GPS Tracker & Sensor Installation Guide
Step-by-step guidance for installing GPS trackers, fuel sensors, AIS-140 devices, CAN-bus units and wiring — for cars, bikes, trucks and commercial fleets across India.
Basic GPS Tracker Installation
A wired GPS tracker draws power from the vehicle's 12V or 24V supply. Installation takes 30–60 minutes by a trained technician.
Find the fuse box — usually under the dashboard or bonnet. This is where constant 12V power and ignition-switched power are tapped.
Red wire (VCC) → constant 12V. Black (GND) → chassis ground. Yellow (ignition) → an ignition-switched fuse line.
Place the GPS antenna on a flat metal surface with clear sky view — dashboard top or roof lining. Keep away from metal obstructions.
Mount in a hidden but accessible location. Zip-tie all cables neatly to prevent rattling or disconnection.
Power on, verify GPS lock and SIM connectivity on the Alphatech platform before reassembling the dashboard panel.
Avoid installing a relay on a brand-new vehicle under manufacturer warranty. Start with a basic wired tracker — add relay later once the warranty period has passed.
Where to Hide the GPS Tracker
Concealment improves theft resistance. The right spot depends on the vehicle type — the antenna still needs a partial sky view.
Hiding inside a full metal enclosure blocks GPS and GSM signals. Keep the antenna within a few centimetres of a non-metallic surface or glass.
Fuel Sensor Installation & Calibration
Fuel monitoring requires hardware installation followed by a 2–3 hour on-site calibration. Both steps are carried out by an Alphatech technician at the vehicle's location.
Installation steps
Wire (capacitive/ultrasonic, inside tank) or BLE (external, no drilling). Selection is based on tank shape and vehicle type.
Drain or partially empty the tank. For internal sensors, drill a fitting hole at the correct diameter and depth for that sensor model.
Insert the sensor, apply the sealant, and tighten to spec. BLE sensors are mounted externally with no drilling needed.
Connect the sensor data line to the GPS tracker's analog or RS-232 input depending on the device model.
Fuel is added in measured increments. The technician records the sensor reading at each level to build an accurate tank profile. Takes 2–3 hours.
Client requirements for calibration day
These must be arranged by the client before the technician arrives. Calibration cannot begin or continue without all of the following.
One person must be assigned to assist the technician with fuel filling and refilling throughout calibration.
A responsible person must remain with the technician for the full 2–3 hour calibration process without interruption.
Sufficient fuel must be available at the calibration location — the process cannot be paused to source fuel mid-way.
Proper fuel measuring equipment (Jerry cans with calibrated markings or a fuel meter) must be provided for accurate readings.
The vehicle must not be moved during calibration. Moving before the profile is complete will require a full restart.
AIS-140 / RTO Device Installation
AIS-140 devices must be installed and configured precisely to transmit data to the government Vahan portal. A wrongly configured device will fail RTO inspection even if the hardware is certified.
Confirm the device carries ARAI or ICAT type-approval. The certification number is on the device label — uncertified hardware will be rejected at RTO.
Wire constant power, ignition, and ground as with a standard tracker. The AIS-140 unit also requires the panic button to be wired separately.
Fix the SOS button within arm reach of the driver — typically on the dashboard or A-pillar. Route the cable cleanly to the main unit.
Insert the M2M SIM and configure the device's APN and server address to point to your state's Vahan transport portal endpoint.
Confirm live data is reaching the Vahan portal before the RTO visit. The RTO checks the portal live during fitness inspection.
Each state RTO uses a different server endpoint. Alphatech configures the device for your specific state before your fitness appointment.
CAN-Bus Device Installation — Teltonika FMB / FMC
CAN-bus devices read engine data directly from the vehicle's OBD/CAN network — RPM, fuel level, temperature, odometer — without additional sensors. Teltonika FMB and FMC series are the most widely used.
FMB devices use a standard SIM card. FMC devices use an embedded eSIM for multi-network connectivity. Both support CAN-bus and standard wired I/O simultaneously.
Locate the OBD-II port (standard on most vehicles post-2005) or the vehicle's proprietary CAN connector. Check the Teltonika vehicle compatibility list for your model.
Yellow (CAN H) and green (CAN L) wires from the FMB/FMC connect to the vehicle's CAN bus lines. Most vehicles have multiple CAN networks — use the correct one.
Connect 12V constant, GND, and ignition line as with a standard wired installation.
Enable the correct CAN profile for your vehicle, set the server address, and define I/O parameters using the Teltonika Configurator (USB or Bluetooth).
Confirm engine RPM, fuel level, and odometer data is appearing on the Alphatech platform before closing the installation.
Common Teltonika models
| Model | SIM | CAN | Best For |
|---|---|---|---|
| FMB120 | External | OBD-II basic | Cars, light vehicles |
| FMB900 | External | None | Budget wired tracking |
| FMB125 | External | Full CAN+OBD | Trucks, HCV |
| FMC125 | eSIM | Full CAN+OBD | Interstate multi-network fleets |
| FMB130 | External | LV/ALL-CAN | Heavy machinery |
Ruptela Device Installation
Ruptela devices are enterprise-grade GPS trackers with advanced I/O, CAN-bus support, and deep fleet management integration.
Always update to the latest firmware using Ruptela Device Center before configuring and deploying. Skipping this causes configuration issues.
Connect VIN (9–30V), GND, and ignition input per the wiring diagram. Ruptela devices support both 12V and 24V vehicle systems.
Depending on the model, connect to the vehicle's CAN-bus, RS-232, or RS-485 data lines per the Ruptela vehicle integration guide.
Wire digital or analog inputs — driver ID readers, temperature sensors, fuel level sensors — to the device's I/O terminals.
Set server endpoints, APN, I/O event rules, and CAN decoding in Ruptela Device Center. Verify position and CAN data on the platform before sealing up.
Wiring Configurations
Different GPS devices use different harness configurations. Here is what each wire does in the most common setups.
- Red — 12V constant (VCC)
- Black — Ground (GND)
- Yellow — Ignition (ACC)
- Orange — Relay / output
- Red — 12V constant (VCC)
- Black — Ground (GND)
- Yellow — Ignition (ACC)
- Green — Digital input 1
- Blue — Digital input 2
- Orange — Relay / output
- Red — VCC constant
- Black — GND
- Yellow — Ignition
- Green — DIN 1
- Blue — DIN 2
- Orange — DOUT 1 (relay)
- Pink — DOUT 2
- Purple — AIN 1
- Teal — RS-232 TX
- Brown — RS-232 RX
CAN / RS-485 / 1-Wire
- Yellow — CAN High (CAN H)
- Green — CAN Low (CAN L)
- Black — GND
- Orange — Data line
- Teal — RS-485 A (+)
- Brown — RS-485 B (−)
Wire colour conventions vary by manufacturer. Always verify against the specific device's wiring diagram. Incorrect wiring can damage the device or the vehicle's electrical system.
Installation FAQ
How long does a basic GPS tracker installation take?
30–60 minutes for a trained technician on a car or light vehicle. Trucks and buses may take longer due to cable routing distances.
How long does fuel sensor calibration take?
2–3 hours at minimum. Exact duration depends on tank size and how many calibration points are required for accurate profiling.
Can I move the vehicle during fuel sensor calibration?
No. Moving the vehicle invalidates the data and requires the calibration to restart from the beginning. The vehicle must remain stationary throughout.
What is the difference between a basic wired tracker and a CAN-bus device?
A basic wired tracker gives you GPS position and ignition status. A CAN-bus device additionally reads engine RPM, odometer, fuel level, and temperature directly from the vehicle's computer without extra sensors.
Does Alphatech supply the installation technician?
Yes. For all products sold by Alphatech, our trained technicians handle installation. For outstation locations, contact our team to arrange scheduling and availability.
Can a GPS tracker drain my vehicle battery?
A quality tracker draws very low current (typically under 25mA standby). This will not drain a healthy battery during normal use, but a sleep-mode tracker is recommended for vehicles parked for long periods.
Need a technician for your vehicle?
Contact our team to book a GPS tracker or fuel sensor installation in your city.