ZF SCALAR EVO Cast Installation Manual
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ZF SCALAR EVO Cast Installation Manual

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SCALAR EVO Cast Installation
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Summary of Contents for ZF SCALAR EVO Cast

  • Page 1 SCALAR EVO Cast Installation Guide...
  • Page 2 This publication is not subject to any update service. Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. ZF CV Systems ZF CV Systems North America LLC...

  • Page 3: Table Of Contents

    Fastening SCALAR EVO Cast ..................... 19 Fastening SCALAR EVO Cast (when bracket is not used) ......22 Connecting hardware ........................

  • Page 4: Symbols Used In This Document

    Description of a possible situation which may result in irreversible injury if the warning is ignored . NOTICE Description of a possible situation which may result in material damage if the warning is ignored . Important information and/or tips Reference to information on the internet SCALAR EVO Cast...

  • Page 5: Information In The Document

    Information in the document Information in the document The WABCO brand and associated trademarks are owned by and proprietary to ZF Group as of May 29, 2020 . Purpose of this document This document is intended to be used by trailer manufacturers and workshops .

  • Page 6: Safety Information

    Park the vehicle on a level surface . Block the wheels to help prevent the vehicle from moving . Support the vehicle with safety stands . Do not work under a vehicle supported only by jacks . Jacks can slip or fall over . Serious personal injury and damage to components can result . SCALAR EVO Cast...

  • Page 7: General Information

    If you have any questions about the material covered in this publication, or for more information about the WABCO product line, please contact WABCO Customer Care Center at (844) REACH-ZF, by email at wabcocustomercare@zf .com, or visit our website: www .zf .com/cv .

  • Page 8: Before Installation

    SCALAR EVO Cast . Liability The installation of SCALAR EVO Cast can be carried out either by a ZF/WABCO Certified iABS Service Partner or by the customer (after ZF training/demo installation) . Contact your service partner in case the iABS/RSSplus data still needs to be activated .

  • Page 9: Wire Management

    The assembly of the parts must be done using the accessories provided . ZF cannot be held responsible for any errors resulting from the use of other materials . ZF wishes to point out that activities which require welding to the trailer, can cause damage to the electronics of the device . It is imperative that the device is disconnected when carrying out such activities .

  • Page 10: Improper Use

    1.3.4 Disposal 4019842a In case you no longer want to use the SCALAR EVO Cast unit, it is prohibited to dispose of it together with domestic waste as the system components are electronic scrap . Batteries are hazardous waste .

  • Page 11: Introduction - Hardware Components

    . It is designed for outside use . It has an RF antenna to be used for tire pressure monitoring . It is designed to be installed under the trailer . SCALAR EVO Cast connects to the trailer’s iABS or RSSplus .
  • Page 12 POINTS 4019845b iABS/RSSplus PORT NOTE: Make sure that the air vent of the SCALAR EVO Cast 4019844c unit is always accessible to air . Make sure that nothing can block the air access of the air vent . (DO NOT apply glue/tape/ silicone along the edges of the unit .) Mounting the unit on any...

  • Page 13: Installation - Scalar Evo Cast Position

    • Verify the installation with an external power source connected to the SCALAR EVO Cast unit . • To obtain a full battery capacity, connect the SCALAR EVO Cast unit to an external power source for 4 hours . •...
  • Page 14 MUST be used to fix the SCALAR EVO Cast. • The unit must be installed below the trailer bed with the front of the SCALAR EVO Cast unit directed to the ground . •...
  • Page 15 • In case the installation includes a TPMS system (connecting to the internal sensors), an installation bracket MUST be used to fix the SCALAR EVO Cast. • Find a suitable location and make sure that the front of the unit has a clear view as much as possible (min .
  • Page 16 Installation – SCALAR EVO Cast position Preferred Installation for SCALAR EVO Cast: Between Axle 2 and 3, Connector Upwards and to Back of the Trailer • In case the installation includes a TPMS system (connecting to the internal sensors), an installation bracket MUST be used to fix the SCALAR EVO Cast.

  • Page 17: Incorrect Installation

    Installation – SCALAR EVO Cast position Alternative Installation for SCALAR EVO Cast: Between Axle 1 and 2, Connector Upwards and to the Front of the Trailer • In case the installation includes a TPMS system (connecting to the internal sensors), an installation bracket MUST be used to fix the SCALAR EVO Cast.
  • Page 18 The general installation instructions to be observed for cables and connectors can be downloaded from: http://inform .wabco-auto .com/intl/drw/9/4490000000 .pdf . After connecting all hardware to SCALAR EVO Cast, ZF recommends using cable ties to relieve tension from the connectors .

  • Page 19: Fastening Scalar Evo Cast

    Fastening SCALAR EVO Cast In case the installation includes a TPMS system (connecting to the internal sensors), an installation bracket MUST be used to fix the SCALAR EVO Cast. If no TPMS system is used, the installation bracket is not required .
  • Page 20 Use hexagon head M8 x 1 .25 . class 8 .8 bolts, nuts and washers (not included) treated for the applicable environment to mount the SCALAR EVO Cast unit on the bracket . Tighten with a maximum torque of 12 .5 Nm .
  • Page 21 Fastening SCALAR EVO Cast 4022810a 4022801a 4022800a SCALAR EVO Cast...

  • Page 22: Fastening Scalar Evo Cast (When Bracket Is Not Used)

    M8 x 1 .25, class 8 .8 and tighten the bolts with a maximum torque of 25 .4 Nm (dry) . Make sure that SCALAR EVO Cast is mounted on a rigid, flat surface. Use both fixing points to fasten the SCALAR EVO Cast device .

  • Page 23: Connecting Hardware

    Connecting hardware Hardware Activation The SCALAR EVO Cast unit is preactivated and will start sending positions as soon as the unit is connected to a power source (iABS or RSSplus) . Connection to SCALAR EVO Cast for iABS or RSS...
  • Page 24 Press down the connector . By pressing down the connector, the yellow clip will automatically move down . 4019858a Finally, press the yellow clip to lock the connection . A distinct “click” should be heard . 4019859a SCALAR EVO Cast...
  • Page 25 Connecting hardware The connector has been plugged in correctly . 4019860a SCALAR EVO Cast...

  • Page 26: Wabco Iabs Subsystems

    In case of a modulator 1M premium (400 500 350 0) or 2M standard (400 500 420 0/400 500 425 0) or 2M premium (400 500 430 0), you can connect SCALAR EVO Cast to the modulator SUBSYSTEMS port using the iABS connection cable .
  • Page 27 (894 600 151 2) which includes POWER and SUBSYSTEMS ports, can be used while connecting it to the power port of the modulator . You can connect the SCALAR EVO Cast to the SUBSYSTEMS port on the hub cable using the iABS connection cable .

  • Page 28: Wabco Rss Subsystems

    WABCO RSS subsystems Hardware Connection In case of RSSplus 2M (480 107 001 0) modulator, you can connect SCALAR EVO Cast to the modulator SUBSYSTEMS port using the RSSplus adapter cable (449 913 050 0) and SCALAR EVO Cast connection cable (894 600 001 2) .

  • Page 29: Connecting To The Internal Sensors

    SCALAR EVO Cast supports the following internal tire pressure sensor type: OptiTire Strap-mounted sensors (SMS): Installation on the rims by means of fastening strap . SCALAR EVO Cast is not compatible with any non-WABCO TPMS solution . Connecting to the Internal Sensors (SMS) For selecting the required valve set and further sensor installation instructions, we refer to the sensor installation instructions .

  • Page 30: Purpose And Function

    The WABCO TPMS Manager can be used to stimulate and read WABCO SMS tire pressure sensor . Data such as temperature, pressure, lifetime of internal batteries, IDs, etc . can be read out . The WABCO TPMS manager can be configured in different languages via its menu. SCALAR EVO Cast...

  • Page 31: Supported Units

    Fahrenheit Bar/ °F kPa/ °F PSI/ °F To control the internal sensor SMS, you may need to update the software version on the ZF WABCO TPMS Manager . WABCO TPMS Manager Software Update Start the WebVT software . Connect the WABCO TPMS Manager to your PC using the supplied USB cable .
  • Page 32 Hold the WABCO TPMS Manager close to the internal sensor, either from the side of the tire sidewall or from the tread . The adjacent wheel may interfere with the radio signal, in which case the respective wheel must be turned . SCALAR EVO Cast...

  • Page 33: Assembly Of The Internal Sensor Sms

    If the housing is visibly damaged, it must be replaced . Replace the internal sensor if you identify: • Foreign bodies can be seen in the pressure opening, or • The battery of the internal sensor has reached the end of its life . SCALAR EVO Cast...

  • Page 34: Preparing The Installation

    4022816a Inside (unmarked) 4022817a Outside (marked) Guide the fastening strap through the center of the drop center and once around the rim . 4022818a Pass the Velcro through the ladder buckle . SCALAR EVO Cast...
  • Page 35 Tighten the fastening strap with a tensile force of ~100 Nm and close the Velcro fastener . 4022820a The sensor must lie flat on the drop-center with the concave underside. 4022821a The Velcro fastener must be pressed firmly over its length. SCALAR EVO Cast...
  • Page 36 Make sure that the internal sensor does not come into contact with fluids (e.g. assembly fluid). „ Do not fill the tires with water. Fit the wheel onto the assembly machine so that the assembly head is on the opposite of the valve, i.e. offset by 180 degrees. 4022824a SCALAR EVO Cast...
  • Page 37 . 10.5 Assembly of the Wheel Fit the complete wheel to the vehicle. When doing this, apply the tightening torques specified by the vehicle manufacturer . Installation of the internal sensor SMS is completed . SCALAR EVO Cast...

  • Page 38: Checking The Installation

    Checking the installation Checking the installation If installing a SCALAR EVO Cast without an iABS or RSSplus, the "ABS/RSS" status indicator will always show as red . The ABS/RSS status indicator can be bypassed for a successful installation . The SCALAR EVO Cast installation can be verified using a smartphone.
  • Page 39 Before checking the data with WABCO Fleet Installer: Make sure iABS or RSSplus is not connected to the TOOLBOXPLUS™ software . Turn ON the vehicle contact . Select the Installation Wizard . Installation wizard: step-by-step wizard for the first installation. SCALAR EVO Cast...

  • Page 40: Installation Wizard

    Trailer Utilization • Trailer Manufacturer • License Plate* • Customer • Number of axles • Axle Brand • Axle Model • Tire Type • Tire Brand • Tire Model *Mandatory input field Press Next to continue . SCALAR EVO Cast...
  • Page 41 In case the Battery status is not OK, verify all cable connections from iABS/RSS to SCALAR EVO Cast or truck to trailer are connected and powered . Press Next to continue . iABS/RSS status: OK/Not OK . 4022830a Verify the iABS/RSS connection status: SCALAR EVO Cast...
  • Page 42 GPS status: OK/Not OK . Verify the GPS status: 4022881a In case the GPS status is not OK, make sure that the position of SCALAR EVO Cast meets the requirements (Step 6 - SCALAR EVO Cast position) . • Satellites: Number of satellites covering the trailer . A minimum 3, but preferably 5 satellites are necessary for a good GPS position .
  • Page 43 Use the TPMS manager (300 200 001 0) to simulate the sensor to make it visible and/ or read the sensor ID . • Repeat these steps until a sensor has been assigned to all tires . SCALAR EVO Cast...
  • Page 44 Checking the installation Create and send a report Email . Send a report via email to confirm the installation. Enter the required parameters: • Email address • Installer • Workshop • Comment Press Send to complete the process . SCALAR EVO Cast...
  • Page 45 . If a common chassis ground point is not present, ZF recommends adding one . Do not add more than one common chassis ground point (connecting the J560 ground pin to the chassis) to help avoid potential ground shifts within the vehicle electrical system .
  • Page 46 4 .7 M 894 600 151 2 0 .5 M Power 4019764a Power HUB Cable 449 943 050 0 Subsystem Subsystem Cable (SCALAR EVO Cast) 4019761a RSSplus Variant List Variants RSSplus 4S/2M Part Number 480 107 001 0 CAN Capable...
  • Page 47 TRAILER CAST – RSS Subsystem Cable 894 600 001 2 0 . 1 5 M RSS Subsystem Cable Socket 4022885a SCALAR EVO Cast – RSS Cable 449 916 253 0 Subsystem 449 916 243 0 4022921a Y Cable SCALAR EVO Cast Variant List...
  • Page 48 For further product details, contact your distributor or the ZF Customer Care Center at (844) REACH-ZF (844-732-2493) (U.S./Canada) or (800) 953-0248 (Mexico). About CVS Division ZF’s Commercial Vehicle Solutions (CVS) division is helping shape the future of commercial transportation ecosystems. Our mission is to be the preferred global technology partner to the commercial vehicle industry.

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