Gasboy Fuel Point PLUS Vehicle User Manual

MDE-486

8F

Fuel Point PLUS

Vehicle Installation and Configuration Manual

This document is based on Orpak’s FuelOmat Gold Vehicle Installation
and Configuration Manual P/N 817407300

SAFETY CONSIDERATIONS

Read all warning notes and instructions carefully. They are included to help you installing the Product safely
in the highly flammable environment of the fuel station. Disregarding these warning notes and instructions
could result in serious injury or property damage. It is the installer responsibility to install, operate and
maintain the equipment according to the instructions given in this manual, and to conform to all applicable
codes, regulations and safety measures. Failure to do so could void all warranties associated with this
equipment.

Remember that the fuel station environment is highly flammable and combustible. Therefore, make sure
that actual installati
a flammable environment, according to the local regulations and relevant standards.

on is performed by experienced personnel, licensed to perform work in fuel station and at

WARNING - EXPLOSION HAZARD

Read all warning notes and instructions carefully. They are included to help you installing the Fuel
Ring equipment safely in the highly flammable environment of the vehicle fuel tank. Disregarding
these warning notes and instructions could result in serious injury or property damage. It is the
installer responsibility to install, operate and maintain the equipment according to the instructions
given in this manual, and to conform to all applicable codes, regulations and safety measures.
Failure to do so could void all warranties associated with thi

s equipment.

Remember that the fuel vehicle fuel tank is highly flammable and combustible. Therefore, make
sure that actual installation is performed by experienced personnel, licensed to perform work in
fuel stations, cars and highly flammable environments.

When working on fuel tank inlet, make sure it is completely empty and closed.

The fumes are volatile and hence harmful to your health, if breathed for an extended period.

WARNING – PASSING VEHICLES

When working in any open area of vehicle fuel tank, beware of passing vehicles that could hit you.
Block off the work area to protect yourself and other persons. Use safety cones or other signaling
devices.

WARNING

Components substitutions could impair intrinsic safety.
Attaching unauthorized components or equipment will void your warranties.

CAUTION

Do not attempt to make any repair on the printed circuit boards residing in the Product, as this will
void all warranties related to this equipment.

WARNING

When using the glue, carefully use and apply the glue over the surfaces in order to prevent any glue
leakage on the vehicle, to avoid any damage to the vehicle.

PROPRIETY NOTICE

This document contains propriety and confidential information. It is the property of ORPAK
SYSTEMS Ltd. It may not be disclosed or reproduced in whole or in part without written consent
of ORPAK SYSTEMS. The information in this document is current as of the date of its
publication, but is subject to change without notice.

DISCLAIMER

This document is provided for reference only. Although every effort has been made to ensure
correctness, ORPAK SYSTEMS does not guarantee that there are no errors or omissions in this
document.

FCC Compliance Statement

The FCC Wants You to Know:
This equ
device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable
protection against harmful interference in a residential installation. This equipment generates uses
and can radiate radio frequency energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communications. However, there is no
guarantee that interference will not occur in a particular installation. If this equipment does cause
harmful interference
equipment off and on, the user is encouraged to try to correct the interference by one or more of
the following
a) Reorient or relocate the receiving antenna.
b) Increase the separation between the equipment and receiver.
c) Connect the equipment to an outlet on a circuit different from that to which the receiver is
connected.
d) Consult the dealer or an experienced radio/TV technician.

Modifications not expressly approved by the manufacturer could void the user authority to operate
the equipment under FCC Rules.

ipment has been tested and found to comply with the limits for a Class B & C digital

to radi

measures :

o or television reception, which can be determined by turning the

FCC Warning

Fuel Ring programming must be done prior to its
installation on the fuel inlet, since the WP (Wireless
Programmer) is not designed for explosive
environments.

WARNING

Wireless Nozzle Reader programming must be done
in a safe area, since the WNRP (Wireless Nozzle
Reader Programmer) is not designed to be use in the
Hazardous Locations.

ATEX Intrinsic Safety Certification

Wireless Nozzle Readers Type (WNR-2 as well) 1, 2 & 3 p/n 800939055, 800939056 & 800939057 have been
issued with an EC-Type Examination Certificate ISSeP09ATEXnnn. This confirms compliance with the

European ATEX Directive 94/9/EC for Group II, Category 1G, II 1 G Ex ia IIB T4 Ga

This image c annot current ly be displayed.

ATEX Intrinsic Safety Certification

Wireless Nozzle Readers Type (WNR-2 as well) 1, 2 & 3 p/n 800939055, 800939056 & 800939057 have been
issued with an EC-Type Examination Certificate ISSeP09ATEXnnn. This confirms compliance with the

European ATEX Directive 94/9/EC for Group II, Category 1G, II 1 G Ex ia IIB T4 Ga

Used Standards:

WARNING

- IEC 60079-0 : General requirements,

- IEC 60079-11 : Equipment protection by intrinsic safety 'i' ,

- IEC 60079-26 : Equipment with equipment protection level (EPL) Ga,

This document is the property of:

ORPAK SYSTEMS Ltd.

ISRAEL

Fuel Point PLUS Vehicle Installation and Configuration Manual

V

TABLE OF CONTENTS

Paragraph

SECTION 1

INTRODUCTION

Page

1-1. SCOPE ................................................................................................................................ 13

1-2. FUEL POINT PLUS SYSTEM DESCRIPTION ............................................................... 13

1-3. MANUAL STRUCTURE .................................................................................................. 14

1-4. USING THIS MANUAL.................................................................................................... 14

1-5. REFERENCES ................................................................................................................... 15

SECTION 2 FUEL RING DESCRIPTION &

INSTALLATION

2-1. OVERVIEW ....................................................................................................................... 16

2-1.1. Fuel Ring Main Components ......................................................................................... 16

2-2. TYPICAL INSTALLATION KITS ................................................................................... 17

2-3. FUEL RING COILS ........................................................................................................... 19

2-3.1. Shaped Coil .................................................................................................................... 19

2-3.2. Self Installed Coil .......................................................................................................... 20

2-3.3. Molded Coil ................................................................................................................... 21

2-4. VEHICLE SURVEY .......................................................................................................... 22

2-5. LIGHT VEHICLES INSTALLATION .............................................................................. 23

2-5.1. General ........................................................................................................................... 23

2-5.2. Preliminary Instructions ................................................................................................. 23

2-5.3. Required Tools ............................................................................................................... 24

2-5.4. Installation Procedure .................................................................................................... 24

2-5.4.1. Installing the ID Chip inside the Trunk..................................................................... 28

2-6. HEAVY DUTY VEHICLES INSTALLATION ................................................................ 30

2-6.1. General ........................................................................................................................... 30

2-6.2. Preliminary Instructions ................................................................................................. 30

2-6.3. Required T

ools ............................................................................................................... 31

2-6.4. Coil Installation.............................................................................................................. 31

2-6.4.1. Long Neck Fuel Inlet Installation Procedure ............................................................ 31

2-6.4.2. Short Neck Fuel Inlet Installation ............................................................................. 33

2-6.4.3. Self Installation ......................................................................................................... 35

2-6.5. Chip Installation ............................................................................................................. 35

2-6.5.1. Installing the Chip with a Security Cover ................................................................. 35

2-6.5.2. Installing the Chip without Security Cover ............................................................... 37

SECTION 3 DATAPASS & µDATAPASS DESCRIPTION

&

Fuel Point PLUS Vehicle Installation and Configuration Manual

VI

Paragraph Page

TABLE OF

INSTALLATION

CONTENTS

3-1. OVERVIEW ....................................................................................................................... 38

3-1.1. Vehicle Data Provided ................................................................................................... 38

3-1.2. Availability of Vehicle Data according to Vehicle Interface Type................................ 39

3-2. DATAPASS DESCRIPTION ............................................................................................. 40

3-2.1. Technical Specifications ................................................................................................ 42

3-2.2. DataPass Pinout.............................................................................................................. 43

3-3. µDATAPASS DESCRIPTION........................................................................................... 44

3-3.1. Technical Specifications ................................................................................................ 45

3-3.2. µDataPass Pinout ........................................................................................................... 47

3-4. TOOLS REQUIRED FOR INSTALLATION.................................................................... 47

3-5. LIGHT VEHICLES INSTALLATION .............................................................................. 47

3-5.1. Checking Vehicle Protocol............................................................................................. 47

3-5.2. Installing the μDataPass ................................................................................................. 48

3-5.3. Installing the DataPass ................................................................................................... 49

3-5.3.1. Adaptor Plug.............................................................................................................. 52

3-5.3.2. Installing a Pulse Divider Device .............................................................................. 53

3-6. HEAVY VEHICLES INSTALLATION ............................................................................ 56

3-6.1. General ........................................................................................................................... 56

3-6.2. Connecting the DataPass to Odometer Pulses Source ................................................... 56

3-6.3. Connecting the DataPass to the Vehicle Bus ................................................................. 60

SECTION 4 PROGRAMMING VEHICLE

UNITS

4-1. GENERAL .......................................................................................................................... 63

4-2. WIRELESS PROGRAMMER............................................................................................ 63

4-2.1. WP Specifications .......................................................................................................... 64

4-2.2. Battery Saving and Battery Chargers ............................................................................. 66

4-3. WIRELESS PROGRAMMER REGISTRATION AND CONFIGURATION .................. 67

4-3.1. FHO Installation ............................................................................................................. 67

4-3.2. WP Tunnel Installation................................................................................................... 67

4-3.3. Establishing WP - HO Communication ......................................................................... 70

4-3.4. Updating Vehicle List .................................................................................................... 73

4-3.5. Local Download ............................................................................................................. 76

4-3.6. Show Files ...................................................................................................................... 78

4-3.7. Update DP SW ............................................................................................................... 80

4-4. WP FUNCTIONAL PRINCIPLES..................................................................................... 82

4-4.1. Main Function Keys ....................................................................................................... 82

4-4.2. Common Actions............................................................................................................ 83

4-4.3. Common Parameters ...................................................................................................... 83

Fuel Point PLUS Vehicle Installation and Configuration Manual

VII

Paragraph Page

TABLE OF

CONTENTS

4-5. FR AND DP PROGRAMMING SEQUENCE FOR HEAVY VEHICLES ...................... 86

4-5.1. Setting DP-Heavy Vehicle Interface Communication Parameters ................................ 98

4-6. FR AND DP PROGRAMMING SEQUENCE FOR LIGHT VEHICLES ........................ 99

4-7. FR AND µDP PROGRAMMING SEQUENCE ................................................................ 105

4-8. PROGRAMMING DP ONLY............................................................................................ 110

4-9. ADDING FP TO DP ONLY............................................................................................... 113

4-10. REPLACING DP ................................................................................................................ 115

4-11. ADD DP TO FP .................................................................................................................. 117

4-12. CLEARING DIAGNOSTIC TROUBLE CODES (DTCS) ............................................... 119

4-12.1. General ........................................................................................................................... 119

4-12.2. Operating Instructions.................................................................................................... 120

SECTION 5

TROUBLESHOOTING

5-1. GENERAL.......................................................................................................................... 122

SECTION 6

APPENDIX A FINDING DP CALIBRATION FACTORS FOR NEW

VEHICLE

GLOSSARY

MODELS

OBD-II

A-1. GENERAL.......................................................................................................................... 126

A-2. DP CALIBRATION PROCEDURE .................................................................................. 126

Fuel Point PLUS Vehicle Installation and Configuration Manual

VIII

LIST OF ILLUSTRATIONS

Figure

Page

Figure 1-1. Fuel Point PLUS System Architecture 14
Figure 2-1. Fuel Ring Components 16
Figure 2-2. Light Vehicle Typical Installation Kit Components 18
Figure 2-3. Heavy Vehicle Kit Description 19
Figure 2-4. Fuel Ring Shaped Coil 20
Figure 2-5. Fuel Ring Self Installed Coil 21
Figure 2-6. Fuel Ring Molded Coil 22
Figure 2-7. Typical Installation Approved Location 24
Figure 2-8. ID Chip Preferred Position 25
Figure 2-9. Inserting One-Way Screw 26
Figure 2-10. Applying Adhesive 26
Figure 2-11. Securing the Clamps 27
Figure 2-12. Securing the ID Chip 28
Figure 2-13. Drillin

g the Trunk 28
Figure 2-14. Securing the ID Chip 29
Figure 2-15. CV Joint Banding Tool and Cutter 31
Figure 2-16. Positioning the Clamps 32
Figure 2-17. Tightening the Clamps 33
Figure 2-18. Complete Coil Installation on Long Neck Inlet 33
Figure 2-19. Securing Clamps on Short Neck Inlet 34
Figure 2-20. Complete Coil Installation on Short Neck Inlet 35
Figure 2-21. Complete Coil Self – Installation 35
Figure 2-22. ID Chip Installed in a Security Cover 36
Figure 2-23. Attaching the Security Cover to a Bar 36
Figure 2-24. Tightening Security Cover 37
Figure 3-1. DataPass f

or Light Vehicles (OBD-II) 41
Figure 3-2. DataPass (J1708/FMS) for Heavy Vehicles 41
Figure 3-3. DataPass Harness 42
Figure 3-4. µDataPass for CAN Bus 45
Figure 3-5. µDataPass for K-Line Bus 45
Figure 3-6. VCM Unit 48
Figure 3-7. Diagnostics Connector 48
Figure 3-8. Pluging the μDataPass 49
Figure 3-9. Tightening the μDataPass 49
Figure 3-10.OBDII Connector Wiring to DataPass Harness 50
Figure 3-11. OBDII Connector Pins Layout 50

Fuel Point PLUS Vehicle Installation and Configuration Manual

IX

LIST OF

Figure Page

Figure 3-12. Removing the Diagnostics Connector Panel 51
Figure 3-13. Soldering DataPass Harness to Diagnostics Connector Wires 51
Figure 3-14. Wrapping Connections in Insulating Tape 51
Figure 3-15. Covering Unconnected Wires with Insulating Tape 52
Figure 3-16. Fastening the DataPass Unit 52
Figure 3-17. Connecting the Adapter Plug 53
Figure 3-18. Connecting the DataPass to the Adaptor Plug 53
Figure 3-19. Pulse Divider 54
Figure 3-20. Tachograph Extraction Slots 57
Figure 3-21. Removing the Tachograph 57
Figure 3-22. Tachograph Wiring 58
Figure 3-23. Connecting DataPass Harness to Tachograph Wiring 58
Figure 3-24. Wrapping Connections in Insulating Tape 58
Figure 3-25. Covering the Harness with Insulating Tape 59
Figure 3-26. Connecting the DataPass 59
Figure 3-27. Fastening DataPass and Harness 60
Figure 3-28. Typical Bus Connector 60
Figure 3-29. J1708 (J1587) 6P Harness – DataPass Connection 61
Figure 3-30. J1708 (J1587) 9P Harness – DataPass Connection 61
Figure 3-31. J1939 Harness – DataPass Connection 61
Figure 4-1. Home Base Solution Wireless Programmer 64
Figure 4-2. WP Battery Chargers 66
Figure 4-3. Administration Setup Screen – General Tab 67
Figure 4-4. WP Tunnel Setup Wizard Welcome Screen 68
Figure 4-5. WP Tunnel Setup Wizard License Agreement Screen 68
Figure 4-6. WP Tunnel Setup Wizard Choose Install Location Screen 69
Figure 4-7. WP Tunnel Setup Wizard Connection Settings Screen 69
Figure 4-8. WP Tunnel Setup Wizard Installation Complete Screen 70
Figure 4-9. Admin Screen – Registration Tab 71
Figure 4-10. WP Tunnel Main Screen 71
Figure 4-11. Approving WP Registration 73
Figure 4-12. WP Tunnel – Vehicle List Update 74
Figure 4-13. WP Tunnel – Vehicle List Update 76
Figure 4-14. U581 OBD-II Memo Scanner 119
Figure 4-15. Memo Scanner Start Up Screen 120
Figure 4-16. Detecting Vehicle's Protocol 120

ILLUSTRATIONS

Fuel Point PLUS Vehicle Installation and Configuration Manual

X

LIST OF

Figure Page

Figure 4-17. Vehicle Diagnosis Menu 121
Figure 4-18. Trouble Codes Screen 121
Figure 4-19. Erasure Confirmation Message 121

ILLUSTRATIONS

Fuel Point PLUS Vehicle Installation and Configuration Manual

XI

LIST OF

TABLES

Table

Page

Table 2-1. Light Vehicle - Kit Description 17
Table 2-2. Heavy Vehicle - Kit Description 17
Table 2-3. Shaped Fuel Rings 19
Table 2-4. Self-Installed Fuel Rings 20
Table 2-5. Molded Fuel Ring 21
Table 2-6. Vehicle Survey – Example 22
Table 2-7. Common Bus Connectors 23
Table 3-1. DP Types 38
Table 3-2. DataPass Plus Vehicle Parameters 39
Table 3-3. Availability of Vehicle Data according to DataPass and Interface Type 39
Table 3-4. DataPass Specifications 42
Table 3-5. DataPass Pinout 43
Table 3-6. μDataPass Specifications 45
Table 3-7. µDataPass Pinout 47
Table 3-8. Harness O

BDII Connections 50
Table 3-9. Pulse Divider Connections 54
Table 3-10. Pulse Divider Pinout 55
Table 3-11. Tachograph – DataPass Harness Connections 56
Table 3-12. Pulse Output Pin in Various Types of Tachographs 56
Table 3-13. BUS Connector Typical Pin Out Description 61
Table 4-1. Wireless Programmer Specifications 65
Table 4-2. WP Upgrade Sequence 72
Table 4-3. Vehicle List Update Sequence 75
Table 4-4. Local Download Sequence 77
Table 4-5. Show Files Address Sequence 78
Table 4-6. Update DP Software Sequence 80
Table 4-5. Wireless Programmer Main Function Keys and Shortcuts 82
Table 4-6. Wirel

ess Programmer Common Actions 83
Table 4-7. Common Parameters 83
Table 4-10. FR and DP Heavy Programming Sequence 86
Table 4-11. DP Heavy Programming Sequence – Pulses Interface 95
Table 4-10. DP – Heavy Vehicle Interfaces Communication Parameters Values 98
Table 4-11. FR and DP Light Programming Sequence 99
Table 4-12. DP Light Programming Sequence – Pulses Interface 103
Table 4-13. FR and μDP Programming Sequence 105
Table 4-16. Program DP Only Sequence 110

Fuel Point PLUS Vehicle Installation and Configuration Manual

X

LIST OF

Table Page

Table 4-17. Add FP to DP Sequence 113
Table 4-18. Replace DP Sequence 115
Table 4-19. Add DP to FP Sequence 117
Table 4-14. U581 OBD-II Memo Scanner Controls and Main Components 119
Table 5-1. Troubleshooting Guide 122
Table A-1. DP Parameters Viewing and Editing Sequence 128
Table A-2. DP Calibration Sequence 130

TABLES

Fuel Point PLUS Vehicle Installation and Configuration Manual

13

SECTION 1

INTRODUCTION

1-1. SCOPE

This manual is provided to assist the user in installing the Fuel Point PLUS vehicle units: Fuel Ring
and DataPass. The vehicle units must be installed as described in this manual to ensure the system
reliability and proper operation. This manual includes a general and functional description of the
vehicle units, their main components and installation requirements. The manual is intended for
qualified authorized installers and technicians of Fuel Point PLUS vehicle units and their
components.

1-2. FUEL POINT PLUS SYSTEM DESCRIPTION

Gasboy's Fuel Point PLUS is an automated system utilized to identify vehicles refueling in gas
stations that utilizes wireless technology for transferring vehicle data. The Wireless Nozzle Reader
(WNR), a self contained unit installed on the fueling nozzle, reads the Fuel Ring using contactless
technology and transmits the encrypted data to the nearest WGT using short range, spread spectrum
wireless communication. The WGT receives both DataPass and Fuel Ring vehicle data, decrypts the
information and transmits it to the station automation system. For further information on the Fuel
Point PLUS station-side equipment, please refer to Station Installation and Setup Manual for New
Deployments, P/N MDE-4851.

Figure 1-1 shows a basic diagram of Gasboy's Fuel Point PLUS architecture.

Fuel Point PLUS Vehicle Installation and Configuration Manual

14

Figure 1-1. Fuel Point PLUS System Architecture

1-3. MANUAL STRUCTURE

This manual comprises the following sections:

Section 1: Introduction

This section provides a general description of the Fuel Point PLUS system in general.

Section 2: Fuel Ring Description and Installation

This section provides a detailed of the Fuel Ring units and comprehensive installation instructions
for light/heavy vehicles.

Section 3: DataPass & µDataPass Description and Installation

This section provides a detailed of the DataPass & µDataPass units and comprehensive installation
instructions for light/heavy vehicles.

Section 4: Programming Vehicle Units

This section provides instructions on the programming sequence of the vehicle units installed in
private and heavy duty vehicles using the Wireless Programmer device, as well as instructions for
setting up the WP.

Section 5: Troubleshooting

This section provides a list of common problems related to the vehicle units or to its communication
with the Fuel Point PLUS system, as well as corrective action instructions.

Section 6: Glossary

Includes a glossary of terms used in the manual.

Appendix A: Finding DP Calibration Factors For New OBD-II Vehicle Models

This appendix describes the procedure for finding out calibration factors of DP/μDP units' odometer
reading for new vehicle models equipped with OBD-II systems.

1-4. USING THIS MANUAL

This manual includes comments planted along the text, in order to draw the reader’s attention to
important issues. The comments are accompanied by symbols for ease of reference. The following
comment types are used:

WARNING

An operating procedure, practice or similar, if not
correctly followed, could result in injury or loss of
life.

Fuel Point PLUS Vehicle Installation and Configuration Manual

15

An operating procedure, practice, or similar, if not
strictly observed, could result in damage to, or
destruction of equipment

TIP

CAUTION

A useful guidance whose purpose is to use the

system more effectively

NOTE

A relevant comment which is important to
emphasize

INSIGHT

Theoretical or functional information regarding the
system, which has to do with the discussed issue

1-5. REFERENCES

For additional and complementary information regarding Gasboy’s Fuel Point PLUS Installation
and Setup, please refer to the following manuals:

 Islander PLUS and ICR PLUS Installation Manual, P/N MDE-4811

 Fuel Point PLUS Station Installation and Setup Manual for New Deployments, P/N MDE-4851

Fuel Point PLUS Vehicle Installation and Configuration Manual

16

SECTION 2

FUEL RING DESCRIPTION &

INSTALLATION

2-1. OVERVIEW

Fuel Ring is a passive vehicle identification tag for refueling (RFID with no internal power sources)
which provides encrypted information on the vehicle identity, corporation or driver identification
and fuel type.

Fuel Ring includes a coil installed around the vehicle's fuel tank inlet and an ID chip. The coil
receives the transmission from the Wireless Nozzle Reader and transmits the chip information to
the Fuel Point PLUS system.

Fuel Ring features a patented removal protection mechanism to eliminate risk of theft or fraud. The
coil and the chip are connected through a cable, so that the ID chip can be installed either in a
concealed place inside the truck or next to the fuel tank inlet in light vehicles (the distance between
the coil and the ID chip must not exceed 39.37"-1M). Enhanced protection is achieved by
correlating the DataPass and the Fuel Ring of the same vehicle

The following section describes two types of installation procedures:



2-1.1. Fuel Ring Main Components

The Fuel Ring comprises two major parts as follows:



A coil (a uniquely designed coil for Fuel Point PLUS vehicle installations)



A one-time programmed ID chip housed in a casting package, protecting the unit from

Installation on private vehicles (see paragraph 2-5)



Installation on heavy vehicles (see paragraph 2-6)

mechanical damage.

Figure 2-1. Fuel Ring Components

Fuel Point PLUS Vehicle Installation and Configuration Manual

17

2-2. TYPICAL INSTALLATION KITS

815801001

Table 2-1 and Table 2-2 show a typical kit description (see also Figure 2-2, Figure 2-3). Note that
the ID chip and the Fuel Ring coil are separate components and do not form part of the light or
heavy vehicle kits.

NOTES

1. Each item in the Fuel Ring kit has a minimum
ordering quantity. Please refer to Gasboy's
marketing personnel for ordering information.

2. Certain items (e.g. glue, Glue Accelerator,
Adhesive) are not supplied and must be
purchased by the customer as they are required
for installation

3. Programming/configuring the Fuel Ring with the
WP must be performed prior to installation, due
to safety requirements.

Table 2-1. Light Vehicle - Kit Description

Kit P/N P/N Description Packs

Qty.

M09678B008 100 Fuel Ring Installation Kit for Light Vehicles, without

glue

815202401 Screw, self drilling, 6x1"flat, 100 pcs 2

815206001 Screw, one-way, 100pcs, 2.9x9.5mm 1

("¼) Cable clamp, black,100 pcs 2

Table 2-2. Heavy Vehicle - Kit Description

Kit P/N P/N Description Packs

M09678B009

100 Fuel Ring Installation Kit for Heavy Vehicles, without
glue

814905500 Fuel Ring security cover 100

Qty.

Fuel Point PLUS Vehicle Installation and Configuration Manual

18

815202401 Screw, self drilling, 6x1"flat, 100 pcs 2

815206900 Screw, security bolt, M8x20 100

815305500

Washer, flat,

M8/EXT=20mm/1 2mm

815801001 ("¼) Cable clamp, black,100 pcs 2

815805802 Nirosta wire, 25pcs 2

815806001 Clamp-coil holder, 100 pcs 3

815806400 Band, Lok-Tie BL213, 7.9x482mm 50

NOTES

1. For cases where fuel inlet neck is short, use the
provided stainless wire; otherwise use the clamp
band

2. If the coil/ID chip cannot be secured using
wires/clamp bands/screws, use Super Glue and a
fast activation accelerator. Cover the device with
a dual component adhesive (such as Epoxy).

The following adhesive substances are recommended for use:

1. SuperGlue, Cyanoacrylate- CA01, HOLDTITE

100

2. Glue, Acrylic, ST3294, high VEL. Black, HOLDTITE

3. Surface cleaning solution

4. Activator, pronto, 60ml (3M)

Figure 2-2. Light Vehicle Typical Installation Kit Components

Fuel Point PLUS Vehicle Installation and Configuration Manual

19

M09678B006

Figure 2-3. Heavy Vehicle Kit Description

To extend SuperGlue and accelerator shelf life, store
the products at a temperature of 200 C or less. High

temperature conditions or direct sunlight reduces
shelf life dramatically. For more details refer to
manufacturer's instructions.

2-3. FUEL RING COILS

The following Fuel Ring coils are available to fit a wide range of fuel inlets:

2-3.1. Shaped Coil

Designed to maintain a distance from metal surfaces, the Shaped coil (see Figure 2-4, Table 2-3)
includes an ID chip connector and three support legs which can be easily glued.

Intended for use in cases where an easy connection to the ID chip is required, mainly when the chip
is close to the Wireless Nozzle Reader, e.g. private vehicles.

The Shaped coil is connected to the ID chip by plugging the chip's connector to the coil's connector.

Table 2-3. Shaped Fuel Rings

NOTE

Part Number

M09678B005

Shaped, 2.95"

Shaped,3.34"

Description

Fuel Point PLUS Vehicle Installation and Configuration Manual

20

M09678B007

M09680B020

Shaped, 3.74"

ID chip

Figure 2-4. Fuel Ring Shaped Coil

2-3.2. Self Installed Coil

The Self Installed coil (see Figure 2-5, Table 2-4) is rubber coated and includes an internal rubber
ring designed for installation in heavy or light vehicles having short fuel inlet necks.

The Self Install coil should not be used in tanks
made of Aluminum. Use supporting legs to keep it
up off the surface.

The ID chip connector should be cut, in order to be connected to the coil's wires.

Table 2-4. Self-Installed Fuel Rings

Part Number

M09678B001 Self-installed, 2.75"

M09678B002 Self -installed, 4.13"

WARNING

Description

M09678B003 Self-installed, 4.72"

M09678B004 Self-installed, 5.11"

M09680B020 ID chip

Fuel Point PLUS Vehicle Installation and Configuration Manual

21

Figure 2-5. Fuel Ring Self Installed Coil

2-3.3. Molded Coil

Widely used, the Molded coil (see Figure 2-6, Table 2-5) is ~7mm thick and can slightly change its
shape.

Table 2-5. Molded Fuel Ring

Part Number

Description

Notes

M09678B010 Molded coil, 2.165" Cable length: 100cm

M09678B011 Molded coil, 3.15"

M09678B012 Molded coil, 3.54"

M09678B013 Molded coil, 3.74"

M09678B014 Molded coil, 4.33"

M09678B015 Molded coil, 4.72" For heavy vehicles

M09678B016 Molded coil, 5.11" For heavy vehicles

M09678B017 Molded coil, 5.71" For heavy vehicles

Fuel Point PLUS Vehicle Installation and Configuration Manual

22

N

of

on

er

d

o

C

VOLVO

S50

2005

80

1 CAN

OBD II

Elect.

12

Germany

5

11

6

nd

9

nd

VPW

85

12

Figure 2-6. Fuel Ring Molded Coil

2-4. VEHICLE SURVEY

Before performing the vehicle installation fill in the following table as shown in Table 2-6 so as to
order to order the relevant equipment for the vehicle (DataPass, µDataPass, adapters, etc.).

Table 2-6. Vehicle Survey – Example

Vehicle

manuf.

Liaz

Mercedes

Ford transit 2003 85

Lada private 1996

Model

25625-

305 2004 75

Year

2005 95

external

diameter

(mm)

Fuel
Inlet/neck
high (mm)

200

250

20

umber

tanks

1

2

1
1

BUS type

ISO9141

K-line

J1850

BUS

Connecti

type

pin, rou

connector

pin, rou

connector

OBD II

Fuel

Inlet

Table 2-7 shows of the most commonly used vehicle plugs:

Odometer

manuf.

Kinzle mechanic

Odomet

type

Elect.

Elect.

Elect.

Mechanical

odometer

connection

thread

1.75" 24

2.25" 24 yes

1.5"

size

Power

12

Articulate

us yes / n

omments

bus

bus

Origin

Russia

Germany

UK

Russia

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Table 2-7. Common Bus Connectors

Type

Connector

OBD II

6-PIN round
connector

9-PIN round
connector

2-5. LIGHT VEHICLES INSTALLATION
2-5.1. General

Two techniques, or a combination of both, are available for installing the coil unit:



By gluing the coil's bottom surface to the vehicle



By gluing the coil's bottom surface to the vehicle and clamping it

Place the coil unit around the fuel inlet. Pay special attention to the coil's flat part direction –
verify that the bottom legs surface of the plastic molded coil type faces the surface of the
vehicle. In general, it is possible to place the coil in a number of ways; still, it is advisable to
place the coil in the center of the fuel tank inlet to achieve better performance.

The ID chip is installed by gluing it to the vehicle and by securing the unit using a special screw
in order to prevent removal and theft. The chip's installation is performed either in a concealed
place in the luggage compartment, or in a visible place near the fuel tank inlet. When properly
secured against theft, the unit becomes damaged the moment it is pulled away from the vehicle
after installation is completed. It is required to place the ID chip in a less acces
theft and tampering. A distance of up to 100cm between the coil and the ID chip is permitted.

2-5.2. Preliminary Instructions

Warranty does not cover defects or damage caused
by improper installation.

NOTE

In order to prevent possible problems and difficulties during the installation, please verify that:

1. The coil in use is larger than the fuel tank inlet to improve coil assembly

2. The coil is being kept away from metal surfaces, maintaining an air gap of at least 5mm

3. The coil is assembled as close as possible to the Wireless Nozzle Reader coil when the
fueling nozzle is inserted

sible location for

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4. The unit is handled and carefully, avoiding mechanical pressure on the chip. Improper
handling could damage the unit and cause malfunction

5. The installation area complies with the approved location as shown in Figure 2-7. Please
note that this drawing applies to an open fuel inlet

6. Fuel Ring should only be installed when fuel inlet cover is closed.

Figure 2-7. Typical Installation Approved Location

2-5.3. Required Tools



Cutter



Crimping tool



Pliers



A drilling machine approved for hazardous environment

2-5.4.Installation Procedure

Proceed as follows:

1. Ensure that the fuel tank inlet cover is closed

Before installing or servicing equipment, carefully
observe the warnings and precautions provided at
the beginning of this manual.

2. Use a Fuel Ring of optimal size (refer to Table 2-5) which can be easily placed around

the fuel tank inlet and allows the opening and closing of the fuel tank inlet cover

3. Choose an optimal and secure position for the ID chip. In cases where the installation is

performed near the fuel tank inlet, it is preferable to choose the upper part of the

WARNING

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25

compartment, at the sides if possible, but not at the bottom, as the fuel nozzle may
damage the ID chip while refueling. The surface must be flat for better gluing and to
ensure that the unit is not damaged by pressure applied during installation

4. Using a soft sandpaper (e.g. #300), slightly sand the area where the ID chip is to be
glued. Pay attention not to damage the car color

5. Clean thoroughly the surface on which the coil and ID chip are to be placed using a
clean cloth and cleaning solution

6. The ID chip is installed with glue with the option of using a special screw, which is also
included in the kit:

a. In the designated area (see Figure 2-8), drill a 0.094" (2.4 mm) diameter hole. Be

careful not to drill through the fuel tank. Upon drilling completion, make sure to
clean the area before applying the glue

CAUTION

Drilling should be performed by authorized
personnel equipped with a dedicated drilling
machine.

Figure 2-8. ID Chip Preferred Position

b. Insert the one-way special screw into the ID chip (see Figure 2-9)

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Figure 2-9. Inserting One-Way Screw

c. Apply instant glue to the back part of the ID chip (see Figure 2-10)

Figure 2-10. Applying Adhesive

d. Secure the screw into position in the space prepared, without applying too much

pressure on the screw. Make sure to go through all the instructions in order to
prevent malfunction

e. Spray instant glue accelerator - Activator, pronto, 60ml (3M) around the glued

area

NOTE

When installing the Shaped coil, first connect the ID

chip to the coil.

7. After connecting the coil to the ID chip, to avoid corrosion caused by humidity and
accumulation of fluid at the connection area (shaped coil only), it is recommended to:
seal the connector's area by applying dual component glue DP-805NS (3M), or neutral
silicon on top of the connectors such as Terostat939, or Holdtite HNCS

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8. To secure the coil using clamps:

a. Place two clamps on the coil

b. Place the coil so that the coil support legs face the metal surface and the cable

extending from the coil faces the ID chip

c. Using two self-drilled screws, secure the clamps (see Figure 2-11). Be very

careful not to drill through the fuel tank.

Figure 2-11. Securing the Clamps

To secure the coil using glue:

a. Clean the surface to be glued

b. Apply few drops of Cyanoacrylate adhesive (SuperGlue) to the bottom of the

coil's support legs surface

c. Place the coil so that the coil support legs face the metal surface and the cable

extending from the coil faces the ID chip and hold for several seconds

d. While securing the coil, spray instant glue accelerator around the area.

9. To secure the unit against theft, apply Acrylic, dual-components (epoxy glue) to the
upper and lower part of the chip only as shown in Figure 2-12

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Figure 2-12. Securing the ID Chip

2-5.4.1. Installing the ID Chip inside the Trunk

As aforementioned, to prevent theft and tampering it is highly recommended to install the ID
chip in a concealed place in the luggage compartment. This procedure is also suggested for
vehicles having plastic fuel inlets.
Proceed as follows:

1. Drill a 0.094" (2.5mm) hole inside the trunk near the fuel inlet using a drilling machine
approved for hazardous environment (see Figure 2-13)

Figure 2-13. Drilling the Trunk

2. Clean thoroughly the surface on which the ID chip is to be placed using a clean cloth
and cleaning solution

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3. Apply instant glue to the back part of the ID chip

4. Secure the screw into position in the space prepared, without applying too much
pressure on the screw (see Figure 2-14)

5. Spray instant glue accelerator - Activator, pronto, 60ml (3M) around the glued area

Figure 2-14. Securing the ID Chip

6. Drill a 0.236" (6mm) hole inside the trunk near the fuel inlet and pass the ID chip wires
through the hole

7. Connect the ID chip to the coil's connector and seal the connector's area as described
above

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2-6. HEAVY DUTY VEHICLES INSTALLATION
2-6.1. General

In order to provide a solution for various fuel tank inlets in different truck models, the following
installation configurations are available:



Long Neck Fuel Inlet Installation



Short Neck Fuel Inlet Installation



Self installation

The coil unit is placed around the fuel inlet. Positioning the Fuel Ring as far as possible from the
surface of the truck, achieves better performance. The coil should be installed using Gasboy's
molded Fuel Ring clamps. Those clamps are used to achieve sufficient distance from the fuel tank
inlet and from the fuel tank surface for maximum performance. The ID chip is secured against theft
and is damaged when pulled away from the vehicle after installation is completed.

2-6.2. Preliminary Instructions

Before installing or servicing equipment, carefully
observe the warnings and precautions provided at
the beginning of this manual.

WARNING

NOTE

Warranty does not cover defects or damage caused
by improper installation.

In order to prevent possible problems and difficulties during the installation, please verify that:

1. The coil in use is larger than the fuel tank inlet diameter by approximately 0.984" (25mm)

2. The coil is assembled as close as possible to the inlet cap, without interfering with the
opening and closing of the fuel tank inlet cover

3. In cases where the fuel tank is made of aluminum, a gap of at least 76mm" is maintained
between the coil and the tank and also between the coil and the fuel inlet (larger coil is
recommended)

4. In cases where the Security cover is used, it is positioned as close as possible to the fuel inlet
and to a side wall to prevent rotation or any movement which could damage the ID chip or
the wiring

5. The coil cable is protected from harsh environment by a metal conduit

6. The ID chip is placed in a less accessible location for prevention of theft and tampering

7. The ID chip is not secured to the fuel tank. The Fuel Ring cable is long enough to allow
placing the ID chip in a safe and hidden place inside the truck (a distance of up to 100cm
between the coil and the ID chip is permitted)