Zonar Systems 80510 80510 User Manual

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REV: 09/15/11

Z-Con™ Hardware Installation Tips

For Professional Installers

Zonar’s equipment will provide years of reliable service if properly installed and maintained. Zonar

equipment is typically installed in heavy vehicle applications and is often subject to extreme temperatures,

dust, dirt, vibration, and shock. Proper installation is the critical first step to equipment longevity and

optimal performance.

This guide is meant to be a general guideline for the professional installer and technician. While we

attempt to point out the most common installation questions and issues; common sense, good

housekeeping procedures, attention to detail, safety adherence, and technical competence of the

professional installer is critical for a successful installation.

Please refer to your specific vehicle manufacturer guidelines for the installation of electrical components

and wiring.

A professional team of Zonar support technicians and engineers are available to answer your installation

questions. Contact Zonar at 1-877-843-3847 or by email at customercare@zonarsystems.com.

Thank you,

Andre J Horochiwsky

Technical Training Manager – Zonar Systems

As Zonar is continuously improving the Product, Zonar may make changes to the Product at any time which may not be reflected in this document.

WOKFLOW

Z-Con • V2JE™/TRUCK SIDE BOARD

Introduction ................................................................................................2

System Overview........................................................................................4

V2JE/Truck Board Hardware ......................................................................5

Basic Workflow...........................................................................................6

General Guidelines .....................................................................................6

V2JE Mounting Plate ..................................................................................7

Wiring Guidelines........................................................................................8

V2JE Pin Configuration...............................................................................8

Cables........................................................................................................9

Antenna Installation ..................................................................................11

Non-Typical System Installation ................................................................12

Truck Install Application & Tool..................................................................13

GPS System Check..................................................................................14

System Checklist......................................................................................15

System Specifications ..............................................................................16

Installation Example..................................................................................17

System Installation ..................................................................................18

Troubleshooting...................................................................................19-20

Truck Windshield Configurations .........................................................21-22

Non-Typical System Installation ................................................................23

Warranty & Notices - FCC Compliance.....................................................24

Notes .......................................................................................................25

INTRODUCTION

patents:

REV: 09/15/11

SYSTEM OVERVIEW

Z-Con detects the truck via ultrasonic sensors and activates the radio in the fuel canopy and infrared transmitter.

The truck’s VIN is validated indicating the truck is authorized to begin fueling.

After fueling has completed, the truck leaves the pump area and the secure connection is broken - ensuring that only the authorized truck

is fueled.

Basic Workflow

1) Unpack all equipment and verify shipment (see page 7).

2) Layout system (see page 7)

3) Install and inter-connect system.

A) V2JE device (see page 7).

B) Electrical/JBus data link (see pages 8-10 and page 16).

C) Antenna(s) (see page 12).

D) Truck board windshield mount and truck board (see page 11)

4) Operational checkout V2JE device (see page 14).

5) Provision Truck Board (see page 13).

BASIC WORKFLOW

Layout

1) Cellular/GSM antennas must be located a minimum of 8”

from any person.

2) Mount all equipment in the interior of the vehicle. External

mounted GPS antenna is the only component installed

externally.

3) Do not install Zonar equipment below windows and doors

which open to the vehicles exterior to prevent water damage.

4) Lay all components out prior to installation to check for proper

cable length and interference issues.

5) Avoid mounting equipment in difficult to access areas. Avoid

mounting in areas which do not allow for direct diagnostic

LED viewing.

6) Avoid mounting equipment in dirty, dusty, or damp areas (e.g.

near floors and entrance ways).

7) Avoid mounting Zonar Equipment, antennas and wiring near

other radio equipment (e.g.,two-way radios), PA equipment

and high energy electrical sources (e.g., cables, relays,

amplifiers, etc.)

Electrical

1) Consult the vehicles manufacturer for specific

installation guidelines. (HIGHLY RECOMMENDED for

Multiplex electrical systems)

2) All power leads (V2JE-Power Cable) must be connected to

the vehicles protected circuitry (e.g. fuse panel, circuit breaker

panel, protected circuits). Never electrically connect Zonar

equipment to unprotected circuits.

3) It is also required that all power leads (V2JE-Power Cable)

be protected with a 3 to 5 amp fuse and inline fuse holder

(included) for optimal system protection.

Cable Management

1) Strain relieve and support all cable installations.

2) Avoid sharp bends and tight radius installations of cables.

3) Avoid moving components (e.g. doors, steering shafts, handles,

fans, etc.).

4) Provide an adequate “Service Loop” i.e. “cable slack” to allow

for servicing of equipment.

5) Avoid routing cables thru doors, windows, and other pinch

points.

6) Avoid routing cables in high personnel traffic areas.

7) Avoid routing antenna cables near radio and PA equipment.

INCORRECT

• Bend radius too tight

• Hole has sharp edges

• Hole has no grommet

CORRECT

• Bend radius adequate

• Hole has grommet

GENERAL GUIDLINES

Drill Holes

1) Capture all drill chips during drilling operations. Do not allow

drill chips to fall onto electrical equipment, furnishings, heating

ducts, etc. Magnets, sticky tape, vacuums, physical barriers,

etc. may all be used to accomplish this task.

2) Deburr all drill holes on both sides of drilled surface. Example

deburr tool:

3) All drill holes must have a rubber grommet or similar anti-

chaffing system installed to protect cable assemblies (e.g.

plastic conduit).

4) Seal all penetration drill holes which may pass rain water (e.g.

GPS antenna cable).

Component Identification

A. V2JE

B.V2JE Mounting Plate and Mounting Screws (provided)

C. Stubby GSM (cellular) Antenna

D.GPS Antenna Aluminum Mount Plate and Screws (optional -

used for non-magnetic exterior rooftop GPS Antenna installs)

E.3M Double Sided Adhesive (used for non-metallic interior roof

attachment) supplied

F. GPS Antenna

G. MiniWing style GSM Antenna (optional)

H. Truckboard Part No. 80510

I. Truckboard Cable - 13 ft. - Part No.80765

J. Standard Back Part No. 80911

K. Angled Back Part No. 80912

Note: See page 11 for detailed information on GPS and GSM

(cellular) antenna requirements and recommendations.

V2JE/TRUCKBOARD

HARDWARE

ZonarV2J

Part#: 10017

GSM Stubby Antenna

Part#: 10019

1.External GPS antenna

2.4 Pin Power Input

3.Z-Con™ Truck Board

4.8 Pin 2010 Vehicle Mount (Optional)

5.12 Pin Discrete Truckboard I/O (Optional)

6.10 Pin J3 input (JBus 1708/1939 Equipped Vehicles)

SYSTEM INSTALLATION

Constant

Power

Supply

2 Pin

Ground

External GPS Antenna

Part#: 10006

Cable Length: 16.5 ft.

Truckboard

Part#: 80510

Cable Length:13ft ft. - Part# 80765

V2JE Mounting Plate & Unit

Follow all General Guidelines as specified on page 6.

2) Mount onto interior flat surface large enough to accommodate

footprint.

3) Do not install below windows or doors which open to the

vehicles exterior to prevent water damage.

4) Avoid mounting equipment in difficult to access areas. Avoid

mounting in areas which do not allow for direct diagnostic

LED viewing.

5) Avoid mounting Zonar Equipment, antennas and wiring near

other radio equipment (e.g.,two-way radios), PA equipment

and high energy electrical sources (e.g., cables, relays,

amplifiers, etc.).

6) Avoid mounting equipment in dirty, dusty, or damp areas (e.g.

near floors and entrance ways).

V2JE MOUNTING PLATE

CAUTION: The mini-GSM antenna

is factory torqued, do not rotate

antenna!!

SAMPLE CABLES

PIN 80441 - V2J WW J1939 TO RETRO ADAPTER

9.33’

PIN 80183 - WW 9-PIN PASS THRU WITH PIGTAIL FLANGED PANEL MOIUNT

9.8’

10.75’

PIN 80339 - J1939 - 15 UNIVERSAL NODER AMP ss

See Page 21-22 for Vehicle Specific Requirements

PIN 80444 - V2J WW J1708 2-PIN DELPHI 16.65’

PIN 80130 - WW 6-PIN PASS THRU WITH PIGTAIL FLANGED PANEL MOUNT

9.8’

Wiring Guidelines for non-terminated wire ends

CONSTANT POWER:

The authorized method for power termination on the Zonar V2JE

system is the use of Add-a-Circuit fuse taps. Whenever possible,

use fuse taps for power termination. If, due to the particular

make/model/year of the vehicle being installed, fuse taps cannot

be used then the poke and weave method of termination can be

utilized. All wiring terminations MUST be fused regardless of Add-

a-Circuit or poke and weave.

When installing Add-a-Circuit fuse taps, ensure that the fuse tap

seats fully in the correct location. If another fuse, a relay, or any

other object in the fuse panel prevents the fuse tap from seating

fully, relocate the fuse tap. It is not permissible for the fuse tap to

rub or make contact with other items in the fuse panel. In addition,

you must be able to re-secure the fuse panel cover or door once

the fuse tap is installed. Whenever possible, use an empty location

in the fuse panel that does not have an existing fuse. If it is not

possible to use an empty location, ensure that the existing fuse is

placed in the correct location on the fuse tap.

See Fig. 11-1

Whenever it is not possible to utilize Add-a-Circuit fuse taps then

the poke and weave method must be used.

A. First locate the proper wire where the poke and weave method

is to be installed. Strip 3/4” to 1” of insulation from the wire in

the vehicle to be installed. Spread the wire strands apart as

shown. See Fig. 11-2

B. Strip 1” to 1 1/2” of insulation from the wire in the fused link

to be installed. See Fig. 11-3

C. Insert the wire from the fused link into the spread wire in the

vehicle. Wrap around the wire several times. See Fig. 11-4

D. Cover the exposed wires with several wraps of electrical tape

or mastic. Place one wire tie over the electric tape over the

exact location where the wires are 'wrapped' together. Place

another wire tie 1” to 2” from the first wire tie, to secure the two

wires together and as stress relief. See Fig. 11-5

GROUND:

Normally affixed to the vehicle chassis with a high quality solderless

ring lug. Ensure good crimp by giving the finished joint a slight tug.

See Fig 11-6

Fig. 11-1

Wire Tie

Fig. 11-5

Fig. 11-4

Fig. 11-3

Fig. 11-2

WIRING GUIDELINES

CAUTION: Only “LitteFuse”

(www.littlefuse.com) Add-A-

Circuit taps are authorized for

use with Zonar Equipment.

Full size: (ATO) P/N FHA200

Mini version: P/N FHM200

Fig. 11-6

External GPS Antenna

Follow all General Guidelines as specified on page 6.

2) May be magnetically mounted or mounted via optional aluminum

plate and screw for non-magnetic surfaces (see page 7).

3) Interior cab mount - non-metallic roof only

4) Suggested installation point - centerline of vehicle roof, minimize

cable run to prevent wind and truck wash damage.

5) Ensure a clear antenna view of the open sky.

6) Maintain a minimum of 6 inches from any rooftop edge or

ledge (see Fig. 12-1).

7) Drill, Deburr, grommet, weather seal, cable thru hole as required.

Drill hole size - 1/2” (.500”); grommet size - 3/8” (.375”).

Note: For optimal system performance Zonar recommends rooftop

mounting with a clear view of the sky.

Fig. 12-2

Fig. 12-1

ANTENNA INSTALLATION

External Rooftop Mount - Preferred

Interior Cab Mount - Non-Metallic Roof Only

1) Clean and dry the surface before placing. To obtain optimum

adhesion, the surface must be clean and dry. The best surface

cleaning solvent is an isopropyl alcohol/water mixture (rubbing

alcohol).

2) Remove the backing from the peel-and-stick (see fig. 12-2).

Press and hold mounting position for 10 seconds to assure

good adhesion.

Adhere peel-and-stick to

top of antenna

6” minimum

from edge

1” - 2” recommended

Cab View

Sky View

External GSM Antenna

(Optional)

1) The attached GSM (cellular) “stubby” antenna is quite robust

and works well in a wide variety of applications. Generally

external GSM (cellular) antennas are only required if the unit is

enclosed behind a metallic panel or in a metallic box. To check

the quality of the cellular connection, turn on the engine and

the GSM LED should be a solid (non-blinking) green within 2

minutes).

Follow all General Guidelines as specified on page 6.

3) Cellular/GSM antennas must be located a minimum of 8 “ from

any person.

4) Mount on unobstructed interior glass surface (e.g. windshield

corner or stationary side window) with a clear view of open sky.

5) Do not install on metallic surfaces, or in metallic enclosures.

6) Do not block drivers view or mirrors.

7) Verify placement acceptability with state DOT/law enforcement

prior to installation.

8) Positioning - Vertical (Optimum), Horizontal (Alternate) ( see

Fig. 12-3).

9) Clean and dry the surface before placing the mounting plate.

To obtain optimum adhesion, the surface must be clean and

dry. The best surface cleaning solvent is an isopropyl

alcohol/water mixture. (rubbing alcohol)

10) Remove the backing from the peel and stick (see Fig.12-4).

Press and hold mounting position for 10 seconds to assure

good adhesion.

Optimum - Mount Antenna Vertically

Fig. 12-4

Fig. 12-3

Alternative - Mount Antenna Horizontally

Non-Metallic Roof

INSTALLATION EXAMPLE

Fig. 13-1

Truck Board Bracket and Truck Board Installation

1) Follow all general guidelines as specified on page 6.

2) Locate proper mounting location. See vehicle specific

information table on pages 21-22.

3) Clean and dry windshield surface. To obtain optimum adhesion

the windshield surface must be clean and dry. The best surface

cleaning solvent is an isopropyl alcohol/water mixture (rubbing

alcohol).

4) Remove the backing from the peel-and-stick (see Fig. 13-1

or 13-2). Press and hold mounting position for 10 seconds to

assure good adhesion.

5) Complete cable routing and connect Truck Board to V2JE

unit.

Fig. 13-2

One Piece Windshield Split Windshield

Standard Back Angled Back

INSTALLER SIGNATURE Date

Customer: Yard: Date: Asset #:

Installer: Location: GPS ID:

Vehicle Odometer Value: Vehicle I.D. (e.g., Vin, Plate#, Make, Model, Year

Vehicle Hour Meter value (if monitoring engine hours)

SYSTEM CHECKLIST

System Check Value Notes

General Layout

General condition - components level, even, straight, etc?

System layout conforms to your established standard?

Clearance check - Vehicle Mount to 2010 Hand Held?

Drilling and Cutting

All drill holes grommeted (or otherwise protected), deburred,

sealed (weather penetrations only)

All chips captured?

Vehicle Mount vacuumed and visually verified to be free of

drill chips or other debris?

Cable Management

All cables properly ran (tight radius, interference, strain

relieved, supported, service looped)?

Electrical

System hookup complies to your established standard?

Verify crimp integrity?

Verify fuse holder and fuse installation?

GPS/J3 System checkout

GPS/J3 LED light check? (engine on/engine off)

Verify GPS position uploaded to GTC website?

Verify power On/Off event

Truck Board System

Truck Board properly provisioned?

Post Job

Key accounted for?

Vehicle secure?

Lights, electrical off?

All debris, refuse, chips removed?

System Check: Minimum Requirements - GPS

1) At a minimum, the installer must perform a “System Check”

to verify proper installation.

2) This procedure covers the minimum requirements for a system

installer. If at all possible a full and complete checkout using

Zonar’s Ground Traffic Control™ website should be performed.

Not all installers will have access to this area, check with a

Zonar Customer Service representative if in doubt.

3) Turn Key On/Engine running, within 2 minutes:

A) GPS Green LED: LED should be solid within 2 minutes

or less. Blinking indicates acquiring satellites, Solid

indicates satellite acquired. GPS antenna must have

a clear view to sky. Do not proceed further until GPS

LED is solid

B) GSM cellular Green LED: LED should be solid within 2

minutes. If blinking, ensure GSM antenna is secure, has

a clear view to the sky and area has cellular coverage.

C) STATUS Green LED: Solid

V 2J Model if blinking or off

i. Call Zonar

D) DL1: Single green blink 1 x per second if J1708/J1587

data is present

E) DL2: Single green blink 1 x per second if J1939 data

is present

F) AUX Red LED: Off (Solid or blinking in the event of

system failure)

G) TAMPER: Off when unit mounted properly in mounting

plate. Solid “On” when not mounted in mounting plate.

4) Turn Key Off, within 2 minutes:

A) DL1: Disregard

B) DL2: Disregard

C) GSM Green LED: Disregard

D) GPS Green LED: Disregard

E) STATUS Green LED: Blinking (Solid may indicate

a problem, check white lead. Call your Zonar

Customer Service Representative if in doubt)

F) AUX: Off (Solid or blinking in the event of

system failure)

Note: A proper and complete system/LED functional check requires

the engine to be running

GPS SYSTEM CHECK

TRUCK INSTALL APP & TOOL

Truck Install App

These tools are for the purpose of ensuring that truck boards

installed in trucks are properly receiving data from the V2J, and to

send information back to Zonar's servers.

The Truck Install/Pump Validation tool is a PCBA with custom

firmware installed on it, along with a standard Zonar radio board,

an IR receiver, and an IR transmitter LED.

The PCBA connects to any

PC via a USB cable

(provided) with the Z-Con

Truck Install App installed.

A screen shot is shown

below.

To Computer

COM port can be selected in the app's dropdown. When a systray

message pops up that says "Your hardware is installed and ready

to use", or something similar, then you can select the tool's COM

port.

If the Truck Install app is running when you plug in a new tool, you'll

need to refresh the COM port list. Do this by unchecking and

rechecking the checkbox next to "Showing active ports" at the

bottom of the app. It may take a moment where it says "Scanning

COM ports..." first.

Standard use and procedure

1) Connect the truck board to the V2J in the truck. Verify it has

power, and the V2J has a GSM connection.

2) Start the truck.

3) Connect the Truck Install tool to your PC via the USB, and

start the Truck Install app.

4) Set the active COM port to the proper port.

5) Point the truck board's IR transmitter at the Truck Install tool's

IR receiver. Click Request ZID. This will cause the truck board

to send its ZID to the Truck Install tool over IR.

6) Once the truck board's green LED stops flashing, click Get

Current Values. This will fill the fields with info gained from the

truck board over radio.

7) Verify that the Engine Hours and Total Fuel are accurate, and

that there are no faults.

8) Make any necessary changes to the Odometer and VIN fields,

fill in Fuel Capacity and DEF Capacity, and click Submit. This

will store the values in non-volatile memory in the V2J.

9) Turn off the truck. The V2J's status light will begin to double-

blink as it sends the new data to the servers. It will single blink

when it's done.

In short, the process is Start truck -> Request ZID -> Get Current

Values -> change values -> Submit -> turn off truck.

Troubleshooting

If the green LED on the truck board does not flash when 'Request

ZID' is pressed:

1) The Truck Install tool might not be receiving power.

-Solution: Check the connections of the USB cable between

the tool and your PC. If problem persists, use a new cable.

2) The wrong COM port may be selected on the Truck Install

app.

-Solution: Select the right COM port for the tool. Try closing

and reopening the app.

If clicking 'Get Current Values' causes the output to return with

"No data received from the truck board" or "Bad data received

from the truck board.", then there are a few possible issues.

1) The return message over radio was corrupt.

- Solution: Bring the Truck Install tool and the truck board

closer together, and click 'Get Current Values' again.

2) The ZID wasn't fully retrieved, or was corrupted.

- Solution: Point the truck board's IR LED directly at the

recessed hole on the left side of the Truck Install tool (as

seen in the picture above). Click 'Request ZID' again. Do

not click 'Get Current Values' until the Truck LED stops

flashing.

Installing the tool

When you first plug in the Truck Install tool, you may need to run

through the automated Windows "Found New Hardware" setup.

Click Next through the dialogs, and the tool should install normally

on your machine.

Thereafter, every time you plug a tool into your machine that hasn't

been plugged in before, you won't need to reinstall the drivers, but

you will need to wait for Windows to identify the tool before its

System Specifications

V2JE™

• Operating Temp -20C to +70C

• DC Input range, 8.0Vdc to 30.0Vdc

GPS Receiver

• WAAS Capable

• Very high sensitivity receiver

• Rapid acquisition of satellites

• GPS signal acquisition, tracking and navigation

• On board GPS data storage

GSM/GPRS Transceiver

• Quad Band 850/1900 900/1800

Approved Antennas

• San Jose SM-19 - GPS

• MiniWing GSM 850/1900

• SPK Electronics Co. GSM 850/1900

Important Notice

It is the Owner's sole responsibility to install and use the Zonar

products in a manner that will not cause accidents, personal injury

or property damage. For the purposes of this notice, "Owner",

"you" and "your" means the party (including any person authorized

by that party to use and/or install the Product) that has either: (a)

purchased the Product; or (b) leased the Product from Zonar

Systems, Inc or its related companies. The Owner of this product

is solely responsible for observing safe driving practices. The

choice, location, and installation of all components of the Product

is critical. If installation is not correct, the Product may not perform

at its designed potential or specifications. If in doubt, consult your

vehicle's manufacturer.

SYSTEM SPECIFICATIONS

V2JE Troubleshooting

Issue Possible Cause Remedy Notes

GSM, GPS, and Status LED Normal condition Normal condition

solid with engine running

No LED lights Non-issue, unit may be Start engine and ensure

sleeping LEDs illuminate

Vehicle Master Kill switch/ Switch Master Kill switch to

battery disconnected switch “Live” to supply power

set to “Kill” (if equipped) to vehicle

Vehicles electrical system Check for dead battery,

malfunction loose or corroded terminals,

bad crimps or solder joints, etc.

Blown or missing fuse in Replace fuse.

Jbus cable

Vehicle uses Multiplex Rewire unit, outside of

wiring system and has put Multiplex wiring circuit

circuit to sleep

Vehicles Jbus port Check voltages at Jbus

miswired system does not connector or constant lead

always supply constant terminal. Contact Zonar for a

power (direct connect Jbus document on the vehicles

cable) or constant power Jbus electrical values

lead (Backbone style Jbus

cable) is not connected to

a constant power supply

Equipment or cable Test with known good

malfunction vehicle, equipment, or cable

All LEDs go out when Jbus port miswired (direct Check voltages at Jbus

the engine is turned off connect Jbus cable) or connector or constant lead

constant power lead terminal

(backbone style Jbus

cable) is not connected to a

constant power supply

GSM/Cellular LED Non-issue, unit is After turning engine on, give

blinking with engine connecting to cellular the unit up to 3 minutes to

running tower connector to cellular tower

Poor cellular coverage Move vehicle to an area with

area, local cell tower not good cellular coverage

operating correctly

Cellular (stubby) antenna Tighten cellular antenna Do not over-torque -

loose or disconnected damage may result

SIM not activated Call Zonar with GPS serial

number and ask to check

for SIM activation

V2JE TROUBLESHOOTING

V2JE Troubleshooting Continued

Issue Possible Cause Remedy Notes

GPS LED blinking with Non-issue, unit is After turning engine on, give If the GPS LED does not

engine running gathering satellite the unit up to 3 minutes to get a solid LED with

information obtain satellite information engine running, GSM

and Status LED will not

behave correctly

Vehicle is located indoors, Move vehicle to an area

under structures, or under where the GPS antenna will

heavy brush have a clear view of the sky

GPS antenna was not Remount GPS antenna

with a clear view of the provide it a clear view to the

open sky open sky

GPS antenna mis-match V2J units have an internal Never connect an

GPS antenna, and are external GPS antenna

typically mounted on the to a V2J. Conversely,

dashboard with a clear view ensure an external GPS

of the sky. V2JE units use antenna with a clear

external GPS antennas that view to the sky is used

are mounted on the vehicles with V2JE models

roof with a clear view of the sky

Status LED - blinking or V2J is not detecting engine Call Zonar

off - engine running RPM from ECM

Status LED - Solid - Equipment or cable Call Zonar

malfunction

AUX/Alert LED solid or Internal issue Call Zonar for a Also see “All LEDs

blinking 3 minutes after replacement unit flashing”

engine start

DL1 and/or DL2 are not Jbus cable not properly Check Jbus cable The DL1 and/or the

blinking green with connected or faulty connections. Replace with DL2 must blink green

engine running known good cable with the engine running

for the system to work

correctly

Vehicles Jbus port Verify pinout and electrical

mis-wired or faulty values from manufacturers

specifications

All LEDs flashing The unit may be booting, For a normal boot, give the

or receiving a Firmware unit up to 3 minutes to

update establish solid LEDs for

GSM, GPS, and Status. For a

Firmware update, give the

unit up to 25 minutes to

receive and install the

Firmware

V2JE TROUBLESHOOTING

Troubleshooting

Issue Possible Cause Remedy Notes

Status LED - Blinking or V2J is not detecting engine Check white lead (Switched

off - engine running RPM from ECM Power). It must have 8-

Call Zonar

Status LED - Solid - Switched power is When engine off White- Be sure to check engine

Engine off connected to an incorrect Switched power lead must off, key position ACC.

power source have 0 volts White-Switched power

lead must read 0 VDC

in this state

AUX/Alert LED solid or Internal issue Contact Zonar for a

blinking 3 minutes after replacement unit

engine start

All LEDs flashing The unit may be booting, For normal boot, give the

or receiving a Firmware unit up to 3 minutes to

update establish solid LEDs for GSM,

GPS, and Status. For a

Firmware update, give the

unit up to 25 minutes to

receive and install the

Firmware

DL1 (Jbus 1708) and/or This is normal with the None Normal Operation

DL2 (Jbus 1939) are engine running. Blinking

blinking Green at 1X per Green indicates that Jbus

second data is available from the

ECM. The DL1 and/or the

DL2 must blink green with

the engine running for the

system to work correctly

DL1 (Jbus 1708) are DL2 Engine not running Start Engine

(Jbus 1939) are both off

(Other LEDs appear to be

functioning normally)

Jbus Cable not connected Connect Jbus Cable

Jbus Cable faulty Test with known good cable

Vehicles Jbus connector Verify pinout and electrical

miswired values from manufactures

specifications

DL1 (Jbus 1708) and/or Normal Boot Sequence None Normal Operation

DL2 (Jbus 1939) are Red at

1X per second

TROUBLESHOOTING

TRUCK WINDSHIELD

CONFIGURATIONS

Mack

Model Year Vertical Distance from left Distance from right Wiring Harness Comments

Angle

Pinnacle (highway) (single pane)

Titan (heavy haul) (split windshield)

Granite (construction) (split windshield)

CH (split windshield)

Freightliner

Model Year Vertical Distance from left Distance from right Wiring Harness Comments

Angle

Century 2007 70deg 2" from center 32" 1998-2003 80130

2004-current 80183

Coronado 70deg 2" from center 32" 2001-current 80183

Columbia 70deg 2" from center 32" 2001-2003 80130

2004-current 80183

FL series 1999 77deg 42" 28" 1996-2002 80130

2003-current 80183

Legacy 1999 75deg 41" 29"

Classic 2000 77deg 2" from center 29" windshield angled

4 deg to right

Cascadia

Peterbilt

Model Year Vertical Distance from left Distance from right Wiring Harness Comments

Angle

330 2007-2011 80183

335 2007-2009 80441 & 80339

340 2007-2009 80183

365 2008-2009 80441 & 80339

367 2008-2009 80441 & 80339

378, 379 2003 66deg 27" or tight against 2007-2009 80441 & 80339 windshield angled

center 14 deg to right

375, 357, 2007-current 80441 & 80339

377, 385

384 2009-2010 80441 & 80339

386 2007-current 80441 & 80082

387 2007-2009 80441 & 80339

388 2008-2009 80441 & 80082

389 2007-2009 80441 & 80339

587

Info To Come

TRUCK WINDSHIELD

CONFIGURATIONS

Kenworth

Model Year Vertical Distance from left Distance from right Wiring Harness Comments

Angle

T600 1999 71deg 31" 27" 2006-current

80441 & 80339

T800 1997-2005 80444

split wrap- 2007 68deg Tight against center 18" 2006-current

around 80441 & 80339

T800 1997-2005 80444 windshield

split flat 2000 68deg tight against center 18" 2006-current 80441 is angled

& 80339 7 deg to starboard

T800 1997-2005 80444

One Piece 2009 66deg measure from right 13" 2006-current 80441 & 80339

T2000 1999 62deg 42" 32"

W900 1997-2005 80444

2006-current 80441 & 80339

International

Model Year Vertical Distance from left Distance from right Wiring Harness Comments

Angle

4700 1999 72deg 37" 29" 1995-1998 80130

1999-2009 80183

4300 2004 64eg 47” 26” 1995-1998 80130

1999-2009 80183

8600 2007 66deg 44" 30" 1995-1998 80130

1999-2009 80183

9000 1992 85deg 36" 31" or tight against 1995-1998 80130 windshield angled

split flat center 1999-2009 80183 7 deg to right

9400 2006 69deg 41" 33" 1995-1998 80130

1999-200980183

ProStar 2011 65deg 45" 27" 2007-current 80183

LoneStar 2009- 2009-2011 80183

2011 should be similar to ProStar

Sterling

Model Year Vertical Distance from left Distance from right Wiring Harness Comments

Angle

Class 8 2002 63deg 41" 27"

Volvo

Model Year Vertical Distance from left Distance from right Wiring Harness Comments

Angle

VNL670, 2006 72deg 43" 31" 2000-current 80441

VHD, VT & 800282

1) Only used during checkout “Status” LED does not illuminate

solid green when engine is running

2) Follow all General Guidelines as specified on page 6.

3) All power leads must be connected to the vehicles protected

circuitry (e.g. fuse panel, circuit breaker panel, protected

circuits). Never electrically connect Zonar equipment to

unprotected circuits. (e.g. directly to battery)

4) It is also required that all power leads (Red and White leads)

be protected with a 3 to 5 amp fuse and inline fuse holder

(included) for optimal system protection.

5) Electrical fuses should be installed as close as possible to the

source of power

5) Power Bundle wiring – 4 Pin, 3 wires

A) Red – Constant DC (+8 VDC - +30 VDC), dependent

on system type)

B) Black – Ground must be less than 1 ohm (measure from

4 Pin connector to chassis attachment point)

C) White - Switched Power

The White wire must be connected to a power source

that is active only when the engine is running or the

system will not track idle time properly

1) Engine running (+8 VDC to +30 VDC)

2) Engine NOT running (0 VDC)

3) Engine not running (key position ACC or Accessory

Mode (0 VDC)

Please contact the vehicle manufacturer for any specific

electrical questions

GPS 4 Pin Power Cable

Connect White/Red

Wires to Protected

Fused Terminal

Caution

Connect White/Red

Wires to Protected

Fused Terminal

Caution

NON-TYPICAL

SYSTEM INSTALLATION

Note: Do not follow the instructions on this page unless

so instructed by a Zonar representative

Limited Warranty

LIMITED WARRANTY: Zonar® warrants that the Hardware provided

under Zonar’s Subscription Agreement is free from material defects

in workmanship for a period of one year for hardware purchased

by customer. THIS LIMITED WARRANTY IS MADE TO CUSTOMER

ONLY AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS

OR IMPLIED. Zonar EXPRESSLY DISCLAIMS ANY IMPLIED

WARRANTY OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, AND ANY WHICH MAY ARISE FROM

COURSE OF PERFORMANCE, COURSE OF DEALING OR USAGE

OF TRADE

CUSTOMER’S SOLE AND EXCLUSIVE REMEDY AND ZONAR’S

ENTIRE OBLIGATION UNDER THESE LIMITED WARRANTIES for

defective equipment is the repair and replacement of the equipment

free of charge by Zonar. Zonar shall not be liable to Customer or

any third party for any general, special, punitive, incidental, indirect

or consequential damages, or any lost profits or business, arising

out of Zonar’s Subscription Agreement.

FCC Compliance Statement (Part 15.19)

This device complies with Part 15 of the FCC Rules and with RSS-

210 of Industry Canada (IC). Operation is subject to the following

two conditions:

1. This device may not cause harmful interference, and

2. This device must accept any interference received, including

interference that may cause undesired operation.

Warning: (Part 15.21)

Changes or modifications not expressly approved by Zonar Systems

could void the user's authority to operate the equipment.

Caution: RF Exposure (OET Bulletin 65)

To comply with FCC RF exposure requirements for mobile

transmitting devices, the antenna(s) used for this transmitter must

be installed to provide a separation distance of at least 20cm (8

Inches) from all persons and must not be co-located or operating

in conjunction with any other antenna or transmitter. Users and

installers must be provided with antenna installation instructions

and transmitter operating conditions for satisfying RF exposure

compliance.

Use only supplied and approved antenna's. Use of unauthorized

antenna's or modifications could impair signal quality, void your

warranty and/or result in violation of FCC regulations.

Industry Canada Compliance Statements

"This device has been designed to operate with an antenna having

a maximum gain of [5] dB. Antenna having a higher gain is strictly

prohibited per regulations of Industry Canada. The required antenna

impedance is [50] ohms."

"To reduce potential radio interference to other users, the antenna

type and its gain should be so chosen that the equivalent is

isotropically radiated power (EIRP) is not more than that required

for successful communication."

"The installer of this radio equipment must ensure that the antenna

is located or pointed such that it does not emit RF field in excess

of Health Canada limits for the general population; consult Safety

Code 6, obtainable from Health Canada's website, www.hc-

sc.gc.ca/rpb"

WARRANTY & NOTICES

FCC/IC COMPLIANCE

REV: 09/15/11

NOTES

Zonar Systems 80510 80510 User Manual

Zonar Systems Inc 80510

User Manual

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