Mastering Zonar
★ Zonar Products · Install Guide
The full V4 install in order: mounting, wiring, fusing, data cables, the GPS antenna and the light check.
A Zonar V4 install follows a fixed order: run the cables first, mount the unit, plug in the power last, then check the lights within two minutes and finish with the key-off and accessory checks. This guide follows Zonar’s own V4 installation manual, in the order the work is done.
Lay every cable and accessory out along the vehicle before anything is mounted. This shows whether the cables are long enough and where they could rub or pinch.
The ID is printed on the back of the unit as GPSID (S/N) 18xxxxxx. Write it down next to the vehicle or asset name, because Zonar Customer Care asks for that pairing.
Take the negative cable off the battery before any wiring starts.
Route it to the unit location. Leave the 4-pin connector unplugged from the V4 for now. Zonar says not to connect it at this time.
Install the discrete input cable and the external GPS antenna only if the job uses them.
Mount the plate on a flat interior surface, then the unit with the Zonar logo toward the sky. Do not drill into the unit.
Plug in every other cable and wire first.
Zonar says the 4-pin power input is the last connection: Disconnect first, reconnect last.
Then connect the OBD-II connector if the vehicle uses one.
Confirm the LEDs within 2 minutes, then run the key-off and accessory checks below.
Finish the job sheet with the GPS ID and the vehicle name.
Mount it on a flat interior surface large enough for the unit, with a clear, non-metallic view of the sky. Two spots Zonar suggests are a horizontal dash mount under an angled windshield with no metal in the way, or an overhead compartment with a clear non-metallic sky view.
The 4-pin cable carries power and ground. The white wire is the one most often wired wrong: it must be live only while the engine runs, or idle time will not track correctly.
| Wire | Connects to |
|---|---|
| Red | Constant power, 8 to 32 volts DC |
| Black | Battery ground. Under 1 ohm measured from the connector to the chassis attachment point |
| White | Switched power. 8 to 32 volts with the engine running, 0 volts with the engine off or in accessory |
| Green | Chassis ground. Only on cable 10030, for vehicles with a negative-side battery disconnect |
Every power lead, red and white, gets a 3 to 5 amp fuse in the inline holder, placed as close to the power source as possible, and goes only to a protected circuit, never straight to the battery.
The cable depends on how the vehicle gives out its data. After connecting any of these, move the vehicle at least 5 mph for at least 100 feet so the data shows up.
| Cable | Part number | Use it for |
|---|---|---|
| Light Duty cable (OBD-II) | 81008 | Light-duty vehicles that are OBD-II compliant. Not for hybrids or vehicles with an aftermarket OBD-II device. |
| 9-pin Diagnostic 500K cable | 81523 | Heavy-duty J1939 vehicles with the 9-pin Deutsch port. An optional adapter, 81632, supports J1708. |
| 2-pin Deutsch 500K cable | 81517 | J1708/J1587 or J1939 data backbone. Needs adapters that depend on the make, model, year and engine maker. |
| 4-pin, 3-wire cable | 10007 | Vehicles with no data connection. |
| 4-pin, 4-wire cable | 10030 | Vehicles with a negative-side battery disconnect. |
On an OBD-II install, connect it with the engine running so the vehicle does not throw a false check engine light.
Mount it at the centerline of the roof with a short cable run and a clear view of the open sky, at least 6 inches from any roof edge or ledge. Use only the supplied antenna, Zonar part 81304 (17 feet).
Check within 2 minutes of turning the key on with the engine running. Do not go on until the GPS light is solid.
| Light | Should show | If it does not |
|---|---|---|
| CELLULAR | Solid green | Blinking: the unit needs cellular coverage |
| GPS | Solid green or orange | Blinking: still finding satellites. Wait for solid before going on |
| STATUS | Solid green | Blinking green: power was briefly removed or Bluetooth pairing is on. Blinking fast red: the internal backup power is in use. Check the cables and the 4-pin pigtail |
| DATALINK 1 | One green blink per second | One red blink per second: no engine computer connection, or a faulty one |
| DATALINK 2 | One green blink per second | One red blink per second: no engine computer connection, or a faulty one |
Tap below to watch each V4 light pattern and hear what it means.
Tap HereSee What the Lights MeanConfirm the light table above. Do not go on until GPS is solid.
The STATUS light should blink green. A solid STATUS can mean a problem with the white wire. Contact Zonar Customer Care if you are unsure.
STATUS must not be solid.
Zonar recommends a complete check through its Ground Traffic Control website. The steps above are the minimum an installer has to do.
Source: Zonar V4 User Manual and Installation Guide.
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