A telematics installation can look straightforward on paper, but the actual work depends on the vehicle. On site, the installer may need to determine where to place the sensor, whether one or two fuel level sensors are required, how to access a difficult fuel tank, where to install the tracker, and how to ensure reliable communication between all system components.
We spoke with an experienced telematics integrator who works with trucks and special-purpose machinery to understand how these decisions are made in practice – and what needs to happen before an installation can be considered complete.
What you’ll learn
In this article, we break down the entire on-site installation process and explain:
- how an installation team prepares for field work;
- what needs to be checked before choosing a sensor installation point;
- when a fuel tank may require more than one sensor;
- how fuel level sensors are installed and calibrated;
- how fuel tank calibration is performed;
- how communication between the sensor, tracker, and monitoring system is checked;
- what needs to be tested and documented before the vehicle is handed back to the customer.
Who this article is for
Telematics integrators, installation teams, technical specialists, and fleet professionals who work with vehicle monitoring systems.
Preparing for an on-site installation
The work begins before the installer arrives at the vehicle. Based on the customer’s request, the integrator confirms the type and number of vehicles, the equipment package, the installation location and date, and the customer’s designated contact person.
The more information about the vehicles is available in advance, the easier it is to prepare for the installation. Bringing a vehicle to the integrator’s workshop is usually the most convenient option, but in practice this is not always possible. A truck can often be sent to a service facility, while an excavator, tractor, or combine harvester may be easier and less expensive to equip directly at its operating site.
Project scale can also vary considerably – from a single vehicle to several dozen new units that need to be equipped within a limited timeframe.
For this reason, the installation team’s vehicle effectively becomes a mobile workshop. Installers need to be prepared not only for the planned work, but also for unexpected replacements, different connection conditions, or limited infrastructure at the site.
Field checklist: what an installation team brings
- spare sensors and trackers
- SIM cards
- consumables
- hand and power tools, including electrical test equipment
- for fuel level sensor installations – containers, a pump, and a fuel meter for tank calibration
- a generator if there is no power supply at the site
Extra devices are carried in case of a malfunction or an unexpected replacement. The same applies to SIM cards: in remote areas, one mobile operator may provide significantly more reliable coverage than another.
If there is no power supply at the site, the team brings a generator. It is primarily used during fuel tank calibration, when fuel needs to be pumped out of the tank and then returned in measured portions.
Poor connectivity does not necessarily stop the work either. If mobile internet is unavailable but voice service is still available, the installer can contact colleagues and ask them to check whether the equipment has appeared in the monitoring system. The photo report can then be submitted later.
Inspecting the vehicle and choosing the installation layout
Once on site, the work begins with an inspection of the specific vehicle. The installer needs to determine the location and shape of the fuel tank, assess access to it, choose the sensor installation point and tracker location, and, when wired equipment is used, plan the cable route.
On a familiar vehicle model, many of these decisions may already be known. With a new or uncommon vehicle, the installer first needs to understand its layout. On buses, agricultural machinery, and special-purpose equipment, reaching the tank may require partial removal of cabin components, flooring, or protective panels.
