PIAGGIO Ape Workshop Manual
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PIAGGIO Ape Workshop Manual

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MANUALE STAZIONE DI SERVIZIO
667270 - 667275 (IT-EN-FR-DE-ES-EL)
APE TM Benzina

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Summary of Contents for PIAGGIO Ape

  • Page 1 MANUALE STAZIONE DI SERVIZIO 667270 - 667275 (IT-EN-FR-DE-ES-EL) APE TM Benzina...
  • Page 2 MANUALE STAZIONE DI SERVIZIO APE TM Benzina © Copyright 2012 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. No part of this publication may be reproduced. This publication has been edited by: After sales - PIAGGIO & C. S.p.A.
  • Page 3 APE TM Benzina WORKSHOP MANUAL This workshop manual has been drawn up by PIAGGIO & C. Spa to be used by the workshops of Piaggio dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.
  • Page 4 Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.
  • Page 5 INDEX OF TOPICS ENERAL GUIDELINES HARACTERISTICS PECIAL TOOLS AINTENANCE CO EM MISSION ONTROLO YSTEM TROUBL ROUBLESHOOTING LECTRICAL SYSTEM NGINE FROM VEHICLE NGINE IFFERENTIAL RAKING SYSTEM TEERING COLUMN USPENSIONS IPPER VERSION HASSIS DELIVERY...
  • Page 6 INDEX OF TOPICS ENERAL GUIDELINES...

  • Page 7: Maintenance Guidelines

    General guidelines Maintenance guidelines RULES TO BE FOLLOWED IN THE EVENT OF INTERVENTION ON THE ELECTRIC SYSTEM - APE A) ESSENTIAL WARNINGS The check or in any case the intervention on the circuits of the devices for the electronic ignition can be done with relative ease by the electronic repairers of Service Station Workshops;...
  • Page 8 APE TM Benzina General guidelines corresponding terminal; for this purpose it is al- ways advisable to consult the electrical circuit diagrams. KEY: 1 = Red (direct current) 2 = White (direct current) 3 = Grey - Red (direct current) 4 = Purple (alternating current engine stop)
  • Page 9 APE TM Benzina General guidelines If replacing restores the ignition operation, the fault lies in the control unit, which obviously needs to be replaced. In the event that the failure persists, it is necessary to carry out checks on the alternator...
  • Page 10 FOR VEHICLES OF NEXT PRODUCTION, THE FAN COVER WILL BE FITTED WITH A REFER- ENCE FOR TIMING, SO THE OPERATIONS DESCRIBED IN POINTS 1 AND 2 WILL NOT BE NECESSARY. RULES TO BE FOLLOWED IN THE EVENT OF INTERVENTION ON THE ELECTRIC SYSTEM - APE TM P703 FL2 A) ESSENTIAL WARNINGS The check or in any case the intervention on the circuits of the devices for the electronic ignition can be done with relative ease by the electronic repairers of Service Station Workshops;...
  • Page 11 APE TM Benzina General guidelines All inspection operations of the system involving disconnection of cables (verification of the connections and devices that are part of the ignition circuit, therefore including the main key switch) must be made with the engine off: otherwise the control unit could be irreparably damaged.
  • Page 12 APE TM Benzina General guidelines In the event of failure and abnormal operation of the ignition, whose causes are not detectable by a visual inspection, it is necessary first to replace the control unit with a corresponding, safely functional one. Remember that the disconnections and connections to replace the control unit must be performed when the engine is off.
  • Page 13 APE TM Benzina General guidelines paragraphs we recommend, therefore, to include in the control tools an Ohm meter with the charac- teristics outlined above. C) IGNITION TIMING CHECK The timing check may be useful for example if the motor is not operating properly (start-up difficulties;...
  • Page 14 INDEX OF TOPICS HARACTERISTICS...
  • Page 15 APE TM Benzina Characteristics Characteristics SIZES millimetres Deck Long Tipper Deck (1) Length 3175 3375 3175 3230 (2) Width 1480 1510 (3) Height 1630 1750 1630 (4) Wheelbase 2170 2170 2170 2170 (5) Track 1300 1300 1300 1300 (6) Turning spokes...
  • Page 16 15 (3.5) 15 (3.5) 15 (3.5) Engine oil (reserve) 3.0 (0.75) 3.0 (0.75) 3.0 (0.75) 3.0 (0.75) Hydraulic oil (*) DIMENSIONS - APE TM KAT - APE TM P703 FL2 millimetres Deck Long Tipper Motor Deck chassis (1) Length 3175...
  • Page 17 APE TM Benzina Characteristics TECHNICAL DATA - CHASSIS - APE TM KAT - APE TM P703 FL2 Specification Desc./Quantity Chassis Sheet steel body and a single central longitudinal arm (inte- grated structure). Versions Sheet metal deck, integrated into the structure.

  • Page 18: Tightening Torques

    APE TM Benzina Characteristics SUSPENSION - APE TM KAT - APE TM P703 FL2 Specification Desc./Quantity Front suspension Built using helical spring. Rear suspension Built with flexible rubber components in progressive rate. Sus- pensions consist of hydraulic shock absorbers. TYRES - APE TM KAT - APE TM P703 FL2 Specification Desc./Quantity...
  • Page 19 APE TM Benzina Characteristics FRONT SUSPENSION UNIT Name Torque in Nm Shock absorber upper anchoring nut 30-40 Shock absorber lower anchoring nut 100-120 Steering upper bearing lock gear 50 to 70 Wheel rim to drum locking 60-70 Wheel locking centre nut...
  • Page 20 APE TM Benzina Characteristics - CLEARANCE "A" UPON FITTING HOULDER RING Name Description Dimensions Initials Quantity Shoulder ring 1st Oversize 1.1 +0 -0.06 0.15 to 0.50 Shoulder ring 2nd Oversize 1.2 +0 -0.06 0.15 to 0.50 Shoulder ring 3rd Oversize 1.3 +0 -0.06...
  • Page 21 APE TM Benzina Characteristics If, however, the cylinder should be increased, the size "E" (see figure) must exceed the size "C" of the piston to be installed (marked on the piston itself) of the indicated value, "Cylinder clearance - pis- ton".

  • Page 22: Oil Pump

    APE TM Benzina Characteristics Specific tooling 19.1.20074 Crankshaft checking tool Rod small end bushing - Pin CONNECTING ROD SMALL END - PIN - ROLL- ER CAGE The connecting rods and cages are divided into 4 categories (marked with incisions at the foot of the same connecting rod and on the cage frames).
  • Page 23 APE TM Benzina Characteristics FRONT AND REAR BRAKE CYLINDERS - CLEARANCE "A" FOR FITTING - APE TM P703 Name Description Dimensions Initials Quantity Cylinder B=25.40 -0 +0.033 0.040 to 0.125 Piston C=25.40 -0.040 -0.092 0.040 to 0.125 CLEARANCE "A" UPON FITTING...
  • Page 24 INDEX OF TOPICS PECIAL TOOLS...
  • Page 25 APE TM Benzina Special tools Tooling PECIAL TOOLS Stores code Description T.0014499 Bearing extractor T.0021467 Bearing extractor T.0017104 Pliers for circlips T.0022465 Pliers for circlips 0023638 Pliers for circlips T.0018119 Tool for fitting shafts ST - 25...

  • Page 26: Special Tools

    APE TM Benzina Special tools Stores code Description 19.1.20000 Tool for front suspension overhaul 19.1.20004 Tool for disassembling steering bearing from the frame 19.1.20024 Crankshaft removal tool 19.1.20041 Steering upper bearing ring nut gear wrench 19.1.20042 Extract the bottom seat of the steering bottom bearing 19.1.20043...
  • Page 27 APE TM Benzina Special tools Stores code Description 19.1.20045 Tool for fitting steering lower bearing low- er seat 19.1.20046 Clutch puller 19.1.20047 Pliers for chamfering nuts 19.1.20049 Window positioning tool 19.1.20050 Lower retainer clamp for strip 19.1.20051 Upper retainer clamp for strip 19.1.20074...
  • Page 28 APE TM Benzina Special tools Stores code Description 0019978 Oven T.0020322 Clutch removal and refitting tool T.0020781 Bearings Fitting Punch T.0021071 Punch to fit bearings and seal rings T.0021330 Steering seats fitting tool T.0023589 Punch for bearings and sealing rings T.0025095...
  • Page 29 APE TM Benzina Special tools Stores code Description T.0025127 Wedge T.0027338 Punch to fit sealing rings T.0030632 Wrench for helical gear nut T.0031729 Clutch stop key T.0033970 Punch for fitting roller bearings T.0035731 Flywheel extractor and differential hous- T.0039152 Punch for roller bearing...
  • Page 30 APE TM Benzina Special tools Stores code Description T.0039153 Punch for roller bearing T.0043062 Stop key of flywheel and dynamotor pul- T.0060824 Control probe axle clearance gear change ST - 30...
  • Page 31 INDEX OF TOPICS AINTENANCE...

  • Page 32: Scheduled Maintenance Chart

    MAIN NUTS AND BOLTS OF THE VEHICLE Locking check • • See the table of locking torque MAINTENANCE OPERATIONS - APE TM KAT * = check. • = replacement. (*)= every two years. (**)= every 12000 km / 36 months. MA - 32...
  • Page 33 65' 22 65' 11 65' 26 65' 20 65' 22 65' 24 MAINTENANCE OPERATIONS - APE TM P703 FL2 * = check. • = replacement. (*)= every two years. x 1000 Km - (Months) Battery - check/top-up Safety blocks - Check...
  • Page 34 APE TM Benzina Maintenance x 1000 Km - (Months) Tyre wear and inflation pres- sure - Inspection Air filter - Replacement • • • • • • • • • Parking brake - Adjustment Electrical system - Inspection Cylinder and fan system - In-...
  • Page 35 APE TM Benzina Maintenance CARBURETTOR CHARACTERISTICS Specification Desc./Quantity Dell'Orto type SHB 22/22 Diffuser mm. 22 Maximum jet 73/100 long Minimum jet 55/100 long Minimum fixed air 100/100 Maximum fixed air 170/100 Starter jet 70/100 CAUTION CHECK THAT THE CARBURETTOR IS WELL LOCKED, THAT THE VALVE COVER AND THE FIT- TINGS OF THE ADMISSION DUCT ARE NOT LOOSE, IN ORDER TO AVOID HARMFUL AIR LEAKAGE AFFECTING THEIR CARBURETION.
  • Page 36 APE TM Benzina Maintenance 5. Minimum jet 6. Starter transmission 7. Minimum air calibrator 8. Maximum air calibrator 9. Starter valve 10. Starter jet 11. Tank 12. Maximum jet 13. Float 14. Needle 15. Throttle valve 16. Inviolability cap 17. Preloading spring screw 18.
  • Page 37 APE TM Benzina Maintenance N.B. THE INTERVENTIONS DESCRIBED AT POINT 2. - 2.1 - 2.2, SHOULD BE MADE ONLY IF AC- TUALLY NECESSARY, SINCE THE CARBURETTORS ARE ALREADY CALIBRATED WHEN PRO- VIDED BY THE MANUFACTURER, SO IN MOST CASES A CORRECT IDLE IS OBTAINED ONLY BY PROCEEDING AS INDICATED IN SECTION 1.
  • Page 38 HEADLIGHT ASSEMBLY. BEFORE CARRYING OUT THIS CONTROL, MAKE SURE THAT THE FRONT AND REAR TYRES ARE INFLATED TO THE PRESSURES SPECIFIED IN THE CHARAC- TERISTICS. HEADLIGHTS AIMING - APE TM P703 FL2 (1) = Distance between the centres of the headlights (2) = (3) x 0.9 (3) = Height from the ground of the centre of the headlights (2) = (3) x 0.95 if the aiming of the headlights is carried out with the vehicle at a distance of 5 metres...
  • Page 39 APE TM Benzina Maintenance HEADLIGHTS AIMING CHECK - APE TM P703 Position the unloaded vehicle on a flat surface and at 10 m (4) away from a white screen located in the dark (see the figure) and make sure that the vehicle axis is perpendicular to the screen.
  • Page 40 INDEX OF TOPICS CO EM MISSION ONTROLO YSTEM...
  • Page 41 APE TM Benzina Emission Controlo System CO check The test must be done after a thorough cleaning of all parts of the carburettor, with the air filter clean and spark plug in good condition. 1) Heat the vehicle for the time necessary to acti- vate the catalytic converter.
  • Page 42 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 43 Remove the hubs and fill the appropriate chamber with special grease. Recommended products AGIP GREASE PV 2 Multipurpose grease NLGI 2 specifications; ISO-LXBIB2 SECONDARY AIR TUBE JOINT FAILURE ON THE SILENCER - APE TM KAT Possible Cause Operation Secondary air blade locking Replace.
  • Page 44 APE TM Benzina Troubleshooting Poor performance POOR PERFORMANCE - POOR COMPRESSION - GAS LEAKS Possible Cause Operation Loosening of screws and nuts Relock nuts and bolts of the specific elements of the engine (carburettor, cylinder head, silencer attachment), observing the values of related torques.

  • Page 45: Troubleshooting

    APE TM Benzina Troubleshooting Possible Cause Operation Loosening of the crankcase halves and the differential cover Check the locks, replace the gaskets if necessary. locking nuts Axle shaft oil seal hood worn or broken Replace. Cracked crankcase Replace. Loose oil drain plug Lock and replace if damaged.
  • Page 46 APE TM Benzina Troubleshooting THE VEHICLE PULLS TO ONE SIDE Possible Cause Operation The pressure of one of the tyres is not right Check and ensure that the inflation pressure is the one pre- scribed (see Characteristics). Rear swinging arms deformed Straighten out if possible, or replace.
  • Page 47 INDEX OF TOPICS LECTRICAL SYSTEM...
  • Page 48 APE TM Benzina Electrical system Electric circuit diagram Electrical System Diagram (version with handlebar) KEY: 1. Horn 2. Front turn indicators, 12V-21W bulbs 3. High beam and low beam headlight, 12V-25/25W twin-filament lamp 4. Front position indicators, 12V-4W bulbs 5. Windscreen wiper 6.
  • Page 49 DITION OF A SENSOR (OPERATED BY THE DECK POSITION AT TIME OF DETACHMENT) LINKED BY A GREY CABLE TO A RED WARNING LIGHT (LAMP 12V - 1.2 W) MOUNTED ON THE CENTRE OF THE DASHBOARD. Electrical system diagram (version with handlebar) - APE TM P703 FL2 ES - 49...
  • Page 50 APE TM Benzina Electrical system KEY: 1. Front headlight fitting with twin-filament high-/low-beam bulb (12V-25W/25W), daylight running light bulb (12V-5W), turn indicator bulb (12V-21W). 2. Horn. 3. Windscreen wiper. 4. Internal light (12V-5W). 5. Light indicator unit (12V-1.2W bulbs). 6. Fuse terminal block (six 8A fuses).
  • Page 51 APE TM Benzina Electrical system 20. Start-up relay. 21. Main fuse (25A). 22. Voltage regulator. 23. Magneto flywheel. 24. Dynamotor. 25. Spark plug. 26. Electronic control unit. 27. Oil warning light control. 28. Rear light with twin-filament daylight running light/stop bulb (12V-5W/21W), reverse bulb (12V-21W for rear right light), rear fog light bulb (12V-21W for left rear light), turn indicator bulb (12V-21W).
  • Page 52 APE TM Benzina Electrical system KEY: 1. Horn 2. Front turn indicators, 12V-21W bulbs 3. High beam and low beam headlight, 12V-25/25W twin-filament lamp 4. Front position indicators, 12V-4W bulbs 5. Windscreen wiper 6. Warning light, daylight running lights on (green light), "All Glass" lamp 12 V - 1.2 W 7.
  • Page 53 DITION OF A SENSOR (OPERATED BY THE DECK POSITION AT TIME OF DETACHMENT) LINKED BY A GREY CABLE TO A RED WARNING LIGHT (LAMP 12V - 1.2 W) MOUNTED ON THE CENTRE OF THE DASHBOARD. Electrical system diagram (version with steering wheel) - APE TM P703 FL2 ES - 53...
  • Page 54 APE TM Benzina Electrical system KEY: 1. Front headlight fitting with twin-filament high-/low-beam bulb (12V-25W/25W), daylight running light bulb (12V-5W), turn indicator bulb (12V-21W). 2. Horn. 3. Windscreen wiper. 4. Internal light (12V-5W). 5. Light indicator unit (12V-1.2W bulbs). 6. Fuse terminal block (six 8A fuses).
  • Page 55 APE TM Benzina Electrical system 20. Start-up relay. 21. Main fuse (25A). 22. Voltage regulator. 23. Magneto flywheel. 24. Dynamotor. 25. Spark plug. 26. Electronic control unit. 27. Oil warning light control. 28. Rear light with twin-filament daylight running light/stop bulb (12V-5W/21W), reverse bulb (12V-21W for rear right light), rear fog light bulb (12V-21W for left rear light), turn indicator bulb (12V-21W).
  • Page 56 (Night parking) - Extractable key - Contacts 30 - INT. and 30/1 - 15. Current to audible warning device, windscreen wiper and internal light. APE TM P703 FL2 (VERSION WITH HANDLE- BAR) Positions of the switch "1". 2 = Ignition off, key can be removed, steering locked.
  • Page 57 (Night parking) - Extractable key - Contacts 30 - INT. and 30/1 - 15. Current to audible warning device, windscreen wiper and internal light. APE TM P703 FL2 (VERSION WITH STEERING WHEEL) Positions of the switch "1". 2 = Ignition off, key can be removed, steering locked.

  • Page 58: Turn Signal Switch

    APE TM Benzina Electrical system Turn signal switch APE TM P703 FL2 (VERSION WITH HANDLE- BAR) Positions of the switch "1". 2= Lights off - no contacts. 3 = Left turn indicator blinking - contact between green and brown cables.

  • Page 59: Headlight Switch

    APE TM Benzina Electrical system APE TM P703 FL2 (VERSION WITH HANDLE- BAR) Horn button "2". N.B. WHEN THE HORN BUTTON IS PRESSED, THERE MUST BE CONTINUITY BETWEEN THE YELLOW-GREY AND BLACK CABLES. APE TM P703 FL2 (VERSION WITH STEERING WHEEL) To activate the horn, press lever (1) upwards.
  • Page 60 APE TM Benzina Electrical system APE TM P703 FL2 (VERSION WITH HANDLE- BAR) Positions of the switch "1". The centre position of the switch corresponds to lights off. 3 = High beams, front and rear daylight running lights, panel lights on - contact between pink and blue-grey cables.

  • Page 61: Voltage Regulator

    APE TM Benzina Electrical system 5: High beams and tail lights on - Contacts 30/2 - 56 a/2 - 30/3 - 56 a/1. APE TM P703 FL2 (VERSION WITH STEERING WHEEL) Positions of the external lights switch "1": 2 = Lights off.
  • Page 62 APE engine is ultimately driven at a rate sufficient to start the thermal cycle. Once the engine is started and leaving the key in the ON position, the field in series is excluded and the dynamotor finds itself in identical conditions with a normal dynamo with field in parallel.
  • Page 63 APE TM Benzina Electrical system If the dynamotor is de-energized (inability to generate power for lack of residual magnetism) reenergize as follows: rotate the Dynamotor 2000 - 3000g /1 ', disconnect the regulator and connect for 3 to 4 sec.
  • Page 64 APE TM Benzina Electrical system BALL BEARING Fit the specific tool fitted with comp. 17, act on the central screw (1) and remove the bearing and the washer. Specific tooling T.0014499 Bearing extractor PULLEY SIDE BALL BEARINGS Remove the flange using the four screws, unscrew...
  • Page 65 APE TM Benzina Electrical system tension is correct if the stroke of the pencil is 7 to 8 mm. Bench tests DYNAMOTOR STARTER MOTOR BOSCH TYPE AND EFEL TYPE CARAT ELECTROMAGNETIC CHECK 1) No-load test: the starter motor, under no-load, must draw a maximum of 15 Amp. with a supply voltage of 11.5 to 12V and must rotate at rpm 1'>=2500.
  • Page 66 APE TM Benzina Electrical system N.B. THE DETECTION SHALL BE MADE WITH REGULATOR ACTIVATED. ALTERNATOR BOSCH TYPE AND EFEL TYPE EXTERNAL CHARACTERISTICS CONTROL Make the electrical circuit diagram, proceeding as follows: maintain, on variable resistive load, a constant voltage of 13.5 V at full excitation and after thermal...
  • Page 67 APE TM Benzina Electrical system Make an electrical circuit diagram and run the dynamotor at 6000 revolutions/1' constant, perform ther- mal stabilisation, through empty operation of the regulator for 15' and then connect it to a battery charger for 5'.
  • Page 68 APE TM Benzina Electrical system Specification Desc./Quantity Voltmeter Voltmeter in DC. (minimum full scale 20 V class 1). Rheostat Rheostat 70 ohm 17 Amp. Battery 12V Battery - 24 to 24 Ah REGULATION CHARACTERISTICS Specification Desc./Quantity Minimum voltage closing switch 12.4 to 13.1 V.
  • Page 69 APE TM Benzina Electrical system THE VOLTAGE OSCILLATES, IS NOT CONSTANT Possible Cause Operation Defective regulator Replace. THE VOLTAGE REACHES EXCESSIVE VALUES Possible Cause Operation Defective regulator Replace. THE DYNAMOTOR OVERHEATS Possible Cause Operation Rotor in short circuit Clean the threads of the manifold; if not getting good results, replace the rotor.
  • Page 70 APE TM Benzina Electrical system BATTERY MAINTENANCE The battery is an electrical device which requires careful monitoring and a very diligent maintenance. The main maintenance rules are: 1) Check the level of the electrolyte The level of the electrolyte, to be controlled frequently, must reach the top level. Only use distilled water, to restore this level.
  • Page 71 APE TM Benzina Electrical system Normal recharging on the bench must be carried out with a current of 2.4 A for approx. 6 to 8 hours. Connections to the power supply must be made by connecting the corresponding poles (+ to+ and - to During the charge the caps of the battery must be removed.
  • Page 72 INDEX OF TOPICS NGINE FROM VEHICLE...
  • Page 73 APE TM Benzina Engine from vehicle REMOVAL OF ENGINE FROM THE FRAME Disconnect the (-) cable from the battery, the elec- trical cables of the dynamotor and the electronic control unit; remove the covers, the carburettor bellows and hot air of the cab, the oil and petrol adduction tubes, throttle grips, gearbox, starter, reverse, clutch, etc.
  • Page 74 APE TM Benzina Engine from vehicle Upon refitting, lubricate the bearings with the recommended grease. - Roller bearings: use new casings at each refitting: observe the following rules: Wash the new case with pure petrol or neutral petroleum to eliminate the rust preventer; after having applied the grease, fit them with the face where the initials are marked facing outward.
  • Page 75 INDEX OF TOPICS NGINE...
  • Page 76 APE TM Benzina Engine Flywheel FLYWHEEL - PULLEY - REMOVAL Anchor the flywheel and the pulley dynamotor us- ing the specific equipment (2), unscrew the nut (3) of the pulley and the nut (6) of the flywheel. Apply, through the 3 screws provided with the rel-...
  • Page 77 APE TM Benzina Engine HALF CRANKCASES COUPLING Both the crankshaft and the multiple gear must be fitted on the clutch side crankcase half and the change gear shaft on the flywheel side crankcase half. To couple the half crankcases proceed as follows: - Clean the mating surfaces thoroughly;...
  • Page 78 APE TM Benzina Engine bolts and nuts to the torque specified in the table "Tightening torques". Fly-wheel side half-crankcase FLYWHEEL SIDE CRANKCASE HALF - RE- MOVAL BENCH ROLLER BEARING - MULTI-GEAR BALL BEARING - ROLLER BEARING CHANGE GEAR SHAFT Position the crankcase half on a support base and...
  • Page 79 APE TM Benzina Engine Allow the crankcase to cool and with the specific punch (3), position the needle bearing of gear shaft (2). Specific tooling T.0039152 Punch for roller bearing Bearings on half-crankcase clutch-side CLUTCH-SIDE CRANKCASE HALF - REMOV- SEAL RING - CIRCLIP - BENCH BALL BEAR-...
  • Page 80 APE TM Benzina Engine MULTI-GEAR PIN ROLLER BEARING Use the special tool (1) provided in items 10 and 19, and pull the roller bearing (3), acting on the central nut (4). Specific tooling T.0021467 Bearing extractor CLUTCH-SIDE CRANKCASE HALF - FITTING Similarly to the procedure for installing the flywheel side crankcase, heat the special tool, the area housing the bench ball bearing.
  • Page 81 APE TM Benzina Engine WARNING TO AVOID POSSIBLE DEFORMATION ON THE CRANK- SHAFT IT IS NECESSARY THAT THE FITTING OF THE RING (2) BE CARRIED OUT AFTER THE APPROPRIATE SPECIAL EQUIPMENT (4) HAS BEEN INTERPOSED BE- TWEEN THE TWO HALF SHAFTS.
  • Page 82 APE TM Benzina Engine After performing the above operations, extract the roller bearing (8) using the specific extractor (7) equipped with component 1 and 9. Specific tooling T.0021467 Bearing extractor T.0035731 Flywheel extractor and differential housing Clutch assembly CAP LOCK RING AND MULTI-GEAR AXLE NUT Using the specific key (1) unlock the nut (2) and remove the cap (3).
  • Page 83 APE TM Benzina Engine CAUTION IN THE REMOVAL OPERATIONS DESCRIBED ABOVE, THE EXTRACTION OF 3 SCREWS (2), NECESSARY FOR THE APPLICATION OF THE EXTRACTOR, AUTOMATICAL- LY CAUSES THE FALL OF CORRESPONDING WASHERS (8) IN THE CLUTCH ASSEMBLY. AS A RESULT OF THIS,...
  • Page 84 APE TM Benzina Engine Specific tooling T.0030632 Wrench for helical gear nut T.0027338 Punch to fit sealing rings Cylinder/piston assy - carburettor BIG END - CYLINDER - REMOVAL After removing the cooling cover, the fan cover and the silencer, unscrew the four fixing nuts and remove the big end and the cylinder.
  • Page 85 APE TM Benzina Engine The vehicles have two separate tanks for petrol and oil. The refilling of the fuel tank must not be carried out with petrol-oil mixture, but only with pure petrol of the normal type for motor vehicles. The oil tank must be filled with specific oil.
  • Page 86 5 = Piston (3) in position to deliver oil to the engine. "L.S." DEVICE - APE TM KAT For the "L.S." device of the version APE TM KAT, the same treatment applies that is given for the APE TM version unless specific type of oil used.
  • Page 87 INDEX OF TOPICS...
  • Page 88 AFTER REASSEMBLING THE GEAR UNIT PROCEED TO CHECK THE AXIAL CLEARANCE AS INDICATED IN THE SPECIFIC SECTION "FITTING CLEARANCES" CHANGE GEARS - STEM - GEAR CONTROL BUSHING - APE TM P703V - REMOVAL Remove the snap ring, the thrust washer and the gears.
  • Page 89 *= Punch for chamfering 1st and 2nd speed cross CHANGE GEARS - STEM - GEAR CONTROL BUSHING- APE TM P703V - FITTING 1) Install the cross (2) on the gearbox shaft, tighten the bushing (left-hand thread) and lock it at a torque of 25 to 30 Nm (2.5 - 3 Kgm)
  • Page 90 APE TM Benzina Gear-box CHANGE CONTROL SUPPORT VEHICLES VERSION WITH STEERING WHEEL Rotate the crankshaft and bring the gears to such a position to allow the stem (2) and the bushing (1) to reach their maximum range, bring the two con-...
  • Page 91 INDEX OF TOPICS IFFERENTIAL...
  • Page 92 (5) of the satellite pin. CHANGE GEARS AND GEARBOX STEM CONTROL - APE TM P703 - REMOVAL After removing the container ring (10), the springs and the 2 balls (6), remove the retaining circlip (11), pull off the shoulder ring (12) and the four gears.
  • Page 93 AFTER REASSEMBLING THE GEAR UNIT PROCEED TO CHECK THE AXIAL CLEARANCE AS INDICATED IN THE SPECIFIC SECTION "FITTING CLEARANCES" CHANGE GEARS - STEM - GEAR CONTROL BUSHING - APE TM P703V - REMOVAL Remove the snap ring, the thrust washer and the gears.
  • Page 94 *= Punch for chamfering 1st and 2nd speed cross CHANGE GEARS - STEM - GEAR CONTROL BUSHING- APE TM P703V - FITTING 1) Install the cross (2) on the gearbox shaft, tighten the bushing (left-hand thread) and lock it at a torque of 25 to 30 Nm (2.5 - 3 Kgm)
  • Page 95 APE TM Benzina Differential CHANGE CONTROL SUPPORT VEHICLES VERSION WITH STEERING WHEEL Rotate the crankshaft and bring the gears to such a position to allow the stem (2) and the bushing (1) to reach their maximum range, bring the two con-...
  • Page 96 INDEX OF TOPICS RAKING SYSTEM...
  • Page 97 APE TM Benzina Braking system RULES TO CHECK THE HYDRAULIC BRAKE If the braking system is malfunctioning and this requires a general inspection, make sure that: a) The metal pipes are in perfect working conditions and are adequately fitted so that they do not interfere with the chassis and may get damaged or flattened.
  • Page 98 APE TM Benzina Braking system BRAKE CONTROL PUMP UNIT KEY: 1. Pump body 2. Cap 3. Tank hose fitting 4. Spring 5. Sealing ring 6. Ring 7. Recovery and compensation hole 8. Piston end stroke screw 9 Piston 10. Stop switch 11.
  • Page 99 APE TM Benzina Braking system - That the hole of recovery and compensation (7) (visible in the section of the pump in the figure) that communicates with the tank of the pump body, is not clogged or dirty. It is advisable to carry out the cleaning of this hole with a jet of compressed air to apply, at reassembly, the special pump components 2-4-5 and 6 positioning them as shown in detail in the figure.
  • Page 100 APE TM Benzina Braking system - Bring the piston to the end of their stroke so that any remaining air and a little oil are expelled. - Plug (by hand) the exit hole of the oil from the threaded shank.
  • Page 101 APE TM Benzina Braking system CAUTION WHEN REFILLING TO LEVEL USE ONLY THE TYPE OF OIL THAT HAD BEEN USED PREVIOUS- SHOE CLEARANCE ADJUSTMENT Once the shoes and their self-regulating device on the hub have been assembled, it is necessary, before installing the break drum on the wheel axle, to proceed, with the device just mentioned, to the pre- adjustment of the shoes with respect to the brake drum.
  • Page 102 APE TM Benzina Braking system Rear brake drum Remove the cap from the hub hole (6), insert a screwdriver until reaching the corresponding hole (7) on the brake shoe (8). Push the parking brake control lever (9) and release the supporting tab of the lever.

  • Page 103: Parking Brake

    APE TM Benzina Braking system Parking brake MECHANICAL BRAKE ADJUSTMENT In order to adjust the travel of the control hand lever, proceed as follows: - Bring the lever to its rest position and move it upward by two teeth on the sector.
  • Page 104 INDEX OF TOPICS TEERING COLUMN...
  • Page 105 APE TM Benzina Steering column Steering box assembly HANDLEBAR - REMOVAL Once the ash tray has been removed, take out the three anchor bolts using a 17-mm T-shaped wrench and tilt the steering wheel backwards. STEERING CONTROL ASSEMBLY (STEERING WHEEL VERSION) - REMOVAL Disconnect the negative cable (-) from the battery to prevent short circuits.
  • Page 106 APE TM Benzina Steering column STEERING WHEEL AND SUPPORTING BALL BEARING (STEERING WHEEL VERSION) - RE- MOVAL Undo the lower locking nut and slide off the steering wheel. First remove the retaining circlip with the specific pliers and then push out the ball bearing with a 28 mm inside diameter punch.
  • Page 107 APE TM Benzina Steering column Insert the rack (9) (complete with steering control lever (4) and retaining circlip (5) until it protrudes from the opposite side by 70 - 72 mm., keeping in mind that with this positioning the steering wheel must be oriented for a straight motion course for the vehicle as shown in the figure;...
  • Page 108 ETC.) OR IF SOME REPAIR HAS BEEN CARRIED OUT IN THE CAB. IF THE VALUE IS NOT AS SPECIFIED, REMOVE OR ADD (AS REQUIRED) ONE OF THE WASHERS (6) TO OBTAIN THE RECOMMENDED DISTANCE. APE TM P703 FL2 (VERSION WITH STEERING WHEEL) N.B. APPLY SPECIFIC GREASE ON ALL THE COMPONENTS OF THE ASSEMBLY (BALL BEARING, AXIS, STEERING WHEEL, RACK, ROLLER, ETC.) BEFORE REFITTING THEM.
  • Page 109 APE TM Benzina Steering column UPPER SEAT OF THE LOWER STEERING BEARING Operate the same way as described in the section "Lower seat of the upper steering bearing" for the expulsion of the lower seat; reusing the specific tool (1) introduced from the upper side of the steering headstock, with the aid of a mallet, remove the upper seat (2) of the lower steering bearing.
  • Page 110 APE TM Benzina Steering column STEERING UPPER BEARING RING - FITTING After the vehicle has been lifted, insert the steering tube into its sleeve, then lower the vehicle until the front wheel touches the ground, apply the specific grease on the lower seat of the upper steering bearing and fit the balls (n.
  • Page 111 APE TM Benzina Steering column Lower housing LOWER SEAT OF THE LOWER STEERING BEARING On the steering tube fit the special tool (1), apply the two half rings (component 5) and lock them with the ring (component 6); then act on the centre screw (2) and pull out the lower seat (3).
  • Page 112 APE TM Benzina Steering column FRONT WHEEL BRAKE DRUM With the tip of a screwdriver remove the dust gaiter; unscrew the lock nut with collar on the wheel axis and, using a mallet, remove the brake drum from its axis.
  • Page 113 APE TM Benzina Steering column LOWER SEAT OF THE UPPER BEARING AND UPPER SEAT OF THE STEERING LOWER BEAR- ING - FITTING Fit on the sleeve the relative seats (1) and (2), introduce from the lower side of the sleeve the special tool (3) (provided with comp.
  • Page 114 APE TM Benzina Steering column SC - 114...
  • Page 115 INDEX OF TOPICS USPENSIONS...
  • Page 116 APE TM Benzina Suspensions Front BALL BEARING- REMOVAL Take out the circlip (1), rest the drum on a suitable base, and expel the ball bearing (2) with the aid of a section of tube, OD 25 mm. ROLLER BEARING - REMOVAL...
  • Page 117 APE TM Benzina Suspensions Proceed to fit the specific roller bearing (3) using the specific punch (2). Once this operation is com- pleted, fit the sealing ring (1). N.B. BEFORE FITTING THE ROLLER BEARINGS, ALWAYS REFER TO THE STANDARDS LISTED IN THE TABLE "TIGHTENING TORQUE".
  • Page 118 Specific tooling 19.1.20047 Pliers for chamfering nuts Recommended products AGIP GREASE PV 2 Multipurpose grease NLGI 2 specifications; ISO-LXBIB2 KEY: *= chamfer. Verifiche e regolazioni FRONT SUSPENSION UNIT OVERHAUL - APE TM - APE P703 - APE P703V SS - 118...
  • Page 119 APE TM Benzina Suspensions For the overhaul of the front suspension, it is essential to proceed to some changes to the specific tool of the particular components, with the addition of the new specific components 20-21-22. Specific tooling 19.1.20000 Tool for front suspension overhaul KEY: * = Grease.
  • Page 120 APE TM Benzina Suspensions THE TWO WEDGE WASHERS - REMOVAL (Manual operation that does not require the use of the press). - With the help of a punch (1) with diameter 14, flatten with a mallet the wedge washer and pull it out with a pointed screwdriver.
  • Page 121 APE TM Benzina Suspensions ROLLER BUSHING 2ND EXPULSION - REMOV- (Manual operation that does not require the use of the press). To expel the second roller, use the component 22 and hit with the mallet. INSTALLING CAUTION DURING THE REMOVAL OPERATIONS DESCRIBED ABOVE, THE ROLLER BUSHINGS ARE DE- STROYED WHEN THE PRESS IS USED.
  • Page 122 APE TM Benzina Suspensions - Provide the specific tool connecting to component 1, bottom end, the comp. 22 and the lower crankcase the component 11. Specific tooling 19.1.20000 Tool for front suspension overhaul Position the swing arm - steering tube unit, provided with guide pin, on the specific tool previously prepared;...
  • Page 123 APE TM Benzina Suspensions NLGI 2 specifications; ISO-LXBIB2 SEALING RINGS - FITTING (Manual operation that does not require the use of the press). - Once the pin has been assembled, remove the unit from the tool and, with light use of the mallet, fit the two spacers component 20.
  • Page 124 APE TM Benzina Suspensions AGIP GREASE PV 2 Multipurpose grease NLGI 2 specifications; ISO-LXBIB2 - Remove from the crankcase of the tool specific the comp 12 (driving) partially ejected during the assembly of the pin (see figure in the specific section "Mounting the pin", always leaving the fitted the comp.
  • Page 125 APE TM Benzina Suspensions WASHERS WEDGING Use the tool supplied in comp. 22 and 11, as already represented in the specific section "Mounting the pin", and push, using the press loaded to approx.1.8 t., until the washer is wedged on the swinging arm.
  • Page 126 APE TM Benzina Suspensions OIL SEALING AXLE SHAFT AND COVER Drain off the oil of the gearbox-differential assem- bly through the oil drainage hole; remove the 3 bolts (1) fixing the hub; remove the oil sealing cov- er from the differential and once the bolt (2) has been removed after having remove the bolt, slide off the oil sealing cover.
  • Page 127 APE TM Benzina Suspensions WHEEL HUB FROM TRIANGLE - REMOVAL Release the parking brake cable; remove the brake oil suction pipe (1), the three anchor bolts (2) and remove the entire hub. BALL BEARING - REMOVAL In a similar manner as per the brake drum, place the hub on the supporting base and expel the ball bearing (1) using a section of tube, OD 32 mm.
  • Page 128 APE TM Benzina Suspensions INTERNAL BUSHING FROM REAR WHEEL AXLE ROLLER BEARING - REMOVAL Apply the specific tool (1), fitted with the reduction rings (comp. 8), as shown in the figure and move tool handle (2) until the bushing (3) can be re- moved from the roller bearing.
  • Page 129 APE TM Benzina Suspensions SEALING RING ON REAR HUB - FITTING Position the seal ring (4) with the specific punch (3). Specific tooling T.0021071 Punch to fit bearings and seal rings BALL BEARING ON REAR HUB - FITTING Operate with the stove as described in the specific section "Ball bearing and circlip on the front brake drum"...
  • Page 130 APE TM Benzina Suspensions CIRCLIP AND SEALING RING ON REAR HUB - FITTING Assemble, using the proper equipment, the circlip (6) and, using the punch (3), position the seal ring (7). WARNING BEFORE REFITTING THE WHEEL AXLE, FILL THE INTERNAL CHAMBER OF THE HUB WITH SPECIFIC GREASE.
  • Page 131 APE TM Benzina Suspensions SS - 131...
  • Page 132 APE TM Benzina Suspensions INTERNAL BUSHING, ROLLER GEARING ON WHEEL AXLE - WHEEL AXLE ON THE REAR HUB - FITTING Heat the oil-coated bushing (8) at approx. 100°. Afterwards, with a section of tube (9), ID 36 mm, fit the bushing in its seat. Once this operation is completed, fit the entire rear wheel axle in the hub, tap with a wood or plastic mallet if required.
  • Page 133 INDEX OF TOPICS IPPER VERSION...
  • Page 134 APE TM Benzina Tipper version Circuito idraulico DISTRIBUTOR CONTROL POSITIONS Position "0" (load box in running position): the oil sucked by the pump is sent into the duct (3) and through the distributor and its duct (4) falls into the tank.
  • Page 135 APE TM Benzina Tipper version *= Pump. **= Distributor. ***= Tank distributor pump unit. ****= Jack. *****=Distributor control. ******= Use duct. DEFECTIVE LOAD BOX LIFTING 1) Check and restore the oil level in the tank with specific oil. 2) If despite having operated as described in 1) the...
  • Page 136 INDEX OF TOPICS HASSIS...
  • Page 137 APE TM Benzina Chassis Windscreen PANE - FITTING Thoroughly clean the area that houses the window pane, remove any adhesive or glass that may have been left (use any mechanical tool, blades, abrasive elements, etc.). Check that the frame profile is not deformed (straighten if required).
  • Page 138 APE TM Benzina Chassis - Centre it with respect to the lower edge of the frame that houses the pane, observing proper dis- tances (lower side and upper side). Also check that the distance of the pane from the edge of the hous- ing frame is the same on both sides.
  • Page 139 APE TM Benzina Chassis Once the adhesive sealing compound is applied, proceed to fit four finishing strips (trimmings) to the sides of the frame, at the positions previously shown in the figure (lower side and upper side), and four profiles until they adhere to the pane and the frame edge.
  • Page 140 APE TM Benzina Chassis - To reuse the window pane not broken, proceed as instructed in the specific section "Pane - Fitting" and before fitting make sure to wipe off any remaining sealant from the window pane edge. Repairs PAINTWORK...
  • Page 141 INDEX OF TOPICS DELIVERY...
  • Page 142 APE TM Benzina Pre-delivery FUEL CONSUMPTION CONTROLS ON ROAD To properly carry out any on road consumption tests, referred to in points 1), 2) and 3) it is advisable to use an auxiliary tank of known capacity, with three-way valve, such as to be inserted at the beginning of the test and removed at the end.
  • Page 143 APE TM Benzina Pre-delivery If the connections are inverted, the regulator will quickly be damaged beyond repair. WARNING DEALERS ARE INVITED TO PERFORM THESE CHECKS ON NEW VEHICLES AS WELL, BEFORE DELIVERY TO THE CUSTOMER. PD - 143...
  • Page 144 Battery: 69 Brakes: 45 Chassis: 137 Clearance: Differential: 81, 92 Engine: 43, 73, 76 Horn: 58 Maintenance: 7, 32 Oil: 22 Products: 34 Switch: 58, 59 System: 37, 41, 48, 97 Tyres: Vehicle: 19, 73 Weights: Wheel:...

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