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 our online support regarding 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
J1939 Backbone Cable	81517
Splice Pack Adapter	81532

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

 

Splice Pack Adapter

IMPORTANT: For backbone cable compatibility with the vehicle you are installing on, you must use the Splice Pack Adapter. Connect the J1939 connection (#3 in the previous section) into the gray connection on the adapter.

 

Vehicle-Specific Installation

J1939 Connection

1. Remove the far right kick panel to access the vehicle’s splice pack.
   
2. Identify the splice pack as shown below. Look for green/yellow wiring and a label stating “250K”.
   

   Disassemble the Splice Pack

3. To remove the cap, the installer must release the two locking tabs at opposite corners of the splice pack assembly.
4. This is most easily done by inserting a small flathead screwdriver into the tabs, down along the side of the splice pack body and gently prying the cap up 1-2 millimeters.
5. Once one side of the cap has been lifted, repeat on the opposite corner.

   Remove the TPA

6. The TPA pulls out of the cable insertion side of the splice
7. The TPA has three locking The large tab can typically be pressed down with a small flathead screwdriver. The TPA can typically then be removed from the other tabs and released. If this is not possible, depress the two smaller tabs as well and pull the TPA out of the connector body.
   

   Insert the Connectors

8. The Zonar splice pack adapter can now be inserted into the back side of the Splice Saver connector body. Make sure the contact is correctly oriented so the contact locks into place. The cutout in the contact should face the center spine of the splice pack.
   

   Selecting the Right Connection Rows

9. Match wire colors along the proper side of the connector (yellow to the yellow row, green to the green row). Make sure that the two J1939 wires are installed directly across from each other, as with slots B and H in the below example.
   

Reassemble the Splice Pack

Check the contacts are locked in place. Install the TPA into the bottom side of the connector body. This should easily snap into place and locks the contacts into the connector body. Reinstall the cap by pressing it into the open top of the connector body. Make sure that the cap is properly oriented (it may have a polarizing notch). There will be other wires coming out the back of the splice pack.

 

Fuse Panel

1. The fuse panel is behind the glove box on the passenger side of the vehicle.
2. Open up the glove compartment and remove the screws that keep it in place.
3. Once the screws have been removed, pull the glove compartment out.
   
4. Remove the black panel to reveal the fuse panel.
   

 

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).