Raven MPV-7100 User manual

Raven 7100 Service Manual

12v Battery Exchange

A

D

B

Battery

Positive

Negative

Terminal

C

Battery

Slide Battery

out

F

E

Tools Needed for Installation:

• 8 mm “T”-Handle Wrench

12 Volt Battery Exchange

Work Instructions

8 mm T-Handle

• 10 mm Socket and ratchet

• 10 mm Open End Wrench

• Volt Meter

• Phillips Screwdriver

• Impact Drill

Wrench

Battery

8 mm socket and

Impact Drill

Parts in Kit:

• Fully Charged 12 V Battery

• Exchanging the 12 Volt Battery

IMPORTANT: Turn off power and remove key.

1.

Remove the 5 bolts from vehicle right side panel using 8 mm

T-handle (Fig. A).

2.

Remove right side panel to access the battery.

3.

Check the battery voltage using the volt meter. Check that

the leads are plugged in to the correct terminals on the meter

and the range is set to “VDC”. The red positive (+) lead of the

meter should be connected to the ‘+’ terminal of the battery

(red cap), and the black negative (-) lead of the voltmeter

should be applied to the ‘-’ terminal of the battery (black cap).

Battery voltage should read 12.8 volts or higher.

4.

If battery voltage is 12.8 volts or higher, reassemble the side

cover using the 5 bolts 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 ratchet or Philips head screwdriver can

also be used for this procedure (Fig. G & H).

IMPORTANT: Use a wrench wrapped in insulating tape

Bolt

Positive

Bolts

10 mm

Wrench

Battery

Retaining

Strap

Bolt

Negative

Terminal

To avoid accidental shorting between the negative and

Positive battery terminals.

d.

Remove the wires and repeat disconnection procedure for

the positive terminal (red cap) (Fig. E).

e.

Slide the battery out of its space (Fig. F).

6.

Send the battery for recharging.

7.

Verify that the voltage of new battery reads 12.8 volts or

higher.

a.

If so, fit the battery into position.

b.

Reconnect the red wires to the positive terminal of the

battery and tighten bolt

c.

Reconnect the black and the green wires to the negative

terminal of the battery and tighten bolt.

8.

Reassemble battery retainer and vehicle side cover as reverse

sequence of removal.

Terminal

G

H

12 Volt Relay Exchange

12 Volt Relay Remove/Replace

Installation Instructions

Tools:

• 8 mm Driver

• 10 mm Driver

Instruction Text

1. To remove the relays from frame use the Driver

to remove the hotplate post (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

48 Volt Battery Pack Removal

Oil Drain Plug

D

Bolt

Battery

Pack

10mm Wrench

E

HD 48V DC Plug

F

48 Volt Battery Removal

Work Instructions

Tools:

• 8 mm T-Handle

• 10mm Wrench

• Jack

• Battery Tray

Parts:

• Battery Tray

Removing the Battery

IMPORTANT: Turn off power & remove key.

1.

Tighten oil plug by hand (Figure A).

2.

Center jack under battery tray assembly located at the

rear of vehicle. Raise jack until unit is just beginning to

lift up (Figure B).

Oil Plug

A

8mm Wrench

Screw

Battery Tray

Assembly

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 stabilizing the battery pack

assembly to prevent it from falling (Figure G).

Battery Pack

Assembly

Oil Drain Plug

C

Battery Pack

Jack

G

Denver Global Products 1000 East Powell Dr. | Lincolnton, NC 28092 U.S.A

Blade Motor Controllers

Un-Connecting the Blade Motor Controller

Installation Instructions

Tools:

• Phillips

screwdriver

• 10 mm driver

• Utility knife

Instruction Text

1. Remove the protective covers with Phillips

screwdriver.(Fig A)

2. The yellow junction box 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

Blade Motor Controller (BMC) Install

Installation Instructions

Tools:

• 10 mm Driver

• Philips screw

driver

• 5mm Allen Driver

Instruction Text

1. Attach BMC by re installing the 5mm button

head screws and the 10mm nut.(Fig A)

2. Attach the three wires on the junction box. Blue

Green and Yellow. The wires should color

match order doesn’t matter as long as routing

doesn’t resurrect covers. (Fig B)

3. The power wire from the controller 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 wires when covers are

installed.(Fig G)

8. Attach covers with Phillips screwdriver. (Fig H)

A

B

C

D

E

F

G

H

Denver Global Products 1000 East Powell Dr. | Lincolnton, NC 28092 U.S.A

Carburetor Replacement

Removal/Installation Instructions

Tools:

Parts:

• Needle-nose pliers

• New Green Gasket

• New Gray Gasket

1. Use needle-nose pliers to carefully remove the speed regulator spring from the speed regulator lever. It may be

necessary 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

Carburetor Replacement

Removal/Installation Instructions

3. Locate manifold spacer and slide of the mounting studs. It will be necessary to lift the spark plug wire to remove it.

Remove and discard the gray carburetor gasket. Ensure that no remnants of old gasket remain.

4. Locate new gray manifold spacer gasket, note correct orientation and slide onto the mounting studs, 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 back until it rests against the manifold

spacer.

Denver Global Products 1000 East Powell Dr. | Lincolnton, NC 28092 U.S.A

Carburetor Replacement

Removal/Installation Instructions

6. Reattach both the 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

Gasket Callout-Carburetor

Instructions

Tools:

• none

Parts:

• gaskets - 5

Gasket Callout

IMPORTANT: Turn off power & remove key.

1.

Identify the gasket used between the engine block and

the manifold spacer (see Figure A). The gasket must

be in the same position as Figure A before attaching.

Identify the gasket used between the manifold

spacer

and the carburetor (see Figure B). This gasket can

be

two different colors - gray or green. The 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. | Lincolnton, NC 28092 U.S.A

Choke Assembly Gasket

D

Carburetor and Choke

Assembly Gasket

C

Manifold Spacer

and Carburetor Gasket

B

Engine Block and

Manifold Spacer Gasket

A

Contactor Fuse Replacement

Contactor Cover and L-Shaped Bracket

Instructions

Tools:

Parts:

• none

•

Impact Drill

8mm W

rench

8mm Socket

Removing Contactor Cover and L-

Shaped Bracket

IMPORTANT: Turn off power & remove key.

1.

Locate the contactor cover and L-shaped bracket on

the right side (if seated in the driver’s seat) of the MPV

(see Figure A).

Remove 3 screws using the impact drill and

8mm

socket (see Figure B).

Remove the last screw (bottom, right hand

corner)

using the 8mm wrench (see Figure C) - the

close

location of the tire prevents the use of the impact

drill.

When finished, four screws should be removed

and

the contactor cover & L-shaped bracket can now

be

removed.

2.

3.

Installing Contactor Cover and L-

Shaped Bracket

IMPORTANT: Turn off power & remove key.

Top Screw

1.

Hold the contactor 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 Figure G for fully installed contactor cover and L-

shaped bracket.

Denver Global Products 1000 East Powell Dr. | Lincolnton, NC 28092 U.S.A

L-Shaped Bracket WITH LIP

ON THE OUTSIDE

Contactor Cover

G

L-Shaped Bracket

WITH LIP TO THE

OUTSIDE

Bottom Screw

Impact Drill with

8mm Socket

F

L-Shaped Bracket

WITH LIP TO THE

OUTSIDE

E

Top Screw on the

Right

Bottom Screw

on the Right

D

8mm Wrench

Last Screw -

Remove Using the

8mm Wrench

C

3 Screws - Remove

Using Impact Drill

B

L-Shaped

Contactor

Bracket

Cover

A

Contactor Fuses

Installation Instructions

Tools:

•

Standard Socket Wrench - 3/8” Drive

7mm Deep Well Socket - 3/8 Drive

8mm Deep Well Socket - 3/8” Drive

14mm Standard Socket - 3/8” Drive

7/16” Wrench

Parts:

•

75A Fuse (x1)

100A Fuse (x2)

Single Fuse Holder (x1)

Double Fuse Holder (x1)

1/4”-20 Stainless Steel Nylock Nut (x3)

M4 Hex Nut (x4)

M4 Flat Washer (x4)

M4 Lock Washer (x4)

Black Rubber Cap (x4)

M6 Stainless Steel Flat Washer (x6)

M8 Hex Nut (x4)

M8 Flat Washer (x4)

M8 Lock Washer (x4)

M5x0.8 x 16mm Flanged Hex Head Cap

Screw

4” Zip Tie (x4)

10” Zip Tie (x1)

Zip Tie Gun

(x4)

Installing the Contactor Fuses

IMPORTANT: Turn off power & remove key.

1.

Before beginning, ALL wires and jumpers

removed from both contactors.

should be

2.

Locate (2) 100A Fuses, the Double Fuse Holder, (2)

1/4-20 SS Nylock Nuts, and (4) M6 SS Flat

Washers

(Fig. A).

Locate the J4 jumper from the red terminal block

and

mount to Fuse B. Place an M6 flat washer over the

fuse

stud followed by the jumper, another flat washer

and

then 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 lock washer and an M8 nut.

Tighten

using a 14mm socket and wrench. Ensure that

red

diode wire is in line with the fuse holder.

Place the green square diode wire and one end of

the

short contactor jumper wire on the large LH post of

the

RH contactor. Secure with M8 flat washer, lock

washer

and nut. Tighten with 14mm socket and wrench

(Fig.

D).

3.

4.

5.

Denver Global Products 1000 East Powell Dr. | Lincolnton, NC 28092 U.S.A

RH Contactor

One End Of

Short Contactor

Jumper Wire

Green Wire

From Square

Diode

D

RH Contactor

Double Fuse

Assembly

Red Wire

From Square

Diode

C

J4 Jumper

Red Terminal

From

Block

Fuse B

Red Deck

Plug Wire

Fuse A

B

Double

Fuse

Holder

100A Fuse

(x2)

Fuse A

Fuse B

Stainless Steel

Hardware

A

Contactor Fuses

Installation Instructions

6.

Locate (1) pair of the 12V wires (yellow/green & green).

The yellow/green wire goes to the small LH post

on

the RH contactor and the solid green wires goes to

the

small RH post (Fig. E). Secure using M4 flat

washer,

lock washer and nut using a 7mm socket and wrench.

Locate the 75A Fuse, the Single Fuse Holder, (1) 1/4-

20 SS Nylock Nut, and (2) M6 SS Flat Washers (Fig. F).

Locate the (+) red battery plug wire and mount to

75A fuse. Place an M6 flat washer over the fuse

stud

followed by the red battery wire, another flat

washer

and then a Nylock nut (Fig. G). Tighten the nut

using

the 7/16” wrench.

Mount the Singe Fuse Assembly to the large LH

post

of the LH Contactor as shown in Fig. H. Place

the

other end of the short contactor jumper wire and

the

brown 48 V battery charge wire on followed by an

M8

flat washer, an M8 lock washer and an M8 nut.

Tighten

using a 14mm socket 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.

K).

12. On the LH contactor, use an 8mm socket and wrench to

remove the (2) M5 x 12mm mounting screws

attaching

the contactor to the frame and replace with (2) M5 x

End Of

Contactor

Wire

LH Contactor

Remove And

Replace With

Longer Screws

L

Denver Global Products 1000 East Powell Dr. |

Lincolnton, NC 28092 U.S.A

Black Rubber

Cap (x4)

K

12V Wiring on LH Contactor

Yellow/Green

Wire

Green

Wire

LH Contactor

J

L

Contactor

(+) Rectifier

I

Wi

Single

Fuse

Assembly

Other

Short

Jumper

LH Contactor

H

75A Fuse

(+) Red

Battery Plug

Wire

G

Singl

e Fuse Hol

der

75A Fuse

Stainless

Steel

Hardware

F

12V Wiring on RH Contactor

Yellow/Green

Wire

Green

Wire

RH Contactor

E

Contactor Fuses

Installation Instructions

16mm mounting screws (Fig. L).

13. On the RH contactor, use an 8mm socket and wrench

to

remove the (2) M5 x 12mm mounting screws

attaching

the contactor to the frame. Replace the LH screw

with

an M5 x 16mm mounting screw. Locate Square

Diode

and mount in the position shown with an M5 x

16mm

mounting screw (Fig. M). Green and red diode

wires

should be pointing to the front of the unit.

14. Refer to Fig. N for Zip Tie placement. Use Zip Tie

Gun

to tighten and trim all zip ties:

•

#1 - use a 4” zip Tie to secure the J4 Jumper and

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 Charging Wire to frame as shown.

TIE

•

15. Re-cover the (4) terminals

terminal covers (Fig. O).

with

the

large

red

rubber

Denver Global Products 1000 East Powell Dr. | Lincolnton, NC 28092 U.S.A

Rubber Covers

O

ZI

P

PLACEMENT

#1

#3

#4

#2

#5

N

RH Contactor

Remove And

Replace With

Mount Square

Longer Screws

Diode as Shown

M

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Raven MPV-7100 User manual

Raven MPV-7100 User manual

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