Fitting and Wiring Instructions

With all systems the colour coding of the harness wires are common to each other.

• Locate a position to mount the unit in the engine bay of the vehicle. For ease installation try and find this position on the same side as the vehicles battery. Mark the position for the self-tapping screws and then check that either the drill bit or screws can damage nothing.
• Cut or lengthen unit wires if necessary.
• With vehicles fitted with duel battery systems always connect to main or start battery.

- RED WIRE -BATTERY POSITIVE (+)
- GREEN WIRE - BODY EARTH (not battery)
- BLUE WIRE - FRONT COUPLER/S
- WHITE WIRE - REAR COUPLER/S

•  Cut red wire to length and crimp ring terminal supplied to end of wire. NOTE: Fuse should go as close as possible to the battery. Cut red wire and put plastic fuse holder in line by crimping in place
• The GREEN wire (earth) must go to the vehicle body, make sure the selected position is not next to a coupler or negative lead off the battery. Ideal position would be approx. 1/2 meter away.
• It is most important to fix the Capacitive Coupler\'s firmly and correctly.
• For vehicle units the coupler is located in the engine bay.
• For 2 coupler 4WD units, position the couplers diagonally opposite each other; e.g.: one in the right hand front side and the other in the left hand rear side.
• For 4 coupler HD4WD units, position 2 couplers up front and 2 couplers at the rear of the vehicle. NOTE: The position for the couplers should be flat (or nearly flat), the surface should have no holes or nicks and most importantly, the surface MUST have a good coating of paint. DO NOT REMOVE PAINT TO APPLY COUPLER
• The ideal position to fit rear coupler/s is on a flat painted surface inside the rear quarter panel inside the vehicle; access to this area can be gained by running a wire either through the chassis or via a wiring loom inside the vehicle .If the vehicle is a Ute or cab chassis, the rear couplers can be fitted to the chassis rail. Make sure the coupler/s will fit the selected area/s and the surface is flat. Before applying the coupler to the chassis, the area must be lightly sanded back to remove any loose paint and to ensure there are no weld spikes that could damage and short out the coupler. Apply a minimum of 2 coats of quick dry enamel to sanded area, this ensures a good painted surface.
• Remove the backing paper on the coupler and then press the coupler firmly into position ensuring that no air bubbles are trapped, make sure edges are firmly pressed down. Seal the edges of the coupler with silicon (Natural Cure Roof & Gutter Sealant will do) this prevents any moisture from creeping under the coupler.
• NOTE: When joining white wire/s to rear coupler wire/s make sure you use a dual insulated 4mm cable or equivalent. Make sure there are NO joins in these wires under the vehicle. All joins should be soldered and sealed with heat shrink.
• NOTE: When joining white wire/s to rear coupler wire/s make sure you use a dual insulated 4mm cable or equivalent. Make sure there are NO joins in these wires under the vehicle. All joins should be soldered and sealed with heat shrink.
• White wires are for rear couplers. Blue wires are for front couplers. Cut coupler wire to length and crimp on female bullet connection. Make sure all wiring is securely in place with cable ties. Ensure all wires are clear of moving parts and exhaust system.
• Testing procedure -
• Insert Fuse to Fuse Holder. You will need a multi or volt-meter. Set meter to at least 500DVC or higher. Place one probe into the blue or white wire female bullet connection and the other probe onto bare metal. Your voltage reading should be over 200 DC volts (average around 350v) depending on the model of the system. This is also a good test to ensure all components are earthed to the vehicle and not insulated.
• Remove fuse, connect wire\'s to coupler\'s. Refit fuse and check that the green light is pulsing.
• NOTE: If green light is not pulsing, please contact Couplertec Head Office immediately on 07 5522 0200.

Fault Finding on Installed Units

1. NO GREEN LIGHT

• Check Fuse
• Check Battery Connection
• Check earth connection
• Check battery voltage - start vehicle and recheck

2. NO OUTPUT/VOLTAGE AT COUPLER

• Check green light is pulsing - if not, see above.
• Check for break in wire to coupler
• Check battery voltage - start vehicle and recheck