Before Installation

Record the GPS ID

The installation technician must record which GPS unit is being installed in each vehicle before any Zonar equipment is installed.

1. Find the GPSID (S/N) number on the back of the unit. This number may be 7 or 8 digits long.
2. Record the asset (vehicle name) and the GPS being installed—this is important in order for the Zonar data to attach to the correct asset.

The following is an example of how to record this information on an Asset sheet:

ASSET	GPS ID
Truck 12345	8xxxxx1
Tractor 54563	11xxxxx2
Service Truck 5432	18xxxxx3

Set Up the Zonar Inspection Tags

Skip this section if electronic inspections (EVIR) will not be used for the vehicle receiving installation.

Vehicle Tags

Clean the surface area of the asset with isopropyl alcohol or brake cleaner before installing tags.

1. Remove the adhesive from the asset tag and record the Tag ID number on an asset sheet:

ASSET	GPS ID	ASSET TAG
Truck 12345	8xxxxx1	5387xxxx1
Tractor 54563	11xxxxx2	5387xxxx2
Service Truck 5432	18xxxxx3	5387xxxx3

2. See the Zonar Configuration Document for proper zone tag placement.
3. Install the zone tags in the proper areas for the corresponding vehicle inspection type. Depending on the configuration, not all zone tags may be used. Extra tags may be discarded.
4. Perform an electronic inspection to ensure correct tag placement.

Trailer Tags

Trailer/Dolly Tags are considered “Extended Asset” tags and may be black or marigold colored. They ship in sets of two (2) or three (3) tags with the name “Ext. Asset” on the back. These tags include both a 9-digit asset number and a zone number 01-03.

Required: Add the trailer to Ground Traffic Control (GTC) like other assets but with the TRAILER asset type. A GPS ID is not required for trailers unless one has been installed.

If a trailer is not created in the system but is used when doing inspections, this can cause inspections to fail. See Failed Inspections for guidance on correcting these.

Operator/Driver Card: Nine (9) digits Specific to driver

Zone Tags: Numbered 01-11 Specific to location on vehicle

Asset Tags: Nine (9) digits Specific  to vehicle

GPS & Cable Overview

Zonar Installation Kit

PART DESCRIPTION	PART NUMBERS	PHOTO
V3 GPS Unit	10079
CABLES FOR CUMMINS ENGINE
J1939 Backbone Cable	81517
Universal Node Met150 Adapter	81527
CABLE FOR FORD ENGINE
Light Duty Cable	81153

The installation instructions below describe how to connect Zonar equipment to a Ford 650/750 vehicle with a Cummins engine installed. If a Ford engine is in use, the Light Duty cable should be used to connect to the OBDII port instead.

Do not install Zonar devices or any excess cabling inside fuse panels, fuse boxes, or in any other location where the device or cabling (particularly unused cable ends/connections) might come into contact with energized circuits. Secure all excess cable lengths, cable runs, and unused cable connections/cable ends so that they cannot move or become loose over the lifetime of the installation.

Backbone Cable - GPS Unit Connections

10-pin connector – provides engine data to GPS 4-pin connector – provides power to GPS Do not plug these cables into the GPS unit at this time.

 

Backbone Cable - Vehicle Connections

Ground Wire Constant Power Wire – must receive 8-30 volts regardless of engine state J1939 Connector (Yellow & Green) J1708 Connector (Orange & Blue) – Not required for this install

 

Universal Node Met150 Adapter

IMPORTANT: For backbone cable compatibility with the Ford F650, you must use the Universal Node Met150 Adapter. Connect the J1939 connection (#3 on backbone cable) into the square 2-pin Deutsch (pictured right: gray connector).

 

Vehicle-Specific Installation

J1939 Connection

1. The primary J1939 is inside the engine compartment.
2. Once located, disconnect the node and connect both ends of the Met150 adapter into the node.

Secondary J1939 Connection Location

An alternate location of the J1939 connection may be found underneath the vehicle frame.

Power and Ground Connections

3. Remove the fuse panel cover to access the fuse panel, which will give you the following available sources:
   • Constant Power
   • Ground Connection

Constant Power

Locate a constant power source that measures 8-30 volts with engine off or on.

Zonar recommends attaching an Add-A-Fuse connector to the constant power wire. This will allow tapping directly into a fuse for ease of installation and maintenance. Connect the Add-A-Fuse as shown and connect it to a socket which provides constant power.

If not using the fuse panel, the constant power wire may be spliced directly into an appropriate power source.

Ground Connection

Any place on the metal frame that is free of paint and rust may be used as an acceptable grounding point. Existing screws or self-tapping screws may be used to connect the ground wire.

Zonar recommends adding a ring terminal to the end of the ground wire for the most reliable connection.

GPS Unit Connections

If you are installing a Connect tablet to this vehicle, skip this section.

On the GPS end of the harness, connect in the following order:

1. Connect the 10-pin (A) to the GPS unit (A).
2. Connect the 4-pin (B) to the GPS unit (B).

 

Confirm Install

Once the GPS unit is connected, check the LEDs on the left side of the unit. They should display the following sequence after everything is connected:

Datalink 1:	Flashing Green (J1708 Connected) or Red (J1708 Not Connected)
Datalink 2:	Flashing Green (J1939 Connected) or Red (J1939 Not Connected)
Cellular:	Flashing Green, turning solid Green after 1-2 minutes
GPS:	Flashing Orange, turning solid Orange after 2-3 minutes
Status:	Flashing Green with engine off, solid Green with engine running

 

Tablet Installation

If you are installing a tablet connected to the TCU, installation method depends on which dock you are using. Select the appropriate dock to review the installation guide.

Confirm Install

Check the GPS lights according to the Confirm Install table above. The following may be used to confirm that the tablet is correctly connected as well:

1. Power on the tablet.
2. On the Driver Login screen, swipe down from the top right.
3. Tap SETTINGS from the sub menu that is displayed.
4. Tap Zonar Settings from the DEVICE section.
   
5. Tap Run Device Diagnostics from the DIAGNOSTICS section.
   
6. The Diagnostics dashboard is displayed. Check to see that the GPS and GSM icons are green. This means that the tablet and GPS unit are communicating properly, and they are getting the needed cellular and GPS information.
   

Further Assistance

If you still require assistance after using this installation document, contact Zonar Customer Care:

Phone:  1-877-843-3847 x1

Email:    customercare@zonarsystems.com

Customer Care operates 24 hours a day, 7 days a week.

Advanced troubleshooting and assistance may require specialists only available during business hours 8:00 am to 5:00 pm Pacific time.

 

Warranty And Legal Notices

For more information regarding Zonar Warranty and Legal Notices, see the Zonar Product Warranty page on our website (https://support.zonarsystems.net).