PIAGGIO Ape TM Instructions Manual
  1. Manuals
  2. Brands
  3. PIAGGIO Manuals
  4. Utility Vehicle
  5. Ape TM
  6. Instructions manual

PIAGGIO Ape TM Instructions Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Piaggio would like to thank you
for choosing one of its products. We have drawn up this booklet to show you all features of our product. Please read the booklet carefully before using
your vehicle. It includes information, suggestions and warnings regarding your vehicle. You will also be informed of features, details and devices that
will prove the excellence of your choice. We believe that if you follow our suggestions you will soon tune in with your vehicle and use it for a long time
at full satisfaction.
This booklet is an integral part of the vehicle, and upon sale, it should be transferred to the new owner.
Ape TM - Ape TM Diesel
Ed. 01_02/2012

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Ape TM and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for PIAGGIO Ape TM

Summary of Contents for PIAGGIO Ape TM

  • Page 1 We believe that if you follow our suggestions you will soon tune in with your vehicle and use it for a long time at full satisfaction. This booklet is an integral part of the vehicle, and upon sale, it should be transferred to the new owner. Ape TM - Ape TM Diesel Ed. 01_02/2012...
  • Page 2 The instructions given in this booklet are intended to provide a clear, simple guide to using your scooter; details are also given of routine maintenance procedures and regular checks that should be carried out on the vehicle at an Authorised PIAGGIO Dealer or Service Centre. The booklet also contains instructions for simple repairs.
  • Page 3 Personal safety Failure to completely observe these instructions will result in serious risk of personal injury. Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent dam- aging the environment. 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: Table Of Contents

    INDEX IDENTIFICATION................. Demisting................59 Vehicle identification number............ MIRRORS AND WINDOW GLASSES......... 61 SAFE RIDING................11 Adjusting the mirror............... 62 Safe drive.................. 12 Wipers and Brushes..............62 Running-in period..............12 INSIDE EQUIPMENT..............65 VEHICLE USE................13 ELECTRICAL SYSTEM............... 67 Checks..................14 Fuel version................
  • Page 6 System Operation..............110 Warnings for Loading and Unloading Operations..... 111 Scheduled Maintenance............114 Extraordinary Maintenance............116 Trouble-Shooting..............117 Warning Plate Symbols............. 120 technical sheet for EC conformity declaration......123 Preface.................. 123 Equipment Layout..............124 Analysis of Risks Connected with the Layout and Operation of the Equipment..............

  • Page 7: Identification

    Ape TM - Ape TM Diesel Chap. 01 Identification...

  • Page 8: Vehicle Identification Number

    Vehicle identification number (01_01, 01_02, 01_03) The identification codes consist of a prefix followed by a number punched on the chassis and on the engine, respectively. Always quote the serial numbers when ordering spare parts. The chassis identification number is located on the crossmember under the seat as shown in the figure.
  • Page 9 CAUTION BE REMINDED THAT ALTERING IDENTIFICATION REGISTRATION NUMBERS MAY LEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE VEHICLE. ETC.)

  • Page 11: Safe Riding

    Ape TM - Ape TM Diesel Chap. 02 Safe riding...

  • Page 12: Safe Drive

    Safe drive (02_01) ENSURE THE SPARE WHEEL IS CORRECTLY SECURED TO THE SEAT THROUGH THE RETAINING STRAP, IN ORDER TO PREVENT IT FROM MOVING IN THE EVENT OF AN EMERGENCY STOP. 02_01 Running-in period During the first 1000 km, do not twist the throttle fully open and avoid driving at constant speed over long stretches of roads.

  • Page 13: Vehicle Use

    Ape TM - Ape TM Diesel Chap. 03 Vehicle use...

  • Page 14: Checks

    Checks (03_01, 03_02, 03_03, 03_04) Before using the vehicle, check: 1. That the oil and fuel (for fuel versions) tanks are filled. 2. The engine/transmission oil level (for diesel versions). 3. The brake fluid level. 4. That the tyre inflation pressure is correct. 5.
  • Page 15 The fuel filler cap is fitted with a lock. To open: insert the supplied key and turn it anticlockwise. To close: put the filler cap back in position, turn the key clockwise and remove. For petrol versions, the recommended fuel is as follows: - unleaded petrol.
  • Page 16 FUEL Total capacity: 15 litres Fuel (Unleaded petrol) 03_01 Oil tank (for petrol versions) The oil tank is provided with a light reserve indicator on the instrument panel. To top up, remove cap «B» and pour in new oil. CAUTION USING OTHER TYPES OF OIL CAN COMPROMISE ENGINE DURABILITY.
  • Page 17 Characteristic Mixer oil (2.0 l) RESERVE: 0.6 l Removing the battery The battery is located under the seat. The latter can be easily tilted removing the two nuts «A» located at the two ends below the seat, as shown in the figure. If it is necessary to remove the battery from its housing (for replacing or charging it), disconnect the cables, remove nut «B»...

  • Page 18: Before Starting The Engine

    Installing a new battery Make sure the terminals are fitted correctly. The battery is an electrical device that requires careful checks and diligent maintenance. CAUTION DO NOT INVERT THE POLARITIES: DANGER OF SHORT-CIRCUIT AND FAULTS IN THE ELECTRICAL DEVICES. Checking electrolyte level The electrolyte level must be checked frequently and must reach the maximum level.

  • Page 19: Engine Start Up

    Engine start up (03_05, 03_06) Engine ignition (gasoline version) Open the fuel cock «A» (turn it counter clockwise to open and clockwise to close). With cold engine, pull the starter lever «C» and insert the start key into the key switch, then turn it to position 2 and at the same time press the accelerator control.
  • Page 20 WARNING EXHAUST GASES ARE TOXIC. DO NOT START THE ENGINE IN A CLOSED PLACE. Engine start up (03_07, 03_08) Starting off (versions with handlebar) With idle engine, pull the clutch lever «A» and turn the gear knob to the 1st gear (position 1 on the gear indicator «B »).

  • Page 21: Stopping The Engine

    Stopping the engine Stopping the engine (handlebar) Before stopping the engine, shift to neutral (position «N» on the gear indicator « B »). Then turn the ignition key to «A». Stopping the engine (steering wheel) Before stopping the engine, move the gearbox to neutral (central position), then turn the switch key to position «A».

  • Page 22: Gear Position

    Before performing this operation, check the reverse lever position. If you cannot start the engine even with the procedure described above, contact an Authorised PIAG- GIO Service Centre. CAUTION NEVER STRESS THE ENGINE AT LOW TEMPERATURES IN ORDER TO AVOID POSSIBLE DAMAGE.

  • Page 23: Driving Tips

    5. To shift from reverse gear to the forward gears repeat the previously described procedures and move the reverse gear control lever to the «A» position (in the gas- oline version and in the handlebar version). Note: in the diesel handlebar version, once the reverse gear control lever has been moved to the «B»...
  • Page 24 2. Carefully adjust the position of rear-view mirrors, to easily check the road behind you. 3. Ensure nothing hinders the pedals stroke (mats, etc.) 4. Ensure that headlights are working properly. 5. To start the vehicle, with idle engine, engage the first gear and gently release the clutch lever, accelerating at the same time.
  • Page 25 ANY CHANGES TO VEHICLE PERFORMANCE, AS WELL AS ALTERATIONS TO ORIGINAL STRUCTURE PARTS, RENDERS THE VEHICLE NO LONGER CON- FORMING TO THE APPROVED TYPE AND THEREFORE DANGEROUS FOR DRIVING SAFELY.

  • Page 27: Doors And Locks

    Ape TM - Ape TM Diesel Chap. 04 Doors and locks...

  • Page 28: Keys

    Keys (04_01) The vehicle is supplied with two copies of the key. «A»: key for the ignition and start-up switch, the door lock and the fuel tank cover. The code numbers, in fact, are the only way to identify the key for future copies. YOU SHOULD KEEP A DUPLICATED KEY AND ITS CORRESPONDING CODE IN ANY PLACE OTHER THAN THE VEHICLE.

  • Page 29: Front Door Windows

    To open both doors from the inside, use the special release control «B». For the handlebar version, the release control «B» must be lifted, while for the steering wheel version it must be pushed rightwards. MAKE SURE IT IS SAFE TO OPEN THE DOORS BEFORE OPENING THEM. BE- FORE STARTING OFF, MAKE SURE THE DOORS ARE CLOSED AND LOCKED.

  • Page 30: Engine Inspection Port

    Engine inspection port (04_05) Lower the rear side board and grip the handle «A» pulling it upwards to release the retain clips «B». On the vehicles with loading body in light alloy with tilting, to access the engine com- partment it is necessary to lower the side and rear boards and then tilt the loading body.

  • Page 31: Seats And Safety Belts

    Ape TM - Ape TM Diesel Chap. 05 Seats and safety belts...

  • Page 32: Using The Safety Belts

    (on the hips) and not at your waist. Ask your doctor for advice. Injured people: PIAGGIO recommends using the seat belt. Ask your doctor for ad- vice. WARNING THE SAFETY BELTS ARE DESIGNED TO EXERT THEIR ACTION ON THE BONE STRUCTURE OF YOUR BODY.

  • Page 33: Fasting The Safety Belt

    BLY. AFTER AN ACCIDENT OF A CERTAIN SEVERITY, WE RECOMMEND THAT YOU HAVE THE SEAT BELT WHICH WAS BEING WORN REPLACED AT AN AU- THORISED PIAGGIO SERVICE CENTRE, EVEN IF IT DOES NOT APPEAR DAM- AGED. Fasting the safety belt (05_01) Take the metal tongue from its housing.

  • Page 34: Adjusting The Safety Belt

    Adjusting the safety belt (05_02) Position the seat belt as low as possible on your hips and not at your waist. Adjust the seat belt so that you can slide your fist between the belt and your chest. Hold the anchoring at a right angle with respect to the belt and pull the belt to lengthen or shorten it.

  • Page 35: Instrument Panel And Controls

    Ape TM - Ape TM Diesel Chap. 06 Instrument panel and controls...

  • Page 36: Handlebars

    Handlebars (06_01) Apetm 1. External light control switch 2. Tachometer and odometer 3. Ashtray 4. Gear indicator 5. Clutch lever 6. Cigar lighter 7. Turn indicator selector 8. Reverse gear command lever 9. Key switch 10. Emergency or parking brake 11.
  • Page 37 06_01 Handlebars (06_01, 06_02) ApetmD 1. External light control switch 2. Tachometer and odometer 3. Ashtray 4. Gear indicator 5. Clutch lever 6. Cigar lighter...
  • Page 38 7. Turn indicator selector 8. Reverse gear command lever 9. Key switch 10. Emergency or parking brake 11. Heater control lever (red) 12. Airflow deflector lever: windscreen - floor heating 13. Brake pedal 14. Headlight switch 15. Horn button 16. Accelerator control 17.

  • Page 39: Steering Wheel

    06_02 Steering wheel (06_03) Apetm 1. Steering wheel 2. Flashing light switch lever 3. Light and horn switch lever 4. Key switch 5. Clutch pedal 6. Brake pedal...
  • Page 40 7. Accelerator pedal 8. External light control switch 9. Windscreen wiper control switch 10. Reverse gear control lever 11. Gearbox control lever 12. Emergency or parking brake 13. Heating control lever (red) 14. Starter lever (only gasoline version) (black) 15. Rear fog light switch 16.
  • Page 41 06_03 Steering wheel (06_03, 06_04) ApetmD 1. Steering wheel 2. Flashing light switch lever 3. Light and horn switch lever 4. Key switch 5. Clutch pedal 6. Brake pedal...
  • Page 42 7. Accelerator pedal 8. External light control switch 9. Windscreen wiper control switch 10. Reverse gear control lever 11. Gearbox control lever 12. Emergency or parking brake 13. Heating control lever (red) 14. Airflow deflector lever: windscreen - floor heating 15.

  • Page 43: Controls

    06_04 Controls (06_05, 06_06, 06_07, 06_08, 06_09) HANDLEBAR VERSION - GASOLINE External light control switch «A» 0 = Lights off; 1 = Front and rear side/taillights and instrument panel lights on; 2 = Headlights (high or dipped beams on).
  • Page 44 Windscreen wiper control switch «B» 0 = Disabled; 1 = Windscreen wiper enabled. 2 = Windscreen wiper + sprayer enabled. 06_05 Light selector «A» 1 = High beams on. 2 = Dipped beams; THE SWITCH POSITIONS ARE SUBJECT TO THE OUTSIDE LIGHT CONTROL SWITCH POSITION.
  • Page 45 Turn indicator selector «C» 0 = Lights off; S = Left turn indicators flashing; D = Right turn indicators flashing. 06_07 Emergency light switch «B» 0 = Lights off; 1 = Direction indicators flashing Rear fog light switch «A» 0 = Light off; 1 = Rear fog light on.
  • Page 46 1 = Taillights on; 2 = Dipped beams on; 3 = High beams on. To actuate the horn, press lever «A» upwards. THE LIGHT SWITCH LEVER POSITIONS ARE SUBJECT TO THE OUTSIDE LIGHT CONTROL SWITCH POSITION. Flashing light switch lever «C» 0 = Lights off;...
  • Page 47 1 = Rear fog light on. Emergency light switch «D» 0 = Lights off; 1 = Direction indicators flashing Cigar lighter«E» Press the lighter button and wait until it automatically returns to its initial position. The lighter is ready for use. 06_09 Controls (06_09, 06_10, 06_11, 06_12, 06_13, 06_14) HANDLEBAR VERSION - DIESEL...
  • Page 48 Windscreen wiper control switch «B» 0 = Disabled; 1 = Windscreen wiper enabled. 2 = Windscreen wiper + sprayer enabled. 06_10 Light selector «A» 1 = High beams on. 2 = Dipped beams; THE SWITCH POSITIONS ARE SUBJECT TO THE OUTSIDE LIGHT CONTROL SWITCH POSITION.
  • Page 49 Turn indicator selector «C» 0 = Lights off; S = Left turn indicators flashing; D = Right turn indicators flashing. 06_12 Rear fog light switch «A» 0 = Light off; 1 = Rear fog light on. Heater fan switch «B» 0 = Fan off 1 = First gear 2 = Second gear...
  • Page 50 Body tilting button «B» (where available) 0 = Body down 1 = Body up In order to improve safety and prevent unintentional operations, the lifting controls only becomes live after releasing the safety lever on the right hand side at the back of the cabin.
  • Page 51 D = Right turn indicators flashing. External light control switch «A» 0 = Lights off; 1 = Lights on. Windscreen wiper control switch «B» 0 = Disabled; 1 = Windscreen wiper enabled. 2 = Windscreen wiper + sprayer enabled. Rear fog light switch «C» 0 = Light off;...
  • Page 52 Cigar lighter«E» Press the lighter button and wait until it automatically returns to its initial position. The lighter is ready for use. 06_14 Emergency light switch «F» 0 = Lights off; 1 = Emergency light on. Body tilting button «G» 0 = Body down 1 = Body up...

  • Page 53: Ignition Switch

    In order to improve safety and prevent unintentional operations, the lifting control only becomes live after releasing the safety lever on the right hand side at the back of the cabin. Remember to bring the safety lever back onto the 'blocked' position once all tilting operations are completed.
  • Page 54 SHOULD THE STARTING DEVICE BE TAMPERED WITH (E.G. A THEFT AT- 06_17 TEMPT) HAVE IT CHECKED AT THE EARLIEST OPPORTUNITY BY A DEALER OR AN AUTHORISED PIAGGIO SERVICE CENTRE BEFORE YOU START DRIV- ING AGAIN. WHEN YOU LEAVE THE VEHICLE, ALWAYS REMOVE THE KEY TO PREVENT SOMEBODY FROM ACCIDENTALLY ACTUATING THE CONTROLS.

  • Page 55: Gauges And Warning Lights

    Ape TM - Ape TM Diesel Chap. 07 Gauges and Warning Lights...

  • Page 56: Instrument Unit And Indicators

    Instrument unit and indicators (07_01) A = Speedometer, odometer/mileometre. B = Preheat glow plug indicator (only on diesel versions - amber colour). C = Flashing lights on indicator (green colour). D = High beams on indicator (blue colour). E = Taillights on indicator (green colour). F = Rear fog light on indicator (amber colour).

  • Page 57: Air Control System

    Ape TM - Ape TM Diesel Chap. 08 Air control system...

  • Page 58: Heating

    Heating (08_01) Cabin heater controls (gasoline): Lever «A» (with red grip): in position 1. Control bar «B»: in position 1 (travel end back) located below the driver's seat to allow opening diaphragm «C». Shuttering outlets «D» in position 1 (OPEN). The cabin heater can be disabled by the shuttering outlets «D»...

  • Page 59: Heating And Demisting

    Heating and demisting (08_03) Cabin defrosting/heating controls (gasoline): Control bar «B» in position 2 (travel end forward). Shuttering outlets «D» in position 1 (OPEN). 08_03 Heating and demisting (08_03, 08_04) Cabin defrosting/heating controls (diesel): Control bar «B» in position 2. 08_04 Demisting (08_05) Cabin defrosting controls (gasoline):...
  • Page 60 Demisting (08_05, 08_06) Cabin heating controls (diesel): Control lever «B» in position 1. The hot air flow may be partitioned through the two outlets «D». 08_06...

  • Page 61: Mirrors And Window Glasses

    Ape TM - Ape TM Diesel Chap. 09 Mirrors and Window Glasses...

  • Page 62: Adjusting The Mirror

    Adjusting the mirror (9_01) Rear-view mirrors are adjusted by moving the mirror body manually until the ideal angle is obtained to guarantee full visibility. CAUTION NEVER ADJUST MIRRORS WHILE DRIVING AS YOU MAY LOSE CONTROL OF THE VEHICLE. 9_01 Wipers and Brushes (9_02, 9_03) Blade •...
  • Page 63 Replacing the windscreen wiper blade Replace the windscreen wiper blade as follows: • Lift the windscreen wiper arm "A" and position the blade so that it forms a right angle with the arm; • Press retainer tab "B" of the latching spring and extract the blade for arm "A";...

  • Page 65: Inside Equipment

    Ape TM - Ape TM Diesel Chap. 10 Inside equipment...

  • Page 67: Electrical System

    Ape TM - Ape TM Diesel Chap. 11 Electrical system...

  • Page 68: Fuel Version

    Fuel version The power for the lighting and indication system devices is provided in direct current by a dynamotor/battery unit, with a voltage regulator separated by the remote control switch unit, both installed under the seat in the compartment. The dynamotor acts as a generator-dynamo and as a starter motor: in particular, upon start-up, it absorbs current from the battery and operates as an electric motor.
  • Page 69 12V-50Ah...

  • Page 71: Emergency

    Ape TM - Ape TM Diesel Chap. 12 Emergency...

  • Page 72: Wheel Replacement

    Wheel replacement (12_01, 12_02) The tyre replacement operation and the use of jack require some precautions which are given below. WARNING SIGNAL THE PRESENCE OF THE VEHICLE AS PRESCRIBED BY THE HIGHWAY CODE IN FORCE. 12_01 PLACE THE JACK IN THE POSITIONS SHOWN SO AS NOT TO DAMAGE ME- CHANICAL PARTS OR THE BODY WARNING WHENEVER POSSIBLE, REPLACE TYRES WITH THE VEHICLE ON LEVEL...
  • Page 73 CAUTION THE JACK CAN ONLY BE USED TO REPLACE THE WHEELS. NEVER USE THE JACK TO PERFORM REPAIRS UNDER THE VEHICLE. THE VEHICLE MAY FALL IF THE JACK IS NOT POSITIONED CORRECTLY CAUTION PERIODICALLY CHECK TYRE PRESSURE ACCORDING TO THE VALUES GIV- EN IN THE: «MAINTENANCE ».

  • Page 75: Maintenance

    Ape TM - Ape TM Diesel Chap. 13 Maintenance...

  • Page 76: Check Engine Oil Level

    Check engine oil level (13_01) Engine oil level check (diesel version) To check the engine oil level, proceed as follows: 1. Check with engine off and vehicle on a flat surface; 2. Extract the level bar from the rear side of the vehicle and check that the level is between the MIN and MAX positions;...
  • Page 77 RESULT IN SERIOUS DAMAGES. CAUTION USED OIL IS HARMFUL TO THE ENVIRONMENT. WHEN REPLACING THE OIL, WE SUGGEST TO CONTACT A PIAGGIO AUTHORISED SERVICE POINTS EQUIPPED FOR DISPOSING SPENT OILS IN THE RESPECT OF NATURE AND IN COMPLIANCE WITH THE LAWS IN FORCE.
  • Page 78 Oil change and oil filter replacement (13_04, 13_05) Engine oil cartridge replacement (Diesel version) To gain access to the oil cartridge proceed as follows: 1. Remove the engine inspection door (or lift the metal alloy plate); 2. Drain the engine crankcase; 3.

  • Page 79: Checking The Brake Fluid Level

    2. Check the oil level is between 1 cm under the surface of cap «A» (MAX level) and 1 cm over the bottom of the reservoir (MIN level). If the oil is under the minimum level contact a PIAGGIO Dealer or Authorised Service 13_06 Centre to have the brake system checked.
  • Page 80 FMVSS DOT 4 Checking the brake fluid level (13_06, 13_07) Level check (Diesel version) The rear brake fluid reservoir is located inside the vehicle, underneath the cover on the right-hand side of the instrument panel. To check the level, remove the two fixing screws and the cover, then follow the pro- cedure outlined in the previous paragraph.

  • Page 81: Gear Box Oil Level

    CEEDS A CERTAIN VALUE, IT WILL LEAD TO INEFFICIENT BRAKING. NEVER USE BRAKE FLUID FROM PREVIOUSLY OPENED OR PARTLY-EMPTY CON- TAINERS. Gear box oil level (13_08, 13_09, 13_10) To check the gearbox oil, proceed as follows: 1. Check with engine off and vehicle on a flat surface; 2.
  • Page 82 To replace the gearbox oil proceed as follows: 1. Remove the cap «A», loosen cap «B» and drain the oil; when drainage is complete, replace cap «B». 2. Pour some oil into the top hole and let the engine run for a few seconds; then, drain the crankcase again.

  • Page 83: Window Washer Fluid Level

    885 grams (approx. 1000 cm3) Window washer fluid level (13_11) Topping up windscreen washer fluid The windscreen washer fluid reservoir is located inside the cab on the front right panel. To fill the reservoir, unscrew cap «A» and top up. Use a specific detergent. 13_11 Cooled fluid (13_12) Coolant top-ups (Diesel version)

  • Page 84: Changing The Engine Cooling Fluid

    Check the coolant circuit hoses for signs of wear (alligatoring of the rubber) and also check that all fittings are properly sealed. If any of the hoses is worn, please contact your nearest Authorised Piaggio Service Centre to have it replaced. Changing the engine cooling fluid Drain the circuit completely and refill following the procedure given in the previous paragraphs.

  • Page 85: Replacing The Fuel Filter

    Checking and replacing the air cleaner element (13_14, 13_15, 13_16) Replacing the air filter (diesel version) To replace the air filter, proceed as follows: 1. Loosen the fixing know «A» and remove the filter box cover «B»; 2. Extract the filtering element «C» and replace it with a new one; 3.

  • Page 86: Air Bleeding

    Air bleeding (13_18) Bleed air once the injection system has been emptied for checking due to running out of fuel. To this purpose, repeatedly actuate the lever controlling the hand pump, until you feel a resistance during the pumping phase. Normally, a totally empty system is filled with about 40 pumping actions.

  • Page 87: Checking And Replacing The Pre-Heating Plugs

    Checking and replacing the pre-heating plugs (13_20) Access the spark plugs as follows: 1. remove the plate releasing the three fixing clamps; 2. disconnect the high voltage wire cap «A» from the spark plug «B»; 3. remove the spark plug using the provided tool; 4.

  • Page 88: Fuses

    Fuses (13_21, 13_22, 13_23) The electrical system is protected by six 8A fuses located underneath the instrument panel, to the left of the steering column. To the left of the fuse-box are two fuses: 15A fuse «G» protecting the cigarette lighter, and 15A fuse «I»...
  • Page 89 IF YOU WANT TO FIT ADDITIONAL UNITS ON THE VEHICLE (E.G. ADDITIONAL LIGHTS) WE POINT OUT THAT INCORRECT DERIVATIONS ON THE ELECTRIC CONNECTIONS MAY CAUSE DAMAGE TO THE INSTALLATION. Handlebar gasoline version A. Dipped beams (left and right), rear fog light circuit. B.
  • Page 90 Handlebar diesel version A. Emergency (key OFF), windscreen wiper, horn, glass bowl. B. Emergency (key ON), flashing lights, indicator circuits (recharge, oil pressure, oil temperature, fuel reserve, preheating, tilting), stop lights, reverse gear lights, solenoid valve, preheating (power circuit excluded). C.

  • Page 91: Exhaust Circulation System (Egr) (13_24

    Dry with compressed air before reassembling. Reinstall the plate into the seat on the two plastic and aluminium covers. Replace the box sealing O-Ring housed in the cover seat at every disassembly. 13_24 TURN TO AN AUTHORISED PIAGGIO SERVICE CENTRE FOR THIS OPERA- TION. Tyres (13_25) •...

  • Page 92: Pressure

    TYRE PRESSURE Front tyre pressure 2.5 atm Rear tyre pressure 4.5 atm Pressure ACCORDING TO THE PROVISIONS OF THE REGULATIONS IN FORCE, THE TYRE TREADS MUST BE OVER 1.6 MM THICK. CHECK TYRE PRESSURE WHEN COLD. INCORRECT TYRE INFLATION PRES- SURE WILL CAUSE UNEVEN THREAD WEAR AND MAKE DRIVING DANGER- OUS.THE TYRE MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITS SET FORTH BY LAW.
  • Page 93 Connectors to the spark plug Restore connection disconnected DIFFICULTIES WHEN STARTING (GASOLINE VERSION) Fuel tank empty Refuel Clogged or dirty filters, jets or Contact an Authorised PIAGGIO carburettor Service Centre Starter control lever in lowered Move it to lifted position position...
  • Page 94 Water in the diesel Drain the water and replace the filter, if required, then bleed the air Injector dirty or faulty Contact an Authorised PIAGGIO Service Centre IGNITION FAILURE (GASOLINE VERSION) No spark on spark plug Check whether the electrodes are clean (clean with white spirit and wire brush or sandpaper).
  • Page 95 POOR COMPRESSION (GASOLINE VERSION) Spark plug seat threading Contact an Authorised PIAGGIO damaged; head bolts insufficiently Service Centre torqued, piston seals worn HIGH FUEL CONSUMPTION AND POOR PERFORMANCE (GASOLINE VERSION) Air filter blocked or dirty Replace the air filter ENGINE IRREGULAR OPERATION (DIESEL VERSION)
  • Page 96 WHITE FUMES UPON EXHAUST (DIESEL VERSION) Injector faulty Contact an Authorised PIAGGIO Service Centre Delayed injection Contact an Authorised PIAGGIO Service Centre BLACK FUMES UPON EXHAUST (DIESEL VERSION) Air filter clogged Replace the air filter Wrong injection pump calibration Contact an Authorised PIAGGIO...
  • Page 97 Drums greasy, brake shoes worn Contact an Authorised PIAGGIO Service Centre Air into the circuit pipes Bleed the air Shoe self-adjustment device faulty Contact an Authorised PIAGGIO Service Centre Irregular friction material wear Contact an Authorised PIAGGIO Service Centre Oil leaks from the circuit...

  • Page 98: Troubleshooting / What To Do If

    If the rpm number reached is excessive, decrease it by knob «A» to reach a regular minimum speed. If this is problematic, go to a PIAGGIO Dealer or Authorised Service Centre. THE IDLE ADJUSTMENT MUST BE PERFORMED WITH HOT ENGINE AND AC- TIVE CATALYTIC CONVERTER.
  • Page 99 CAUTION IN CASE OF PROBLEMS WHEN ADJUSTING THE IDLE SPEED, IT MAY BE NEC- ESSARY TO ADJUST EXHAUST EMISSIONS (CO). THIS OPERATION MUST BE PERFORMED AT AN AUTHORISED PIAGGIO SERVICE CENTRE. Characteristic Idle adjustment (approx. 1250 - 1450 rpm) Troubleshooting / What to do if... (13_26, 13_27)
  • Page 100 Air bleeding from the braking system In case of anomalies of the brake performance, accompanied by idle pumping, have the system drained by the Concessionaires or Authorised PIAGGIO Service Cen- tres. IN FACT, THE BRAKE FLUID IS HIGHLY CORROSIVE AND IT MUST BE DIS- POSED ACCORDING TO PRECISE REGULATIONS.
  • Page 101 Troubleshooting / What to do if... (13_29, 13_30) Brake pedal adjustment (steering wheel version) Adjust the brake pedal stroke as follows: 1. Remove the nut «A» locking the adjustment screw «B». 2. Adjust the stroke by means of screw «B»; 3.
  • Page 102 13_32 Troubleshooting / What to do if... (13_32, 13_33) Front turn indicators Replace the front turn indicator bulbs as follows: 1. Remove the plastic lens by removing the two screws «A»; 2. Extract the flashing light bulbs «B» pressing them and turning them clockwise. 13_33 Troubleshooting / What to do if...
  • Page 103 Troubleshooting / What to do if... (13_34, 13_35) Number plate light In order to remove the number plate light bulb, proceed as follows: 1. Remove the screw «A» fixing the bulb cover. 2. Replace the bulb and reassemble. 13_35 Troubleshooting / What to do if... (13_35, 13_36) Front ceiling light The cabin is provided with a courtesy light located above the internal rear-view mirror, whose switch is located on the glass bowl.
  • Page 104 THE ADJUSTMENT OF THE HEADLIGHTS ORIENTATION IS AN OPERATION THAT, IF NOT PERFORMED PROPERLY, INFRINGES ON A SPECIFIC RULE OF THE ROAD CIRCULATION CODE. FOR CHECKING AND ADJUSTING THE AIM OF THE HEADLIGHTS, WE SUGGEST TO CONTACT A PIAGGIO DEALER OR AUTHORISED SERVICE CENTRE. CAUTION BEFORE CARRYING OUT THE OPERATION FOR HEADLIGHTS AIMING, CHECK THAT THE TYRES ARE INFLATED TO THE INDICATED PRESSURES.
  • Page 105 Troubleshooting / What to do if... (13_38) Wheel replacement Replace the wheel as follows: 1. Stop the vehicle so that it is not a hazard for oncoming traffic and so you can replace the wheel safely. The ground should be flat and adequately compact; 2.

  • Page 107: Spare Parts And Accessories

    Ape TM - Ape TM Diesel Chap. 14 Spare parts and accessories...

  • Page 108: Warnings

    Warnings WE RECOMMEND THE USE OF "ORIGINAL PIAGGIO SPARE PARTS", THE ON- LY ONES TO OFFER THE SAME GUARANTEE OF QUALITY AS THE ORIGINAL PARTS INSTALLED ON THE VEHICLE. REMEMBER THAT THE USE OF NON- ORIGINAL SPARE PARTS WILL AFFECT YOUR RIGHTS AND INVALIDATE THE...

  • Page 109: Tipper Version

    Ape TM - Ape TM Diesel Chap. 15 TIPPER Version...

  • Page 110: System Operation

    System Operation (15_01) The equipment works as follows: 1. Releasing the safety lever «B»: Before activating the load bed tilting system, disengage the tailboard release handle and the safety lever «B». 2. Lifting the load bed: Pressing the «A» control pushbutton closes the electrical circuit and the battery power activates the electrical motor and the pump.

  • Page 111: Warnings For Loading And Unloading Operations

    In order to improve safety and prevent unintentional operations, the lifting control only becomes live after releasing the safety lever on the right hand side at the back of the cabin. Remember to bring the safety lever back onto the 'blocked' position once all tilting operations are completed.
  • Page 112 • For avoiding the risk of instability during use; before carrying out loading and unloading operations, park the vehicle on an even, horizontal surface and check the side board and tailgate locking and blocking systems. • Loading should be gradual and the weight of the loaded cargo must not ex- ceed the vehicle's allowable load mass (overall and per axle).
  • Page 113 During unloading operation check: • that the tailboard is open. Otherwise, stop the unloading operation immedi- ately and set the load bed at rest; do not force the side boards open when the load bed is in tilted position. • Carry out gradual unloading until the load bed is completely empty.

  • Page 114: Scheduled Maintenance

    The vehicle load must not exceed the maximum tolerances set for in the Road Reg- ulations or the allowable tolerances specified by the manufacturer. For information on load tolerances (overall and per axle) refer to the Technical Specifications section. The value for the overall mass is given in the vehicle registration papers. Remember that loading the vehicle in excess of the values given in the Traffic Regu- lations and on the manufacturer's plate, even for short trips, runs the serious risk of damage to the vehicle due to the excessive stress exerted on the vehicle's parts and...
  • Page 115 Ensure the hinges are free to move and have no excessive clearance or deformation. Cylinder and jack Check that the jack stem is properly extended and that it is free of scratches, dents or deformations. In the event of faults, please contact the manufacturer or an authorised workshop.

  • Page 116: Extraordinary Maintenance

    HV hydraulic oil (High viscosity index). ISO-L-HV; DIN 51524-3 HVLP. Pneumatic and electrical control circuits, controls and warning lights. Check the standard operation of the controls, warning lights and relevant circuits and pipes. In the event of faults, please contact the manufacturer or an authorised work- shop.

  • Page 117: Trouble-Shooting

    Trouble-Shooting Body does not start lifting and control unit does not emit any noise Possible cause: • no supply (low battery, loose terminals). • supply to the electrical circuit is interrupted (defective fuse, faulty switch, loose electrical connections). • end-stroke device jammed. Solutions to be undertaken: •...
  • Page 118 Solutions to be undertaken: • check the end-stroke device • check the oil level Body does not come down Possible cause: • control switch faulty • clogged exhaust pipe • by-pass defective Solutions to be undertaken: • check the control switch, pipes and by-pass Body lifts without activating the controls Possible cause: •...
  • Page 119 Possible cause: • switch faulty Solutions to be undertaken: • check the switch Warning light and buzzer not working Possible cause: • warning light bulb defective or buzzer faulty (if only one of the two not working) • switch or electric circuit faulty if both not working Solutions to be undertaken: •...

  • Page 120: Warning Plate Symbols

    Warning Plate Symbols (15_05) All labels are fitted individually or in series in different parts of the vehicle: counter- chassis, instrument panel, side boards, etc...
  • Page 121 15_05...
  • Page 122 ABELS READ THIS MANUAL CAREFULLY AND FOLLOW THE INSTRUCTIONS IT CONTAINS. KEEP AT A SAFE DISTANCE FROM T HE VEHICLE DO NOT REST UNDER THE LIFTED LOADING PLATFORM IF THE SAFETY BAR HAS NOT BEEN SECURED. STOP ENGINE REMOVE THE KEY AND THE EMERGENCY FUSE BEFORE CARRYING OUT MAINTENANCE OPERATIONS.

  • Page 123: Technical Sheet For Ec Conformity Declaration

    technical sheet for EC conformity declaration This manual contains information on the vehicle's tilting system. Thorough knowledge of the manual's content is fundamental to ensure proper use and adequate functioning of the installed equipment. Even in the case of equipment that is easy to use, operators must be familiar with common safety measures and must pay special attention during manoeuvring in order to ensure proper vehicle operation at the various stages of the operating cycle.

  • Page 124: Equipment Layout

    forth in directive 89/392/EEC and amendments, in the 91/368/EEC, 93/44/EEC ap- plicable standards and CUNA standards NC 173-01, 173-02, 173-03,173-04 and 173-05 Reference: • drawings of the overall vehicle, the chassis, the tilting system components, the control and safety devices. •...
  • Page 125 1. Base chassis. 2. Lifting jack stem. 3. Safety bar. 4. Body hinges. 5. Jack upper pivot attachment 6. Body reinforcing structure. 15_06 1. Vehicle's counter-chassis 2. Safety bar support. 3. Safety bar. 4. Base chassis. • Rear hinges fastened onto appropriate brackets, bolted onto the overhang of rear chassis members.
  • Page 126 • - pump driven by an electrical motor powered by the vehicle's battery, dis- tributor fitted with a by-pass valve, • - high-pressure pipelines connecting the pump to the jack, • - electrical system equipped with controls and safety devices; Safety devices consisting of: •...

  • Page 127: Analysis Of Risks Connected With The Layout And Operation Of The Equipment

    Tailgate and closure mechanism 1. Tailgate 2. Locking lever hinge 3. Locking bolt for closure mechanism. 4. Locking lever 15_10 Analysis of Risks Connected with the Layout and Operation of the Equipment Possible risks are evaluated as per Directive no. 89/392/EEC, as modified and inte- grated by EEC Directives 91/368, 93/44, 93/68 with regard to the layout and operation of the equipment as applicable to the type and operational specifications of the equip- ment itself.
  • Page 128 The overall equipment design and manufacture, meets the requirements set forth in section 1.1 of the Technical Appendix to the Standards, in addition to the above men- tioned CUNA norms. Controls and control devices. All controls comply with the applicable Directives regarding the type and operational specifications of the equipment and its use.
  • Page 129 The warning indicators are turned on by pressing a pushbutton when disengaging the load bed release lever at the beginning of the lifting operation, and they remain illu- minated until the release lever is re-engaged. The warning lights and buzzers are activated as soon as the load bed lifting operation starts and are deactivated when the load bed reaches its home position.
  • Page 130 Precautions for avoiding the risk of instability during use The precautions to be adopted are given in the instructions and concern the following: • Position of the vehicle during the loading and unloading operations, in par- ticular, the nature of the wheels' resting surface (non-planarity, irregularity, and poor consistency).
  • Page 131 There are warning plates with writings or symbols referring to the above mentioned requirements. Risks associated to falling or flying objects During loading, unloading, or transport, there is a risk of objects falling off the load bed. Such risk may be avoided solely by taking adequate precautions against such contingencies.
  • Page 132 Protection measures against mechanical hazards comply with the requirements set forth in the Directive's technical appendix on "safety measures to avoid mechanical risks" and the above mentioned CUNA standards. Protective Measures Against Other Hazards The equipment is driven by hydraulic fluid, which may reach high temperatures during operation, resulting in the danger of burns in the event of leaks from pipes, valves, or fittings.
  • Page 133 All operations requiring the load bed to be lifted, for whatever reason, must only be carried out after the safety prop has been carefully positioned underneath the load bed. The safety prop prevents the load bed from dropping. It does not offer the same safety guarantee when the load bed is loaded.
  • Page 134 NOTE: For the total mass and the mass on the relative axes, reference should be made to what indicated on the label installed on board the vehicle. In addition, at several points of the device, there are adhesive warning labels with symbols of com- mon use.

  • Page 135: Technical Data

    Ape TM - Ape TM Diesel Chap. 16 Technical data...
  • Page 136 VEHICLE LENGTH A NORMAL BODY 3175 mm LONG BODY 3390 mm TILTING BODY 3225/3335 mm(*) 3210 mm MOTOR CHASSIS 3150/3210 mm VEHICLE WIDTH B NORMAL BODY 1480 mm LONG BODY 1500 mm TILTING BODY 1500 mm 1480 mm MOTOR CHASSIS 1455 mm VEHICLE HEIGHT C NORMAL BODY...
  • Page 137 1780 mm MOTOR CHASSIS 1630 mm VEHICLE WHEELBASE D NORMAL BODY 2170 mm(Ο) - 2130 mm(∆) LONG BODY 2170 mm(Ο) - 2130 mm(∆) TILTING BODY 2170 mm(Ο) - 2130 mm(∆) 2130 mm (Ο) MOTOR CHASSIS 2170 mm(Ο) - 2130 mm(∆) LOAD COMPARTMENT LENGTH E NORMAL BODY 1770 mm...

  • Page 138: Vehicle

    TILTING BODY 1810/1920 (*) mm 1770 mm Vehicle (16_01) (*) For Diesel versions only. (O) Handlebar. (∆) Steering wheel.
  • Page 139 16_01...
  • Page 140 TECHNICAL SPECIFICATIONS - PERFORMANCE Engine Single cylinder, two strokes, with revolving timing system with three transfer ducts. Bore 68 mm Stroke 60 mm Displacement 217.9 cm3 Compression ratio 8.6 : 1 Ignition advance (before TDC) 14°±1°30" Carburettor Dellorto SHBC 22/22 Spark plug BOSCH W3AC - CHAMPION RL78C - NGK BR8HS...
  • Page 141 CAPACITY (including reserve): 15 litres Mixer oil RESERVE: 0.75 litres CAPACITY (including reserve): 3 litres Gearbox oil CAPACITY (including reserve): 1000 cc VERSION Normal body LOADLESS WEIGHT(with driver): 465 kg CAPACITY (excluding driver): 805 kg MAX WEIGHT: 1270 kg Long body LOADLESS WEIGHT (with...
  • Page 142 LOADLESS WEIGHT (with driver): 505 kg CAPACITY (excluding driver): 765 kg MAX WEIGHT: 1270 kg Fixed motor chassis MAX WEIGHT: 1270 kg Tilting motor chassis MAX WEIGHT: 1270 kg TECHNICAL SPECIFICATIONS - PERFORMANCE Engine Diesel cycle, 4 strokes, indirect injection, single cylinder Bore 83 mm Stroke...
  • Page 143 - RM = 1/39.8 Engine-wheel transmission ratio - - 1st speed = 1/35.4 4 gear version (handlebar) - 2nd speed = 1/19 - 3rd speed = 1/10.9 - 4th speed = 1/7.1 - R.M. = 1/35.4 Maximum speed ~ 65 km/h REFUELLING Diesel CAPACITY 15 litres (reserve: 3.5...
  • Page 144 CAPACITY (excluding driver): 715 kg MAX WEIGHT: 1270 kg Motor chassis MAX WEIGHT: 1270 kg TECHNICAL SPECIFICATIONS Fuel supply By an injection pump, fed by a membrane pump. Fuel Automotive diesel Lubrication Pressure by lobe pump. Oil filter With cartridge and total capacity. Timing system Camshaft on the cylinder head, controlled by a toothed belt.
  • Page 145 With 5 gears on the steering wheel version. Differential Connected to the gearbox shaft by cylindrical gears. The planetary and satellite gears are bevel. The differential box is connected to the two axle shafts that transmit the motion to the wheels by flexible couplings.
  • Page 146 stroke; in full load condition, the wheels have a vertical setup. Brakes With expansion on the three wheels: Front and rear with hydraulic control pedal direct controlled brake pump. - Safety or parking with mechanical control on the rear wheels. The control lever is located on the central instrument panel column in the driving cabin.
  • Page 147 The amount injected for each cycle is adjusted, depending on the power required, through the rotation of the pumping element of the injection pump by the adjustment bar. Fuel supply control The adjustment bar is actuated by the regulator. It is flanged on the side of the engine head and is pulled by a shaft actuated by the camshaft.

  • Page 149: Scheduled Maintenance - Checks

    Ape TM - Ape TM Diesel Chap. 17 Scheduled maintenance - Checks...

  • Page 150: Scheduled Maintenance Service

    Adequate maintenance is fundamental to ensure long-lasting, optimal operation con- ditions and performance. For this purpose, PIAGGIO offers a series of checks and maintenance operations to be performed at the owner's expense, which are summarised in the table on the next pages.
  • Page 151 Gearbox, gas and clutch control - check/adjust Belt tension - tension check/adjust Electric system and batteries - efficiency check Gearbox oil - replacement Headlights - check/adjust Idle carburation - check/adjust Tyre pressure - check AT 4,000 KM AT 20,000 KM AT 28,000 KM AND AT 44,000 KM Braking system - vehicle test/check Parking brake - check/adjust...
  • Page 152 Air filter and SAS box (sponge) - clean SAS reed support - check AT 8,000 KM AT 16,000 KM AT 32,000 KM AND AT 40,000 KM Braking system - vehicle test/check Locking external nuts and bolts - check Parking brake - check/adjust Brake pump tank oil level - check Gearbox, gas and clutch control - check/adjust Belt tension - tension check/adjust...
  • Page 153 Carburettor - Cleaning Hinges and door closures - lubricate Air filter and SAS box (sponge) - clean SAS reed support - check AT 12,000 KM AND AT 36,000 KM Braking system - vehicle test/check Parking brake - check/adjust Brake pump tank oil level - check Belt tension - tension check/adjust Spark plug - check/clean/electrodes adjustment Tyre pressure - check...
  • Page 154 AT 24,000 KM AND AT 48,000 KM Braking system - vehicle test/check Locking external nuts and bolts - check Parking brake - check/adjust Brake pump tank oil level - check Gearbox, gas and clutch control - check/adjust Belt tension - tension check/adjust Electric system and batteries - efficiency check Gearbox oil - replacement Spark plug - check/clean/electrodes adjustment...
  • Page 155 SAS reed support - replacement Scheduled maintenance service DIESEL VERSION AFTER 1,000 Braking system - Test drive - Inspection Brake fluid level - Check External nuts and bolts lock - Inspection Tappets - Inspection/Adjustment Gearbox, gas and clutch control - Inspection/Adjustment Electric system and batteries - Efficiency check Injection dynamic advance and timing belt tension - Inspection Tyre pressure - Inspection...
  • Page 156 Tappets - Inspection/Adjustment Brake fluid level - Check Preheat glow plug - Inspection Tyre pressure - Inspection Cylinder head, piston head, exhaust pipe, water radiator - Cleaning Levers and controls engine side - Greasing Engine oil - Replacement 10,000 30,000 50,000 KM AND AT Braking system - Test drive - Inspection...
  • Page 157 Levers and controls engine side - Greasing Engine oil level - Inspection Hinges, door closures and flexible transmissions - Greasing Fuel filter - Replacement Air filter - Replacement Cooling circuit pipes - Inspection 20,000 40,000 70,000 KM AND AT Braking system - Test drive - Inspection External nuts and bolts lock - Inspection Tappets - Inspection/Adjustment Brake fluid level - Check...
  • Page 158 Engine oil - Replacement Oil filter - Replacement Fuel filter - Replacement Air filter - Replacement Coolant - Replacement RECOMMENDED PRODUCTS Product Description Specifications AGIP CITY TEC 2T Oil for 2-stroke petrol engines JASO FC, ISO-L-EGD Specifications AGIP ROTRA MP 80W-90 Oil with specifications SAE 80W-90, API GL-5 Gearbox oil AGIP BRAKE 4 Brake fluid...
  • Page 159 TABLE OF CONTENTS Wheel: 39, 41, 72 Windows: 29 Belt: 33, 34 Identification: 7, 8 Pressure: 92 Instrument panel: 35 Checks: 14, 149 Safe riding: 11 Control: 57 Keys: 28 Safety: 31–34 Safety belts: 31, 32 Seats: 31 Switch: 53 System: 57, 67, 91, 110 Doors: 27 Level: 76, 79–81, 83...
  • Page 160 © 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. V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi) ITALY www.piaggio.com...

This manual is also suitable for:

Ape tm diesel

Table of Contents

Save PDF