JL Audio Car Speaker ZR800 CW User Manual

ZR800-CW  
Subwoofer  
o w n e r ’ s m a n u a l  
Thank you for choosing a JL Audio Evolution ZR Component Woofer for your  
automotive sound system. With proper installation, your new speaker  
will deliver years of listening pleasure.  
We strongly recommend that you have your new Evolution speaker installed  
by your authorized JL Audio dealer. The installation professionals employed by your  
dealer have the necessary tools and experience to disassemble your interior panels,  
install your new speakers and reassemble your vehicle properly. If you prefer to  
perform your own installation, please read this instruction manual  
completely before beginning the process.  
 
APPLICATION INFORMATION  
The ZR800-CW is a powerful 8-inch  
component woofer designed to operate  
in automotive sound systems reproducing  
the frequency range between 30 Hz  
and 400 Hz. It can be used in infinite-  
baffle or enclosed applications as an  
extremely potent, dedicated mid-  
bass speaker or as a full woofer.  
Infinite Baffle:  
As a dedicated mid-bass speaker operating  
above 50 Hz (with active filtering) the  
ZR800-CW can be safely operated at  
power levels momentarily exceeding 200  
watts per woofer. When operating below  
50 Hz as a true woofer, power should be  
limited to no more than 125 watts per  
woofer in infinite baffle applications.  
Active Filtering is Recommended:  
When used as a mid-bass speaker, we  
recommend the use of dedicated amplifier  
channels and active filtering (electronic  
crossovers) with the ZR800-CW.  
Enclosed Operation:  
The ZR800-CW can also be used in sealed  
or ported enclosures as recommended  
in this manual. Again, power should be  
limited to no more than 125 watts per  
woofer if being played below 50 Hz.  
More power can be used if appropriate  
active high-pass filtering is applied.  
The ZR800-CW maintains smooth frequency  
response characteristics up to 500 Hz, so it  
is advisable to cross it over with mid-range  
speakers at 300-400 Hz to ensure a smooth  
transition. Pushing it higher than this range  
may result in uneven response which may  
require equalization to correct.  
JL AUDIO ZR800-CW  
 
3
GETTING STARTED  
SPEAKER INSTALLATION  
• Turn off the audio system. It is also  
advisable to disconnect the negative  
(–) terminal of your vehicle’s battery  
whenever performing installation work.  
• Before cutting, drilling or inserting any  
screw, check clearances on both sides  
of the planned mounting surface. Also  
check for any potential obstacles, such  
as window tracks and motors, wiring  
harnesses, etc. Check both sides of the  
Run speaker wire to the desired mounting  
location. If you are running wires into a door,  
use existing factory wiring boots whenever  
possible. If you are drilling new holes, file  
their edges and install rubber grommets  
into each hole. Then, cover the wires with a  
protective PVC sleeve and run them through  
the door jamb. Make sure that the wires will  
clear door hinges and other structures in the  
door. If you are unsure about any part of this  
process, please contact your JL AUDIO dealer  
for installation help.  
a pilot hole in the center of the speaker  
mounting hole at this time. Then, using a  
saber saw, make the circular cut out for the  
speaker. File any rough edges. Insert the  
mounting clips with the flat side towards  
the speaker as shown in Diagram B (below).  
It is absolutely vital that the speaker frame  
fits into the mounting hole cleanly. This must  
be checked prior to tightening the screws.  
Do not force the frame into a hole that is  
too small. Do not tighten the speaker onto  
an uneven surface. This will damage your  
speakers. The speaker should also fit so that air  
does not leak around the mounting flange. Air  
leaks will cause a severe degradation in sound  
quality. Seal any air leaks with an automotive-  
grade sealant material.  
vehicle, many vehicles are not symmetrical!  
• Always wear protective eyewear.  
WARNING  
!!  
Double check the clearance for both  
speakers before proceeding. Many cars are  
different from one side to the other!  
Connect the speaker wires, observing  
correct polarity, and install the speaker and  
grille tray as shown in Diagram A (page 5).  
Hand-tighten the screws evenly to avoid  
bending the speaker frame!  
Select an even surface. Tightening a  
speaker onto an uneven surface can damage  
it. Use the supplied template to mark the  
desired mounting location. Mark the center  
and the outline of the mounting hole as  
well as the mounting screw positions. Before  
drilling or cutting on your interior panels,  
use a utility knife to cut any fabric, vinyl or  
leather from hole locations. These materials  
can easily be snagged by a drill or a saw,  
causing damage to the panel and possible  
bodily injury. Drill eight 1/8-inch (3 mm)  
holes for the speaker’s mounting screws at  
the positions you have marked. Also drill  
Break off small pieces of the supplied butyl  
adhesive putty and place them on the inside  
of each grille tray. This adhesive will hold  
the grille in place firmly and prevent rattling.  
Then insert the metal grille into the grille tray,  
squeezing gently around its edge until it seats  
firmly into the tray.  
4
JL AUDIO ZR800-CW  
 
Diagram A:  
Typical Woofer Installation  
JL AUDIO ZR800-CW  
5
 
ENCLOSURE SPECIFICATIONS  
Driver  
Recommended Sealed Design  
External Dimensions  
Volume  
F3  
(Hz)  
Fc  
(Hz)  
Qtc  
(net int.)  
(Width x Height x Depth)  
0.750 ft3  
ZR800-CW  
15.5 in. x 12 in. x 10.5 in.  
394 mm x 305 mm x 267 mm  
60  
80.73  
1.155  
21.2 litres  
Sealed Design  
Ported Design  
Driver  
Recommended Ported Design  
Enclosure External Dimensions Round Port Specs  
Volume  
Tune to:  
(Hz)  
F3  
(Hz)  
(net int.)  
(Width x Height x Depth)  
(Inner Diameter x Length)  
1.125 ft3  
31.9 litres  
18 in. x 15 in. x 10.5 in.  
457 mm x 381 mm x 267 mm  
2 in. x 5 in.  
51 mm x 127 mm  
ZR800-CW  
32  
50  
The enclosure recommendations listed are external dimensions which assume the use of 3/4” (19mm) thick material. If you are using 5/8” (16mm) thick  
material, subtract 1/4” (6.5mm) from each dimension. Do not use any material with a thickness of less than 5/8” (16mm) as this may compromise the rigidity  
of the enclosure.  
All enclosure volumes listed are net internal volumes! Box volume displacement, port displacement and brace displacement must be added to obtain  
the final gross internal volume. All enclosure dimensions listed have already taken this into account.  
6
JL AUDIO ZR800-CW  
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RECOMMENDED CONTINUOUS (RMS) POWER RANGE FOR ONE COMPONENT WOOFER:  
MEDIUM GRAY (MINIMUM):  
LIGHT GRAY (OPTIMUM):  
This zone represents the best  
DARK GRAY (MAXIMUM):  
BLACK (WARRANTY VOID):  
We do not recommend operating  
woofers at this level of power. In this  
From a reliability standpoint, this zone  
represents a very comfortable operating  
power range for each driver. This level  
of power will not stress the woofer but  
will not extract all of its performance  
potential, either.  
Use of less than the minimum power  
level will not damage the woofer, but may  
result in unsatisfactory performance.  
Slightly more SPL will be gained by  
pushing the power into this zone, but  
typically not more than 2dB, compared to  
the light gray zone. The subwoofer driver  
is designed to operate safely up to this  
power range, but not beyond. Operate  
with caution.  
compromise  
between  
long-term  
reliability, high-output and low-distortion  
performance. This power level is lower  
than the woofer’s continuous power rating  
(as published in its specifications), but  
you will still be taking advantage of the  
woofer’s, low-distortion performance  
range without undue risk of failure.  
zone, there is  
a
very high probability  
that the driver will fail due to excessive  
heat and/or mechanical stress.  
Drivers operated at these levels of  
power are NOT covered under warranty.  
When designing systems with our drivers, it is very important to achieve a good power match between the subwoofer amplifier and the subwoofer driver's capabilities.  
The power levels listed in the above chart represent continuous (RMS) amplifier power per woofer and assume that the user will regularly make full use of that power  
without drastically overdriving the amplifier(s). Make sure you factor system impedance and the total number of subwoofers into your calculations. Adhering to these  
power recommendations will result in systems that are both reliable and enjoyable.  
JL AUDIO ZR800-CW  
 
7
LIMITED WARRANTY - (USA) AUTOMOTIVE SPEAKER SYSTEMS  
JL AUDIO warrants this speaker to be free of defects in materials  
Any applicable implied warranties are limited in duration to the  
and workmanship for a period of one (1) year from the original date period of the express warranty as provided herein beginning with  
of purchase.  
the date of the original purchase at retail, and no warranties, whether  
express or implied, shall apply to this product thereafter. Some  
states do not allow limitations on implied warranties, therefore these  
exclusions may not apply to you. This warranty gives you specific  
legal rights, and you may also have other rights which vary from state  
to state.  
Damage caused by the following is not covered under warranty:  
accident, misuse, abuse, product modification or neglect, failure  
to follow installation instructions, unauthorized repair attempts,  
misrepresentations by the seller. This warranty does not cover  
incidental or consequential damages and does not cover the cost  
of removing or reinstalling the unit(s). Cosmetic damage due to If you need service on your JL AUDIO product:  
accident or normal wear and tear is not covered under warranty.  
All warranty returns should be sent to JL AUDIO freight prepaid  
This warranty is not transferable and applies only to the through an authorized JL AUDIO dealer and must be accompanied by  
original purchaser of the product from an authorized JL AUDIO proof of purchase (a copy of the original sales receipt.) Direct returns  
dealer. Warranty is voided if the factory-applied product serial  
number is removed or defaced.  
from consumers or non-authorized dealers will be refused unless  
specifically authorized by JL AUDIO with a valid return authorization  
number. Warranty expiration on products returned without proof  
of purchase will be determined from the manufacturing date code.  
Coverage may be invalidated as this date is previous to purchase date.  
Return only defective components. Non-defective items received  
will be returned freight-collect. Customer is responsible for shipping  
charges and insurance in sending the product to JL AUDIO. Freight  
damage on returns is not covered under warranty. Always include  
Should service be necessary under this warranty for any reason due  
to manufacturing defect or malfunction, JL AUDIO will, at its discretion,  
repair or replace the defective product with new or remanufactured  
product at no charge.  
For Service Information in the U.S.A. please call:  
JL Audio customer service: (954) 443-1100 during normal business hours (Eastern Time)  
JL Audio, Inc  
10369 North Commerce Parkway, Miramar, FL 33025  
International Warranties:  
Products purchased outside the United States of America are covered only by that country’s distributor and not by JL Audio, Inc.  
Printed in USA  
JLA-ZR800CW-0608-SKU#011267  
 

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