................ 26
4.3.3 Hall-effect Sensors ........................................................................................................ 28
4.3.4 Determining Suitability of a Speed Signal ..................................................................... 29
5 Standard of Work .......................................................................................................................... 30
5.1 Electrical Wire Connections .................................................................................................. 30
5.1.1 Cable ............................................................................................................................. 30
5.1.2 GPS aerial extensions ................................................................................................... 30
5.1.3 Terminations “SOLDER, TAPE, CABLE TIE” ............................................................. 31
5.1.3.1 Splicing to vehicle wiring ..................................................................................................................... 31

5.1.3.2 Soldering ............................................................................................................................................. 31
5.1.3.3 Electrical Tape ..................................................................................................................................... 34
5.1.3.4 Using Cable Ties ................................................................................................................................. 34
5.1.4 Heatshrink ..................................................................................................................... 34
5.1.5 Sleeving ......................................................................................................................... 35
5.1.6 Crimp Terminals ............................................................................................................ 36
5.1.7 Routing of Cables – Split Gland Tubing ........................................................................ 37
5.1.8 Fuse Holders ................................................................................................................. 38
5.1.9 Drilling Holes ................................................................................................................. 39
5.1.9.1 Truck.................................................................................................................................................... 39
5.1.9.2 Trailer .................................................................................................................................................. 39
6 Installation ..................................................................................................................................... 40
6.1 Document Existing Damage (as part of the Installation Certificate) ..................................... 40
6.2 Planning the Installation ........................................................................................................ 40
6.3 Tools and Consumables ....................................................................................................... 40
6.3.1 Tools .............................................................................................................................. 40
6.3.2 Consumables ................................................................................................................ 41
6.3.3 Health and Safety Equipment ....................................................................................... 41
6.4 Connections – Ignition, Battery, Ground, Speed Signal........................................................ 42
6.4.1 Ignition – always fused at source .................................................................................. 42
6.4.2 Power Supply – always fused at source ....................................................................... 42
6.4.3 Ground .......................................................................................................................... 43
6.4.4 Speed Signal ................................................................................................................. 43
6.5 Ehubo/ EhuboLite Installation ............................................................................................... 44
6.5.1 Ehubo/ EhuboLite Position on Windscreen ................................................................... 44
6.5.1.1 Clean Windscreen ............................................................................................................................... 45
6.5.1.2 Remove Protective Film from Mount ................................................................................................... 45
6.5.1.3 Press Mount against Windscreen ....................................................................................................... 45
6.5.1.4 Slot Ehubo into Mount ......................................................................................................................... 45
6.5.2 Ehubo/ EhuboLite Wiring Requirements ....................................................................... 46
6.5.2.1 Digital Inputs ........................................................................................................................................ 47
6.5.3 Typical Connection Diagrams: Ehubo/ Ehubolite ......................................................... 48
6.5.3.1 No Driver ID + No Auxiliary Inputs ...................................................................................................... 48
6.5.3.2 Auxiliary Inputs + No Driver ID ............................................................................................................ 49
6.5.3.3 Driver ID + No Auxiliary Inputs ............................................................................................................ 50
6.5.3.4 Driver ID + Auxiliary Inputs .................................................................................................................. 51
6.5.4 Dangerous Good Vehicles ............................................................................................ 52
6.5.5 Ehubo Trouble Shooting – Interference and Noise ....................................................... 53
6.5.5.1 Noise Sources ..................................................................................................................................... 53
6.5.5.2 Radiated Noise .................................................................................................................................... 53
6.5.5.3 Conducted Noise ................................................................................................................................. 53
6.5.5.4 Induced Noise ..................................................................................................................................... 53
6.5.5.5 What is EMI? (Electromagnetic Interference) ..................................................................................... 53
6.5.5.6 What is EMI Shielding? ....................................................................................................................... 53
6.5.5.7 What does Grounding Have to do with EMI Shielding? ...................................................................... 53
6.5.5.8 Device and Antennae Installation Proximity: ....................................................................................... 53
6.5.5.9 Voltage Spikes and Grounds .............................................................................................................. 54
6.5.5.10 Spikes .............................................................................................................................................. 54
6.5.5.11 Grounds ........................................................................................................................................... 54
6.5.5.12 Voltage Drop ................................................................................................................................... 54
6.5.5.13 Checking the GND Terminal ........................................................................................................... 55
6.5.5.14 The AC Ripple Test ......................................................................................................................... 55
6.5.5.15 Twisted Pair ..................................................................................................................................... 56
6.6 Driver ID ................................................................................................................................ 57
6.7 Tubo Installation .................................................................................................................... 58
6.7.1 Wiring ............................................................................................................................ 59
6.7.1.1 Power Option 1 – Pin 5 of 7 Pin Trailer Plug if Available .................................................................... 59
6.7.1.2 Power Option 2 – Pin 5 of 7 Pin Trailer Plug Used for Work Lights .................................................... 59
6.7.1.3 Power Option 4 – Install 15-pin plug ................................................................................................... 60
6.7.1.4 Tubo Charger Smart Charger Wiring .................................................................................................. 62
6.7.2 Tubo Box Enclosures .................................................................................................... 63
6.7.3 Speed Sensor Options .................................................................................................. 63
6.7.4 Pole Wheel Installation Instruction ................................................................................ 64
6.7.5 External GPS Antenna .................................................................................................. 67
APPENDIX 1 – Full Parts List ............................................................................................................... 68
APPENDIX 2 – Ehubo/ EhuboLite Quick Check ................................................................................... 69
APPENDIX 3 – Tubo Quick Check ....................................................................................................... 70
APPENDIX 4 – Administration Quick Check ......................................................................................... 71
APPENDIX 5 - Accreditation ................................................................................................................. 72
APPENDIX 6 – Auditing ........................................................................................................................ 74

1 Overview
EROAD was the first in the world to develop a comprehensive weight based tax collection device and fully integrated
system based on distance covered. There are immense advantages to transport operators in terms of reduction in
business and compliance costs in utilising all that the EROAD product has to offer.
EROAD is a NZTA licensed agent and is authorised to collect Road User Charge (RUC) tax. As part of that agency
agreement NZTA has audit oversight on the key processes including those around the installation and swap outs of
the various EROAD units.
A good installation is essential to the success of the EROAD system. The installation process starts from when the
installation planner is sent out right through the physical install, completion and finally photographs and paperwork.
The automotive environment is harsh in terms of shock, vibration and corrosion, noise and voltage transients. These
factors will cause some aspect of the installation to fail over time if it is not performed to a very high standard.
Recalling a vehicle and correcting problems creates enormous cost and customer aggravation and can be avoided by
simply doing the job properly to start with.
Vehicle manufacturers go to great lengths to ensure their vehicles are reliable and the installation must follow the
same basic principles and practices.
This Installation Manual covers general installation practices and is applicable to all EROAD equipment installations.
Product-specific installation instructions are available on the EROAD Installer website www.eroadinstaller.co.nz.
EROAD installer accreditation is based on compliance with these guidelines and may be revoked if the standard of
work falls below them.
1.1 Audience
This guide should be read in its entirety by installers of EROAD equipment as well as managers and business owners
involved with installations. It covers the following sections:
 Administration. This section covers various aspects of the administration side of the business including
pre-installation advice that is sent to installers to discuss with customers.
 Health & Safety. Recommendations on what equipment installer staff should be supplied.
 Technical background. This section explains the technology used by EROAD and how installation quality
will affect system operation. This will provide insight on how to plan the installation to be most effective.
 Standard of work. This section defines the expected standard of workmanship and the correct methods to
use during installations.
 Installation. This section deals with the installation itself and how the various components should be installed
and wired. This is backed up by more detailed information on the EROAD Installers website

2 Administration
2.1 Installer Website
The EROAD Installer website assists with the installation of EROAD products. It includes information relating to
vehicle wiring, sensor positions and EROAD parts and part numbers.
The content is continuously being updated as more information becomes available.
This should be the first place you check for any installation-specific information. You will need to register and be
approved by EROAD to get access to this information.
www.eroadinstaller.co.nz
2.2 The Installation Process
The installation process covers everything from the initial paperwork, through health and safety, installation of
accessories, installation of hardware and, most importantly, dealing with the customer.
The installer is the EROAD representative who in most cases spends the largest amount of time with the customer
and their vehicles. It is the installer who creates the impression of EROAD that will dictate if we are judged as a
professional organisation or a bunch of cowboys (EROAD does not engage cowboys as installers!)
On going business and referrals are vital to EROAD’s continuing growth which in turn impacts the number of
installations and corresponding income for the EROAD installer network.
The full process is as follows:
 Installation and accessory planners are created by EROAD and forwarded to the nominated installer for
completion.
 The installer liaises with the customer and returns the planner to EROAD with critical information completed.
o At this point a decision needs to be made as to whether the installer is to charge the customer direct
or to charge EROAD. This affects how accessories are charged out.
o Ideally the preference is for EROAD to be charged so the risk of the debt is with EROAD and not with
the installer.
 Goods and accessories (where necessary) are dispatched as per the planner.
 The installation is completed as per EROAD guidelines both for the vehicle and general auto electrical wiring
guidelines.
 Vehicle is driven to allow for the calibration to occur.
 Post-installation processes are completed:
o Customer is handed RUCHO form.
o Photographs taken and sent to EROAD.
o Installation Certificate is completed and sent to EROAD.
 Installer invoices EROAD/ customer as per installation charge price list. The up-to-date list is available on the
EROAD Installer website www.eroadinstaller.co.nz.

2.2.1 Installation and Accessory Planners
The installation and accessory planners are generated from the sales documentation. The planners are to be
completed by the installer and may in some cases be completed by the dealer.
EROAD will send an email header with the installation and accessory planners attached. The email will indicate what
the working day lead time is to deliver the units to the installer once the planner is returned.
2.2.1.1 Accessory Planner

The accessory planner advises EROAD of key pieces of information required to ensure the right equipment is sent to
the correct address and the correct parties are charged.
If you do require further parts for the installation, please download an accessory order form from
www.eroadinstaller.co.nz, complete it, and send to [email protected].

2.2.1.2 Installation Planner
The installation planner allows EROAD to programme production to meet the installation date.

2.2.2 Installation Documentation
When the EROAD unit is sent to you it will also come with several documents including
 Installation certificate
 RUCHO information slip
 EROAD unit installation instructions
As part of the Agency Agreement EROAD holds with NZTA there is a requirement for EROAD to hold details of all
installations so they can be audited at a later date if required.
Accordingly the following administrative tasks do need to be completed post-installation. EROAD may withhold
payment may be held we do not receive this information.
Installation Certificates fully completed.

 See example overleaf.
 Originals to be sent/ emailed to EROAD.
2.2.2.1 Photographs
Photos are to be taken and emailed to [email protected]. The email subject line must include the customer name
and the vehicle registration. The photos to be 100kb to 300kb in size and must include as a minimum:
Ehubo/ Ehubolite/ Elocate - Photographs

 First photo to be of number plate (this allows easy identification of following photos)
 Damage – any damage seen during the pre-installation check
 All taped and cable tied wiring joins (power, ignition, speed sensor)
 Position where ground/ earth has been connected
 Calibrated** EROAD Ebox
 Where Ebox has been installed on the vehicle windscreen (stand 3 metres back)
 Where Driver ID is sited (if fitted)
 RUCHO form left in dash (if unable to pass to customer/ office staff)
Tubo - Photographs
 First photo to be of number plate (this allows easy identification of following photos)
 Damage – any damage seen during the pre-installation check
 GPS antenna siting (Tubo installation) (stand 3 metres back)
 Speed sensor connection – heat shrink and cable ties (Tubo installation)
 Siting of Tubo and Tubo battery box (stand 3 metres back)
 Crimp connections within Tubo and Tubo battery box (one photo of each opened box)
 Photo of cables coming from grommets under the Tubo and Tubo battery box (Tubo installation)
 Calibrated** EROAD Ebox
 If hole drilled through chassis web,– photo of hole position in relation to Tubo etc
 Please also take photos of anything that should be included on the www.eroadinstaller.co.nz website for
future reference.
** If the unit cannot be calibrated then a photo of the install screen must be taken instead.
##
Does not apply to Elocates
Ebox - Swap-Out Photos – see Section 2.2.2.5 for flow diagram

2.2.2.2 Installation Certificate

2.2.2.3 Installation Instructions
Depending on the EROAD unit being installed, the accompanying installation instructions will be relevant to the unit
being installed.
Whereever possible installers will be kept informed on any changes to current installation practices, but please always
glance through the installation instructions to ensure you are up to date
2.2.2.4 Calibration of the Vehicle

When first powered up make sure that the registration plate of the vehicle matches the plate number showing on the
Ebox. If it doesn’t, contact EROAD Support as soon as possible.
When the physical installation is complete the vehicle needs to be driven to allow the Ebox to be calibrated,
at a constant speed (above 50km/h and no more than 90km/h).
Depending on the cell and GPS coverage the average distance required to be travelled is 2 – 5km.
If there are any issues with the calibration please call EROAD Support.
There will be situations where the vehicle cannot be driven. This is acceptable – a note will be required on the
installation certificate as to why it could not be calibrated.
Once the calibration is complete the following grid indicates what the Ebox status lights mean:
Product
Active Ehubo / Ehubo Lite / Tubo (Connected) Tubo - Disconnected
green: on green: blinking (1s on 1s off)
No Tamper
Active- Ign On or Movement blue: off blue: off
before Sleep Mode green: on green: blinking (1s on 1s off)
Tamper
blue: 1s on, 1s off blue: 1s on, 1s off
green: on green: blinking (5ms on 1s off)
No Tamper
Sleep Mode (15 Min after no blue: off blue: off
movement and ign off or
Trailer stationary for 15 min) green: on green: off
Tamper
blue: 1s on, 1s off blue: 5ms on, 1s off
green: off green: off
No Supply or Tubo battery flat
blue: 5ms on, 10s off blue: 5ms on, 10s off
Label Colour
Power Green
Status Blue
I Orange (Not Used - will flash before installed State)
II Orange (Not Used - will flash before installed State)

2.2.2.5 RUCHO Information Sheet
This form is to allow the customer to be able to complete an online RUCHO through the EROAD Depot. Please
complete and pass to the customer contact you have been liaising with.
If no one is available, ensure that you leave it over the vehicle instrument panel and take a photo as part of the photos
you are taking for the installation.

2.2.2.6 Swap-Out Process

2.3 Warranties
As per the signed installer agreement there is an expectation that warranties will be provided by any installer for
workmanship and accessories when installing EROAD equipment.
 Installation of cabling, EROAD hardware, accessories etc 12 months

 Miscellaneous accessories (not supplied by EROAD) 12 months
 Any rework 6 months
Obligations under the warranty:

In the event of an issue with any aspect of the installation the installer has the first right of refusal to remedy the
situation, replace parts etc as guided by EROAD.
In the event that a third party has to be engaged to complete the remedial work, an EROAD ‘internal installer labour
rate’ will be used, the details of which can be found on the EROAD Installer website www.eroadinstaller.co.nz.
2.4 Charge-Out Rates
EROAD has a schedule of charge-out rates for installations completed. They can be found on the EROAD Installer
website www.eroadinstaller.co.nz.
Any variations in the charge-out rates must be brought to the attention of the EROAD Service Delivery team before
the work commences.
2.5 Submission of Invoices
2.5.1 Installations - Invoicing
Invoices for installations are to be submitted as soon after the physical installation as possible. In most cases there is
an expectation that EROAD is charged for the work and not the customer. This ensures that the risk of the debt lies
with EROAD and not the installer.
Please ensure that the following details are contained within the invoice:
 One invoice per vehicle.
 The purchase order used is the vehicle registration.
 The “RUC’ Job number must be shown. This can be found at the top of the Installation Certificate:
 The customer name must be shown on the invoice.

 There is a description of the work completed.
 Any variations from the charge-out rates will have been discussed prior to the installation occurring – please
note who at EROAD this was discussed with.
If the customer already has a pre-existing account or relationship with the installer the installation can be charged
direct to the customer using the EROAD charge-out rates as per paragraph 2.4 above.

2.5.2 Remedial Work - Invoicing
Invoices for remedial work require key pieces of information to ensure the correct party is charged for the work
completed.
No work can be approved for payment unless an EROAD case number has been issued and is included on the
invoice
Please ensure that the following details are contained within the invoice:
 One invoice per vehicle.

 The purchase order used is the “EROAD Case Number’. These are issued by EROAD Support (call 0800 437
623 Option 2).
 The vehicle registration must be shown on the invoice.
 The customer name must be shown on the invoice.
 There is a description of the work completed.
Please offer an informed opinion as to whether the issue is customer related (ie damage, fair wear and tear)
or otherwise.
 All accessories used must be listed by line.
2.6 Remedial and Returns Process
Request for remedial work can come from several different sources:
 Customer initiated – installer contacts EROAD Support to obtain an EROAD case number (this must be
obtained). EROAD Support – 0800 437 623 – Option 2
 EROAD Support initiated. EROAD Support will contact the installer in the event that a fault has been detected
that will require further investigation or in extreme circumstances the swap-out of the Ebox will be required.
There will be those situations (after hours) where obtaining a case number may not be possible. When this does occur
please proceed with the remedial work, but contact EROAD Support as soon as possible for a case number. At that
stage explain what work has been conducted and why.
2.6.1 Remedial Work
Whereever possible EROAD Support will give direction in terms of the suspected fault and possible causes.
It is expected that the installer will carry out best practice in terms of rectifying the fault by appropriate inspection of the
cabling/ fuses/ sensors etc to aid the correct diagnosis.
When the work is completed the installer must immediately contact EROAD Support so any faults can be reset.
2.6.2 Ebox Return Process (see Flow Diagram 2.6.3)
In instances where an Ebox must be swapped out, EROAD will send out a unit along with a ‘Returned Item Request”
form (see Sect 2.6.4).
The lower section of the form must be completed by the installer and returned along with the old Ebox.
These are to be returned as quickly as possible to EROAD Operations.

2.6.3 Ebox Return Flow Diagram

2.6.4 Faulty Accessories Return
In the event of a product failing within the warranty period, please return it to EROAD for warranty processing.
Please enter details

in this section after
the work is
complete.

3 Health and Safety
Installers are responsible for the health and safety of their staff whilst working on customer sites etc. Please adhere to
any customer site health and safety requirements. You may be required from time to time to undergo an induction
process on these sites.
EROAD recommends that each technician have readily available to them the following health and safety equipment:
 Safety boots
 Appropriate Hi Viz and Safety clothing
 Appropriate safety glasses
 Appropriate ear protection
 Vehicle first aid kit and fire extinguisher
 Road cones as required to indicate working around a stationary vehicle
 Orange flashing light for transiting restricted areas
 Knee pads for comfort/protection when kneeling on stony or rough ground.
When installing into a powered vehicle ensure the keys are removed from the ignition and if possible placed
in ‘your pocket’. This will ensure the vehicle cannot be moved when you are working underneath it.
Dangerous Goods vehicles do require a higher level of safety – see section 6.5.4.
4 Technical Background
4.1 Brief description of GPS system
24 to 32 satellites circle the earth about twice a day each at a height of about 20,000km above the earth’s surface.
They follow different paths to effectively cover the earth’s surface. They each transmit a unique signal containing
timing information and information about their position in space that is received by the GPS receiver in the Ehubo. The
time taken for each received signal to reach the receiver is used to calculate the receiver’s position.
GPS Satellite Constellation

The important concepts here are:
1. The satellites only transmit at low power, so by the time the signal reaches the earth, 20,000 km away, the signal
is very weak. Covering the receiving antenna with any material, or obstructing its view of the sky, will significantly
reduce performance.
2. The receiver works out the time taken for the signal to reach it, so if that signal bounces off various objects before
it reaches the receiver, an error will be introduced.
GPS antennae require a direct view of the sky to work efficiently
4.2 GPS Antenna basics
Every antenna has a radiation pattern (beam shape) that can be thought of in terms of a headlight. The antenna can
“see” signals in the beam, but cannot “see” those outside it, just as we can only see objects in the light beam of a
headlight.
Electrical noise is always a problem for the sensitive GPS receiver. All major sources of electrical noise are man-made
and originate from the earth, so it suits the receiver to have the antenna beam pointed at the satellites and away from
the surface of the earth. A GPS antenna that is pointed horizontally will have a significantly degraded reception of the
satellite signals, and also pick up a lot more noise which reduces the receiver sensitivity.
The maximum sensitivity beamwidth of a typical GPS patch antenna of the type used by EROAD is about 65° as
shown in GPS Antenna beamwidth.
The antenna may appear to work in orientations other than vertical, but performance will be degraded and it
may not work when different satellites are overhead at a different time of the day.
See section 6.7.4 for antenna installation instructions.
GPS Antenna beamwidth

4.2.1 Wire Size and Current Capacity
Wire size must always be rated to carry the maximum current of the fuse it is protected by without excess heat
generation. Many tables are published showing maximum current for a particular wire gauge, but most are based on a
specific temperature rise, not voltage dropped over the wire length. We are more interested in what the voltage will be
at the end of the wire to ensure the product will still have enough voltage to operate.
The voltage dropped in the wire follows Ohm’s law V=I x R. The voltage “lost” in the wire depends on the current (I) in
the wire and the resistance (R) of the wire. The thinner the wire, the higher the resistance and the higher the voltage
drop in the wire.
Wire gauge (size or cross-section area) is chosen so that there is a maximum of 0.5V lost in the wire for a specific
current and length. The following table provides guidance on wire gauge selection. Remember that for power supply
wiring, the total wire length must be taken into account as there will be an equal voltage drop in both the supply
(positive) and return (negative) wires. This means that the voltage seen by the unit will be 1V less than the supply
voltage
Do not use the following table based on maximum fuse ratings. It should be used based on actual operating current
drawn by the unit to be powered.
The Tubo draws 1.7A at 12.7V (use 3A fuse in the table for simplicity) maximum when charging its internal back-up
battery. For example, using the table, if the total distance is 20m (19m is the closest number in the table) from supply
connection point to Tubo we can see that 16AWG wire is required.
The Ehubo draws 300mA maximum, but can draw higher current very briefly when sending GPRS messages. The
maximum current consumed by the Ehubo is assumed to be 1A for wire size calculations.
Truck powered for trailer – 10 A fuse to be fitted.

Ehubo
1 Tubo
2 Tubo
Wire Wire Maximum Current

Gauge area
(AWG) (mm²) 1A 2A 3A 4A 5A 6A 7A 8A 9A 10A
10 5.27 152m 76m 51m 38m 30m 25m 22m 19m 17m 15m
11 4.15 121m 60m 40m 30m 24m 20m 17m 15m 13m 12m
12 3.31 96m 48m 32m 24m 19m 16m 14m 12m 11m 10m
13 2.63 76m 38m 25m 19m 15m 13m 11m 10m 8m 8m
14 2.08 60m 30m 20m 15m 12m 10m 9m 8m 7m 6m
15 1.65 48m 24m 16m 12m 10m 8m 7m 6m 5m 5m
16 1.31 38m 19m 13m 9m 8m 6m 5m 5m 4m 4m
17 1.04 30m 15m 10m 8m 6m 5m 4m 4m 3m 3m
18 0.82 24m 12m 8m 6m 5m 4m 3m 3m 3m 2m
19 0.65 19m 9m 6m 5m 4m 3m 3m 2m
20 0.52 15m 8m 5m 4m 3m 3m
21 0.41 12m 6m 4m 3m 2m
22 0.33 9m 5m 3m 2m
Maximum wire lengths for 0.5V volt drop
A simplified table for the required wire size for positive and negative supply based on length
is given below:
Cable Length Cable Length

AWG AWG
(meters) (meters)
10 18 10 16
20 16 20 14
30 14 30 12
40 14 40 12
Single Tubo Installation Dual Tubo Installation (B-Train)
Maximum Tubo power supply wire length

4.3 Speed Sensors
4.3.1 Inductive (variable reluctance) sensors
Inductive sensors are used as wheel speed sensors or gearbox-mounted speed sensors. They usually have two
wires, although some have only one. If only one wire is present, the other is connected to ground (chassis negative) at
the sensor. They do not require power.
They are made up of a coil of very fine wire, usually with a resistance of 1 kΩ to 3 kΩ, and a permanent magnet.
When ferrous metal is moved past the tip of the sensor, the magnetic field is bent through the coil and this generates a
voltage pulse. If they are placed close enough to a rotating gear, sprocket or punched metal wheel (Pole-wheel), they
will produce a series of pulses that correspond to the gear teeth.
These sensors typically need to be less than 0.5mm from the rotating wheel and will only produce a voltage of about
100mV when the wheel is moving slowly.
A Speed Signal Amplifier, part number MSE000040D-G, is available from EROAD to convert the low voltage signal to
a 7V square wave (digital signal) to be used as a stable speed input to the Ehubo or Tubo. The amplifier will also
reject any electrical noise picked up from the vehicle electrical system by both sensor wires provided twisted pair wire
is used.
The very small voltages generated by the sensor mean that there is a good chance electrical noise picked up by the
wiring will interfere with it.
To prevent interference, twisted pair wiring must be used from the sensor to the amplifier or EHubo. The twists
in the wiring ensure that any noise that gets into both wires at the same time (common mode noise) will be cancelled
out.
The screenshot below shows a typical signal from an inductive sensor, along with the corresponding amplified output:
Amplifier input (green) and output (yellow)

Freightliner Sensor - Slot c/w Plug & Contacts - MSE000210
BOSCH Speed Sensor – Trailer - MSE000056
Freightliner Sensor - Screw type - MSE000202
Fault Finding Methods (Inductor – Variable Reluctance)
Measuring the resistance of the sensor in or out of circuit, you should get the correct resistance reading as stated
below. You should get a very high resistance between each sensor lead and chassis (ground), if it is low or very close
to the sensor resistance you may have a short on the line to chassis (ground).
If you put your DMM on AC and connect it to the sensor connections, by moving a metal object close to the sensor
you will see an increase in AC voltage. (Keep the metal object moving from side to side. If you keep it stationary the
AC voltage generated by the sensor will fall away)
If you have the trailer wheel lifted and rotate the wheel you will be able to measure the AC voltage on your DMM
generated by the sensor between 0.1Vac to 0.4Vac across the sensor when the wheel is given a spin by hand. If you
have a frequency input on your DMM you will be able to measure the frequency generated. Poll wheels have varying
teeth counts, normally about 180 – 200 teeth per poll wheel.
By using an oscilloscope you will be able to see the waveform generated.
NOTE: At slow speeds the speed sensors have a low output amplitude and as the speed increases so does the
amplitude.
Sensor resistance table:
Part Number Description Resistance

MSE000202 Freightliner Sensor - Screw type 650 Ohms (0.650 K ohms)
MSE000210 Freightliner Sensor - Slot c/w Plug 2.2 K Ohms
MSE000056 BOSCH Speed Sensor - Trailer 1.77 K Ohms

Speed Pulse Amplifier
The speed pulse amplifiers are used on vehicles where the speed pulse output is very low < 300 mV p-p. The majority
of the amplifiers are used on SCANIA trucks manufactured later than 2003.
The Amplifier will amplify the low level analogue signal to a 7.5V digital signal and needs to be connected within
300mm to the sensor output.
It can be used on sensors with a single or balanced output.
Connection information for the speed pulse amplifier will be supplied with the unit.
Part Number Description
MSE000040D-G Speed Pulse Amplifier IP50
Speed Pulse Amplifier Installation Instructions – also available on www.eroadinstaller.co.nz
MSE000040D-G Speed Pulse Amplifier - Installation Instructions
 Amplifier being fitted on a truck must be positioned within 300mm of where the speed sensor signal is
being taken from.
 Open amplifier enclosure cover.
 Using fork/ split ring crimp terminals, connect the amplifier as shown in the wiring diagrams. If a single wire
sensor is used, the negative sensor input must be connected to GND.
 Screw the enclosure lid down and tighten the cable glands to apply strain relief to the cables.
 To assist with installation, the red LED will flash when sensing pulses from the speed sensor. It may remain
on or off when no movement is detected.
 The enclosure is not sealed and must be protected from water ingress.

4.3.2 Speedometer Cable-Driven Sensors
If only a cable-driven speedometer is available, a speedo cable sensor can be used to generate an electrical speed
signal. This device is connected between the gearbox and speedometer drive cable, and is available from EROAD.
This sensor has three wires, positive, negative and output.
Some speedometer cable sensors have an output termed “Open Collector”. This type of sensor output can only pull to
ground and may need a pull-up resistor between the output and positive to pull it up to supply (i.e. older gear box
sensor RIS-8PT MSE000064A). The instructions provided with the sensor will indicate whether a pull-up resistor is
required or not.
The open-collector output can be thought of as a switch that is open when the sensor is not triggered, and closed as
the sensor triggers. When the “switch” is open, the signal, or pulse, wire is pulled up to the supply voltage. When the
sensor triggers, the “switch” will close and the signal wire will be pulled to ground (GND), or 0V. In reality, the voltage
may be anywhere between 0V and 1.5V when the sensor triggers.
All mechanical speed sensors supplied by EROAD will be supplied with a voltage regulator. These regulators have
two functions:
 Reduce the vehicle supply voltage to 7.2V on all vehicles (12V or 24V).
 Assist in the supplying of a good reference source to the sensor that won’t be affected by the vehicle’s
electrics (voltage variations when cranking or sub-standard alternator performance).
Part Number Description

MSE000061A-G Gearbox Sensor – Brantz with regulator (No Pull-up resistor Required)
Brantz Gearbox Sensor (and regulator) – MSE000061A-G

Installation – testing: Do not connect to the gearbox initially. Spin to check the signal is coming through before final
connection. This validates the sensor is working and issues discovered later are more likely to be a gearbox issue.
Brantz Gearbox Speed Sensor Installation Instructions – also available on www.eroadinstaller.co.nz

Robinson Gearbox Sensors are the older style of speed signal sensors and are no longer used in the field.
Older Robinson Gearbox Sensor – RIS8PT

12/24V MSE000064A (needed Pull-up resistor
4K7)
4.3.3 Hall-effect Sensors
Hall-effect sensors like the speedometer cable sensor, typically have three wires, positive, negative and output. Some
types need a magnet to be attached to the rotating part it is sensing, but some include the magnet in the sensor and
sense the change in magnetic field when a ferrous metal is brought near it.
A hall-effect sensor already has an amplifier built in, so the output is digital and can connect directly to the Ehubo.
A hall-effect sensor is likely to have an open-collector output, so a pull-up resistor to supply will be required on the
output wire. The value of the resistor is dependent on the maximum output current of the hall-effect sensor and will be
different for different sensor types. The manufacturer’s recommendations for resistor value must be followed. Note
that the resistor value will change depending on the supply voltage.
Open Collector

4.3.4 Determining Suitability of a Speed Signal
Under no circumstances connect to any part of a vehicle’s

ABS/EBS braking system. This includes power from ABS/EBS
modules/junction boxes and ABS/EBS wheel sensors.
It is important to note that vehicle OEM speed sensors are not always adequate for the EROAD system.
Some gearbox sensors do not output a signal at low speeds at all. This is not an issue for the truck itself as some
speedometers only display speeds above 10km/h or 20km/h. It will cause problems for the EROAD installation
however.
Also, some trucks have inductive sensors in the gearbox, connected directly to the speedometer with normal wires in
the wiring harness. The signal on these wires is very small at low speeds, so an EROAD amplifier would typically be
connected.
If twisted pair wiring is not used, as in the paragraph above, any noise from fan motors etc. will be amplified
and treated as a valid speed signal. This situation must be avoided.
The best and quickest way to determine if a vehicle speed signal is suitable is to measure it with a hand-held
oscilloscope. This will show the amplitude (voltage) of the signal any noise that may be present. This test must always
be done at low speed as that is generally when the signal is smallest. It is essential to also switch on ignition and other
circuits such as fans and windscreen wipers to determine if they cause noise on the speed signal.
More detail on speed signal options is available in sections 6.4.3 and 6.7.2.

5 Standard of Work
5.1 Electrical Wire Connections
Ensuring that there is a clean electrical source for each of the inputs required is vital to ensuring the correct operation
of the EROAD units. Installation instructions accompany each EROAD product and are also available on the EROAD
installer website www.eroadinstaller.co.nz.
5.1.1 Cable
Cable must be round so there is a tight fit when it passes through a cable gland when used to wire a Tubo.
The standard of cable must be suitable for auto electrical work, not sound/ speaker cable. The minimum cable to be
used is 1.0mm (17AWG)
Elocate - EROAD wiring loom supplied
EhuboLite - EROAD wiring loom supplied
Ehubo - EROAD wiring loom supplied

Gearbox transducer (cable driven speedometer) Three core cable
Speed sensors Twisted pair cable
Speed pulse amplifier EROAD wiring loom can be used
Tubo - Standard Configuration
Cable between Tubo battery box and Tubo Five core cable
Cable between Tubo battery box and Trailer Plug Two core cable
Cable to Wheel Speed Sensor 10M Wabco twisted pair cable supplied by EROAD
Piggyback Configuration
Cable between Tubo battery box and Tubo Six or seven core cable
Cable between Tubo battery box and Trailer Plug Two core cable
Cable to Wheel Speed Sensor 10M Wabco twisted pair cable supplied by EROAD
Driver ID EROAD wiring looms supplied
5.1.2 GPS aerial extensions
Where an external GPS aerial is fitted and an extension is required, EROAD offers a 4 metre extension cable (SMA
male to SMA female ends). Only two extension cables can be used before a degradation of the signal strength will
occur.
EROAD part number: CB000202A
If the GPS cable is too long do not coil tightly - it must be installed in long loop with a minimum bend radius of 50mm.
Short coils will become an inductor and be susceptible to interference.

5.1.3 Terminations “SOLDER, TAPE, CABLE TIE”
All joints are to be made using the solder technique – the use of crimp joiners to join cable is not sanctioned by
EROAD.
As a follow-up the join is then taped and then cable tied.
5.1.3.1 Splicing to vehicle wiring

Wherever possible, avoid cutting original vehicle wiring. The insulation of the vehicle wire should be stripped back by
using wire strippers that pull the insulation back. Ensure no copper strands are broken.
5.1.3.2 Soldering
 All wiring joins are to be soldered (no crimps of any type are to be used).
 Again, this is only effective if done correctly.
 To solder an EROAD wire to a vehicle wire, strip back the insulation of the vehicle wire 10mm to 15mm.
 Strip back the EROAD wire end by about 20mm, depending on the wire size of the vehicle wire being
soldered to. There must be enough wire stripped back to wrap around the vehicle wire at least twice.
Strip back wires
Twist wires together
 Ensure that the EROAD wire is held parallel with the vehicle wire so the joint can be taped and cable tied
easily. If it comes in at 90°, it will form a T that will be awkward to tape and cable tie.
 Allow the soldering iron sufficient time to heat up fully.
 Ensure that the soldering iron tip is clean and well tinned with solder. It can be wiped on a wet sponge to
clean off old solder and flux once it is hot.
 Apply the tip of the soldering iron to the joint, ensuring both wires are being heated. A small drop of solder on
the iron will allow the heat to transfer to the wire better.

 Apply the solder to the wire junction NOT the soldering iron. Once the wires are hot enough, the solder will
flow and adhere to the wire.
Apply solder to joint, NOT iron

 Allow the solder to wick into the joint, rather than just remain on the top of the wire. If this does not happen,
the wire is not getting hot enough and a higher wattage soldering iron may be required.
 Apply enough solder that the individual strands of the wire are no longer visible. Ensure that the solder has
wicked into both wires sufficiently to completely cover the joint. There should be no un-tinned copper on the
underside of the joint. Too much solder will result in a blob that hangs from the joint.
Too much solder
 Allow the solder joint to cool without moving the wires.

 The solder joint should look shiny and smooth. A dull, rough texture, or plainly visible wire strands is termed a
“dry joint” and will fail in time.
 Always ensure that no sharp solder points or wire ends are left on the joint before insulating as they will just
protrude through.

Good solder joint
Poor “dry” solder joint

5.1.3.3 Electrical Tape
 All wire joints must be properly insulated, either with insulation tape or heatshrink.
 If a number of wires are to be insulated, each must be individually taped and then the entire bundle can be
taped. Individual wire joins must be staggered along the length to avoid a large bundle.
 When applying insulation tape, use a good brand and wrap overlapping layers. The tape should cover the
insulation on either side of the exposed copper by at least 15mm
 Apply light tension to the tape while wrapping it on to ensure the tape sticks firmly and does not cover the joint
loosely.
 Avoid touching the adhesive backing while taping as this reduces its effectiveness due to oil in our skin.
Taped and cable tied
5.1.3.4 Using Cable Ties

 Cable tie the taped join – this will reduce the possibility of the cable unravelling due to poor quality tape or
excess heat affecting the tape glue.
 Once you have highlighted the cable ties, you must completely remove the tails.
 When attaching the EROAD loom to existing cabling, the cable ties cannot be spaced more than 300mm
apart.
5.1.4 Heatshrink
 If using heatshrink, check the diameter and shrink ratio to ensure it will shrink small enough to compress onto
the joint. Heating the end of a small piece to confirm the shrunk size before you start is a good idea. Again,
make sure the length used will extend well past the exposed copper, and ensure the heatshrink is centred on
the joint before shrinking.
 Use a hot air tool, or cool gas flame to gently and evenly heat the heatshrink. Do not use a soldering iron tip
or direct flame to contact-heat it. If it starts to smoke or singe, too much heat has been applied

5.1.5 Sleeving
 Most automotive manufacturers use split corrugated sleeving to protect wiring harnesses from chafing and
damage.
 It is required that all EROAD harnesses are run in split, corrugated sleeving wherever possible, especially in
areas where they could be prone to mechanical damage or high temperatures.
To sleeve or not to sleeve:
Under Dash Sleeved – 10mm diameter

Cable runs under 600mm to be taped, above 600mm to be sleeved.
Under Bonnet (ie Engine Bay) Sleeved
Trailer Speed Sensor to Loom Sleeved

Sleeve the speed sensor cable from the sensor holder up to where the cable can be run with an existing wiring loom.
Tubo GPS Aerial Sleeved

5.1.6 Crimp Terminals
Where wires are required to be connected to studs or terminal blocks, the appropriate terminal must be crimped to the
wire first.
A ring terminal is required for terminating to a stud, while a split-ring terminal must be used when terminating to the
barrier-block terminal strips used in some EROAD products.
The screws in the barrier blocks do not unscrew fully – they will shear if unscrewed fully.
Barrier block and split-ring terminal
Stud terminations and ring terminal
The correct terminal size for the wire gauge must always be used, as must the correct crimp tool for the terminal.
Always perform a pull-off strength test on crimp terminals after crimping. If the terminal can be pulled off the
wire, it is not correctly crimped. Obviously only moderate force should be used.

5.1.7 Routing of Cables – Split Gland Tubing
All cables must be routed under the dash or behind pillars except for the security clamp/ heat shrink and cord from the
Ebox. The only exception will be the tail of the Driver ID cable that plugs into the back of the unit.
Do not route cables through holes dedicated to air conditioner drains – this can result in water draining back into the
cab.
Wherever possible the cables are placed inside split gland tubing. As the wiring loom enters the tubing, tape it to
reduce the opportunity of the cabling moving/ chafing within the tubing. The tubing is taped every 150mm to reduce
the possibility of the cable popping out if the tubing is twisted or bent.
Split Gland Tube used to protect earth cable.
Split Gland Tube used in International

Engine Bay
Split Gland Tube used in Trailer

Installation

5.1.8 Fuse Holders
Fuse holders and the appropriate fuses are supplied as all connections (except ground) must be fused.
The fuse holders must be sealed so as be able to indicate a tamper as well as protection from the possibility of a short
circuit occurring. The procedure is as follows:
 Attach fuse holders as required to the vehicle wiring.

o Ensure there is a colour match of the fuse wire to the EROAD wiring loom
o Place as closely as possible to the source of the supply to reduce the possibility of overload.
 Once the installation is complete, cable tie the fuse holder as per photo below.
 Tape the bottom of the fuse holder(s) starting on the holder itself and continuing for at least 50mm of the fuse
holder wiring.

5.1.9 Drilling Holes
5.1.9.1 Truck
DO NOT DRILL HOLES IN A DASH WITHOUT THE OWNERS (NOT THE DRIVER’S) PERMISSION.
 Holes will be required at times to be drilled through the floor pan or similar. Ensure you are not compromising
the integrity of a firewall.
5.1.9.2 Trailer
 Ensure that holes being drilled are at least 50mm away from any welds and flange joins (top and bottom).
 All holes drilled must have a grommet or cable gland used to protect the cable from chafing.
 Ensure that all swarf is cleaned up from the work completed.

6 Installation
Vehicles suitable for installation encompass all types within a wide range of industries.
EROAD has a product for each of these vehicles:
Ehubo - all powered heavy transport vehicles that traditionally required a mechanical hubodometer
Tubo - all trailer units
EhuboLite- all diesel-powered vehicles that traditionally did not require a mechanical hubodometer
Elocate - all other vehicles and assets
Driver ID - any vehicle
Each of these products has a variety of auto electrical and in some cases mechanical requirements for the correct
installation of EROAD equipment.
If you have any concerns regarding completing the installation on time please keep the customer within the
communications loop. Advise them why there will be a delay and when the installation will be completed.
6.1 Document Existing Damage (as part of the Installation Certificate)
 Any existing damage to the vehicle exterior or interior must be documented before the installation begins and
should be signed by the owner or driver.
 It is equally important to bring the owner or driver’s attention to anything that is in obvious need of repair that
is discovered during the installation. It is the natural reaction of the driver to blame any failure, related to the
installation or not, to the latest part fitted.
 This typically includes wiring of aftermarket devices where the wiring is sub-standard or dangerous. Dirty
battery terminals or fuse clips are also something that could result in failure of the EROAD system, or be
attributed to the installation.
6.2 Planning the Installation
 It is important to evaluate the installation and properly plan it before commencement. Take 10 minutes to look
at the vehicle, determine how the cable will be routed, and discuss with the customer where the EROAD unit
will be best sited.
 If any mechanical work is required, such as welding of brackets or fitting of pole wheels, the vehicle must be
taken to a reputable mechanical workshop or service centre that specialises in that type of work.
 Every aspect of the installation must be performed in a professional manner to the same standard as the OEM
equivalent. If any aspect of the installation is beyond the scope of the installer, it must be passed to a qualified
professional in that field.
6.3 Tools and Consumables
The following hand tools and consumables are the minimum required for an installation
6.3.1 Tools
 Set of screwdrivers
 Socket set, metric and imperial
 Torx bits
 Sharp knife
 Wire strippers
 Side-cutters
 40W to 80W soldering iron or gas soldering iron.

 A quality digital multi-meter, with settings for Ohms, DC Volts and AC Volts. A frequency counter option is
handy for checking speed sensors.
 A cheap, hand-held oscilloscope is a very valuable tool for finding usable speed signal and is highly
recommended. Contact EROAD for details.
 A good quality battery drill with sufficient rechargeable batteries and charger
 Sharp drill bits
 Wire brush
 Crimp tool for crimp terminals and splices
 Heat-gun
 Extension cord
 Camera
6.3.2 Consumables
 Good quality insulation tape (not PVC)

 Alcohol swabs (one supplied with each Ehubo installation kit).
 Resin-core solder 60-40 (60% tin, 40% lLead)
 Crimp terminals various types (Faston, ring, split-ring etc) and sizes
 Heatshrink
 Automotive grade wire. Several sizes and colours.
 Spare fuse holders. Use EROAD approved part only
 3A (Tubo Enclosure) and 10A blade fuses to suit truck power waterproof fuse holder.
6.3.3 Health and Safety Equipment
EROAD recommends that each technician should have readily available to them the following Health and Safety
equipment:
 Safety boots
 Appropriate Hi Viz and safety clothing
 Appropriate safety glasses
 Appropriate ear protection
 Vehicle first aid kit and fire extinguisher
 Road cones as required to indicate work being done on a stationary vehicle
 Orange flashing light for transiting restricted areas.
 Knee pads for comfort/protection when kneeling on stony or rough ground.

6.4 Connections – Ignition, Battery, Ground, Speed Signal
Be aware that there is a growing trend for new vehicles to come with CANBUS. Do not connect in any way to the
CANBUS system as this is not sanctioned by EROAD. As an indication CANBUS cabling is predominantly twisted
pair.
It is important that all wires and cables are positioned and run in the same manner as original equipment on the
vehicle. All wires and cables must:
 Be routed with existing wiring harnesses wherever possible.
 Be routed such that they will not chafe or rub on parts of the vehicle during normal use of the vehicle.
 Be routed such that they cannot be snagged on persons or equipment in the vehicle.
 Be tied securely out of the way so that there are no cables seen dangling or hanging.
 Pass-through protective rubber grommets or dedicated plugs when passing through a metal barrier or
bulkhead.
 Be covered with split or spiral sleeving to hold the cable bundle together and protect it.
 Be rated for the maximum fused current it might carry. This means that the wire must be rated for 10A if it is
protected by a 10A fuse, even if the equipment connected to it only draws 2A.
 Be rated for the temperature in the environment it is run. If it is run through the engine bay, it must be rated to
125°C and be protected by high temperature sleeving.
 Be routed through sealed grommets if they pass through an engine bay bulkhead to prevent water or exhaust
gases passing into the cab.
6.4.1 Ignition – always fused at source
There are two options for connecting to ignition:
 The preferred option (when installing an Ehubo) is to connect to “true idle” (connect to a point that is live while
the engine is running – alternator or OBC) irrespective of ignition switch position. This will overcome turbo
timer and isolation switch issues. See www.eroadinstaller.co.nz for more information by vehicle.
 Ignition switch connection (connected to the ignition and live in the start position) and off when in the ACC or
the OFF position.
6.4.2 Power Supply – always fused at source
POWER SUPPLY MUST NOT BE TAKEN FROM ANY ABS/ EBS RELATED SYSTEM
The main positive power supply must be connected to an unfused 12V or 24V supply whenever possible. The best
place to find supply will be in the fusebox.
The EROAD-supplied fuse holder and fuse must be connected as close to this connection as possible to protect the
entire positive power feed.

6.4.3 Ground
A common ground bar or junction is the best place to connect the negative wire. A ring terminal may be required to be
crimped to the negative wire to terminate it to a ground stud.
Connecting the negative wire to any chassis bolt is not acceptable. A dedicated ground point must be used. In
some cases this will be a bolt into the metal surround of the fusebox. Always remove paint from around the stud and
use a star washer when using such an earth point to ensure a good connection.
Power supply feed must always be live irrespective of ignition key position.
With vehicles that have a power ‘kill switch” - you cannot bypass the switch – you must connect on the isolated side of
the switch.
6.4.4 Speed Signal
The EROAD system relies on a reliable speed signal from the vehicle. Wherever possible, a conditioned, digital signal
from the speedometer or an ECU should be used. Often, a digital speed signal is available at the speedometer cluster
or the main ECU. Where this is not possible, a vehicle speed sensor can be connected under the following conditions:
 It is properly conditioned with the use of an EROAD-supplied and approved amplifier (Scania 2004+).
 It is confirmed by measurement with a multi-meter that no short circuits or open circuits have been introduced
in the original vehicle system.
 It is confirmed by test driving the vehicle that all vehicle systems using the sensor still operate correctly and no
dashboard warning lights or error codes have been introduced.
 No original vehicle wiring may be cut in order to connect to it. Connection to the sensor must be made
at a junction box, or by splicing to a wire without breaking it.
 All new wiring must conform to the original vehicle wiring in terms of routing, sleeving, taping and water-
proofing.
Under no circumstances may any part of the vehicle braking system be connected to. This includes power
from ABS/EBS modules and junction boxes as well as speed signals from wheel sensors.
EROAD carries ex stock, numerous sensors, adapters, voltage regulators or peripherals required for sourcing
of a suitable speed signal.
Any use of non OEM or sensors not obtained from EROAD must be approved by EROAD Technical Services
prior to use.
A list of approved parts is available on the EROAD Installer website: www.eroadinstaller.co.nz

6.5 Ehubo/ EhuboLite Installation
6.5.1 Ehubo/ EhuboLite Position on Windscreen
It is a LEGAL REQUIREMENT that the RUC licences and vehicle distance readings displayed on the Ehubo
can be easily read from inside and outside of the vehicle.
Make sure the registration plate of the vehicle matches the plate shown on the Ebox screen, if not phone
EROAD Support as soon as possible.
Please discuss with owner of the vehicle and select a suitable mounting location that:
 does not obscure the driver’s view
 is on the left hand side of the windscreen
 allows the Ehubo to be read from outside the vehicle
 does not interfere with any driver controls.
 does not obstruct any safety systems such as airbags, seatbelts etc.
 is on a flat section of the windscreen
 is clear of stone guards, windscreen wipers and rear view mirrors
 is 200mm or more away from the A Pillar
 is 50mm or more above the dashboard
 does not prevent the glovebox lid opening all the way
 does not restrict airflow from a demister vent to the windscreen
Ehubo position on Windscreen

6.5.1.1 Clean Windscreen
Clean the windscreen using the Isopropyl Alcohol (IPA) wipe included with the kit, wiping in one
direction only. Dry the windscreen with a new paper towel and leave the surface to dry for at least 5
minutes.
PLEASE ALLOW AT LEAST 5 MINUTES FOR THE ALCOHOL TO DRY. IF THIS IS NOT DONE
THE TAPE WILL BE AFFECTED AND NOT ADHERE TO THE SCREEN.
If the windscreen is particularly dirty, a degreaser or solvent-based cleaner may be required to remove heavy oil or
grease.
6.5.1.2 Remove Protective Film from Mount

Dab silicone (preferably clear) or suitable windscreen adhesive in each
corner of the windscreen mount.
Remove the protective film from the adhesive tape on the sides and
bottom of the windscreen mount.
6.5.1.3 Press Mount against Windscreen

Press the windscreen mount firmly against the window and hold for 60 seconds to ensure a good bond.
◦
If the temperature of the windscreen is less than 10 C or the screen is damp due to high humidity then it will need to
be warmed before the adhesive tape will bond properly.
Please use the vehicle demister to heat the windscreen – NOT A HEAT GUN, WHICH WILL CRACK THE
WINDSCREEN
Do not slide Ehubo into the mounting bracket until the wiring has been installed, allowing time for the adhesive tape
bond to strengthen.
6.5.1.4 Slot Ehubo into Mount

When all other steps, aside from calibrating the Ehubo, have been completed:
 slide the Ehubo into the windscreen mount (downwards motion).
 ensure Ehubo can be easily removed so that the screen can be read from inside the vehicle.
Slide Ehubo
into Mount
.
Inserting Ehubo into mount

6.5.2 Ehubo/ EhuboLite Wiring Requirements
The Ehubo requires the minimum following connections to the vehicle:

1. 12V or 24V permanent power RED
2. Ground BLACK
3. Ignition YELLOW
4. Vehicle Speed Signal (SPD/VSS) BLUE AND/ OR PURPLE
Power, ground and Ignition must be fused (2A) as close to source as possible using the in-line fuse holders supplied
by EROAD.
COLOUR PIN FUNCTION

ORANGE 1 Auxiliary – 1 – FUSED (2A) (PTO)
BROWN 2 Auxiliary – 2 - FUSED (2A) (SOS-Panic)
RED 3 Power FUSED (2A)
WHITE 4 [No Connection]
GREEN 5 [No Connection]
GREY 6 Auxiliary – 3 – FUSED (2A) (High Rail/Seatbelts)
YELLOW 7 Ignition FUSED (2A)
BLUE 8 Analogue (-ve) speed signal OR if using digital signal this
must be connected to Ground
PURPLE 9 Analogue (+ve) speed signal OR
Digital speed signal input
BLACK 10 Ground

6.5.2.1 Digital Inputs
Additional connections are available for 3 digital inputs – the orange, brown and grey wires. All of these must also be
fused (2A) using the auxiliary fuse kit HR000074A.
Fuse Holder Standardising Digital I/O Connections – not

Input Wire
Label mandated.
Auxiliary 1 Orange 'AUX 1' PTO or other inputs
Panic Button/ SOS

Auxiliary 2 Brown 'AUX 2'
or other Inputs
Auxiliary 3 Grey 'AUX 3' HiRail or Seatbelt monitoring, or other inputs.
The fuse holder is to be placed as closely as possible to where the input source is being taken from. Once complete
the fuse holders can be joined together and security sealed with the cable tie supplied.
Anything above 9 volts is deemed as ON and below will be off. It is preferable that the input is to switch from 0 to 12 or
24 volts.
If you have an input that goes to ground then switching it through a relay (diode protected) will work fine.
Note that some digital outputs may not be able to supply enough current to switch an automotive relay.
Please make sure you use automotive relays that have a diode to protect against back EMF. Relays without diodes
can cause voltage spikes that can kill sensitive equipment.
Recommended relays are:
Bosch 12V - 12V Diode relay Bosch 7-0-332-209-158

Bosch 24V - 24V Diode relay Bosch 7-0-332-209-204

6.5.3 Typical Connection Diagrams: Ehubo/ Ehubolite
6.5.3.1 No Driver ID + No Auxiliary Inputs

6.5.3.2 Auxiliary Inputs + No Driver ID

6.5.3.3 Driver ID + No Auxiliary Inputs

6.5.3.4 Driver ID + Auxiliary Inputs

6.5.4 Dangerous Good Vehicles
As at Oct 2012 only Ehubos can be fitted (within the cab only) to DG vehicles.
There are some specific requirements to installing into DG vehicles and must be strictly adhered to.
Requirements:
 The door must be closed at all times during the installation.

 The windows must be closed at all times during the installation.
 Gas solders can be used but as per above doors and windows must be closed.
Installations will be completed off site (ie not a fuel tank site etc).

6.5.5 Ehubo Trouble Shooting – Interference and Noise
Before going through the trouble-shooting procedures for the EROAD units, we should look at the potential areas that
could affect the performance of the Ebox and discuss the “Mysterious Supply Spike and Noise”, the consequences of
a bad ground, EMI and other important information you should know and always be aware of.
6.5.5.1 Noise Sources

The three major noise sources:
 Radiated noise
 Conducted noise
 Induced noise
6.5.5.2 Radiated Noise

Radiated noise enters the Ebox through the antenna along with the desired signal and can block or degrade desired
communication. It can be generated by power lines, fluorescent lights, or by electrical discharges from static build-up,
ignition systems, or electrical motors. Radiated noise is the most common cause of mobile radio interference.
6.5.5.3 Conducted Noise

Conducted noise enters the Ebox through the points where the device is attached to the vehicle's electrical system
such as battery cables, ignition switch, chassis ground, etc.
6.5.5.4 Induced Noise

Induced noise enters the Ebox through the proximity of the Ebox wiring to other wiring in the vehicle.
6.5.5.5 What is EMI? (Electromagnetic Interference)

EMI is electromagnetic radiation that adversely affects circuit performance. Many types of electronic circuits are
susceptible to EMI and must be shielded to ensure proper operation and performance. Conversely, emissions
radiating from sources inside electronic equipment itself may interfere with circuits within the same or nearby
equipment.
6.5.5.6 What is EMI Shielding?

Shielding is the use of conductive materials to reduce radiated EMI by reflection and/or absorption. Shielding can be
applied to different areas of the electronic devices from equipment enclosures to individual circuit boards and cables.
Effective placement of shielding interrupts the path of the electromagnetic waves, thus reducing the effect of the EMI
on your equipment.
6.5.5.7 What does Grounding Have to do with EMI Shielding?

Grounding issues affect both safety and EMI emissions. If a system is properly grounded, all conductive elements,
which a user might touch, are theoretically at zero potential. Shielding against EMI emissions is commonly provided by
a conductive enclosure. The separate parts of the enclosure must be electrically connected and grounded for the
shielding to work. Disruptions in the conductive continuity between parts adversely affect shielding performance.
Proper grounding of PCBs and shielding enclosure and components is also a method for reducing board-generated
EMI. However, improper or ineffective grounding may actually increase EMI emission levels, with the ground itself
becoming a major radiating source.
6.5.5.8 Device and Antennae Installation Proximity:

The closer two transmitting devices are installed together, the more likely the possibility of interference between the
two units will occur. Keeping as much separation between them as possible is always the best practice. GSM and RT
will be the main cause for interference on a vehicle. Likewise faulty GSM and RT antennaes will cause high reflected
power; this itself can increase the RFI (radio frequency interference) and may affect the performance of the devices, it
could knock out the GPS or the speed sensor feed.
6.5.5.9 Voltage Spikes and Grounds
6.5.5.10 Spikes
Voltage spikes are produced whenever a magnetic field collapses. When the current is turned off to any coil, an
inductive voltage is created that is many times higher than the input voltage. This is the principle on which the ignition
coil works to create the thousands of volts necessary to bridge the spark plug gap.
However, when voltage spikes are created in circuits where we don't want them, they can cause serious problems.
There are two general spike sources: coils and contacts. Consider for a moment the number of coils in today's cars,
besides the ignition coil. There are numerous relays and solenoids, all with coils of their own. Now, consider all the
switches across whose contacts an arc could be created.
Relays have both a coil which, when energised, creates a magnetic field and a set of contacts. Some examples are
horn relays, fuel pump relays and starter relays. Solenoids are similar, but the coil is hollow and surrounds a ferrous
pole piece that moves when the coil is energised. They are electromechanical devices that usually do some kind of
work. Examples include the starter solenoid, which engages the starter drive.
Voltage is increased even more when the magnetic field collapses around a metal core, as in an ignition coil. High
voltage is useful from the ignition coil, but unwanted when it comes from something else. In order to prevent a voltage
spike from going somewhere it does not belong, the circuit usually has some sort of protection, most commonly
clamping diodes, capacitors and resistors.
A diode acts like an electrical check-valve and only lets current flow in one direction. A capacitor acts like an electrical
cushion and a resistor acts like an electrical sponge. All three act to prevent stray voltage spikes from harming circuits.
Most relay solenoids have a diode across the coil to prevent back EMF when the voltage collapses. If this diode is
blown, the protection is lost. The back EMF from the coil can be several times higher than the supply voltage. This
high back EMF can cause damage in time to the circuitry that drives it, often some type of on-board computer /
microprocessor system. This explains why certain components and tracks on OBC’s are sometimes damaged.
6.5.5.11 Grounds
The ground circuit is one of the most neglected and possibly most often misunderstood and misdiagnosed circuits in a
vehicle. Basic electricity theory says that a circuit must be a complete loop.
Rather than run a return wire for every circuit, automotive engineers use the car's metal body to carry the current back
to the battery. The most common problem with the ground side is a missing or weak ground. Missing grounds are
often the result of a forgetful vehicle auto technician who did not replace a ground strap between the engine block and
the firewall or fender. Sometimes the ground strap just breaks as a result of corrosion. If there is poor contact due to a
loose screw or due to corrosion at the ground connection, resistance is created in the circuit. The ground is still there,
but it is resistant to the flow of electricity, which looks for the path of least resistance home to the battery.
6.5.5.12 Voltage Drop

How important is measuring voltage drop?
Using a Digital Multi Meter, accurate to within 10mV on AC or DC measurements. Correctly used, it will save you a lot
of time and money unnecessarily changing devices or vehicle wiring. Resistance in a circuit causes the voltage to
drop. This is normal if the resistance is a light bulb or “blower” resistor. However voltage drop caused by bad circuits
can create some strange symptoms including rough running engines, starting problems, chattering relays, radio
interference, false problem codes from service computers and problems with on board computers (OBC).

Don’t use an Ohm meter to measure resistance when looking for voltage drop. An ohmmeter's small internal batteries
are only pushing milliamps through a circuit, and so the resistance measurement would read close to zero ohms.
However, if several amps take the same path, any resistance along that path will create a voltage drop across that
path. Therefore measuring the volt drop across the component will give a clear indication of any resistance there
might be in the circuit under load.
Here are some voltage maximums you can use as a general rule. These are absolute voltage listings, which may still
be too high for certain sensitive OBC’s.
 Across a connector = 0.00V

 Across ground = 100mV
 Across a wire or cable (depending on the length) = 200mV
 Across a switch = 300mV
Important: The circuit must be live during the measurement.

Voltage drop test for the negative and positive terminals of the battery.
6.5.5.13 Checking the GND Terminal

Set your Digital Multi Meter to the low voltage scale or the millivolt scale. The most positive point in any automotive
circuit is the battery positive post, not the battery cable terminal. In fact, check this connection first for any voltage
drop. Connect your voltmeter positive lead to the battery post and the negative lead to the terminal. Turn on the
headlights so that the system is drawing a lot of power. If there is any drop whatsoever remove the terminal and clean
it along with the battery post and check again. You must know what the base voltage is to know the total drop later. To
check the drop from the block to the battery, connect the positive lead to the block, the negative lead to the negative
battery terminal, crank the engine, and note the reading. It, too, should be below 100mV.
Ground connection voltage drop is acceptable if it is below 100mV, but many technicians claim that anything in excess
of 50mV in the grounds for electronic computer controls is too high. Computer controls usually operate on 5V and
carry extremely low currents that are incapable of punching through even the slightest corrosion. The lower the
ground-side voltage drop, the better.
Follow the same procedure above for the positive terminal of the battery.
6.5.5.14 The AC Ripple Test

The electrical systems in all vehicles operate from a DC power source. By using an accurate Digital Multi Meter we
can measure the AC ripple from a DC power source. An ideal measurement would be zero volts. Unfortunately this is
not possible due to the noisy accessories, starters, alternators etc. operating off the vehicles power source. The test
measurement must be carried out with the engine running.
Always measure for ripple at the connector end of the power source.
Put the test leads across the positive and negative source and note the reading. The measurements must be done
through the various RPM ranges readings 40mV and less are normally acceptable. Readings above 40mV may
indicate the following problems on the vehicles electrical system.
Readings between 40mV and 100mV: -
Typically the issue is bad or corroded battery terminals and connections. These need to be checked and cleaned. A
thin film of corrosion may have formed around the poles that cannot be seen.
Readings above 100mV: -
You may have a battery that cannot hold charge any longer. The rectifier diodes or regulator in the alternator may be
faulty. Faulty electrical accessories in the vehicle may be inducing noise in the supply line, e.g. clamping diodes
across a relay coil that may be blown.
6.5.5.15 Twisted Pair
In balanced pair operation, the two wires carry equal and opposite signals and the destination detects the difference
between the two. This is known as differential mode transmission. Noise sources introduce signals into the wires by
coupling of electric or magnetic fields and tend to couple to both wires equally. The noise thus produces a common-
mode signal which is cancelled at the receiver when the difference signal is taken.
This method starts to fail when the noise source is close to the signal wires; the closer wire will couple with the noise
more strongly and the common-mode rejection of the receiver will fail to eliminate it. This problem is especially
apparent in telecommunication cables where pairs in the same cable lie next to each other for many miles. One pair
can induce crosstalk in another and it is additive along the length of the cable. Twisting the pairs counters this effect
as on each half twist the wire nearest to the noise-source is exchanged.
Providing the interfering source remains uniform, or nearly so, over the distance of a single twist, the induced noise
will remain common-mode. Differential signaling also reduces electromagnetic radiation from the cable, along with
the associated attenuation allowing for greater distance between exchanges.

6.6 Driver ID
Ensure you check with the customer as to where the unit will be sited. Installation of the
Driver ID does require four screws to be fitted onto the dash, centre console etc.
Installations
Two looms are supplied with each driver ID. One plugs into the Ehubo wiring loom (male
and female ends) and the other cable (CAT5) plugs from the molded section of the main
loom into the back of the Driver ID.
Test Driver ID by scanning a driver licence and pressing the ‘ID’ button. 
Driver ID should beep when login and logout occurs. 
LED should change to green for login and red for logout 
TROUBLE SHOOTING - Installations
Symptom Possible Causes Action

No Beeps Incorrect installation Check wiring and connections
Ehubo not configured to support Driver ID Contact EROAD Support
No LED Incorrect installation Check wiring and connections

Contact EROAD Support
LED stays red after driver’s Possible issue with Driver ID Check wiring and connections
licence is inserted hardware
Contact EROAD Support

6.7 Tubo Installation
Make sure the registration plate of the vehicle matches the plate shown on the Ebox screen, if not phone
EROAD Support as soon as possible.
Pre-installation inspection -- liaise with customer at all times.

 Tubo siting
o The siting of the Tubo MUST be on the left hand side of the trailer – this is a legal requirement.
o It should be in a position that is protected from road debris and tyre delamination.
o It must be clear of the ‘flow path’ on any tankers especially with a CIP wash (caustic).
o Not facing forwards behind wheels – road debris will damage units.
o On a tipper ensure the bin is down when determining the best position.
o On a trombone trailer fit the unit with the trailer extended, be aware of pinch points for cabling.
o On a skelly or logging trailer a guard of some sort may need to be fabricated prior to installation to reduce
the risk of damage.
o When fixing to a chassis rail ensure the Tubo bottom case is not ‘racked’ due to a distortion in the rail.
This will prevent a weather tight seal being formed with the front of the case and water damage will occur.
o Do not drill holes within 50mm of any structural welds.
 Tubo battery box siting

o The battery box can be fitted anywhere on the trailer. Usually it is sited next to the Tubo or ‘back to
back on the chassis rail with the Tubo.
o The battery box has been fitted on the opposite chassis rail on a tipper.
 Aerial siting
o As Tubos are most often mounted under the deck, the GPS reception is very poor. An external Tubo
button aerial is provided as part of the installation kit and wherever possible must be used.
 Power
o Independent – run two core from powered pin on trailer socket direct to TUBO battery box (can be run
from trailer junction box if fitted)
o DO NOT connect to EBS/ ABS Power Feeds
 Wheel speed sensor/ pole wheel

o Fit where ever possible on right hand side of trailer as there is less road debris that can flick up and
damage sensor.
o Put a dab of silicon around the base of the sensor before pushing into the block

6.7.1 Wiring
When connecting the cabling between the Tubo and Tubo battery box, you must connect the cabling to the Tubo first.
The Tubo battery box is cabled last, working from the left of the barrier block (first connection RX In and the last
connection should be Positive In)
Several wiring options exist for the Tubo depending on the trailer type and configuration. The power supply to the
TUBO must be independent and connection via a splice into the trailer wiring harness is not sanctioned.
6.7.1.1 Power Option 1 – Pin 5 of 7 Pin Trailer Plug if Available

The truck must be wired to power the trailer. In this case, route the positive wire from a permanent positive 12V or 24V
in the truck, using a 10A fuse and EROAD-approved fuse-holder, to pin 5 of the 7-pin trailer plug. On the trailer side,
route a wire from pin 5 to the positive supply of the Tubo and remember to connect ground to correct pin of the trailer
socket (usually Pin 3)
6.7.1.2 Power Option 2 – Pin 5 of 7 Pin Trailer Plug Used for Work Lights
If Pin 5 of the 7-pin trailer plug is not available, but used for work lights or reversing lights, it may be possible to use
this for Tubo power. In this case, the switch for the work lights will need to be moved to the trailer instead of in the
truck. Permission from the driver/ owner is required before commencing work.
 Connect the wire from pin 5 on the truck plug to permanent 12V or 24V via a fuse that is sufficient for both the
Tubo (10A) and the work lights. This may involve just connecting the two wires of the switch together if the
circuit is already fused correctly.
 Remove the switch in the truck.
 Add a sealed, outdoor switch with the correct current rating to the circuit in the trailer.
 Connect an EROAD-approved fuse holder and 2A fuse to the un-switched side of the positive supply on the
trailer and connect to the Tubo positive.

6.7.1.3 Power Option 4 – Install 15-pin plug
EROAD is in the process of establishing a standard surrounding the use of 15-pin plugs as a supercession to the
existing 7-pin power solution.

15 Pin Accessories- Part Numbers and pictures
Part No Description
CN000300A-G 15 -Pin Plug
CN000310A-G 15-Pin Socket
CB000320A-G 15-Pin Suzy Cable

3.5mtr
CB000280A-G 15-Core Cable (per

metre)
CB000310A-G 15-Pin Plug + 5mtr of 15

Core Cable
CB000311A-G 15-Pin Plug + 10mtr of

15 Core Cable
CB000300A-G 15-Pin Socket + 5mtr of

15 Core Cable
CB000301A-G 15-Pin Socket + 10mtr of

15 Core Cable

6.7.1.4 Tubo Charger Smart Charger Wiring
Chargers LED’s get damaged when cables are connected onto the board at installation.
BE CAREFUL
The charger does get warm when charging (2 black square inductors especially)

6.7.2 Tubo Box Enclosures
The Tubo and Tubo battery boxes have been manufactured to an IP69K standard, i.e. high pressure, high
temperature, wash down liquid and dust tight.
Prior to leaving the production facility the front and back of the enclosures are tested to 5 psi pressure to ensure a
water and dust tight seal is present.
During the installation the enclosures must be split to allow fitting to the trailer. Please ensure that when closing up the
enclosure that:
All sealing faces are kept clean and scratch-free. 
Bolts cross-tightened lightly when closing to evenly compress the seal, then cross tightened to a torque

of 1.5Nm. A torque-limited screwdriver must be used.
All cables in and out of enclosures are round in cross-section and between 6mm and 9.5mm diameter

so the cable glands seal around them.
Peel off protective plastic film covering Tubo screen. 
6.7.3 Speed Sensor Options
There are several options available for connection to a speed signal. They are listed below in order of preference:
1. If the trailer is fitted with pole wheels and suitable for use and sensors that are not used by the ABS/EBS system,
then one of these can be used together with the EROAD to generate a speed signal.
2. An OEM kit for the trailer can be used. This will typically include a pole wheel, bracket and wheel sensor.
3. If a pole wheel is fitted, but no sensor or sensor bracket, an EROAD-supplied bracket can be welded in place and
an EROAD-supplied sensor and cable used to generate the speed signal.
4. If there is no pole wheel fitted at all, an EROAD-supplied pole wheel must be fitted, as described in section 6.7.4.
Part No Description
MSE000250 ROR Sensor Holder – Drum Brake
MSE000252 ROR Sensor Holder – Disc Brake
MSE000310 SAF Sensor Holder + Screws

6.7.4 Pole Wheel Installation Instruction
The following procedure must be carried out by suitably qualified technicians.

The EROAD pole wheel, is specifically manufactured for use with EROAD’s products. The pole wheel is manufactured
with extra material in the inner and outer diameters so that it can be machined to fit a variety of different wheel hubs.
The optimum position for a pole wheel is on the right hand side of the trailer as there is less road debris in the middle
of the road compared to the kerbside.
Teeth - 80
EROAD Pole Wheel

The sensor mounting block, pictured below, is installed together with the Pole Wheel. The bottom surface is concave
to make fitting to round axle beams easier.
EROAD sensor bracket
Once the road wheel/ hub assembly has been removed and stripped (refer to axle manufacturer’s instructions before
carrying out this operation), check to see if the is a machined step on the back side of the hub to accept the pole
wheel. If no step is present then one will need to be machined to suit. This must be carried out by suitably qualified
technicians. The pole wheel needs to have its inner diameter machined so that it is a tight/shrink fit onto the step on
the hub. Once in place it should not be able to move.
Wheel hub with OEM Pole Wheel
A wheel hub with its OEM pole wheel can be seen above prior to the bearings being repacked and the hub seal
installed. Once at this stage (with no seal installed), refit the hub to the axle and locate a suitable position to fit the
wheel sensor mounting block. Note that there needs to be enough clearance to remove and replace the sensor should
it fail. Also pay attention to the routing of the sensor cable so that it does not become entangled in the brakes or any
other moving parts.

EROAD sensor bracket installed
The sensor mounting block needs to be mounted at right angles to the pole wheel and close enough so that the wheel
sensor can touch the pole wheel when pushed fully home. Tack the mounting block into position taking care not to
allow any welding spatter to enter the wheel bearings. Remove the hub and weld the mounting block into position.
If there is no hole in the brake backing plates for the sensor cable to pass through this will need to be drilled as well.
EROAD sensor installed
Fit the sensor complete with its clamping sleeve and refit the wheel hub again without the hub seal. The clamping
sleeve holds the sensor firmly in the mounting bracket, but allows it to be pushed up against the pole wheel. As the
pole wheel turns after installation, it pushes the sensor back by the minimum amount. The maximum run-out on the
pole wheel is 0.5mm and the sensor must never be further from the pole wheel than that amount.
The wheel sensor can now be tested with either an oscilloscope or a voltmeter set to AC to ensure that it is putting out
a signal. This should be more than 0.2Vac when turning by hand.
The wheel hub can now have its bearings repacked, hub seal fitted and reassembled following the manufacturer’s
recommended procedure. Don’t forget to push the wheel sensor fully in towards the pole wheel as part of the final
assembly.

6.7.5 External GPS Antenna
The Tubo has a connector available so an external GPS antenna must be fitted. This is required when the Tubo is
mounted in a position that obscures the internal antenna’s view of the sky.
The Ehubo does not have provision for an external GPS antenna as it is always mounted on the windscreen and this
provides the internal antenna with a good view of the sky.
The GPS antenna will not function correctly unless it is mounted correctly.
The GPS antenna must be mounted in a location that:
 Allows the antenna to be mounted horizontally with an unobstructed view of the sky for at least 65° as shown
in GPS Antenna beamwidth.
 Will not interfere with the normal use of the vehicle.
 Does not protrude from the vehicle so as to be prone to damage during normal use of the vehicle.
 Allows the cable to be routed such that it is protected from damage by brushes during washing of the vehicle,
or snagging on overhanging trees or foliage.
 Provides the largest possible horizontal metal area beneath it that will form the ground plane.
 Is on the right side of the vehicle if it cannot be on top. This reduces the effect of roadside trees blocking the
antenna’s view of the sky.
The ideal position is on the roof of the cab, which provides a large ground plane area and an unobstructed view of the
sky.
Trailers provide the most difficult mounting arrangement for the antenna, but the rules above must still be followed.
This may require a bracket to be fabricated to hold the antenna horizontally in a particular position. The bracket also
forms a ground plane that improves the performance of the antenna.
External GPS Antenna position efficiency

APPENDIX 1 – Full Parts List
TRUCKS
MSE000040D-G Speed Pul s e Ampl i fi er IP50
MSE000041B-G Speed Pul s e Ampl i fi er IP65
MSE000061A-G Gea r Box Sens or (Bra ntz)

Not Stocked Gea r Box Sens or Ada pter Ca bl e (300mm)
MSE000202 Frei ghtl i ner Sens or - Screw In

MSE000210 Frei ghtl i ner Sens or - Sl ot c/w Pl ug & Conta ct
MSE000400 Mercedes / VW Speedo Termi na l Conta ct
HR000072-G Wi nds creen Mounti ng Ki t

HR000070A-G Securi ty Ca bl e Cl a mp Ki t (EHUBO)
MS000536-G Securi ty Sea l Hea ts hri nk (ELOCATE, EHUBOLITE)
HR000074A-G Auxi l i a ry Inputs - Fus e Hol der Ki t
HR000071B Ehubo Wi ri ng Loom
CB000270A-G Dri ver ID - CAT 5 ca bl e
CB000050B-G Dri ver ID - mol ded l oom
TRAILERS
POLL WHEEL & ACCESSORIES
MSE000054 Pol l Wheel Ki t; Pol l Wheel , Bl ock & Sens or
MSE000055 EROAD Pol l Wheel
MSE000053 EROAD Sens or Mounti ng Bl ock (to s ui t a xl e)
MSE000058 EROAD Sens or Mounti ng Bl ock (recta ngul a r confi gura ti on)
MSE000056 BOSCH Speed Sens or
MSE000250 ROR Sens or Hol der - Drum Bra ke
MSE000252 ROR Sens or Hol der - Di s c Bra ke & Ha rdwa re Ki t
MSE000310 SAF Sens or Hol der & Screws (x2)
CABLE & PLUG ACCESSORIES

CBE000102 WABCO, Extens i on Ca bl e , 10 metres
AAE000201 TUBO Ins ta l l a ti on Acces s ory Ki t
GRE00004-G Ca bl e Gl a nd
FS000003-G 3 AMP Fus es for TUBO Ba ttery
AT000050-G GPS Antenna , MP54, SMA-M 7M, Modi fi ed

CB000202A-G GPS Antenna Extens i on - 4m
BKE000004A-G GPS Antenna Mounti ng Pl a te MP54
AT000004-G Whi p (Brooms ti ck) Aeri a l
AAE000238 Tubo Ba ttery Box, Ba ttery a nd Cha rger Boa rd

CSE000029A-E Tubo - Rea r Ca s e Onl y
PLUGS, SOCKETS, CABLE

CN000017 7 Pi n Pl ug
CN000018 7 Pi n Socket
CN000300A-G 15 Pi n Pl ug
CN000310A-G 15 Pi n Socket
CB000320A-G 15 Pi n Suzy Ca bl e 3.5mtr
CB000280A-G 15 Core Ca bl e - per metre
CB000310A_G 15 Pi n Pl ug + 5mtr of 15 Core Ca bl e
CB000311A-G 15 Pi n Pl ug + 10mtr of 15 Core Ca bl e
CB000300A-G 15 Pi n Socket + 5mtr of 15 Core Ca bl e
CB000301A-G 15 Pi n Socket + 10mtr of 15 Core Ca bl e

APPENDIX 2 – Ehubo/ EhuboLite Quick Check

APPENDIX 3 – Tubo Quick Check

APPENDIX 4 – Administration Quick Check

APPENDIX 5 - Accreditation
The accreditation of individuals to install EROAD products is to ensure that there is a continuity of installation
standards throughout the country. Please note it is the individual that is accredited and not the organisation.
Those staff that have not been accredited can work through an installation, however an accredited technician must
complete the wiring terminations and sign off on the installation certificate. This allows ‘apprentices’ to become familiar
with the EROAD installation process prior to any formal accreditation.
At all times the accredited technician has the final responsibility for the standard of installation.
Accreditation is valid for 12 months. The internal review process occurs after the second audit (which are conducted
every 6 months) has been completed.
Assessment Points:
 At least 2 satisfactory audits over the previous 12 months
 Review of last 3 installations including photographs and completed Installation Certificates
 Feedback from EROAD customer services and service delivery staff
There are six levels of accreditation:
Grade 1 – Installation of Elocate only.

Trained and certified to install an Elocate into any vehicle.
Grade 2 – Installation of Elocate, EhuboLite, Driver ID and Ehubo only.
Trained and certified to install an Elocate, EhuboLite, Driver ID and an Ehubo into any vehicle.
Grade 3 – Installation of Elocate, EhuboLite, Driver ID, Ehubo and Tubo.
Trained and certified to install an Elocate, EhuboLite, Driver ID, Ehubo and a Tubo into any vehicle.
Grade 4 – Installation of Elocate, EhuboLite, Driver ID, Ehubo and Tubo and Intrinsically Safe Eboxes
Trained and certified to install an Elocate, EhuboLite, Driver ID, Ehubo, Tubo and Intrinsically Safe Eboxes
into any vehicle.
Grade 5 – As per Grade 4 plus In Field Ebox Part Replacement.
Grade 6 – As per Grade 5 plus In Field Product Diagnosis and Resolution
The accreditation level is confirmed when sufficient in field training with an EROAD certified trainer has been
conducted.
Training Process
The training takes place generally over three installations of the same unit type.
The training format is a “Watch, Assist, Solo” process:
Watch - the technician watches the first installation as it is being completed by the trainer.
Assist - the technician assists the trainer with the second installation.
Solo - the technician completes the third installation under the scrutiny of the trainer.
Throughout the training the Trainer will be explaining the process and particular techniques. There will be an
expectation that the technician is familiar with the EROAD installation process through prior study of the EROAD New
Zealand Installation Manual and product-related installation documents.

The process will include:
In-Vehicle Units:
1. Discussion with the customer on unit siting (Ehubo, Driver ID etc).
2. Run through of pre-install checklist on Installation Certificate checking for damage – Photographs.
3. Clean Windscreen – preparation for windscreen holder.
4. Opening of dash panels – care to be taken.
5. Check where electrical sources are and determine wiring loom routing.
6. Fit Windscreen mount (allows silicon to set before inserting the Ehubo) – Photographs.
7. Siting of security lock (Ehubo only).
8. Sleeving wiring loom and cable tying as wiring loom is run.
9. Earth terminations – Photographs.
10. Speed Signal source – if analogue, must use twisted pair cable.
11. Power – clean source.
12. Ignition – correct connection (not ACC).
13. Fuse holder siting – close to source – cable tie and tape as dash is about to be closed. – Photographs.
14. Soldering technique, plus tape and cable tie. – Photographs.
15. Powering up Ebox
16. Observing screen for installation process.
17. Observe screen calibrating whilst vehicle is being test driven.
18. Reassemble dash.
19. Housekeeping – Clean up swarf/ wire ends/ wipe dash and seats.
20. Paperwork – Post installation check and RUCHO slip. – Photographs.
Trailer Units:
1. Discussion with the customer on unit siting (Tubo and Tubo battery box).
Tubo box must be installed on left hand (kerb) side of trailer. – Photographs.
2. Check where to take power from - pin 5 of 7-pin plug. Marker lights with waterproof switch, 15-Pin Plug?
DO NOT splice into trailer wiring loom.
3. Tipper body/ Trombone – has this been taken into consideration when running cables?
4. Run through of Pre-Install checklist on Installation Certificate checking for damage – Photographs.
5. Check where speed signal is to be sourced from – spare sensor/ spare slot/ pole wheel?
Best site is right hand side of trailer.
Sleeve speed sensor wire from back of hub to past the connection to the Wabco plug. – Photographs.
6. GPS aerial to get best view of sky, excess GPS loom to be laid out in lazy coil. Do not tightly coil.
Sleeve GPS cable. – Photographs.
7. Run cables inside existing loom sleeving,/ behind existing cable runs/ along with air lines etc.
Cable Tie to existing loom no more than every 300mm.
8. Soldering technique - plus tape and cable tie.
9. Round cable must be used going into Tubo boxes – Photographs.
One cable per grommet.
Tighten grommets thoroughly.
Cable tie each cable inside Tubo boxes as strain relief to stop cable pulling back through.
10. Use EROAD supplied crimps.
Screws from terminal block cannot be unscrewed fully – they do break!
Crimps are positive connect.
Connect as per installation document that came with Tubo unit. – Photographs.
5 Wire – Battery In +, Battery In - , Trailer Supply +, TX out & RX in.
2 Wire – Speed Signal.
GPS connected to bottom of Tubo.
11. Test drive, close up.
12. Housekeeping – Clean up swarf/ wire ends.
13. Paperwork - Post installation check and RUCHO slip.

APPENDIX 6 – Auditing
To ensure that there is a consistent level of installations occurring throughout the network, random audits will be
conduct by EROAD assessors, approximately every 6 months.
Feedback will be given after each audit and where required, remedial work will be directed to be actioned.
The audits will follow the checklist below:
VEHICLE AUDIT REPORT - CHECKLIST

Da te Audi tor
Cus tomer
Vehi cl e Rego Uni t Seri a l Number NZ
Checklist (where applicable)

EHUBO
Igni ti on s ource
Speed s i gna l s ource
Power s ource
Check Ea rth -connection (ring terminal?)
Fus es s i ted i n s ui ta bl e pos i ti on
Check fus e ra ti ng - under da s h - 2A
Check s ol der connecti ons / ta pe/ ca bl e ti e
Check ca bl e routi ng - Split gland tubing used if required
Ca bl e ti ed to a ppropri a te poi nts
Check wi nds creen hol der pos i ti on - cables not pinched

Silicon or similar used
Auditor to ta ke photo from outs i de
Check s ecuri ty cl a mp/ hea t s hri nk i n pl a ce

Stuck to appropriate surface
Check power s uppl y l i ne for Tubo
Check fus e ra ti ng - truck s uppl y to Tubo 10A
TUBO
Ca bl e i s round
Ca bl e termi na ti ons ha ve been cri mped correctl y i n box
One ca bl e per grommet, ca bl e ti e reta i ner?
Grommets ti ght
Al l s crews i n tubo fa ce a re ha ve been s crewed i n a n

a l terna te fa s hi on a nd s et a t 1.5nm
Tubo mounted fl a t (no ra cki ng of ca s e a l l owi ng poor s ea l )
GPS Aeri a l Ins ta l l a ti on Pos i ti on (Photo)

GPS ca bl e i s cover i n s pl i t ca bl e gl a nd
Uni t fi tted i n on l eft ha nd s i de of the tra i l er a nd ea s i l y

vi ewed from s i de of the roa d
Speed s i gna l connecti on i s joi ned correctl y a nd ta ped

Pl ug a s s embl y i s to rea r of a xl e a nd ca bl e ti ed
Ca bl e routi ng fol l ows tra i l er wi ri ng l oom/ a i r hos es

Al l ows for a i r ba g expa ns i on
Ca bl e i s routed through a ny exi s ti ng protecti ve s l eevi ng

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EROAD New Zealand Installation Manual

© EROAD 2012 – form 001071A Commercial In Confidence Page 1 of 74

© EROAD 2012 – form 001071A Commercial In Confidence Page 2 of 74

© EROAD 2012 – form 001071A Commercial In Confidence Page 4 of 74

© EROAD 2012 – form 001071A Commercial In Confidence Page 5 of 74

2.1 Installer Website

2.2 The Installation Process

The full process is as follows:

© EROAD 2012 – form 001071A Commercial In Confidence Page 6 of 74

2.2.1.1 Accessory Planner

© EROAD 2012 – form 001071A Commercial In Confidence Page 7 of 74

© EROAD 2012 – form 001071A Commercial In Confidence Page 8 of 74

Installation Certificates fully completed.

Ehubo/ Ehubolite/ Elocate - Photographs

Ebox - Swap-Out Photos – see Section 2.2.2.5 for flow diagram

© EROAD 2012 – form 001071A Commercial In Confidence Page 9 of 74

© EROAD 2012 – form 001071A Commercial In Confidence Page 10 of 74

2.2.2.4 Calibration of the Vehicle

© EROAD 2012 – form 001071A Commercial In Confidence Page 11 of 74

© EROAD 2012 – form 001071A Commercial In Confidence Page 12 of 74

© EROAD 2012 – form 001071A Commercial In Confidence Page 13 of 74

 Installation of cabling, EROAD hardware, accessories etc 12 months

Obligations under the warranty:

2.4 Charge-Out Rates

2.5 Submission of Invoices

2.5.1 Installations - Invoicing

 The customer name must be shown on the invoice.

© EROAD 2012 – form 001071A Commercial In Confidence Page 14 of 74

 One invoice per vehicle.

2.6 Remedial and Returns Process

2.6.1 Remedial Work

2.6.2 Ebox Return Process (see Flow Diagram 2.6.3)

© EROAD 2012 – form 001071A Commercial In Confidence Page 15 of 74

© EROAD 2012 – form 001071A Commercial In Confidence Page 16 of 74

Please enter details

© EROAD 2012 – form 001071A Commercial In Confidence Page 17 of 74

4.1 Brief description of GPS system

GPS Satellite Constellation

© EROAD 2012 – form 001071A Commercial In Confidence Page 18 of 74

GPS antennae require a direct view of the sky to work efficiently

4.2 GPS Antenna basics

See section 6.7.4 for antenna installation instructions.

GPS Antenna beamwidth

© EROAD 2012 – form 001071A Commercial In Confidence Page 19 of 74

Truck powered for trailer – 10 A fuse to be fitted.

© EROAD 2012 – form 001071A Commercial In Confidence Page 20 of 74

Wire Wire Maximum Current

Maximum wire lengths for 0.5V volt drop

Cable Length Cable Length

Maximum Tubo power supply wire length

© EROAD 2012 – form 001071A Commercial In Confidence Page 21 of 74

4.3.1 Inductive (variable reluctance) sensors

Amplifier input (green) and output (yellow)

© EROAD 2012 – form 001071A Commercial In Confidence Page 22 of 74

BOSCH Speed Sensor – Trailer - MSE000056

Freightliner Sensor - Screw type - MSE000202

Fault Finding Methods (Inductor – Variable Reluctance)

By using an oscilloscope you will be able to see the waveform generated.

Sensor resistance table: