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Section 01 TECHNICAL MANUAL

Subsection 02 (AIR CONTROLLED SUSPENSION (ACS))

Outlander 800R LTD

vmr2010-004-105_a

OUTLANDER 800R LTD MODEL

1. ACS compressor relay (R5)

28

vmr2010-004

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Содержание 2010 ACS

Страница 1: ...Technical Manual 2 1 9 1 0 0 3 8 8 DPSTM ACS DPSTM ACS 2010 ...

Страница 2: ...2010 DPS ACS Technical Manual ...

Страница 3: ...s Inc BRP 2009 Printed in Canada Technical Publications Bombardier Recreational Products Inc BRP Valcourt Quebec Canada and the BRP logo are trademarks of Bombardier Recreational Products Inc BRP or its affiliates Can Am Renegade DPS XPS Outlander This document contains the trademarks of the following companies AMP is a trademark of Tyco Electronics Corporation Loctite is a trademark of Loctite Co...

Страница 4: ...OOTING 8 PROCEDURES 9 DPS UNIT 9 PITMAN ARM 22 02 AIR CONTROLLED SUSPENSION ACS 23 GENERAL 25 SYSTEM DESCRIPTION FEATURES 25 SYSTEM DESCRIPTION COMPONENTS 27 TROUBLESHOOTING 30 DIAGNOSTIC TIPS 30 TROUBLESHOOTING GUIDELINES 30 TROUBLESHOOTING WITH B U D S 31 PROCEDURES 31 ACS SOLENOID VALVE 31 ACS MANIFOLD 33 ACS MODULE 35 ACS COMPRESSOR RELAY R5 37 ACS COMPRESSOR 37 ACS AIR FILTER 42 PRESSURE TRAN...

Страница 5: ...recom mended when considering replacement of any component Dealer and or distributor assistance should be sought in case of doubt The engines and the corresponding components identified in this document should not be utilized on product s other than those for which it was designed WARNING Unless otherwise specified engine should be turned OFF and cold for all maintenance and repair procedures This...

Страница 6: ... Red Steel grey 2MAA 2MAB 2MAC 2MAD RENEGADE ENGINE MODEL COLOR MODEL NUMBER 800R X xc Black 4DAA 4DAB 4DAC The information and component system descriptions contained in this manual are correct at time of writ ing BRP however maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on products previously manufactured Due to late chan...

Страница 7: ...IV vmr2010 002 ...

Страница 8: ...SERVICE TOOLS INDEX FLUKE 115 MULTIMETER P N 529 035 868 Page 9 11 32 35 37 38 43 44 OETIKER PLIERS P N 295 000 070 Page 44 SPRING REMOVER P N 529 036 007 Page 46 1 ...

Страница 9: ...2 ...

Страница 10: ...ERING DPS SERVICE TOOLS Description Part Number Page FLUKE 115 MULTIMETER 529 035 868 9 11 SERVICE TOOLS OTHER SUPPLIER Description Part Number Page SNAP ON TELESCOPING GAUGE SET LST 52616 20 SERVICE PRODUCTS Description Part Number Page XPS SYNTHETIC GREASE 293 550 010 19 vmr2010 003 3 ...

Страница 11: ...NG DPS 38 N m 28 lbf ft If torqued by screw head XPS synthetic grease 400 g NEW NEW XPS synthetic grease 400 g NEW 24 5 N m 18 lbf ft NEW NEW 72 N m 53 lbf ft NEW NEW 24 5 N m 18 lbf ft If torqued by elastic nuts 24 5 N m 18 lbf ft vmr2010 003 001_a 4 vmr2010 003 ...

Страница 12: ... posi tion there is no steering assist Steering torque may also come from the wheels due to rough terrain Steering kickback is reduced while providing feedback to the driver The greater the power steering assist the greater the load on the electrical system When the electrical system is under high load battery not at full charge operating the vehicle for prolonged periods of time at slow speed and...

Страница 13: ...0 003 003 DPS UNIT The DPS module provides DC power to the mo tor The amount and duration of that DC power is determined by the inputs to the DPS module The direction in which the motor turns is changed by reversing the polarity of the circuit current The DPS motor does not spin but rather turns in very small increments based on the amount du ration and direction of DC power delivered by the DPS m...

Страница 14: ... adjusting steering alignment the sensor torque offset must be reset to zero for proper system operation PART ADJUSTED OR REPLACED WHAT TO DO DPS unit Steering column bearing Tie rod Tie rod end Knuckle Wheel bearing Ball joint Front suspension arm lower upper Steering alignment Reset Torque Offset in Setting DPS 1 Ensure proper STEERING ALIGNMENT refer to appropriate Shop Manual subsection 2 Conn...

Страница 15: ...tailed in this subsection Repair or replace wiring connectors as required 4 No engine RPM signal from ECM If engine RPM can be displayed in the multifunc tion gauge when the engine is running carry out a DPS UNIT COMMUNICATION LINK CAN CON TINUITY TEST as detailed in this subsection Re pair or replace wiring connector as required If engine RPM cannot be displayed in the multi function gauge use B ...

Страница 16: ...pear in the multifunction gauge If it comes on button and wiring to gauge are good If OVERRIDE message does not appear in gauge test drive vehicle to determine if OVERRIDE func tion can be activated If the function can not be activated test the OVERRIDE DPS switch and wiring If the function is activated test wiring from switch to multifunction gauge PROCEDURES DPS UNIT DPS Unit Power Fuse Test A 4...

Страница 17: ...ight between each DPS PWR connector pins A and B and the battery negative terminal The test light must come on bright DPS Unit Input Voltage Test Control Side 1 Disconnect DPS CTRL control connector and turn ignition switch ON 2 Set the ignition switch to ON 3 Set the engine RUN STOP switch to RUN 4 Test for 12 Vdc power to the DPS module at DPS1 A as per following table MULTIMETER PROBE POSITIONS...

Страница 18: ...S unit must receive an RPM signal to provide power steering assist Disconnect the DPS control connector and the di agnostic connector Test continuity of CAN Bus Wires at DPS1 C and DPS1 D MULTIMETER PROBE POSITIONS RESISTANCE 20 C 68 F DPS control connector pin C and diagnostic connector pin 1 rmr2008 028 094_a DPS control connector pin D and diagnostic connector pin 2 rmr2008 028 094_b Below 1 If...

Страница 19: ...utton on the multimeter to engage the MIN function mmr2009 023 027_e 1 MIN function selected 9 Turn the handlebar momentarily against the steering frame stops to each side NOTE Do not hold steering against frame stops for and extended period of time 10 Read the MIN charging system voltage recorded while the handlebar was turned against each stop DPS SYSTEM LOAD TEST PROBE POSITIONS STEERING POSITI...

Страница 20: ...h stop and observe the indications on the B U D S DPS Monitoring page The DPS Torque Sensor Nm increase with torque applied to handlebar The DPS Current ammeter should increase pro portionately to the torque applied and decrease with the torque as steering assist is provided vmr2010 003 009_a TYPICAL LH TURN 1 Torque sensor indication negative 2 DPS current indication positive vmr2010 003 010_a TY...

Страница 21: ...014 055_d TYPICAL 1 Shift lever guide plate 2 Guide plate screws forward screw not visible NOTE It is not necessary to disconnect the shift lever 5 Loosen the gear clamp securing the air filter housing duct to the throttle body vmr2010 003 012_a 1 Gear clamp to loosen 6 Remove the screws securing the engine air fil ter housing 7 Move the shift lever and guide plate slightly to the right 8 Lift up ...

Страница 22: ...lumn pinch bolt and retaining nut Discard the retaining nut vmr2010 003 017_a 1 Steering column pinch bolt 14 Remove and discard the elastic nuts from the 2 hexagonal screws that secure steering column half bushings to the support on the frame vmr2010 003 018_a 1 Elastic nuts to remove and discard 2 Frame support 3 Steering column half bushings 15 Remove the 2 hexagonal screws from the ECM support...

Страница 23: ...cures both tie rod ends to the pitman arm steering lever Discard cotter pins vmr2010 003 022_a 1 Pitman arm 2 Tie rod ends NOTE Leave the tie rod ends on the pitman arm at this time They will come off easily when the DPS unit is lifted from its frame support vmr2010 003 023 TIE ROD ENDS HARDWARE REMOVED 19 Remove the 4 hexagonal flanged screws se curing DPS unit to frame NOTE Discard the 4 conical...

Страница 24: ...ard ened steel washers on the tie rod ends DPS Unit Installation NOTICE The following procedure MUST be followed as specified Failure to do so may re sult in steering column DPS misalignment and poor DPS operation due to an induced erro neous torque on the DPS shaft 1 If installing a new DPS unit install the two M5 hexagonal forming screws on the mounting flange of the DPS unit vmr2010 003 026_a 1...

Страница 25: ...teer ing column and ensure the two O ring seals are installed on the shaft and in good condition Re place as required vmr2010 003 029_a 1 O ring seals on steering column 6 Index steering column splines with DPS unit splines NOTE The DPS shaft splines have a key which must be aligned with the keyway in the steering column end vmr2010 003 031 STEERING COLUMN INDEXED TO DPS SHAFT SPLINES 7 Fully inse...

Страница 26: ...remain floating over the DPS housing vmr2010 003 016_a 1 Locking tie location 2 Steering column bellows vmr2010 003 033_a 1 Drainage hole in DPS ring flange 2 Steering column bellows 9 Apply XPS SYNTHETIC GREASE P N 293 550 010 to the inside of both steering column half bush ings vmr2010 003 034 10 Loosely secure the steering column to its frame support by installing the following parts to provide...

Страница 27: ...2010 003 036 STEERING COLUMN SHIM MEASUREMENT NOTE Ensure the forward end of the tool is in the center of the steering column and the rearward end does not protrude through the notch in the support 13 Measure the telescoping gauge using a Vernier caliper or a micrometer and com pare the measured distance to the following table to establish the required shim thickness vmr2010 003 037 STEERING COLUM...

Страница 28: ...xagonal SCREWS retaining the steering column to 38 N m 28 lbf ft vmr2010 003 021_b Step 1 Hold elastic nuts with wrench not illustrated Step 2 Apply specified torque to hexagonal screws NOTE If torque is applied to elastic nuts in stead of hexagonal screw head use 24 5 N m 18 lbf ft 16 Install hardware on LH and RH tie rods on pit man arm Follow parts assembly sequence as in following illustration...

Страница 29: ...ered up The check engine light will come on and a DPS FAULT message will appear in the multi function gauge When DPS unit installation is complete carry out the following steps 1 Connect the ATV to the latest B U D S soft ware 2 Select the Read Data button 3 In the Module menu choose the DPS sub menu and install the latest DPS software Update file as applicable to the type ATV Out lander or Renega...

Страница 30: ...LLED SUSPENSION ACS SERVICE TOOLS Description Part Number Page FLUKE 115 MULTIMETER 529 035 868 32 35 37 38 43 44 OETIKER PLIERS 295 000 070 44 SPRING REMOVER 529 036 007 46 SERVICE PRODUCTS Description Part Number Page LOCTITE 592 PIPE SEALANT 293 800 018 33 34 41 47 vmr2010 004 23 ...

Страница 31: ...UAL Subsection 02 AIR CONTROLLED SUSPENSION ACS 53 N m 39 lbf ft NEW 53 N m 39 lbf ft 53 N m 39 lbf ft Loctite 592 pipe sealant ACS module NEW ACS compressor ACS solenoid release valve ACS hose vmr2010 004 033_a 24 vmr2010 004 ...

Страница 32: ... automatically keeps air pres sure constant with changing rider weights or loads applied The system can be adjusted on the fly to suit rider s preferences The multifunction gauge indicates suspension set ting as follows vmo2010 004 005_d 1 Requested setting set point 2 Actual setting pressure transducer reading Refer to the following table to know the ACS pres sure related to multifunction gauge s...

Страница 33: ...l be displayed instead of acknowledgement message Using the Auxiliary Line to Inflate Tires The ACS system is equipped with an auxiliary line specially designed to inflate tires The air pressure in this auxiliary line is controlled by a second pres sure transducer connected to the ACS module vmo2010 004 201_a 1 Auxiliary line adaptor to inflate tire To ensure that the use of the auxiliary line wil...

Страница 34: ...NTS Fuse and Relay ACS Fuse F14 1 ACS fuse F14 is located in the front fuse box FRONT FUSES BOX NO DESCRIPTION RATING F14 ACS 20 A vmo2007 003 017_b TYPICAL FRONT SERVICE COMPARTMENT 1 Front fuse box ACS Compressor Relay R5 Compressor relay is located in the front fuse box under front service compartment panel Note that the relay is not at the same position on a 500 LTD and on a 800R LTD models Re...

Страница 35: ...Section 01 TECHNICAL MANUAL Subsection 02 AIR CONTROLLED SUSPENSION ACS Outlander 800R LTD vmr2010 004 105_a OUTLANDER 800R LTD MODEL 1 ACS compressor relay R5 28 vmr2010 004 ...

Страница 36: ... pressure zone To monitor the air pressure of the auxiliary line Pressure transducer High pressure zone To monitor the air pressure of the shock absorbers Check valve compressor To protect the compressor Check valve between both zones To eliminate air pressure variation between low and high pressure zone Auxiliary line To inflate tire Cluster To monitor the air pressure setting Filter Compressor C...

Страница 37: ... Requested Setting Display Does Not Change in Gauge 1 Check the override ACS button as detailed in OVERRIDE SWITCH in the LIGHTS GAUGE AND ACCESSORIES subsection of the appro priate Shop Manual Suspension Setting Can Not Be Changed 1 Check the override ACS button as detailed in OVERRIDE SWITCH in the LIGHTS GAUGE AND ACCESSORIES subsection of the appro priate Shop Manual 2 Check fuse F14 3 Check A...

Страница 38: ...and fittings with soapy water to locate the faulty component If no leak is detected from hoses or fittings in spect the compressor check valve and the auxil iary line check valve with soapy water vmr2010 004 202_b 1 Compressor check valve vmr2010 004 401_a 1 Auxiliary line check valve ACS Air Pressure Monitoring To monitor air pressure in the system during trou bleshooting operation proceed as fol...

Страница 39: ...4 Set suspension mode to ACS 2 using the ACS button 5 Wait until the actual setting shows 2 LH dis play vmr2010 004 101_a 1 Actual setting pressure transducer reading NOTE Make sure to wait enough time in order to let the system adjust the air pressure 6 Set the FLUKE 115 MULTIMETER P N 529 035 868 to Vdc 7 Back probe solenoid connector without discon necting vmr2010 004 102 8 Set suspension mode ...

Страница 40: ...ale threads ACS MANIFOLD ACS Manifold Removal 1 Release air pressure refer to RELEASING AIR PRESSURE IN SYSTEM FOR SERVICING in this subsection 2 Remove solenoid valve Refer to ACS SOLE NOID VALVE REMOVAL 3 Disconnect the following hoses from manifold air fittings Manifold air inlet hose from compressor Module hose Shocks hose vmr2010 004 005_a 1 Manifold air inlet hose from compressor 2 Module ho...

Страница 41: ...apply sealant it should be already applied on male threads On pneumatic valve check valve and solenoid valve apply LOCTITE 592 PIPE SEALANT P N 293 800 018 on all male threads Install check valve with arrows pointing toward manifold vmr2010 004 007_b Install air fittings pneumatic valve and check valve as follows vmr2010 004 007_a RETAINING SCREWS ARE OFFSET TOWARD MODULE FITTING 1 Manifold air in...

Страница 42: ...CE Gauge pin 19 BE GN Module pin 6 WH BE Close to 0 ACS Module Input Voltage Test 1 Remove seats and RH side panel 2 Disconnect module connector vmr2010 004 011_a 1 Module connector 3 Set the FLUKE 115 MULTIMETER P N 529 035 868 to Vdc 4 Place ignition switch to ON position 5 Measure voltage as per the following table TEST PROBES VOLTAGE Pin 12 OR GN Battery negative post Battery voltage 12 Vdc AC...

Страница 43: ...12_a 1 Module retaining bolt 5 Remove module from vehicle ACS Module Installation The installation procedure is the reverse of re moval procedure however pay attention to the following If a new ACS module is installed check diode D7 of the solenoid valve to ensure that it is not de fective as it can damage the ACS module The diode D7 is located on the main harness near the ACS sub harness junction...

Страница 44: ...ive post Battery voltage 12 Vdc Outlander 800R LTD TEST PROBES VOLTAGE Fuse box pin 12A OR GN Battery negative post Battery voltage 12 Vdc Outlander 500 LTD TEST PROBES VOLTAGE Fuse box pin 7D BE PK Battery negative post Battery voltage 12 Vdc Outlander 800R LTD TEST PROBES VOLTAGE Fuse box pin 12B BE PK Battery negative post Battery voltage 12 Vdc If voltage is not as specified check wiring con n...

Страница 45: ...resistance as per the following table Outlander 500 LTD TEST PROBES RESISTANCE Compressor pin C BE VI Fuse box pin 6C BE VI Close to 0 Outlander 800R LTD TEST PROBES RESISTANCE Compressor pin C BE VI Fuse box pin 11A BE VI Close to 0 ACS Compressor Input Voltage Test 1 Release air pressure refer to RELEASING AIR PRESSURE IN SYSTEM FOR SERVICING in this subsection 2 Set the FLUKE 115 MULTIMETER P N...

Страница 46: ...y vmr2010 004 013_a 1 Storage tray 4 Remove solenoid valve Refer to ACS SOLE NOID VALVE REMOVAL 5 Remove manifold Refer to ACS MANIFOLD REMOVAL 6 Remove module Refer to ACS MODULE RE MOVAL 7 Remove connector of auxiliary line pressure transducer from support vmr2010 004 014_a 1 Connector of auxiliary line pressure transducer 8 Disconnect compressor connector vmr2010 004 015_a 1 Compressor connecto...

Страница 47: ...aining bolts and nuts vmr2010 004 017_a 1 RH side retaining bolt vmr2010 004 018_a 1 LH side retaining bolt 12 Remove compressor front retaining screws vmr2010 004 019_a 1 Front retaining screws 13 Remove compressor from vehicle by pulling it upwards vmr2010 004 020 14 Detach compressor connector from front sup port 15 Remove mounting nuts from compressor front support 16 Remove front support from...

Страница 48: ...ever pay attention to the following If fitting or valve is the one previously removed old one apply LOCTITE 592 PIPE SEALANT P N 293 800 018 on all male threads If fitting or valve is a new one do not apply sealant it should be already applied on male threads Install T fitting with an angle of 45 as shown on following illustration vmr2010 004 025_a A 45 Ensure that check valve is installed with ar...

Страница 49: ...ate ACS compressor air filter 6 Unscrew ACS compressor air filter from air box vmo2010 004 009_a 1 ACS compressor air filter 7 Push tabs then open cover vmo2010 004 010_a 1 tabs 8 Remove prefilter foam and filter disc vmo2010 004 011_a 1 Prefilter foam 2 Filter disc The installation is the reverse of removal proce dure ACS Air Filter Cleaning Remove ACS compressor air filter refer to AIR FILTER RE...

Страница 50: ...cer connector vmr2010 004 104_a 1 Pressure transducer connector 4 Set the FLUKE 115 MULTIMETER P N 529 035 868 to 5 Measure resistance as per the following table TEST PROBES RESISTANCE Pressure transducer pin 2 PK BR Module pin 3 PK BR Close to 0 Refer to the following illustration for the pressure transducer connector pinout vmr2010 004 108 Pressure Transducer Input Voltage Test 1 Remove seats an...

Страница 51: ...p 4 Remove pressure transducer from hose vmr2010 004 030_a 1 Auxiliary line pressure transducer 2 Connector 3 Oetiker clamp 5 Install a new pressure transducer on hose 6 Install a new Oetiker clamp using OETIKER PLI ERS P N 295 000 070 7 Connect pressure transducer connector 8 Ensure that there is no air leaks from pressure transducer hose Refer to ACS SYSTEM LEAK TEST WITH B U D S ACS HOSES ACS H...

Страница 52: ...ted into fitting vmo2010 011 103 HOSE PROPERLY INSERTED INTO FITTING SHOCK ABSORBERS Shock Absorber Removal 1 Lift rear of vehicle until rear shock absorbers are fully extended 2 Install jack stands or blocks under the frame to support the vehicle 3 Unscrew air hose from shock absorber as fol lows 3 1 Install an appropriate wrench on shock fit ting to hold it in place 3 2 Unscrew air hose fitting ...

Страница 53: ...ck Absorber Inspection Inspect the spring for damage Replace if neces sary Secure the end of shock body in a vise with its rod upward A14F0BA 1 TYPICAL 1 Clamp here NOTICE Do not clamp directly on shock body Inspect shock absorber as following 1 Examine the shock absorber for leaks 2 Extend and compress the shock absorber shaft several times over its entire stroke 3 Check that the shock absorber s...

Страница 54: ...e 3 Lower cap 4 Upper cap 5 Large sleeve Install shock absorber cap opening at 180 from spring stopper opening Torque upper and lower shock absorber bolts to 53 N m 39 lbf ft If the same shock absorber is reused apply LOC TITE 592 PIPE SEALANT P N 293 800 018 on air hose sleeve male threads While holding shock fitting with a wrench tighten air hose fitting to 19 N m 168 lbf in vmr2010 004 47 ...

Страница 55: ...that there is no air leaks from shock ab sorber fitting and air hose Refer to ACS SYSTEM LEAK TEST WITH B U D S NOTICE Never screw shock absorber air hose by using the air hose fitting only To avoid damaging the shock fitting threads in stall a wrench on the shock fitting to hold it in place while screwing the air hose fitting 48 vmr2010 004 ...

Страница 56: ...NOTES ...

Страница 57: ...NOTES ...

Страница 58: ...ARDIER RECREATIONAL PRODUCTS INC OR ITS AFFILIATES 2009 BOMBARDIER RECREATIONAL PRODUCTS INC ALL RIGHTS RESERVED PRINTED IN CANADA 219 100 388 CA DPS ACS TECHNICAL MANUAL ENGLISH MANUEL TECHNIQUE DPS ACS ANGLAIS FAIT AU MADE IN CANADA U M P C ...

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