REV: 09/15/11
WOKFLOW 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.
INTRODUCTION Z-Con • V2JE™/TRUCK SIDE BOARD Introduction ................................................................................................2 System Overview........................................................................................4 V2JE/Truck Board Hardware ......................................................................5 Basic Workflow...........................................................................................6 General Guidelines ...........................
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 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).
GENERAL GUIDLINES Layout Drill Holes 1) 1) 2) 3) 4) 5) 6) 7) Cellular/GSM antennas must be located a minimum of 8” from any person. Mount all equipment in the interior of the vehicle. External mounted GPS antenna is the only component installed externally. Do not install Zonar equipment below windows and doors which open to the vehicles exterior to prevent water damage. Lay all components out prior to installation to check for proper cable length and interference issues.
V2JE/TRUCKBOARD HARDWARE 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.
SYSTEM INSTALLATION ZonarV2J GSM Stubby Antenna Part#: 10019 Part#: 10017 External GPS Antenna Part#: 10006 Cable Length: 16.5 ft. 1. 2. 3. 4. 5. 6. External GPS antenna 4 Pin Power Input Z-Con™ Truck Board 8 Pin 2010 Vehicle Mount (Optional) 12 Pin Discrete Truckboard I/O (Optional) 10 Pin J3 input (JBus 1708/1939 Equipped Vehicles) Truckboard Part#: 80510 Cable Length:13ft ft.
V2JE MOUNTING PLATE CAUTION: The mini-GSM antenna is factory torqued, do not rotate antenna!! V2JE Mounting Plate & Unit 1) 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.
SAMPLE CABLES See Page 21-22 for Vehicle Specific Requirements PIN 80441 - V2J WW J1939 TO RETRO ADAPTER 9.33’ PIN 80444 - V2J WW J1708 2-PIN DELPHI PIN 80339 - J1939 - 15 UNIVERSAL NODER AMP ss 16.65’ 10.75’ PIN 80183 - WW 9-PIN PASS THRU WITH PIGTAIL FLANGED PANEL MOIUNT 9.8’ PIN 80130 - WW 6-PIN PASS THRU WITH PIGTAIL FLANGED PANEL MOUNT 9.
WIRING GUIDELINES 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 Adda-Circuit or poke and weave.
ANTENNA INSTALLATION External GPS Antenna 1) 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.
INSTALLATION EXAMPLE Truck Board Bracket and Truck Board Installation 1) 2) 3) 4) 5) Follow all general guidelines as specified on page 6. Locate proper mounting location. See vehicle specific information table on pages 21-22. 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). Remove the backing from the peel-and-stick (see Fig. 13-1 or 13-2).
SYSTEM CHECKLIST Customer: Yard: Date: Installer: Location: GPS ID: Vehicle Odometer Value: Asset #: Vehicle I.D. (e.g.
GPS SYSTEM CHECK System Check: Minimum Requirements - GPS 1) 2) 3) 4) Note: A proper and complete system/LED functional check requires the engine to be running At a minimum, the installer must perform a “System Check” to verify proper installation. 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.
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. COM port can be selected in the app's dropdown.
SYSTEM SPECIFICATIONS Important Notice System Specifications 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.
V2JE TROUBLESHOOTING V2JE Troubleshooting Issue Possible Cause Remedy GSM, GPS, and Status LED Normal condition solid with engine running Normal condition No LED lights Start engine and ensure LEDs illuminate Non-issue, unit may be sleeping Notes 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 malfunction Check for dead battery, loose or corroded terminals, bad crimps o
V2JE TROUBLESHOOTING V2JE Troubleshooting Continued Issue GPS LED blinking with engine running Possible Cause Remedy Notes Non-issue, unit is gathering satellite information After turning engine on, give the unit up to 3 minutes to obtain satellite information Vehicle is located indoors, under structures, or under heavy brush Move vehicle to an area where the GPS antenna will have a clear view of the sky GPS antenna was not with a clear view of the open sky Remount GPS antenna provide it a clear v
TROUBLESHOOTING Troubleshooting Issue Possible Cause Remedy Status LED - Blinking or off - engine running V2J is not detecting engine RPM from ECM Check white lead (Switched Power).
TRUCK WINDSHIELD CONFIGURATIONS Mack Model Year Vertical Angle Distance from left Pinnacle (highway) (single pane) Titan (heavy haul) (split windshield) Granite (construction) (split windshield) CH (split windshield) Distance from right Wiring Harness Comments Info To Come Freightliner Model Year Vertical Angle Distance from left Distance from right Wiring Harness Century 2007 70deg 2" from center 32" 1998-2003 80130 2004-current 80183 Coronado 70deg 2" from center 32" 2001-current 8
TRUCK WINDSHIELD CONFIGURATIONS Kenworth Model Year Vertical Angle Distance from left Distance from right Wiring Harness T600 1999 71deg 31" 27" T800 split wrap- 2007 around 68deg Tight against center 18" 1997-2005 80444 2006-current 80441 & 80339 2000 68deg tight against center 18" 1997-2005 80444 2006-current 80441 & 80339 T800 One Piece 2009 66deg measure from right 13" T2000 62deg 42" 32" T800 split flat 1999 W900 Comments 2006-current 80441 & 80339 windshield is angled
NON-TYPICAL SYSTEM INSTALLATION GPS 4 Pin Power Cable Note: Do not follow the instructions on this page unless so instructed by a Zonar representative Connect White/ Wires to Pro Red Fused Termintected al Connect White/Red Wires to Protected Fused Terminal Caution Caution 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.
WARRANTY & NOTICES FCC/IC COMPLIANCE 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.
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