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.

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 V4 GPS Unit	10079 10096
Cascadia Retrofit Cable	81635

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.

Vehicle-Specific Installation

Accessing VPDM

The Vehicle Power Distribution Module (VPDM) is where the GPS unit will be mounted and where the connections to the vehicle power will be made.

Remove the passenger side dashboard panel by locating the PULL handle on the lower left side of the panel.

The panel should be removable by pulling, as there are no screws holding it in place.

Removing the panel reveals the VPDM, secured by the retaining frame.

Remove the frame by removing the screws holding it in place.

Remove the VPDM cover to reveal the fuse panel.

Remove the screws securing the fuse panel to the dash, and remove the panel.

GPS Unit Mounting

Behind the VPDM fuse panel, there are a number of tray slots. The GPS unit can be installed into the open tray here.

If the vehicle came with a Virtual Technician unit pre-installed, it will be located here.

J1939 Connection

The J1939 connection will be a splice pack found on the bottom right-hand side of the passenger dash. More disassembly will be required.

Remove the passenger side hand rail.

Remove the door sill plate.

Remove the lower kick panel.

The splice pack will be located behind the kick panel at the end of a long cable loom. It may be buried deep inside the dash and will require locating.

Using the following instructions, attach the green and yellow wires from the retrofit harness into the splice pack. 

Disassemble the Splice Pack

1. To remove the cap, the installer must release the two locking tabs at opposite corners of the splice pack assembly.
2. 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.
3. Once one side of the cap has been lifted, repeat on the opposite corner.

Remove the TPA

4. The TPA pulls out of the cable insertion side of the splice
5. 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

6. 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

7. 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.

Power Connections

The remaining three wires on the retrofit cable will be plugged into the back of the VPDM fuse panel.

As shown, there are three matrix panels on the VPDM. These act similarly to a splice pack.

Note the labels on each wire on the cable. The first combination of letter and number corresponds to one of the panels. The second combination corresponds to a column and row of that panel (the panel is labeled accordingly). 

If the location on the panel is already occupied by a wire, you will need to splice the Zonar wire into the existing wire.

If the location on the panel is empty, you will need to connect the Zonar wire similarly to a splice pack.

Remove the screw holding the panel (located on the front of the VPDM).

Slide the green connector locks out from the side of the splice pack panel.

Connect the wire to the appropriate spot on the panel, then reassemble.

Repeat this process for all three wires. Once complete, the Zonar equipment may now be connected.

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).