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48 Volt Battery Pack Removal

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Содержание MPV-7100

Страница 1: ...Raven 7100 Service Manual ...

Страница 2: ...12v Battery Exchange ...

Страница 3: ...olts and the 8 mm T handle wrench 5 If battery voltage is less than 12 8 volts then proceed as follows to remove the battery a Remove the two bolts securing the battery retaining strap using an impact drill with an 8 mm socket Fig B b Remove the battery retaining strap Fig C c Loosen the bolt on the negative terminal of the battery black cap using the 10 mm open end wrench Fig D A 10mm socket and ...

Страница 4: ...12 Volt Relay Exchange ...

Страница 5: ...ost fig A 2 Use the 8 mm drive to remove the 8mm screw fig B 3 Simply unplug the relay from the wiring harness Fig D And remove the 8mm Screw 4 The Relays are called out C8 AVR Relay C9 Back Fire Relay C10 Back Fire Relay C11 Blade PTO Relay C11 C10 C9 C8 Denver Global Products 1000 East Powell Dr Lincolnton NC 28092 U S A 2014 Denver Global Products RATO All rights reserved ...

Страница 6: ...48 Volt Battery Pack Removal ...

Страница 7: ...y Jack B 3 Use the 8mm wrench or T Handle to remove the screw that connects the oil drain plug to the battery pack assembly Figure C 4 Pull up on oil plug place it on unit frame back left corner Figure D 5 Remove all four 4 10mm bolts using the 10mm wrench two on each side connecting the battery pack assembly to the vehicle Figure E 6 Unplug HD 48V DC plug Figure F 7 Slowly lower the jack while st...

Страница 8: ...Blade Motor Controllers ...

Страница 9: ... covers should be removed Please observe the junction box with the opt coupler Fig B 3 Also the motor sensor plug and the 12 volt signal plugs should be unplugged Fig D 4 To remove the motor controller Mounting nut is 10mm and under is 5mm Allen button head 5 Picture in figure F shows the unconnected deck Denver Global Products 1000 East Powell Dr Lincolnton NC 28092 U S A 2014 Denver Global Produ...

Страница 10: ...r should be placed under the controller wire as shown Fig C 4 Be sure the covers are tight and for the side with optocoupler use Loctite 242 and longer screw Fig D 5 Connect the sensor wire from the blade motor to the connector from the BMC Fig E 6 Connect 12V signal connector The male connector is from the optocoupler Fig F 7 The wires should be zip tied and correct neat fitment to not pinch wire...

Страница 11: ...Carburetor Replacement ...

Страница 12: ...ary to turn the lever by hand in order to remove the spring Carefully remove the speed regulator pull rod from the speed regulator lever It may be necessary to turn the lever by hand in order to remove the rod 2 Carefully slide the carburetor assembly off the mounting studs Remove and discard the gray carburetor gasket Denver Global Products 1000 East Powell Dr Lincolnton NC 28092 U S A 2014 Denve...

Страница 13: ... followed by the manifold spacer Slide both back against the engine DO NOT USE MANIFOLD SPACER TO PUSH GASKET BACK as it may damage the gasket Push the spark plug wire back down onto the manifold spacer 5 Carefully slide the new green gasket onto the mounting studs and ensure that small hole on top aligns correctly with the manifold spacer Slide new carburetor onto the mounting studs and push it b...

Страница 14: ...he speed regulator pull rod and spring to the speed regulator lever It may be necessary to turn the lever by hand in order to install both rod and spring Denver Global Products 1000 East Powell Dr Lincolnton NC 28092 U S A 2014 Denver Global Products RATO All rights reserved ...

Страница 15: ...gasket must be in the same position as Figure B before attaching Identify the gasket used between the carburetor and the choke assembly see Figure C The gasket must be in the same position as Figure C before attaching Identify the gasket used for the choke assembly see Figure D The gasket must be in the same position as Figure D before attaching 2 3 4 Denver Global Products 1000 East Powell Dr Lin...

Страница 16: ...Contactor Fuse Replacement ...

Страница 17: ...r cover in place with one hand while tightening the top screw on the right using the impact drill and 8mm socket Use the 8mm wrench to tighten the bottom screw on the right total of 2 screws installed see Figure D 2 Install the L shaped bracket with lip to the outside see Figure E using the impact drill and 8mm socket on the top and bottom screws total of 2 screws installed see Figure F 3 See Figu...

Страница 18: ...a Nylock nut Locate the red deck plug wire and mount to Fuse A in the same manner Fig B Tighten the nuts using the 7 16 wrench The jumpers should be coming off the fuses at a 45 angle pointed towards the front of the unit Mount the Double Fuse Assembly to the large RH post of the RH Contactor as shown in Fig C Place the red wire from the square diode on next followed by an M8 flat washer an M8 loc...

Страница 19: ...t and wrench 7 8 9 48 V Wire 10 Locate the second pair of the 12V wires yellow green green The yellow green wire goes to the small LH post on the LH contactor and the solid green wires goes to the small RH post Fig J Secure using M4 flat washer lock washer and nut using a 7mm socket and wrench 11 Locate the 4 Black Rubber Caps and place over the 4 small terminal posts on each of the contactors Fig...

Страница 20: ... Red Deck Plug Wire from Step 3 together 2 use a 4 zip tie to secure green and red Square Diode wires together approximately 3 from diode 3 use a 4 zip tie to secure green and red Square Diode wires together approximately 6 7 from diode 4 Bend excess 48V Charging Wire from Step 5 together as shown and secure with a 4 zip tie 5 Use a 10 zip tie to secure the main Y Harness and portion of 48V Chargi...

Страница 21: ...Drive Motor Controller Replacement ...

Страница 22: ...ve 1 seat console 82041 H200100 0001 off of unit Using an Impact Drill with a 5mm Allen Bit Remove 2 M6x16 hex socket screws 90111 0TY0200 0001 and using an Impact Drill with a 4mm Allen Bit Remove with 2 M5x12 hex socket screws 90111 0TY0500 0001 2 To remove the side panels 1 left side cover 82311 H200100 0001 attached to bracket using an Impact Drill with a 5mm Allen Bit Remove both 2 M6x16 hex ...

Страница 23: ...to remove 4 10mm bolts 2 on each side Fig E Locate the yellow junction box below the drive motor control and remove 2 screws using a phillips screwdriver Remove the cover of the junction box Fig F Use the 10mm T Handle to remove 3 10mm nuts on the junction box Fig G Remove DMC wiring from terminal posts Locate the 48V positive negative wiring and plastic Board 2 3 4 5 6 Frame 7 Red Terminal Post w...

Страница 24: ... hang by the wiring 12 Locate the white and gray plugs the gray plug is partially covered by a black rubber cover Fig M 13 Push the black rubber cover away from the gray plug then disconnect the gray plug by pressing tab on top of male end and carefully pulling the gray plug apart Fig N 14 Disconnect the white plug by pressing tab on top of male end and carefully pulling the white plug apart Fig P...

Страница 25: ... tighten the 4 M8 x 20mm mounting bolts 2 per side until the DMC is secured to the frame Fig C D Locate the 3 motor cables yellow blue green and route them to the yellow junction box Slide each one onto the post with the matching color Fig E Tighten each cable to junction box using 10mm T Handle and a M6 Hex Nut Flat Washer and Lock Washer Fig F IMPORTANT Ensure that all nuts are tight Look for st...

Страница 26: ...ect Fig I 11 Locate the 2 plugs under the large rubber boot and reconnect to their corresponding receptacles Fig J 12 QC INSPECTION Steps 8 11 must be checked and verified by Quality Control 13 Place plugs back inside rubber boot M8 Nut Flat Washer Lock Washer Red Power Post 13mm Wrench Wiring From DMC H Denver Global Products 1000 East Powell Dr Lincolnton NC 28092 U S A 2014 Denver Global Produc...

Страница 27: ...Gas Gauge Check Replacement ...

Страница 28: ...steners Fig B 3 Remove the heat shrink to expose the connector Fig C 4 After the wires are removed from the fuel gauge the screws on the face can be removed the screws are the securing lock Fig D 5 The fuel gauge can then be removed from the plastics Fig E 6 Repeat steps for reassembly A B C D E Denver Global Products 1000 East Powell Dr Lincolnton NC 28092 U S A 2014 Denver Global Products RATO A...

Страница 29: ...k wire of the wiring harness 2 subline respectively GND black wire is also connected to the black wire of the fuel gauge and the signal wire yellow wire is connected to the yellow wire of the fuel sensor The brown wire is connected to the orange wire of the subline see Figure B Denver Global Products 1000 East Powell Dr Lincolnton NC 28092 U S A 2013 Denver Global Products RATO All rights reserved...

Страница 30: ...Oil Separator Replacement ...

Страница 31: ...mp is completely compressed and slid back approximately 1 Fig D This will allow for easier separation Carefully pull under existing cables wiring and disconnect the other end of the filter from the hose connected to the fuel pump Fig E 2 3 4 Use needle nose pliers to connect the top of the new oil separator filter to the hose connected to the fuel pump Fig G Hose Clamp Compress and Slide Back 1 5 ...

Страница 32: ...e strap back over the hose and then guide an 8 Zip Tie around the filter body under the engine bracket and up through the hole in the bracket Fig K 7 Leave Slight Gap Between Clamp and Hose End 8 G 9 10 Use a Zip Tie gun set to the lowest setting to tighten and cut the zip tie Fig L 11 Fig M shows replacement a completed oil separator filter Denver Global Products 1000 East Powell Dr Lincolnton NC...

Страница 33: ...PCB Replacement ...

Страница 34: ...d Fig D 5 Locate the bottom bolt Fig E Depending on your model this may be an 8 mm or 10 mm bolt Remove both bolts on the top and bottom of the PCB board 6 Rotate the PCB board up to locate and remove the two screws Fig F Detach old PCB board 7 Locate new PCB board and ensure that a label verifying the new Program is has been installed is located on the bottom Fig G 8 Install the new PCB board usi...

Страница 35: ...e attach the switch cover 14 Replace the fender extension with the 5 mm Allen wrench 15 QC INSPECTION Steps 12 and 13 must be verified by Quality Control 16 Close the service hatch I J 17 Place the old PCB board in a box marked for quarantine Denver Global Products 1000 East Powell Dr Lincolnton NC 28092 U S A 2014 Denver Global Products RATO All rights reserved ...

Страница 36: ...ck drive Direct DC motor Cut height adjustment yes Overall length 85 Overall width with deck 55 Overall width no deck 44 Weight 870 lbs Overall height 50 Frame type Welded tubular steel Transmission type Foot pedal DC motor to HD differential Towing capacity 550 lbs Suspension type Ground compliant ATV style shocks frame suspension front Fuel capacity 5 US gallons Fuel gauge yes Oil filter type n ...

Страница 37: ...agger capable yes 3 bins bagger sold separately Mulching capable yes plug sold separately Generator running Watt range 6500 Watts Generator Starting surge Watts 7100 Watts Generator voltage 120 VAC Generator Run time at full load 4 5 Hours Generator cord set included no Number of AC outlets 5 Number of 12 VDC Car plug outlets 1 Storage bed yes Seat type high mid back Adjustable seat yes Cup holder...

Страница 38: ...s 35 ft Ibs Transaxle Hi Lo lever 40 ft Ibs Tie Rob castle Nuts 19 ft Ibs Steering shaft Bolt 20 ft Ibs Upper shock mount 40 ft Ibs Rear lug nuts 40 ft Ibs Contactor post 5 ft Ibs U Bolts 35 ft Ibs Parking brake pawl 30 in pounds Power Terminals 5 ft Ibs Loctite 425 Blade Stud Nut Blade Fastener 40 ft Ibs Loctite 263 1 full ampule per stud motor shaft 24 hour cure 72 F Blade Motors 20 ft Ibs Locti...

Страница 39: ...WHITE PURPLE YELLOW GRAY GREEN GRAY ORANGE WHITE RED YELLOW YELLOW WHITE R BLUE GREEN RED BLACK YELLOW ORANGE WHITE PINK BLUE 48VDC 48V COMMON 12V GROUND 5VDC FROM DRIVE SPEED COMMAND TO DRIVE 5VDC COMMON 48V COMMON REVERSE TO MAGNETO 48VDC 12V GROUND 4 5VDC THROTTLE 12VDC 12VDC YA2 YA3 YB2 YB3 START MAG 12VDC 12V GROUND YC1 STARTER YC3 YD2 LOW GEAR YD3 BATT MODE YE1 YE2 YE3 YF1 SSR YF2 48V YF3 OR...

Страница 40: ...F4 20A F5 BLUE BLUE BLUE BLUE RED WHITE ROTOR EXCITATION BLACK BLACK 20VAC CHARGING GENERATOR M M1 X1 X2 BLACK RED 05 9 05 14 05 2 04 3 04 9 K7 STARTER SOLENOID M M2 STARTER MOTOR Y4 HOUR METER PTO DECK PLUG 05 7 05 8 DRIVE MOTOR 04 8 04 1 05 12 RECEPTACLES 48VDC 48V COMMON 12V GROUND 12VDC SUPPLY FROM CONTACTOR COILS FROM SEAT SWITCH TO KEY SWITCH STARTING BATTERY 12V 9AH RECTIFIER OUTPUT RECTIFI...

Страница 41: ...10 50 14 122 Storage 20 50 4 122 Standard Charging method 25 Current 0 9A Time 5 10h Quickly Charging method 25 Current 4 5A Time 1h Maximum charging current 9A Terminal material Pb Maximum discharge current 135A 5 sec Feature Motorcycle use Absorbent glass mat technology Maintenance free Highly efficient Low shelf discharge Long cyclic life Discharge Characteristics 25 0 Voltage v 10 6 8 12 13 9 ...

Страница 42: ...mperature range Storage 20 50 4 122 Current 2 0A Standard Charging method 25 Time 5 10h Current 10A Quickly Charging method 25 Time 1h Maximum charging current 20A Terminal material Pb Maximum discharge current 300A 5 sec Feature Absorbent glass mat technology Maintenance free Highly efficient Low shelf discharge Long cyclic life Discharge Characteristics 25 0 Voltage v 10 6 8 12 13 9 8 7 6 5 4 3 ...

Страница 43: ... voltage while under load by drive system Ideal should read 54 1 If the voltage drops to 40 volts a cell in battery pack may be failed This should be preformed in electric mode Generator switch is in ON position 100A battery fuse 48V battery missing or failed open circuit 12V starter battery low contactor s stuck open Move Generator switch to OFF position Check Continuity on fuses Check 100A fuse ...

Страница 44: ...ter Rollover vent valve failure and or vent line pinched under hood Hose is pinched by hood assembly Remove gas cap listen for vacuum sound Test vent line and valve to ensure it is unrestricted Shorten hose or simply reroute Engine shuts off while driving on hills Low Oil Oil level switch shuts off engine Check oil level Low fuel level Check fuel level See if magneto is unplugged This is a black w...

Страница 45: ...ngine is shut down Generator panel on off switch hit by foot seat switch defective opto etc Verify Rider weight Parking brake is on Unit is in neutral on transaxle 100A fuse failed or missing 48V battery Accelerator pedal failure Accelerator pedal connector to harness failure or loose connection Check connector is fully seated and check for visible wire damaged Bad seat switch or seat switch conne...

Страница 46: ...cuit Vehicle controller is powered by 12V starter battery and performs a safety shut down when the starter battery is low or defective Replace 12V battery or charge the battery if it is simply low 30A fuse open and or failure in the 12V charging system Drive is jerky in engine and or mowing mode Rider weight Seat switch Drive is jerky on hills or rough terrain Rider weight Seat Switch Transaxle in...

Страница 47: ...ance Wrong blades installed High lift blades are stamped 23 1125 Reg are H200110 Dull blades Sharpen and balance blades Cannot mow high enough Unit is shipped from factory with maximum height range established Range cannot be adjusted higher Cannot mow low enough Unit is shipped from factory with maximum height range established See owner s manual for lowering cutting height range High Level Check...

Страница 48: ...BMC or Motor failure Bad seat switch or seat switch connector Check pins for all 4 wires fully inserted in plastic housing Test and replace switch if necessary Opto switch failure Deck Clogged BMC or Motor failure Deck shuts off in very high grass Shut sysytem down wait 10 mins BMC current overload tripped Shut down machine and re start then mow more slowly and increase mowing height Deck lift han...

Страница 49: ...e 10A breaker 12V starter battery does not charge and 12V DC outlet provides no power 30 amp fuse blown or not seated correctly 30A fuse open failed regulator 30A fuse open bad battery damaged charger 30A fuse not seated What kind of oil do I use for the transaxle 90 weight gear oil add oil until oil reaches the 1 below the bottom edge of the fill hole note this depends on which version of the tra...

Страница 50: ...nty Batteries are automatically charged when the engine is running except when being used solely as a stationary Generator If using in only electric mode batteries will not be recharged In this case an external battery charger should be purchased The MPV alerts the operator to recharge the 48V batteries by bumping back and forth while driving in Electric mode Stop driving immediately and start the...

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