• Before Installation
• Required Equipment
• Best Practices
• Installation
• Post-Install Checkout

Before Installation

Jouley buses by Thomas Built Bus come line-fit with a V4 TCU and virtual IOs. No installation of the TCU or IOs is necessary. Contact Zonar Systems to activate the onboard unit.

Record Necessary Information

The installation technician must record which equipment 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 following information, which is necessary to correctly associate Zonar data with the vehicle after installation:
   • Asset number or name
   • VIN
   • GPSID
   • Tablet S/N (if installing a tablet)
   • Any other serialized equipment numbers being installed

The following is a sample sheet used to record necessary information:

ASSET	VIN	GPS ID	TABLET SN
Truck 12345
Tractor 54563
Service Truck 5432

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 the asset sheet along with the necessary information above:

ASSET	VIN	GPS ID	TABLET SN	ASSET TAG
Truck 12345				5387xxxx1
Tractor 54563				5387xxxx2
Service Truck 5432				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 returned to the customer.
4. Perform an electronic inspection to ensure correct tag placement.

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

Required Equipment

Below are lists of equipment necessary to have on hand for installing each Zonar system. Zonar-provided equipment will have part numbers listed, while equipment without part numbers must be supplied by the site or installers.

Tablet equipment

This information will apply to most if not all make/model installs:

• Tab Active3
  • Tab Active3 tablet
  • ProClip dock
  • Cable assembly 
  • RAM mount with backing plate 

Tablet installation equipment

• 7/8 in. inner diameter grommet for routing wiring through dashboard
  
• Zip ties for keeping wiring secured
• 7mm nut driver with hollow shaft for securing RAM mount
  
• Alternate mounting equipment when a RAM mount backing plate cannot be used
  • #10-24 coarse Nylon lock nuts
  • 3/16” x 1 – ¼ in. fender washers
  • Round head machine screws #10-24 x 1-1/2 in.

Z Pass equipment

• Z Pass SRT (p/n 30025)
• Z Pass RAM mount kit (p/n 30024)
• Z Pass SRT accessory kit (p/n 30033)

Z Pass install equipment

• 5/8 in. inner diameter grommet

Best Practices

Cabling

• All cables and wiring must be secured properly and out of sight.
• Bundle the excess cables and wiring lengthwise rather than circular.
• Secure the excess cables and wiring to existing factory wiring or dash brackets to prevent the cables from rubbing against sharp edges behind the dash.
• Always use enough zip ties to properly secure the cables and wiring.
• Always cut or trim zip ties as flush as possible, and avoid trimming at an angle.

Mounting

Tablet

• The provided backing plate must be used when installing the RAM mount whenever possible.
• The base of the RAM mount must seat flush against the dash surface.
• Avoid mounting the RAM mount in locations that cause the tablet to be above the top edge of the dash line.
• Avoid mounting the RAM mount over the top of information placards.
• Flush mounting the tablet dock is acceptable if there is enough space.

  Consult state and local regulations for acceptable locations for driver interface equipment.

Z Pass

• The backing plate is crucial to provide sufficient reinforcement for the Z Pass reader.
• Flush mounting the Z Pass reader is acceptable if there is enough space.
• Avoid mounting the Z Pass reader in a location where it will be a snag hazard.

  Consult state and local regulations for acceptable locations for passenger interface equipment.

Installation

The tablet and ZPass unit are installed on the passenger control dash panel.

Remove the panel by removing the panel bolts and lifting the panel to the side.

 

Tablet Install

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.

Z Pass Install

1. Mounted as pictured below using the supplied 3M double-sided adhesive.
   
2. Connect 6-pin plug to Z Pass unit.
3. Route wiring through dash to TCU.
4. Connect 6-pin plug to TCU.

EVIR tags

Tags must be placed in locations that will support Tab Active scanning. The Tab Active NFC scanner is located roughly in the center of the tablet. The screenshot of the EVIR app below demonstrates more precisely where the tablet can scan EVIR tags.

Tab Active3 Scan Location

Tab Active 2 Scan Location

Post-Install Checkout

Every install should have the following done at checkout:

1. Perform a key on/key off, i.e., “keycheck” to ensure V4 recognizes valid constant and run/ignition power.
2. Perform a Z Pass card scan. The Z Pass unit lights up green and beeps upon a successful swipe. If it fails, it may be necessary to contact Zonar for a firmware update.
3. Perform an EVIR inspection.
4. Activate the I/Os. Successful recording of I/O activation must be confirmed by a person with access to Ground Traffic Control.