Before Installation

Record Necessary Information

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

Find the GPSID (S/N) number on the back of the unit. This number may be 7 or 8 digits long.
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.

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

See the Zonar Configuration Document for proper zone tag placement.
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.
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.

Base Equipment

TCU (one required)
- V4 variant (V4, V4 Base, V4R)
Vehicle Connection Cable Options
- 9 pin diagnostic cable (p/n 81523)
  OR
- 9 pin splitter cable (p/n 81658)
  Splitter cable is not compatible with black-capped 9-pin cables.

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

I/O equipment

Zonar I/O harness (p/n 80059)
18 AWG spools of wire to run to each monitored circuit
Butt-splice connectors to attach wire to I/O harness
1N4001 diodes when installing more than one I/O

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

V4 (TCU)

Never mount the V4 to removable objects or moving parts
Never mount the V4 in a manner that would interfere with the clutch, brake, or gas pedals.
Avoid mounting Zonar equipment near doors and windows that could leak to avoid water damage.
Keep the V4 location consistent within fleets or like vehicles.
If you can’t see or feel behind the area, look for a different mounting location.
Use one of the following methods to secure the TCU mounting bracket, in order from most to least desirable:
- Screws: Included with installation kit. Use a minimum of two (2) screws when mounting.
- Zip ties: Acceptable when there is no place to secure the TCU using screws. Use a minimum of two (2) ties when mounting.
- Adhesive tape: Use the tape on the back of the TCU mounting bracket only when no other options are available.

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.

Discrete I/Os

Connect the I/O leads to active high circuits when possible (0 volts inactive, 12 volts active).
Avoid involving 3rd-party switches when possible.
When installing more than one I/O, ensure all I/Os are consistent in polarity (all active high or active low).
Never connect to a momentary switch.
Never use more than two (2) butt connections per I/O circuit.
If you aren't sure that the I/O circuit is already fuse protected, install a 1-amp inline fuse closest to the power source.
Keep I/O wire color consistent across the fleet.
When installing more than one I/O, 1N4001 diodes must be installed (in-line) on the I/O harness to prevent unwanted voltage back-feed to I/O circuits #2-5.

Installation

The TCU, tablet, and ZPass unit are installed on the auxiliary dash panel.

Remove and lift the panel to the side.

Base TCU Install

Connect the 9-pin diagnostic cable to the vehicle's diagnostic port.
Connect the 8-pin Molex plug on the diagnostic cable to the TCU.
Connect the 4-pin Molex plug on the diagnostic cable to the TCU.
Mount the TCU and secure cabling within the dash once post-install checkout has been completed. Use zip ties to secure the 9-pin diagnostic cabling to factory wiring/loom as high as possible within the dash.

If using a splitter cable, attach the split diagnostic port on the cable in an accessible location.
Use a 1.5 in. hole saw to cut a mounting hole for the open diagnostic port.

Example location of open diagnostic port mounting:

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.

Gamber Johnson Dock — Gamber-Johnson Dock

Z Pass Install

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

I/O Install

I/O wiring should be spliced into the desired system such that it reads 0 volts when the system is inactive and 12 volts when the system is active.

Install 1N4001 diodes into the wiring as described in the diode installation section below.

Once the wiring is connected, connect the 12-pin plug to the TCU.

Common I/O connections

IO Number	Wire Color	System
1	Black	Door Open/Close
2	Brown	Stop Arm
3	Orange	Reverse Light
4	Yellow	Wheelchair Lift

Door I/O Options

Option #1 Key Switch (if equipped)

Option #2 Above Entrance Door (air operated)

Option #3 Door Open/Close Switch

*Make the I/O connection after the white plug. The picture on the right is an example of what not to do. Thus, if the door switch ever needs replaced the I/O connection does not need to be replaced.

Stop Arm I/O:

Wheel chair I/O:

Reverse lights I/O:

Diode Installation

Cut ½ inch of each end of the diode so it can be fully encapsulated in a 22-18 AWG Perma-seal butt connector:

The diode must be oriented in the correct direction between the I/O wire connected to the monitored circuit, and the I/O harness on the V4. For example, a circuit that sends 12 volts when activated, the Anode should be pointed towards the incoming voltage, and the cathode is pointed towards the V4 (see below):

Heat shrink all the perma-seal butt connectors around the diodes, I/O wires; properly secure with zip-ties in a manner that will keep diodes from taking un-necessary abuse

Using a digital multi-meter to verify monitored circuit voltage for each I/O at V4 I/O Molex plug.

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:

Perform a key on/key off, i.e., “keycheck” to ensure V4 recognizes valid constant and run/ignition power.
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.
Perform an EVIR inspection.
Activate the I/Os. Successful recording of I/O activation must be confirmed by a person with access to Ground Traffic Control.