Product Safety Information Bulletin
Zonar® Light Duty Cable
Product Safety Information Bulletin ZNR-LDC-19-01
*** Potential Risk of Shorting & Fire if Cable Connectors Exposed to Water***
To: selected zonar customers using a ld dongle to connect zonar telematics control units (V3 or V4 TCU) to an obdii port
Zonar Systems, Inc. has decided to initiate this Product Safety Information Bulletin to advise customers of a potential safety issue that only appears to arise under abnormal operating conditions where water is allowed to access the internals of the power/data cable identified in this bulletin.
Products covered by this service bulletin
This Product Safety Information Bulletin is directed to the Zonar LD Dongle (Part #81008). This product is also referred to as a:
- Light Duty Cable
- LD Cable
- OBD-II Cable
Overview of condition
Zonar’s Engineering Staff has identified the possibility that if water is allowed to intrude into the circuitry of the LD Dongle, this can lead to corrosion on the circuit board in the LD Dongle. This can cause a short that will lead to failure of the LD Dongle, and in certain failure modes such shorts can lead to a fire.
The LD Dongle is not intended to be used in wet conditions, and under normal operating conditions the LD Dongle should not be exposed to moisture.
Vehicles that leak water near the dashboard/instrument panel, or vehicles operating in conditions such that snow and or ice can accumulate within the driver compartments, may be at risk.
Inspect for evidence of corrosion in the interface between the LD Dongle and the Diagnostic Link Connector (DLC). If no evidence of corrosion is seen, apply two (2) dielectric grease packs to the OBD-II connector on the LD dongle. If evidence of corrosion is seen, have the DLC replaced before replacing the LD Dongle.
Note that the use of the dielectric grease is to prevent water from entering the internals of the LD Dongle, thereby preventing any corrosion of circuitry that can lead to failure of the LD Dongle. While the risk of moisture entering the internals of the LD Dongle appears quite low, Zonar recommends the use of the dielectric grease as a simple and effective safety precaution.
Zonar has dielectric grease in stock and will provide that material at no charge to its customers that have ordered LD Dongles. To order dielectric grease please determine the number of LD Dongles you have in service and contact Zonar Customer Care at:
- E-mail: email@example.com
- Phone: 1(877) THE-EVIR
Remove LD Dongle and inspect for corrosion on the dongle and the DLC.
Example of corroded LD Dongle
Example of corroded DLC
If the DLC and or LD Dongle is corroded have the DLC replaced, inspect for and repair any sources of water intrusion into the DLC, and replace the LD Dongle before continuing this procedure.
Apply both Dielectric Grease containers (pictured below) to the LD Dongle as shown below. Ensure that the connector is completely filled with grease.
Plug the LD Dongle into the DLC. The grease will protrude through the unused cavities in the DLC.
The engine must be running before the LD Dongle is inserted into the DLC. Failure to observe this step may trigger a false Check Engine light on the dash on first engine start after installation. This will require that the fault be manually cleared.
Pack the excess grease into the back of the DLC as shown.
Contact Zonar Customer Care at 1-877-843-3847 or email us at firstname.lastname@example.org with any questions.