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:

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:

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.

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. The J1939 terminating resistor is located behind the radio near the windshield.

2. Unscrew the trim from the dashboard.
3. Carefully remove the trim.

4. Remove the screws holding the top cover.
5. Carefully remove the top cover.

6. The terminating resistor will be located in a large group of wires behind the radio.

Disassemble the Splice Pack

• To remove the cap, the installer must release the two locking tabs at opposite corners of the splice pack assembly.
• 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.
• Once one side of the cap has been lifted, repeat on the opposite corner.

  Remove the TPA

• The TPA pulls out of the cable insertion side of the splice
• 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

• 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

• 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 of the back of the splice pack.

J1708 Connection

1. The J1708 connection is located in the middle of the dash underneath the radio.
2. Connect the J1708 connector into the vehicle’s junction block.

Ground & Constant Power

1. The constant and ground connections are both located near the J1939 connection.
2. Look for two splice packs labeled Power Battery and Ground Electronics.

3. Cut the zip ties to separate the splice packs.

4. Splice the Zonar constant wire to the power battery splice pack.

5. Splice the Zonar ground wire to the ground electronics splice pack.

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:

Tablet Installation

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).