Piaggio APE TM 2012 User Manual [it]

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MANUALE STAZIONE DI SERVIZIO

667270 - 667275 (IT-EN-FR-DE-ES-EL)

APE TM Benzina

MANUALE

STAZIONE DI

SERVIZIO

APE TM Benzina

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

MANUALE STAZIONE DI

SERVIZIO

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. Any important changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along with the specific tool catalogue. The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions/models shown in this publication are available in all countries. The availability of single versions should be checked at the official Piaggio sales network.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. Refers to

specific procedures to carry out for preventing damages to the vehicle. Refers to specific procedures to carry out for preventing damages to the vehicle. Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

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 damaging 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.

INDEX OF TOPICS

GENERAL GUIDELINES GEN

CHARACTERISTICS CH

SPECIAL TOOLS ST

MAINTENANCE MA

EMISSION CONTROLO SYSTEM CO EM

TROUBLESHOOTING TROUBL

ELECTRICAL SYSTEM ES

ENGINE FROM VEHICLE EV

ENGINE EN

GEAR-BOX GE

DIFFERENTIAL DI

BRAKING SYSTEM BS

STEERING COLUMN SC

SUSPENSIONS SS

TIPPER VERSION VR

CHASSIS CH

PRE-DELIVERY PD

INDEX OF TOPICS

GENERAL GUIDELINES GEN

APE TM Benzina General guidelines

Maintenance guidelines

RULES TO BE FOLLOWED IN THE EVENT OF INTERVENTION ON THE ELECTRIC SYSTEM - APE TM

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; it is essential, however, that they take observe the notices below, since, in case of failure to observe, they could irreparably damage the devices. 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.

The ignition circuit works on AC, and obviously, must be definitely separated from that of DC In fact the latter, powered by the battery and dynamotor, serves only for the service user groups (city lights, stop, horn, lights, headlight, etc.).

KEY: 1 = Red (direct current) 2 = White (direct current) 3 = Grey - Red (direct current) 4 = Purple (alternating current engine stop) 5 = Black (ground) 6 = White - Red (direct current)

* = Connection connected to the red cable of the condenser charging coil. ** = Connections with electronic ignition.

If there is a connection of two circuits, i.e., if the ignition one was routed by the DC, there would

be instantaneous deterioration of the control unit. It is therefore necessary and important that, in case of removal or disconnection of cables,

particularly of those which depend on the main key switch and the control unit, during reassembly pay attention to correctly reconnect each cable to the

GEN - 7

General guidelines APE TM Benzina

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) 5 = Black (ground) 6 = White - Red (direct current) 7 = Grey (direct current) 8 = Black

* = Connection connected to the red cable of the condenser charging coil. ** = Connections with electronic ignition.

For obvious reasons it is essential that, in case of replacement of one or more devices in the system (main switch, stator unit of the flywheel, control unit) during reassembly, a device is used that is similar to the existing one: if in fact similar devices were used, but not specific to the same ignition system, they would not work, risking irreparable damage to the control unit.

KEY: 1 = White 2 = Red 3 = Green

B) INSPECTIONS TO BE PERFORMED IN THE EVENT OF IGNITION IRREGULARITIES

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.

GEN - 8

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 and on the stator components as follows: After a visual inspection of the connections, stator and couplings, measurements are carried out on the charging coil and the ignition coil using an Ohm meter, capable of detecting resistance from 1 to 1000 ohm, as follows:

- Connect the instrument between the WHITE cable and the RED cable; there must be continuity and ohmic value (430 to 480 ohm);

KEY:

1) White

2) Red

3) Green

- Connect the + terminal of the instrument with the WHITE cable and the - terminal of the instrument with the RED cable there must be continuity and ohmic value (7 to 9 ohm).

KEY:

1) White

2) Red

3) Green If failures are detected in the inspections of the charging coil and ignition coil, proceed to replace the

damaged parts.

If there is no tool available to check the stator, when it is established that the ignition problem is not related to the power control unit nor to other visible causes (bad connections, damaged cables, damaged spark plug), proceed to replace the complete stator. In relation to what described in the preceding paragraphs we recommend, therefore, to include in the control tools an Ohm meter with the characteristics outlined above.

C) IGNITION TIMING CHECK

GEN - 9

General guidelines APE TM Benzina

The timing check may be useful for example if the motor is not operating properly (start-up difficulties; decreased performance and power; difficult or irregular recovery speed etc.); if the failure does not depend on the carburetion, it may be caused by irregularities of the ignition timing. This possibility is, however, considered quite rare since, due to the characteristics of the ignition system, the timing adjustment remains unchanged over time; since the problem arises in most cases from irregular operation of the control unit, to be sure please follow the steps outlined on the side for verification of the aforementioned device.

If however, after checking the carburetion and the control unit, the desired improvements are not obtained and there is doubt whether the anomalies are due to the ignition timing, proceed to check the latter, operating as follows:.

1) Insert, into the hole (1) a rod of Ø 5 mm.; run the engine manually until when the end of the rod, coming into correspondence with the other hole on the rotor, does not fit.

In this condition the engine is in ignition advance position.

2) Make a mark with white paint on the fan cover, in correspondence with the flap of the flywheel bearing the reference for the timing.

3) Connect a stroboscopic lamp (type TECNOTEST 130/P or other similar) at ignition; the connection will be made directly on the spark plug or on the H.V. cable, etc. depending on the type of stroboscopic lamp available and the specific operating instructions. Then start the engine and bring it to about 4000-5000 rpm.

4) The engine will be properly timed to the lamp when the two marks are aligned, or at most, moved to within a tolerance range of 4° (i.e., within 2° to the right and 2° to the left of alignment position).

5) If the mark of the flywheel rotor is shifted compared to the crankcase more than the allowed tolerance (or other major irregularities appear during the check), replace the stator or the control unit.

N.B.

FOR VEHICLES OF NEXT PRODUCTION, THE FAN COVER WILL BE FITTED WITH A REFERENCE 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

GEN - 10

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.

KEY: 1 = Red (direct current) 2 = White (direct current) 3 = Red (direct current) 4 = Purple (alternating current engine stop) 5 = Black (ground)

* = Connection connected to the fuses. ** = Connection connected to the starter relays. *** = Connection connected to the white-red cable of the light switch. **** = Connections with electronic ignition. ***** = Connection connected to the voltage regulator.

If there is a connection of two circuits, i.e., if the ignition one was routed by the DC, there would

be instantaneous deterioration of the control unit. It is therefore necessary and important that, in case of removal or disconnection of cables,

particularly of those which depend on the main key switch and the control unit, during reassembly pay attention to correctly reconnect each cable to the corresponding terminal; for this purpose it is al-

ways advisable to consult the electrical circuit diagrams.

For obvious reasons it is essential that, in case of replacement of one or more devices in the system (main switch, stator unit of the flywheel, control unit) during reassembly, a device is used that is simi- lar to the existing one: if in fact similar devices were used, but not specific to the same ignition system, they would not work, risking irreparable damage to the control unit.

B) INSPECTIONS TO BE PERFORMED IN THE EVENT OF IGNITION IRREGULARITIES

GEN - 11

General guidelines APE TM Benzina

- Connect the instrument between the WHITE cable and the RED cable, there must be continuity and ohmic value (430 to 480 ohm);

KEY: 1 = White 2 = Red 3 = Green

- Connect the + terminal of the instrument with the WHITE cable and the - terminal of the instrument with the GREEN cable there must be continuity and ohmic value (7 to 9 ohm).

KEY: 1 = White 2 = Red 3 = Green If failures are detected in the inspections of the charging coil and ignition coil, proceed to replace the damaged parts.

GEN - 12

APE TM Benzina General guidelines

paragraphs we recommend, therefore, to include in the control tools an Ohm meter with the characteristics outlined above.

C) IGNITION TIMING CHECK

1) Insert, into the hole (1) a rod of Ø 5 mm.; run the engine manually until when the end of the rod, coming into correspondence with the other hole on the rotor, does not fit.

In this condition the engine is in ignition advance position.

2) Make a mark with white paint on the fan cover, in correspondence with the flap of the flywheel bearing the reference for the timing.

- 5000 rpm.

N.B.

FOR VEHICLES OF NEXT PRODUCTION, THE FAN COVER WILL BE FITTED WITH A REFERENCE FOR TIMING, SO THE OPERATIONS DESCRIBED IN POINTS 1 AND 2 WILL NOT BE NECESSARY.

GEN - 13

INDEX OF TOPICS

CHARACTERISTICS CH

APE TM Benzina Characteristics

Characteristics

SIZES

millimetres Deck Long

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 3300 3300 3300 3300

WEIGHTS

(*) = without the driver (*) = including the driver

Van Tipper

Kilograms (kg) Deck Long

Deck

Dry weight (*) 445 450 465 465 Vehicle weight in running order (with refuelling, tools and accessories) 1160 1160 1160 1160 Load capacity (**) 715 710 695 695

Van Tipper

TECHNICAL DATA - CHASSIS

Specification

Chassis Sheet steel body and a single central longitudinal arm (inte-

grated structure). Removable deck integrated into the struc-

Driver's cab Welded to the chassis.

Seats in driving cab Two.

Desc./Quantity

ture.

TECHNICAL DATA - ENGINE

Specification

Matriculation data The identification codes consist of a prefix (ATM2T on the

chassis, ATM2M on the engine) and a number.

Engine Single-cylinder, 2-stroke engine, with "rotating" timing and with

three transfer ducts, with transmission and differential grouped

Engine capacity 217.9 cm³

Bore X Stroke 68 x 60

Compression ratio 8.6 : 1

Ignition advance 14° ± 1°30' before T.D.C.:

Carburettor Dell'Orto SHB 22/22.

Fuel Pure petrol with separate engine lubrication, "LS" device.

Spark plug Marelli CW7N, or Bosch W4AC; Lodge 3HN; Champion L82;

Maximum speed (CUNA STANDARDS) 60÷65 km/h.

Air filter At the intake of the type with paper cartridge filter.

Cartridge AC AIRAC FLAT PACK.

Consumption (CUNA) ~4.3 litres per 100 km.

Km range Around 330 Km.

Desc./Quantity

on the axis of the rear wheels.

AC430Z; NGK B7HS.

TRANSMISSION

Specification

Gear ratio First 1/48.47

Gear ratio Second 1/26.54

Gear ratio Third 1/15.56

Gear ratio Fourth 1/9.16

Gear ratio Reverse 1/80.78

Desc./Quantity

CH - 15

Characteristics APE TM Benzina

STEERING

Specification Desc./Quantity

Steering Built with tube pivoted on the arm with front wheel-holder os-

cillating hub.

SUSPENSION

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

Specification Desc./Quantity

Wheel rim From 3.50".

Front wheel and spare wheel "Normal" type 4.00-12 C- PR6.

Rear wheels "Radial" type 4.00-12 C- PR6. (for example Michelin C-XZX

Front tyre pressure 2.8 bar

Rear tyres - inflation pressure 4.5 bar

N.B.:

When installing the spare wheel in place of one of the rear wheels (for example due to a puncture) it is recommended to replace it as soon as possible by reinstalling the "radial" tyre which is more suitable for use. It is not advisable to install the radial tyre on the front wheel as there would be excessive sensitivity, especially when driving on twisting or bumpy roads.

PR.6. for deck, van, tipper, Urban Cleansing van and cabriolet

versions).

"Radial" type 4.00-R12 C- PR8. (for example Michelin C-XZX

PR.8. for versions with external fixed elaborations and those

with hydraulic tipping).

REFILLING

(*)= specific for versions with tipper deck.

Litres (l)

Fuel tank (reserve) 15 (3.5) 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 (*) 3.0 3.0 3.0 3.0

Deck Long

Deck

Van Tipper

DIMENSIONS - APE TM KAT - APE TM P703 FL2

millimetres

(1) Length 3175 3390 3210 3225 3150 (2) Width 1480 - - 1500 (3) Height 1630 1630 1780 1630 (4) Wheelbase 2170 2170 2170 2170 (5) Track 1300 1300 1300 1300 (6) Turning spokes 3300 3300 3300 3300

Deck Long

Deck

Van Tipper Motor

chassis

WEIGHTS - APE TM KAT - APE TM P703 FL2

(*) = without the driver (*) = including the driver

Kilograms (kg)

Dry weight (*) 465 465 505 505 Vehicle weight in running order (with refuelling, tools and accessories) 1270 1270 1270 1270 Load capacity (**) 805 805 765 765

Deck Long

Deck

Van Tipper

CH - 16

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-

Versions Sheet metal deck, integrated into the structure.

Aluminium alloy deck, hydraulic tipper for engine inspection.

Driver's cab Welded to the chassis.

Seats in driving cab Two.

TECHNICAL DATA - ENGINE - APE TM KAT

Specification Desc./Quantity

Matriculation data The identification codes consist of a prefix (ATM2T on the

chassis, ATM2M on the engine) and a number.

Engine Single-cylinder, 2-stroke engine, with "rotating" timing and with

three transfer ducts, with transmission and differential grouped

Engine capacity 217.9 cm³

Bore X Stroke 68 x 60

Compression ratio 8.6 : 1

Ignition advance 14° ± 1°30' before T.D.C.:

Carburettor Dell'Orto SHB 22/22.

Fuel Pure petrol with separate engine lubrication, "LS" device.

Spark plug Champion RL78C; NGK BR8HS.

Maximum speed (CUNA STANDARDS) 60÷65 km/h.

Air filter At the intake of the type with paper cartridge filter.

Consumption (CUNA) ~4.1 litres per 100 km.

Km range Around 330 Km.

grated structure).

Long deck.

on the axis of the rear wheels.

TECHNICAL DATA - ENGINE - APE TM P703 FL2

Specification

Matriculation data The identification codes consist of a prefix (ATM2T on the

chassis, ATM2M on the engine) and a number.

Engine Single-cylinder, 2-stroke engine, with "rotating" timing and with

three transfer ducts, with transmission and differential grouped

Engine capacity 217.9 cm³

Bore X Stroke 68 x 60

Compression ratio 8.6 : 1

Ignition advance 14° ± 1°30' before T.D.C.:

Carburettor Dell'Orto SHB 22/22.

Fuel Pure petrol with separate engine lubrication, "LS" device.

Spark plug Bosch W4AC; Lodge 3HN; Champion L78C AC430Z.

Maximum speed (CUNA STANDARDS) 60÷65 km/h.

Air filter At the intake of the type with paper cartridge filter.

Consumption (CUNA) ~4.1 litres per 100 km.

Km range Around 330 Km.

Desc./Quantity

on the axis of the rear wheels.

TRANSMISSION - APE TM KAT - APE TM P703 FL2

Specification

Gear ratio First 1/48.47

Gear ratio Second 1/26.54

Gear ratio Third 1/15.56

Gear ratio Fourth 1/9.16

Gear ratio Reverse 1/80.78

Desc./Quantity

STEERING - APE TM KAT - APE TM P703 FL2

Specification

Steering Built with tube pivoted on the arm with front wheel-holder os-

Desc./Quantity

cillating hub.

CH - 17

Characteristics APE TM Benzina

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

Wheel rim From 3.50". Front tyre (handlebar version) 4.00-12CNTL Rear tyre (handlebar version) 125R12C XZX TL

Front tyre (steering wheel version) 125R12C XZX TL Rear tyre (steering wheel version) 125R12C XZX TL

Front tyre pressure 2.5 bar

Rear tyres - inflation pressure 4.5 bar

REFILLING - APE TM KAT - APE TM P703 FL2

(*)= specific for versions with tipper deck.

Litres (l) Deck Long

Deck

Fuel tank (reserve) 15 (3.5) 15 (3.5) 15 (3.5) 15 (3.5) Engine oil (reserve) 3.2 (0.75) 3.2 (0.75) 3.2 (0.75) 3.2 (0.75) Hydraulic oil (reserve) (*) 15 (3.2) 15 (3.2) 15 (3.2) 15 (3.2)

Van Tipper

Tightening torques

ENGINE UNIT

Name

Transmission cross control stem 35 to 40 Nm (a)

3rd and 4th speed cross control stem 19 to 21 Nm (b)

1st and 2nd speed cross control stem 25 to 30 Nm (b)

Spark plug 18 to 24 Nm

Bolts locking dynamotor to differential crankcase 30 to 35 Nm

Bolts locking dynamotor to engine crankcase 20 to 25 Nm

Clutch assembly locking nut 180 to 220 Nm

Multi-gear pin nut 35 to 40 Nm

Fan flywheel locking nut 60 to 65 Nm

Silencer manifold fixing nut 19 to 21 Nm

Silencer to crankcase fixing bolts 18 to 22 Nm

Clutch cover fixing bolt 13 to 17 Nm

Cylinder head fixing bolt 20 to 23 Nm

Engine to deck fixing bolt 20 - 25 Nm

Spring line to frame fixing bolt 20 - 25 Nm

Spring line to frame anchor bolt 20 to 25 Nm

Oil drain plug 22 to 25 Nm

Bolt connecting the crankcase halves 13 to 15 Nm

Dynamotor pulley lock nut 35 to 40 Nm

Crankcase admission joint lock bolts 14 to 18 Nm

Change control support lock bolts 14 to 18 Nm

(a)= Specific for version with handlebar (b)= Specific for version with steering wheel

Torque in Nm

CH - 18

DIFFERENTIAL UNIT

Name

Differential box toothed sprocket lock bolts 54 to 64 Nm

Differential cover fixing bolt 30 to 40 Nm

Torque in Nm

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 100-120

Shoes self-centring plate lock nuts 20 - 25

REAR SUSPENSION UNIT

Name Torque in Nm

Wheel to drum lock nut 60-70

Drum centre lock nut 200 to 240

Shock absorber lower lock nut 100 to 140 Nm

Shock absorber upper lock nut 30-40

Swinging arm lock nut 40-50 Nm Flexible coupling lock nut 40 - 50 Hub to axle shaft lock nut 50-70

Hub to wheel axle lock nut 140-180

Hub to swinging arm lock nut 40 - 50

Shoes self-centring plate lock nut 18 to 20 Nm

Name Torque in Nm

Handle bar to steering tube lock bolts 42 to 52 (a)

Steering control lever to steering tube lock bolts 30 to 35

Steering housing lock nuts 20 to 25 (b)

Steering wheel lock nut 30 to 35 (b)

Rack pressure roller lid lock nuts 8 to 12 (b)

Pressure roller adjustment screw lock nut 40 to 60 (b)

Lever holder locking screw 7 to 8.5

Brake oil pump piston end stroke screw 6 to 10 Nm

Pedal assembly bolt lock nut 15 to 25

Stop switch 1.5 to 3

Cab doors lock bolt 23 to 30 Windshield wiper motor lock 8 to 9 Brake pump body lock bolts 12 to 20 (a) Brake pump body lock bolts 8 to 12 Floor to cab panel lock bolts 20 - 25

Floor to centre cross member lock nuts 20 - 25

(a) Specific for versions with handlebar (a) Specific for versions with steering wheel

Vehicle overhaul data

Assembly clearances

FRAME ASSEMBLY

SHOULDER RINGS

Specification

Shoulder ring (Nominal sizes) B= 1 +0 -0.06 (mm)

Desc./Quantity

CH - 19

Characteristics APE TM Benzina

SHOULDER RING - CLEARANCE "A" UPON FITTING

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 0.15 to 0.50 Shoulder ring 4th Oversize 1.5 +0 -0.06 0.15 to 0.50

For the clearance check, use the specific equipment.

N.B.

IF YOU DO NOT GET THE CLEARANCE "A" WITH SHOULDER RING "B", REPLACE THE LATTER WITH A RING LARGE ENOUGH TO GET THE REQUIRED CLEARANCE.

Specific tooling

T.0060824 Control probe axle clearance gear change

Cylinder-piston oversizes

FITTING CLEARANCES

Pistons and cylinders supplied as spare parts by the Manufacturer are marked with the letters of the alphabet. When both pistons and cylinders are replaced, the pieces with the same letter must be matched.

NORMAL CYLINDER- PISTON NOMINAL SIZES

Specification

Normal cylinder nominal sizes E=68 +0.025 - -0.005

Normal piston nominal sizes C=67.76 +0.025 -0.005

CYLINDER COUPLING - PISTON

Name

Coupling: 1st Oversize 68.20 to 68.22 67.96 to 67.98 0.24 Coupling: 2nd Oversize 68.40 to 68.42 68.16 to 68.18 0.24 Coupling: 3rd Oversize 68.60 to 68.62 68.36 to 68.38 0.24

Initials Cylinder Piston Play on fitting

Desc./Quantity

CH - 20

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".

Fitting clearance

Cylinder - piston clearance 0.24

CAUTION

AT REPLACEMENT OF PISTON IN THE CYLINDER, MAKE SURE THAT THE ARROW STAMPED ON THE PISTON SPROCKET IS FACING THE EXHAUST PORT OF THE CYLINDER.

Piston ring oversizes

SEALING RINGS

Specification Desc./Quantity

Seal ring (Nominal sizes) Diameter = 68 (mm)

CLEARANCE "A" UPON FITTING

Name

Sealing ring 1st Oversize 68.20 0.25 to 0.40 Sealing ring 2nd Oversize 68.40 0.25 to 0.40 Sealing ring 3rd Oversize 68.60 0.25 to 0.40

Description Dimensions Initials Quantity

Crankshaft alignment check

With the proper equipment (1), check that the eccentricity of the surface of Ø "E" and "F" are contained within 0.03 mm. (the maximum reading limit on the dial gauge clock); also check the eccentricity of the diameter "D", for which there shall be a maximum reading of 0.02 mm. In the case of eccentricities not much greater than that prescribed, perform the straightening of the shaft by means of counterweights with a wedge, or tightening it in a vice (equipped with aluminium bushings) as needed.

CH - 21

Characteristics APE TM Benzina

Specific tooling

19.1.20074 Crankshaft checking tool

Rod small end bushing - Pin

CONNECTING ROD SMALL END - PIN - ROLLER 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).

CONNECTING ROD - ROLLER CAGE

Connecting rod Roller cage

1st category 4th category 2nd category 3rd category 3rd category 2nd category 4th category 1st category

CAUTION

IN CASE OF NOISE, USE CAGE OF LOWER CATEGORY.

Oil pump

Name

Cylinder B=22.225 -0 +0.033 0.040 to 0.106

Piston C=22.225 -0.040 -0.073 0.040 to 0.106

Name

Cylinder B=25.40 -0 +0.033 0.150 to 0.125

Piston C=25.40 -0.040 -0.092 0.150 to 0.125

FRONT BRAKE CYLINDER - CLEARANCE "A" FOR FITTING

Description Dimensions Initials Quantity

REAR BRAKE CYLINDERS - CLEARANCE "A" FOR FITTING

Description Dimensions Initials Quantity

CH - 22

APE TM Benzina Characteristics

FRONT AND REAR BRAKE CYLINDERS - CLEARANCE "A" FOR FITTING - APE TM P703

FL2

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

Name Description Dimensions Initials Quantity

Cylinder B=19 +0.033 -0 0.040 to 0.106

Piston C=19 +0.040 -0.073 0.040 to 0.106

CH - 23

INDEX OF TOPICS

SPECIAL TOOLS ST

APE TM Benzina Special tools

Tooling

SPECIAL 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

Special tools APE TM Benzina

Stores code Description

19.1.20000 Tool for front suspension overhaul

19.1.20004 Tool for disassembling steering bearing

19.1.20024 Crankshaft removal tool

19.1.20041 Steering upper bearing ring nut gear

19.1.20042 Extract the bottom seat of the steering

from the frame

wrench

bottom bearing

ST - 26

19.1.20043 Rear wheel hub roller bearing fitting punch

19.1.20044 Front wheel hub roller bearing fitting punch

APE TM Benzina Special tools

Stores code Description

19.1.20045 Tool for fitting steering lower bearing low-

19.1.20046 Clutch puller

19.1.20047 Pliers for chamfering nuts

er seat

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 Crankshaft checking tool

ST - 27

Special tools APE TM Benzina

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 Engine support plane

ST - 28

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

ing

ST - 29

Special tools APE TM Benzina

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

ley

change

ST - 30

INDEX OF TOPICS

MAINTENANCE MA

Maintenance APE TM Benzina

Scheduled maintenance chart

MAINTENANCE OPERATIONS - APE TM

In the event of prolonged vehicle inactivity, adhere to the following standards:

1) Clean the vehicle

2) Remove the fuel from the vehicle

3) Remove the air filter, and with the engine running at low speed and put 30 cc. of specific oil through the diffuser of the carburettor.

4) Apply antirust grease to the unpainted metal parts

5) Lift the wheels off the ground. A) Operation to be performed with the engine warm. Amount of new oil: approximately 885 gr., keeping in mind that in the controls of the oil level it must always be between the "min." and "max" positions marked on the rod of the cover. B) Operation to be performed with bent iron wire or also with compressed air fed into the nozzle fastening to the cylinder, after heating of the external exhaust pipe. C) Use the specific oil to restore the oil level in the tank and for replacement. *) Mainly use of the vehicle on dusty roads; clean the filter housing and replace the filter cartridge more frequently.

Unit After the

first 1000

ENGINE Carburettor locking • See the table of locking torque Piston - big end - cylinder lights descaling Cleaning and descaling of the still usable engine parts TRANSMISSION - DIFFERENTIAL Oil replacement • (▲ - A) • (▲ - A) • (▲) Specific (▲) oil Check and restore oil level • (▲) IP DUE T (▲) oil air filter Replace *)• SPARK PLUG Electrode gap and descaling check • • Marelli CW 7N; Bosch W 4AC-Lodge

Replacement • Marelli CW 7N; Bosch W 4AC-Lodge

SILENCER Cleaning of the exhaust pipe •(B) BEARINGS Grease •(◘) •(◘) (◘) IP Athesia Grease 3 or FIAT Jota

ARTICULATIONS AND CONTROL LEVERS (ENGINE SIDE) Grease •(+) •(+) (+) IP Autogrease LZ or FIAT Zeta 2

HYDRAULIC BRAKE Check and restore oil level •(x-C) •(+) (+) IP Autofluid FR Oil or FIAT Blue

FLEXIBLE TRANSMISSIONS Adjust • Lubricate •(■) •(■) MAIN NUTS AND BOLTS OF THE VEHICLE Locking check • • See the table of locking torque

Every

4000 km

• See the table of locking torque

Every

8000 km *)

= every

16000 km

In the

event of a

review

• See the table of locking torque

3HN; Champion L82-AC430Z; NGK

Notes

B7HS

3 Grease

Grease

label DOT 3 Liquid

MAINTENANCE OPERATIONS - APE TM KAT

* = check.

• = replacement. (*)= every two years. (**)= every 12000 km / 36 months.

MA - 32

APE TM Benzina Maintenance

x 1000 Km - (Months) 1

Battery - check/top-up * * * * * * * * * * * * * * * * * * Safety blocks - Check * * * * * * * * * * Carburetion - Inspection/Adjustment Ignition spark plug - Replacement Door hinges - Lubrication * * * * * * * * * Dynamotor belt - Inspection/ Adjustment Transmissions (gas, clutch, drive) - Inspection/Adjustment Tyre wear and inflation pressure - Inspection Air filter - Replacement • • • • • • • • • Parking brake - Adjustment * * * * * * * * * * * * * * * * * * * Electrical system - Inspection * * * * * * * * * * Cylinder and fan system - Inspection Light transmission on the engine - Lubrication Brake fluid level - Inspection * * * * * * * * * * * * * * * * * * * Brake fluid - Replacement (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) Engine oil and differential Replacement Headlight - Inspection/Adjustment Vehicle and brake test - Inspection Suspension - Inspection * * * * * * * * * Piston cylinder head exhaust port - Cleaning Flexible transmissions - Lubrication Exhaust pipe - Cleaning • • • • • • • • • Pressure flexible brake pipes

- Replacement Cleaning air filter and SAS box (sponge) - Inspection/ Replacement SAS reed support - replacement Labour time 90' 65' 200'65' 225'65' 240'65' 225'65' 110'65' 260'65' 200'65' 225'65' 24

(4)5(12

* * * * * * * * * *

* * * * * * * * * * * * * * * * * * * * * * * * * * * * *

* * * * * * * * * * * * * * * * * * *

• • • • • • • • • • * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

(**) (**) (**) (**) (**) (**) (**) (**) (**) (**) (**) (**) (**) (**) (**) (**) (**) (**) (**)

(24

)

• • • • • • • • • • • • • • • • • •

• • • • • • • • •

• • • • • • • • • • • • • • • • • •

* • * • * • * • * • * • * • * • * •

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90

(36

)

* * * *

• • •

MAINTENANCE OPERATIONS - APE TM P703 FL2

* = check.

• = replacement. (*)= every two years.

x 1000 Km - (Months)

(4)5(12

* * * * * * * * * *

* * * * * * * * * * * * * * * * * * * * * * * * * * * * *

(24

)

• • • • • • • • • • • • • • • • • •

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90

(36

)

MA - 33

Maintenance APE TM Benzina

x 1000 Km - (Months) 1

Tyre wear and inflation pressure - Inspection Air filter - Replacement • • • • • • • • • Parking brake - Adjustment * * * * * * * * * * * * * * * * * * * Electrical system - Inspection * * * * * * * * * * Cylinder and fan system - Inspection Light transmission on the engine - Lubrication Brake fluid level - Inspection * * * * * * * * * * * * * * * * * * * Brake fluid - Replacement (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) (*) Engine oil and differential Replacement Headlight - Inspection/Adjustment Vehicle and brake test - Inspection Suspension - Inspection * * * * * * * * * Piston cylinder head exhaust port - Cleaning Flexible transmissions - Lubrication Exhaust pipe - Cleaning • • • • • • • • • Pressure flexible brake pipes

- Replacement Labour time 90' 55' 190'55' 215'55' 230'55' 215'55' 190'55' 250'55' 190'55' 215'55' 23

(4)5(12

* * * * * * * * * * * * * * * * * * *

• • • • • • • • • • * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

(24

)

• • • • • • • • • • • • • • • • • •

• • • • • • • • •

• • • • • • • • • • • • • • • • • •

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90

(36

)

* * * *

• • •

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

Secondary air blade locking Replace. Secondary air filter clogging Clean the filter and the box.

Clogging of the secondary air joint on the silencer Descale the joint taking care to not let the residues fall into the

Operation

silencer.

Engine

THE ENGINE STOPS

Possible Cause

Idle speed too low Work on the appropriate adjuster screw del of the carburettor.

Dirt or water in the mixture or in the ducts Clean thoroughly.

Inefficient spark plug Clean and adjust the gap between the electrodes or replace.

Cock obstruction Clean.

H.V. cable or spark plug hood damaged Check or replace.

Fuel tank cap breather obstruction (defective fuel system) Clean properly.

CRANKSHAFT KNOCKS

Possible Cause

Excessive clearance of the main bearings Replace.

Big end failure Replace the crankshaft.

Crankshaft unbalanced Check the alignment

Piston pin worn Replace.

Operation

RINGING OF THE PISTON

Possible Cause

Excessive clearance between the piston and cylinder Replace the piston and correct the cylinder.

Excessive clearance of the roller pin-connecting rod small end

or piston pin

Inspect (for any replacement of the rollers of the connecting rod

small end, see the section Fitting clearances).

Operation

TROUBL - 43

Troubleshooting APE TM Benzina

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

LOW POWER

Possible Cause Operation

Timing incorrect Carry out the checks required for the Ignition Timing Con-

Head, cylinder or spark plug not fitted correctly Correct the fitting and the locking.

Current leakage of the ignition system. Locate the leakage and act accordingly.

Excessive incrustation on the lights of the cylinder. Descale.

Silencer blocked Descale with iron wire bent into a hook or with compressed air

(carburettor, cylinder head, silencer attachment), observing the

values of related torques.

trol.

introduced into the cylinder nozzle fixed to the cylinder prior

external exhaust pipe heating.

Starting difficulties

Possible Cause

Clogged jets, carburettor body or cock Remove and clean in petrol;

Air filter clogged or dirty Replace.

Inefficient spark plug Clean and adjust the electrodes or replace.

Discharged battery The battery is the electrical device in the system that requires

Inefficient dynamotor Identify defects and make any revisions as stated in the section

Rapid inefficiency of the regulator and battery Check that the connections to the battery have not been re-

STARTING PROBLEMS

Operation

Dry with a compressed air jet.

the most frequent inspections and thorough maintenance. Fre-

quently check that the fluid level fully covers the plates; if not,

restore the level by adding distilled water (never use natural

water, even if it is drinking water) and check fluid density at the

same time, as described in the "Battery" section.

If the vehicle is not used for some time (1 month or longer) the

battery needs to be recharged periodically. The battery runs down completely in the course of three months. When the battery is being placed on the vehicle, make sure that the connections are not misplaced, keeping in mind that the black ground cable with the silencer attached to the frame is to be connected to the negative terminal whereas, the other cable, must be con-

nected to the terminal marked +.

"Disassembly and reassembly of dynamo motor".

versed.

Gearbox

TRANSMISSION NOISE

Possible Cause

Excessive clearance between the gears of the transmission Review and replace the worn components.

Insufficient oil in the differential transmission Restore the oil level or replace.

Bearings of the gear shaft are noisy Replace.

OIL LOSS FROM THE DIFFERENTIAL UNIT

Possible Cause

Overfilling of the differential gear oil Bring back to level.

TROUBL - 44

Operation

APE TM Benzina Troubleshooting

Possible Cause Operation

Loosening of the crankcase halves and the differential cover

locking nuts

Axle shaft oil seal hood worn or broken Replace.

Cracked crankcase Replace.

Loose oil drain plug Lock and replace if damaged.

Brakes

BRAKES BLOCKED

Possible Cause Operation

Return springs stretched Replace.

Compensation hole on the pump clogged Clean and bleed the air out of the system.

Rubber gaskets swollen or sized Inspect the system, replace all rubber parts and the liquid (see

ELASTIC ACTION OF THE BRAKE PEDAL

Possible Cause Operation

Air in the system Purge.

The flexible pipe inflates under pressure due to wear Replace.

Air leak in the pump due to poor tightness of rubber rings Replace the rings.

Check the locks, replace the gaskets if necessary.

Rules to check the hydraulic brake) purge air from the system: use the oil specified in General maintenance and lubri-

cation regulations and in Priming the oil pump.

BRAKE PEDAL VERY YIELDING

Possible Cause

Deteriorated valve ring Replace the valve.

The oil used is not suitable Replace the oil with that prescribed.

The bleed hole on the pump cap causes loss of pressure in the

pump and allows air to enter the sealing gasket

Fluid leak from fittings, cylinders and hoses Review and replace the worn components.

Clean the tank cap and bleed the system.

Operation

BRAKES OVERHEATING

Possible Cause

Insufficient clearance between shoes and drums Self-adjusting device locked.

Shoe return spring weak or damaged Replace.

Piston locked Inspect the unit.

Drums and shoes worn or scored Replace.

Operation

Suspensions and steering

FRONT WHEEL NOISE

Possible Cause

Hub bearings worn or with excessive clearance Replace.

The wheel hub chamber needs to be greased Disassemble or apply grease.

Hydraulic absorber inefficient or discharged Replace.

Roller bearings of swinging arm worn Replace.

FAILURE ON ONE WHEEL

Possible Cause

Inefficient or leaking shock absorbers Replace.

Worn rubber buffers Replace.

Excessive tyre wear due to incorrect inflation pressure or ex-

cessive loads

Check and restore the tyre to the prescribed pressure or re-

place it (if necessary) and recall the user's attention.

N.B.: In case of replacement of wheels or tyres, at replace-

ment, lock the nuts while respecting the table of tightening

Operation

torques.

TROUBL - 45

Troubleshooting APE TM Benzina

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-

Rear swinging arms deformed Straighten out if possible, or replace.

Worn rubber buffers Replace.

The vehicle "pulls" to one side due to deformation of the steer-

ing tube

Steering is hard or knocks Check the steering fifth wheels: if they are loose they must be

Irregularities in road holding Check the tyre pressure, the efficiency of the suspension and

Check the steering tube and replace if necessary.

properly tightened; if marked with pricks, they must be re-

Pay attention that the load is not badly distributed on the deck.

scribed (see Characteristics).

placed.

the locking of the wheel nuts.

TROUBL - 46

INDEX OF TOPICS

ELECTRICAL SYSTEM ES

Electrical system APE TM Benzina

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. Warning light, daylight running lights on (green light), "All Glass" lamp 12 V - 1.2 W

7. Warning light, high beam lights on (blue light), "All Glass" lamp 12 V - 1.2 W

8. Warning light of turn indicators operation (green light), "All Glass" lamp 12 V - 1.2 W

9. Oil reserve warning light (red light), "All Glass" lamp 12 V - 1.2 W

10. Fuel reserve warning light (amber light), "All Glass" lamp 12 V - 1.2 W

11. Warning light indicating dynamo battery charger low voltage (red light), "All Glass" lamp 12 V - 1.2

12. "All Glass" lamp for lighting odometer 12 V - 1.2 W

13. Engine start-up switch

14.Voltage regulator

15. Protection fuse 25A

16.Remote control

ES - 48

APE TM Benzina Electrical system

17. Windscreen wiper switch

18. Switch for external lighting

19. Protection 8A fuse valves to electrical system

20. 12V - 24Ah battery

21. Switch for external lighting with horn button

22. Turn indicator switch

23. Ceiling lighting bulb inside the cab 12V - 4W

24. Electronic control unit

25. Spark plug

26. Flywheel fan

27. Dynamotor

28. Heated switch

29. Oil tank level indicator

30. Rear stop lights switch

31. Fuel tank level indicator

32. Rear turn indicators, 12V - 21W bulbs

33. Rear position lights and stop lamps 12V - 5/21W.

WARNING

THE MARKS --- INDICATE THE ELECTRICAL INSTALLATION VARIANTS FOR THE VAN BODYWORK.

KEY: A. 8A Protective fuse valve. B. Lamp for lighting inside the van. C. Push-button light switch, controlled by the back door.

N.B.

THE ELECTRICAL SYSTEM DIAGRAM FOR THE TIPPER VERSION DIFFERS DUE TO THE ADDITION 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

Electrical system APE TM Benzina

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).

7. Cigarette lighter fuse (15A).

8. Turn indicator control device.

9. External light control switch.

10. Windscreen wiper control switch.

11. Rear fog light switch.

12. Emergency lights switch (12V-1.2W).

13. Cigarette lighter (12V-1.2W).

14. Turn indicator selector.

15. Reverse button.

16. Key switch.

17. Stop button on rear brake.

18. Low fuel warning light control.

19. 12V-32Ah battery.

ES - 50

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).

29. License plate light (12V-5W bulb).

30. Load box tilting device warning light (12V-3W).

31. Load box tilting button.

32. Van lighting fuse (8A).

33. Van lighting bulb (12V-5W).

34. Van lighting switch.

35. Headlight switch and horn button. COLOUR CODE: Ar: Orange Az: Blue Bi: White Gi: Yellow Gr: Grey Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

Electrical System Diagram (version with steering wheel)

ES - 51

Electrical system APE TM Benzina

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. Warning light, high beam lights on (blue light), "All Glass" lamp 12 V - 1.2 W

8. Warning light of turn indicators operation (green light), "All Glass" lamp 12 V - 1.2 W

9. Oil reserve warning light (red light), "All Glass" lamp 12 V - 1.2 W

10. Fuel reserve warning light (amber light), "All Glass" lamp 12 V - 1.2 W

11. Warning light indicating dynamo battery charger low voltage (red light), "All Glass" lamp 12 V - 1.2

12. "All Glass" lamp for lighting odometer 12 V - 1.2 W

13. Engine start-up switch

14.Voltage regulator

15. Protection fuse 25A

16.Remote control

17. Windscreen wiper switch

18. Switch for external lighting

19. Protection 8A fuse valves to electrical system

ES - 52

APE TM Benzina Electrical system

20. 12V - 24Ah battery

21. Switch lever for external lighting with horn button

22. Turn indicator switch lever

23. Ceiling lighting bulb inside the cab 12V - 4W

24. Electronic control unit

25. Spark plug

26. Flywheel fan

27. Dynamotor

28. Heated switch

29. Oil tank level indicator

30. Rear stop lights switch

31. Fuel tank level indicator

32. Rear turn indicators, 12V - 21W bulbs

33. Rear position lights and stop lamps 12V - 5/21W.

WARNING

THE MARKS --- INDICATE THE ELECTRICAL INSTALLATION VARIANTS FOR THE VAN BODYWORK.

KEY: A. 8A Protective fuse valve. B. Lamp for lighting inside the van. C. Push-button light switch, controlled by the back door.

N.B.

Electrical system diagram (version with steering wheel) - APE TM P703 FL2

ES - 53

Electrical system APE TM Benzina

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).

7. Cigarette lighter fuse (15A).

8. Turn indicator control device.

9. External light control switch.

10. Windscreen wiper control switch.

11. Rear fog light switch.

12. Emergency lights switch (12V-1.2W).

13. Cigarette lighter (12V-1.2W).

14. Light switch lever, turn indicators switch, and horn.

15. Reverse button.

16. Key switch.

17. Stop button on rear brake.

18. Low fuel warning light control.

19. 12V-32Ah battery.

ES - 54

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).

29. License plate light (12V-5W bulb).

30. Load box tilting device warning light (12V-3W).

31. Load box tilting button.

32. Van lighting fuse (8A).

33. Van lighting bulb (12V-5W).

34. Van lighting switch. COLOUR CODE: Ar: Orange Az: Light Blue Bi: White Gi: Yellow Ma : Brown Gr: Grey Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

ES - 55

Electrical system APE TM Benzina

Key-switch

APE P703 (VERSION WITH HANDLEBAR) Positions of the switch "1". 2: Everything turned off - Extractable key - Con-

tacts 30/1-15 coil feeder grounded electronic device - Current to audible warning device, windscreen wipers and internal light. 3: Running position - Arrangement of utilities and external lights - Contacts 30 - 16 and 30 - INT. Current to audible warning device, windscreen wipers and internal light. 4: Engine starter - Non-extractable key with return to position "3" - Contacts 30 - 16, 30 -INT. and 30

- 50. 5: Arrangement of utilities and external lights (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 HANDLEBAR) Positions of the switch "1". 2 = Ignition off, key can be removed, steering

locked. Contacts 15- 30/1 3 = Running position arrangement of utilities and external lights - contacts 30 - INT. 4 = Engine start-up The position is marked with the "START" logo. Once the engine starts, the key moves back to the running position "3" - contacts 30 - INT and 30 - 50.

ES - 56

APE TM Benzina Electrical system

APE P703V (VERSION WITH STEERING WHEEL) Positions of the switch "1". 2: Everything turned off - Extractable key - Con-

tacts 30/1-15 coil feeder grounded electronic device - Current to audible warning device, windscreen wipers and internal light. 3: Engine starter - arrangement of utilities and external lights - Contacts 30 - INT. - 30 - 16. Current to audible warning device, windscreen wipers and internal light. 4: Engine starter - Non-extractable key with return to position "3" - Contacts 30 - 16, 30 -INT. and 30

- 50. 5: Arrangement of utilities and external lights (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. Contacts 15- 30/1. 3 = Running position arrangement of utilities and external lights - contacts 30 - INT. 4 = Engine start-up The position is marked with the "START" logo. Once the engine starts, the key moves back to the running position "3" - contacts 30 - INT and 30 - 50.

ES - 57

Electrical system APE TM Benzina

Turn signal switch

APE TM P703 FL2 (VERSION WITH HANDLEBAR) Positions of the switch "1". 2= Lights off - no contacts. 3 = Left turn indicator blinking - contact between

green and brown cables. 4 = Right turn indicator blinking - contact between green and blue cables.

APE TM P703 FL2 (VERSION WITH STEERING WHEEL)

Positions of the turn indicators control lever:

1 = Lights off - no contacts. 2 = Left turn indicator blinking - contacts L - 2. 3 = Right turn indicator blinking - contacts L - 5.

APE P703 (VERSION WITH HANDLEBAR) Positions of the switch "5". 6: Turn indicators off - No contact. 7: Right indicators - Contact between green and

blue cables. 8: Left indicators - Contact between green and brown cables

Horn button

APE P703 (VERSION WITH HANDLEBAR)

Button for audible warning device "2". Audible warning device activated contact between black and yellow/grey cables.

ES - 58

APE TM Benzina Electrical system

APE TM P703 FL2 (VERSION WITH HANDLEBAR) 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.

N.B. WHEN THE LIGHT SWITCH AND HORN LEVER IS MOVED

UP, THERE SHOULD BE CONTINUITY BETWEEN THE RED AND THE YELLOW-GREY CABLES.

Headlight switch

APE P703 (VERSION WITH HANDLEBAR)

Positions of the light switch "1". High beam on, contact between pink and grey/ black cables. Low beam on, contact between pink and grey/blue cables.

APE P703 (VERSION WITH HANDLEBAR) Positions of switch "1". 2: External lights off - No contact 3: Daylight running lights activated - Contacts L-I 4: Daylight running lights, high or low beam, acti-

vated - contacts L-I-U

ES - 59

Electrical system APE TM Benzina

APE TM P703 FL2 (VERSION WITH HANDLEBAR)

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. 4 = High beams on, front and rear daylight running lights, panel lights on - contact between pink and black-grey cables.

N.B. THE SWITCH POSITIONS ARE SUBJECT TO THE POSI-

TION OF THE EXTERNAL LIGHTS CONTROL SWITCH.

APE TM P703 FL2 (VERSION WITH HANDLEBAR) Positions of switch "1". 2= Lights off - no contacts. 3 = Daylight running lights on - contacts 2-3 and

6-7. 4 = High and low beams on (if the head lights switch is in position 3 or 4) - contacts 3-4 and 7-8.

APE P703V (VERSION WITH STEERING WHEEL) TURN INDICATORS CONTROL LEVER Positions of lever "6": 7: Turn indicators off - No contact. 8: Right indicators - Contacts L - 5. 9: Left indicators - Contacts L - 2.

APE P703V (VERSION WITH STEERING WHEEL) LIGHT DEFLECTORS AND EXTERNAL LIGHT SWITCH COMMAND LEVER Position of lever "1" with switch "2" activated. 3: Tail lights on - No contact. 4: Low beams and tail lights on Contacts C - 56 B.

ES - 60

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. 3 = Lights on.

N.B. WHEN THE SWITCH IS SET TO POSITION "3", THERE

MUST BE CONTINUITY BETWEEN THE WHITE-RED AND RED-GREY CABLES.

APE TM P703 FL2 (VERSION WITH STEERING WHEEL)

Positions of the light switch and horn lever "1" with the external light switch "2" set to the ON position:

3 = Tail lights on - no contact. 4 = Low-beam lights and daylight running lights on

- contacts C - 56b. 5 = High-beam lights and daylight running lights on

- contacts 30/2 - 56a/2.

N.B. THE SWITCH POSITIONS ARE SUBJECT TO THE POSI-

TION OF THE EXTERNAL LIGHTS CONTROL SWITCH.

Voltage regulator

The controller is basically composed of two groups:

a) Minimal switch, consisting of a nucleus, on which are mounted two coils (voltmeters, and ammeter). b) Three-contact voltage regulator ("soft" voltage) also consists of a nucleus on which other two coils

are mounted, ammeter and voltmeters. The minimal switch has the task of inserting the dynamo in the battery circuit when the dynamo reaches a certain speed (coupling rpm) and switch it off as soon as a reverse current occurs, as well as verifying, when the vehicle is stationary, that the tension of battery exceeds that of the dynamo. The voltage regulator has the task of maintaining the voltage within limits that ensure a rapid charging of the battery when it is low, and to prevent overloading, regardless of the speed variations and the electrical charges activated.

Starter motor

OPERATION OF DYNAMOTOR

The dynamotor acts as a generator and as a starter motor. The creation of this device is a direct consequence of the principle of reversibility of the dynamo and in particular of the dynamo excited in parallel,

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Electrical system APE TM Benzina

which passes easily from one mode of operation to another, without changing the direction of rotation. The combination of the two functions is facilitated by the fact that, structurally, dynamo and starter motor are similar enough that the various components be confused, even constructively. Upon start-up, the dynamotor absorbs current from the battery and operates as an electric motor; after starting the APE engine and reaching a certain speed, the dynamotor acts as a normal dynamo, charging the battery and powering the vehicle electrical system. To get more torque at start up, the starter motors have the excitation field in series; the dynamos, though, require excitation field in parallel: the dynamotor is therefore equipped with both a series and a parallel field. When the machine is at rest, the contacts of the minimum switch are open, while those of the voltage regulator are closed and short-circuit the adjustment resistance, turning the ignition key, the current from the battery runs the field in the series and the rotor of the dynamotor; the parallel field also makes its contribution and the 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.

MAIN CHARACTERISTICS OF THE DYNAMOTOR

Specification

Dynamotor Type Bosch G 14V 11 A 39. 12V 0.9 PS. and type EFEL 12V.

Rated voltage 12V.

rated power starter motor section 0.9 CV.

Weight 7.6 kg.

Rotation Right.

Connection to the engine By belt transmission.

Control Key switch and relays.

DYNAMOTOR MAINTENANCE

As you have to remove the dynamotor before any maintenance operation, disconnect the cable connected to its positive terminal (1). During the operation copper and carbon powder is often deposited between the slats of the manifold: so it is necessary to clean the manifold after every 200 hours of operation of the dynamotor. For this purpose, use a clean rag soaked in petrol and blow the manifold with compressed air.

If the manifold is damaged by burns or is oval, lathe it again, bearing in mind that the reduction on the diameter must not exceed 0.5 mm; after lathing, remove the mica to a depth of 1 mm and thoroughly

Desc./Quantity

0.9 PS. 11 A.

dynamo section 90 W.

clean. The maximum eccentricity of the manifold, on the sliding surface shall not exceed 0.03 mm. Also check the condition of the brushes and their working conditions: for this purpose, raise, without distorting, the wiper pressure springs and make sure that the brushes slide freely in their tracks; if they were blocked or slide with difficulty, clean the brushes and tracks with a rag soaked in petrol.

If the brushes are worn, replace them with originals of the same type. If just one brush is worn, it is advisable to replace the pair of brushes. After replacement, run the Dynamotor lightly loaded until the brushes balance, i.e. until their contact surface perfectly adheres to that of the manifold.

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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. (2 to 3 times) the terminal (1) to the positive battery and the ground terminal (2).

DYNAMOTOR - REMOVAL

BRUSHES

Remove the protective strip, lift the spring (1) taking care not to exhaust it, slip off the brush and remove it by removing the screw (2). Repeat the operation for the rest of the brushes.

ROTOR

Remove the four screws (3) and remove the brush holding flange (4) paying attention to the flexible washer (*) which must be repositioned at the time of replacement, then, if necessary, with light mallet blows, remove the rotor.

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Electrical system APE TM Benzina

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 the two screws (2), remove the plate (1) and from the part opposite to that shown in the figure, with a punch of external Ø 22 mm eject the bearing.

FIELD WINDINGS

With the help of a strike screwdriver, as shown in the figure, remove the four anchor screws (1) of the windings, unscrew the two nuts (3) and (2) and remove the windings themselves.

N.B.

THE UNIT IS ASSEMBLED PROCEEDING IN THE OPPOSITE ORDER AS FOR REMOVAL AS DESCRIBED ABOVE.

DYNAMOTOR - FITTING

The Dynamotor is assembled on the engine unit as described above: position the dynamotor, anchoring it to the crankcase with the relative bolts without locking them, adjust the belt by moving the dynamotor toward the rear of the engine and lock the bolt (1), then the other two in the order shown in the figure. Remove the cap from the track (4) on the scroll putting a pencil in contact with the belt, push the pencil to the bottom and check its course; the belt

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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.

2) Load test: braking the starter motor so that it draws 120 Amp, and with a supply voltage of 9.2 to 9.4 V a torque >= 520 kgm must be obtained, for no lower than 1000 at 1'.

3) Pickup test: with rotor locked and a supply voltage 7.5 to 7.8V the current drawn must not be higher than 260 Amp and the torque must be no lower than 1200 kgm.

KEY: *= Starter button

**= Solenoid ***= Voltage regulator ****= Dynamotor *****= 12V battery - 24 Ah

N.B.

THESE CHARACTERISTICS ARE TO BE OBSERVED ONCE YOU HAVE FOR TURNED THE DYNAMOTOR FOR 30" IN THE CONDITIONS DESCRIBED IN POINT 1).

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Electrical system APE TM Benzina

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 stabilisation, which can be achieved through the operation of the alternator to the supply of 90W for 15', proceed to detect the characteristic values of the external alternator, which must be those indicated in the respective tables:

BOSCH TYPE ALTERNATOR

Specification Desc./Quantity

Number of revolutions - Power 3850 revolutions ~ 10 W. Number of revolutions - Power 3900 revolutions ~ 50 W. Number of revolutions - Power 4000 revolutions ~ 90 W. Number of revolutions - Power 4100 revolutions ~ 130 W.

EFEL TYPE ALTERNATOR

Specification Desc./Quantity

Number of revolutions - Power 3350 revolutions ~ 10 W. Number of revolutions - Power 3400 revolutions ~ 50 W. Number of revolutions - Power 3500 revolutions ~ 90 W. Number of revolutions - Power 3600 revolutions ~ 130 W.

KEY:

****= Dynamotor

BOSCH TYPE AND EFEL TYPE VOLTAGE REGULATOR ADJUSTMENT CHARACTERISTICS CONTROL

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APE TM Benzina Electrical system

Make an electrical circuit diagram and run the dynamotor at 6000 revolutions/1' constant, perform thermal stabilisation, through empty operation of the regulator for 15' and then connect it to a battery charger for 5'. Stop the dynamotor and restart it until you reach 6000 revolutions/1' required for the voltage control on loads that must match the values reported in the following tables:

BOSCH TYPE REGULATOR

Specification Desc./Quantity

Load 0 Amp. 14.3-15.4 V. Load 6 Amp. 13.8-15.2 V. Load 11 Amp. 13.2-14.5 V.

EFEL TYPE REGULATOR

Specification Desc./Quantity

Load 0 Amp. 14.3-15.8 V. Load 6 Amp. 14-14.9 V. Load 13 Amp. 13.6-14.6 V.

KEY:

***= Voltage regulator ****= Dynamotor *****= 12V battery - 24 Ah ******= Warning lamp

Specification

Ammeter Ammeter in DC. (minimum full scale 20 Amp.).

TOOLS USED FOR THE CONTROLS

Desc./Quantity

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Electrical system APE TM Benzina

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.

Return current 2 to 7.5 Amp.

N.B.

THE VOLTAGE REGULATOR MUST BE FIXED ON A VIBRATION FREE AND HEAT-CONDUCTING BENCH.

Verifiche e controlli

STARTER FAILURES DUE TO ALTERNATOR UNIT

Possible Cause Operation

Failure of motor rotation Check that:

- the terminals of the ignition switch or the battery are not oxi-

- the brushes are not worn and the springs are pressing on them

- the rotor or the inductor are not grounded.

Very slow engine rotation In addition to performing the checks in case of rotation failure

of the motor, check that the coils of the inductor winding or rotor

Excessive noise Check that the bearings of the supports are not worn.

WARNING

THE AXIAL CLEARANCE OF THE ROTOR MUST NOT BE MORE THAN 1 MM.

WARNING

THE NARROWING OF THE INSULATION BETWEEN THE MANIFOLD BLADES MUST HAVE A DEPTH OF NOT LESS THAN 0.4 MM.

- the battery is not drained dised or loose

sufficiently (minimum load 0.850 kg)

are not shorted.

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THE BATTERY DOES NOT CHARGE WHILE RUNNING

Possible Cause

Break of the charging circuit Locate and repair the break (in most cases they are oxidised

Fuse blown Defective regulator: Replace

Damaged battery: Replace.

Fuse holder with oxidised contacts.

Defective contact of brushes with the manifold Restore the sliding between brushes and guides.

Lack of residual magnetism Reenergise the Dynamotor.

Interrupted or ground rotor Replace the rotor.

Rotor in short circuit Clean the threads of the manifold; if not getting good results,

Broken belt Replace.

Defective regulator Replace.

Operation

or loose terminals).

replace the rotor.

THE BATTERY CHARGES ONLY PARTIALLY

Possible Cause

Defective regulator Replace.

Belt slide Register or replace.

Operation

THE BATTERY RUNS DOWN WITH THE DYNAMOTOR OFF

Possible Cause

Defective regulator Replace.

Operation

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,

RAPID CONSUMPTION OF THE BRUSHES

Possible Cause Operation

Eccentric manifold Lathe the manifold again and remove the mica.

EXCESSIVE SPARKS AT MANIFOLD

Possible Cause Operation

Rotor interrupted Replace the rotor.

Rotor unsoldered to the manifold Remake the welds when the rotor is well preserved.

Wiper presser springs loose Replace the springs.

Brushes consumed Replace the brushes.

Projection of mica on the manifold Remove the mica from the manifold.

Short circuit in charge indicator bulb Replace the lamp.

replace the rotor.

Battery charge - charging curve

BATTERY 12V 24 to 27 Ah

Use of dry-charge batteries:

1) Having removed the adhesive tape and the caps, put sulphuric acid inside the elements of the type for accumulators with specific weight 1.26 corresponding to 30° Bé at a temperature not lower than 15° C, until the level does not pass the separators by 5 mm.

2) Let it rest for two hours.

3) Charge at a rate of approx. 1/10 of capacity until the voltage reaches a value of about V 2.7 for each

element, with an acid density around 1.27, corresponding to 31° Bé with stable values. The operation must last approx. 15-20 hours.

WARNING

IF NECESSARY, THE CHARGING TIME MAY BE REDUCED TO 5-6 HOURS.

4) When charging is over, bring the acid to level (by adding distilled water or, if in excess, remove the

acid), plug and carefully clean.

5) After carrying out the operations above, install the battery on the vehicle, correctly observing the connections described previously.

BATTERY GAS DISCHARGE OUTSIDE THE CAB.

CAUTION

IN ORDER TO ENSURE A REGULAR DISCHARGE, OUTSIDE THE CAB, OF THE GASES THAT FORM IN THE BATTERY, CONNECT TO THE BATTERY THE SPECIAL EXHAUST TUBE KEEPING IN MIND THAT THE END OPPOSITE THE ONE CONNECTED TO THE BATTERY MUST FIT INTO THE HOLE ON THE FLOOR OF THE CAB TO ALLOW FOR THE ESCAPE OF THE GASES.

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Electrical system APE TM Benzina

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. If it becomes necessary to add water too frequently, check the vehicle's electrical system: the battery works overcharged and is subject to quick wear.

2) Load status check

After topping-up the electrolyte level, check its density using special density gauge. When the battery is charged the density should be of 30°-32° Bé corresponding to a specific weight of 1.26-1.28 for a temperature not lower than 15° C. When the density drops below 20° Bé the battery is completely discharged and it must be recharged. In addition with the battery under charge the voltage of each element must be of 2.6-2.8V. The discharge limit for each element is 1.8V. These voltage checks must be performed fitting into the outside circuit of the battery a lighthouse lamp.

*=Hold the tube vertically **= Detect the level by eye ***= The float must be freed

3) Recharging the battery

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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. At the end of the charge, the level and the density of the electrolyte as well as the voltage of each element must be checked. If the vehicle is not used for a period of time (1 month or more) it will be necessary to periodically recharge the battery. The battery runs down completely in the course of three months. When the battery must be placed back on the vehicle make sure that + (positive) and - (negative) terminals are well connected with their respective cables; in particular the negative terminal must be reconnected with the cable grounded to the frame.

4) Cleaning the battery

The battery must be kept clean and dry especially the top part; for cleaning use a hard bristle brush. To prevent corrosion of the cable terminals they must be kept clean and covered with a layer of pure petroleum jelly: do not use lubricating grease since, reacting with the acid of the battery or with its vapour produces conducting salts with the subsequent leakage of current that favours corrosions. Connections to the terminals must be well tightened to prevent contact resistance. Anchoring and disanchoring the positive (+) cable of the battery must always be done after the negative cable has been disanchored (grounded to the frame)

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INDEX OF TOPICS

ENGINE FROM VEHICLE EV

APE TM Benzina Engine from vehicle

REMOVAL OF ENGINE FROM THE FRAME

Disconnect the (-) cable from the battery, the electrical 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. After carrying out the above steps: remove, using the 3 anchor bolts, the axle shaft hubs (left and right) from the elastic coupling; then hold the engine differential unit using a lifting device, remove three anchor bolts (two in front of the cross member and one at the rear of the load box) and remove the engine differential unit.

DRAIN OIL FROM ENGINE

Install the engine-differential unit in the support (1) included in components 30, 33, 37 and proceed to empty, in a special clean from engine oil bowl through the drain hole "2".

N.B. TO FACILITATE THE EMPTYING, UNSCREW THE OIL FILL-

ER CAP.

Specific tooling

T.0025095 Engine support plane

NOTES RELATING TO REASSEMBLY

To reassemble the vehicle, we illustrate those operations that require special tools or expedients. Those operations that are easy to perform, that can be easily carried out with screwdrivers, wrenches, normal pliers, etc. and which can be easily perceived by the operator are not included: similarly, the operations which are already described for the disassembly phase, for which it is necessary to simply follow the procedures in reverse order are not described. Upon refitting, all components that have been disassembled must be subjected to accurate cleaning and to an inspection of the wear condition. To be remembered in particular that:

-The half crankcases of the engine must not show cracks or deformations; the seats of the bearings must be free of abrasions.

- Ball bearings: make sure they are in perfect conditions, without excessive axial and radial clearances; make sure they run freely turning them by hand: if after they have been cleaned (washing with petrol), surface roughness is felt, replace them.

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Engine from vehicle APE TM Benzina

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. For their positioning, operate as indicated in the respective figures of this chapter, using the specific equipment.

- Shafts and axles: sliding and rolling surfaces must not show notches and abrasions such as to impair the proper operation and must be properly lubricated.

- Clutch: check the wear of the disks, the efficiency of the spring and all the components included in the clutch assembly; if necessary replace damaged components.

- Gears: inspect the wear conditions of the teeth, if they are chipped or badly worn replace them with new components.

- Front wheel axle chamfered nut.: at every reassembly a new nut must be applied, to be chamfered on the corresponding shaft according to the instructions given in specific section "Locking the front wheel brake drum."

- Always use new gaskets, split pins and brake washers.

Recommended products

AGIP GREASE PV 2 Multipurpose grease

NLGI 2 specifications; ISO-LXBIB2

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INDEX OF TOPICS

ENGINE EN

Engine APE TM Benzina

Flywheel

FLYWHEEL - PULLEY - REMOVAL

Anchor the flywheel and the pulley dynamotor using 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 relevant spacers interposed between the extractor and flywheel in order not to interfere with the stator coils, the specific equipment (4), and unscrew the central screw (5) until the extraction has taken place.

WARNING TO CARRY OUT THE EXTRACTION OF THE DYNAMOTOR

PULLEY, IT IS NOT REQUIRED TO USE ANY TOOL, AS THE DISASSEMBLY IS CARRIED OUT MANUALLY.

Specific tooling

T.0043062 Stop key of flywheel and dynamotor pulley

T.0035731 Flywheel extractor and differential housing

Crankcase splitting

DIFFERENTIAL HOUSING COVER AND SEPARATION OF HALF CRANKCASES

Remove the connecting nuts and bolts and, acting with a few mallet blows, remove the cover.

SEPARATION OF HALF CRANKCASES

Proceed as described above for the differential cover, remember in particular that you can not decouple the engine crankcases before dismounting the differential cover, which is necessary to loosen the inner nut (1) connecting the half crankcases.

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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; spread with mastic the gasket to be interposed with putty (on both sides) and fit on the flywheel side crankcase half.

- To successfully fit the half crankcases together, act if necessary with a wooden mallet on the flywheel side crankcase half: never act on the end of the crankshaft.

DIFFERENTIAL COVER - FITTING DIFFERENTIAL HOUSING BALL BEARING ROLLER BEARING CHANGE GEAR SHAFT

Heat, with the specific tool, the bearing housing area and fit in its place the ball bearing (1) and with the tip of a screwdriver insert the retainer circlip (2). Wait until the cover is cooled and with the specific punch (3) position the roller bearing (4). Insert the inverter gear in its housing, install the reverse gear command lever and, with light mallet blows, insert the differential housing, anchoring it with the retainer circlip.

Specific tooling

0019978 Oven T.0039153 Punch for roller bearing

After cleaning the mating surfaces and fitting the gasket (spreading the mastic) on the crankcase, apply the thrust washer (5) on the differential cover, holding it in position with a layer of grease, shift into sliding gear the slider of the reverse gear control lever so you can pair with ensuring that the two parts fit together perfectly and lock with the relative

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Engine APE TM Benzina

bolts and nuts to the torque specified in the table "Tightening torques".

Fly-wheel side half-crankcase

FLYWHEEL SIDE CRANKCASE HALF - REMOVAL BENCH ROLLER BEARING - MULTI-GEAR BALL BEARING - ROLLER BEARING CHANGE GEAR SHAFT

Position the crankcase half on a support base and after removing the crankshaft seal ring with the end of a screwdriver expel, with a punch of external Ø of 39 mm., the outer ring of the bench roller bearings (1). With a punch of external Ø of 37 mm., eject the roller bearing gear shaft (3) and, acting on the side opposite to that shown in the figure, with a flat head punch of Ø 28 mm., remove the ball bearing of the multi-gear pin (2).

FLYWHEEL-SIDE CRANKCASE HALF - FITTING

Place the crankcase half on a supporting base and using a heat gun warm up the crankcase half to approx. 80 °C in the area of the bearing seat with the appropriate tool (1).

Specific tooling

0019978 Oven BENCH ROLLER BEARINGS - MULTI-GEAR BALL BEARING - ROLLER BEARING GEAR

SHAFT Assemble, with the help of a flat head punch of Ø 44 mm. if necessary, the bench roller bearing (1) and operating from the side opposite that represented in the figure, with a section of tube with external Ø 40 mm. the ball bearing of the multigear pin.

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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 - REMOVAL SEAL RING - CIRCLIP - BENCH BALL BEARING

Remove, using a screwdriver, the seal ring, the retaining circlip, with specific pliers and then, with a section of tube with outer Ø of 54 mm., remove, by acting on the side opposite to that shown in the figure, the ball bearing (2).

Specific tooling

T.0022465 Pliers for circlips

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Engine APE TM Benzina

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.

BENCH BALL BEARING - MULTI-GEAR ROLLER BEARING

Insert, using the special tool (1), the bench ball bearing (2) in its housing, wait until the crankcase has cooled, and fit, with the appropriate tool, the roller bearing (4) of the multi-gear pin.

Specific tooling

T.0023589 Punch for bearings and sealing rings

T.0033970 Punch for fitting roller bearings CIRCLIP - SEAL RING

Assemble, with the help of specific pliers, the circlip (1) and, redeploying the specific tool (2), the seal ring (3).

Specific tooling

T.0022465 Pliers for circlips T.0023589 Punch for bearings and sealing

rings SPACER - BENCH ROLLER BEARING INTER-

NAL RING

Insert the clutch side crankshaft on a support base with internal Ø of 36 mm. and, after mounting the spacer (1), mount the inner ring (2), heated in an oil bath at 100°C, of the bench roller bearing on the crankshaft (flywheel side) using as a punch (3) a section of pipe with internal diameter of 29 mm.

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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 BETWEEN THE TWO HALF SHAFTS.

Specific tooling

T.0025127 Wedge CRANKSHAFT ON CLUTCH SIDE CRANKCASE HALF

Insert crankshaft on clutch side crankcase half as represented in the figure; apply specific tool (1) equipped with components 24 and 25 and act on the nut until pulling the stop crankshaft on the ball bearing of the crankcase half.

Specific tooling

T.0018119 Tool for fitting shafts

Differential assembly

DIFFERENTIAL BOX - REMOVAL

Using specific pliers, remove the differential box retainer circlip. Fasten, with the 4 special screws, the extractor (1) equipped with component 3 and act on the central screw (2) until the removal of the box.

Specific tooling

0023638 Pliers for circlips T.0035731 Flywheel extractor and differential

housing DIFFERENTIAL BOX BALL BEARING - INVERTER GEAR - ROLLER BEARING CHANGE GEAR SHAFT

With the help of a screwdriver remove the circlip (3) and, re-using the special extractor equipped with component 5, from the part opposite to that shown in the figure, eject the ball bearing (4). With a plug of Ø of 4.5 mm. remove the spring pin (9), remove the reverse gear command lever (5) and the reversing gear (6).

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Engine APE TM Benzina

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). Remove the clutch cover and with the specific key, lock the unit; then with a T-shaped wrench of 19 mm. unscrew the nut (4) of the multi-gear pin.

Specific tooling

T.0030632 Wrench for helical gear nut T.0031729 Clutch stop key CLUTCH ASSEMBLY - REMOVAL

Lock the assembly with the appropriate key (1) and unscrew the lock nut. Apply the extractor (3) using the 3 screws (2) fixing the plates, and act on the central screw (4) until the assembly is extracted; if it does not occur it is necessary to act by means of mallet blows on the periphery of the clutch housing to loosen up the cone and thus cause the extraction of said clutch.

Specific tooling

19.1.20046 Clutch puller

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APE TM Benzina Engine

CAUTION IN THE REMOVAL OPERATIONS DESCRIBED ABOVE,

THE EXTRACTION OF 3 SCREWS (2), NECESSARY FOR THE APPLICATION OF THE EXTRACTOR, AUTOMATICALLY CAUSES THE FALL OF CORRESPONDING WASHERS (8) IN THE CLUTCH ASSEMBLY. AS A RESULT OF THIS, IT IS ABSOLUTELY NECESSARY, BEFORE REFITTING, TO RECOVER, FROM INSIDE THE CLUTCH ASSEMBLY, THE THREE WASHERS (8) AND CORRECTLY REPOSITION THEM.

With the assembly fixed in the specific tool (provided with the new component 4) compress the spring, by operating the nut (5), until making possible the extraction of the elastic retainer ring (7); unscrew the three anchor bolts (9) of the plates, and after removing the nut (5) of the tool, remove the different components.

Specific tooling

T.0020322 Clutch removal and refitting tool CLUTCH ASSEMBLY - FITTING

Apply the thrust washer (1), bushing (8), (7), engine gear (2) and thrust washer (3) on the crank shaft, then install the clutch assembly, making sure that the crankshaft stick correctly engages on the drive disc track. With the specific key, hold the assembly firmly and, after fitting the cone (6) and washer (4), lock the nut (5) at 180 to 220 Nm (18 to 22 kgm).

Specific tooling

T.0031729 Clutch stop key SEAL RING - MULTIPLE PIN NUT - CAP AND RING

Hold the clutch assembly locked, leaving the specific key fitted and tighten the multi-gear nut (9), install the gasket, the cap (10) and, with the help of specific key (12), lock the ring nut (11). Then fit the sealing ring (14) with the specific tool (13).

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Engine APE TM Benzina

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.

PISTON PIN - REMOVAL

With the help of specific pliers, remove the circlips (1) and expel the pin with a punch of Ø 16 mm.

Specific tooling

T.0017104 Pliers for circlips

Crankshaft

Position the special tool (1), using the appropriate screws, then act on the central screw (2) until completely loosening the crankshaft from its housing.

Specific tooling

19.1.20024 Crankshaft removal tool

BENCH ROLLER BEARING INTERNAL RING

Apply the specific extractor (1) equipped with the specific reduction rings of component 27, and act on the handle (2) until extracting the bearing track.

Lubrification

"L.S." DEVICE

EN - 84

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. The petrol is sent to the carburettor with the normal gravity system; the oil is sent to the crankshaft (and sprayed by it inside the cylinder) by means of an "LS" device, consisting of a variable stroke piston pump, operated by the crankshaft through a gear drive (1) and (2). Similar to the fuel tank, the oil tank also is equipped with a reserve detector connected to a red light signal lamp (12V-1.2W) with a symbol of recognition; this lamp is installed inside the cab in the middle of the instrument panel dashboard.

Recommended products

AGIP CITY TEC 2T Oil for 2-stroke petrol engines

JASO FC, ISO-L-EGD Specifications

"L.S." DEVICE CHARACTERISTICS

Oil quantity Time it takes for the oil consumption

with maximum throttle control of lever

1 cm³ 24" to 27" 1'.45" to 2'.35"

Time it takes for the oil consumption

with minimum throttle control of lever

THE ABOVE TIMES MUST BE DETECTED BY ROTATING THE GEAR CONTROL OF THE MIXER TO 5000 RPM.

CAUTION

IN CASE OF REMOVAL, REVIEW AND REINSTALLATION OF THE "LS" DEVICE, THE DUCTS MAY STAY FREE OF OIL. TO ALLOW THE "L.S." DEVICE TO PROGRESSIVELY AND SAFELY REFILL THESE, YOU ARE ADVISED THEREFORE - AFTER THESE OPERATIONS - TO SUPPLY THE FUEL TANK WITH APPROXIMATELY 3 (L) OF 2% MIXTURE OF SPECIFIC OIL. WITH THIS SUPPLY EXHAUSTED, SUBSEQUENT REFUELS MUST OBVIOUSLY BE CARRIED OUT WITH PETROL ONLY.

Recommended products

AGIP CITY TEC 2T Oil for 2-stroke petrol engines

JASO FC, ISO-L-EGD Specifications

EN - 85

Engine APE TM Benzina

KEY: 3 = Oil piston. 4 = Piston (3) in position to sample oil from the tank. 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.

Recommended products

AGIP CITY TEC 2T Oil for 2-stroke petrol engines

JASO FC, ISO-L-EGD Specifications

EN - 86

INDEX OF TOPICS

GEAR-BOX GE

Gear-box APE TM Benzina

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. Unscrew the stem (8) (left-hand thread), remove the bushing (9) and the cross (7).

Specific tooling

T.0022465 Pliers for circlips

CHANGE GEARS AND GEARBOX STEM CONTROL - APE TM P703 - FITTING

Insert the cross (7) in the transmission gear shaft, then place the bushing (9), coat the threads of the stem (8) with the specific product, and screw it (left-hand thread) on the cruise (7) with torque of 35 to 40 Nm (3.5 to 4 kgm). Reassemble the remaining components in reverse order of disassembly, taking care to orient the gears of the fourth, third and second speed with the collar facing outwards and the first gear speed with the collar turned inward.

N.B.

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. Unscrew the control stem of the 3rd and 4th speed and the 1st and 2nd speed bushing (left-hand thread), then pull out the two crosses.

N.B.

GE - 88

APE TM Benzina Gear-box

AFTER REASSEMBLING THE GEAR UNIT PROCEED TO CHECK THE AXIAL CLEARANCE AS INDICATED IN THE SPECIFIC SECTION "FITTING CLEARANCES"

KEY:

*= 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)

2) Obtain two conical appendages (3) and (4) on a metal sheet profile (1) (7 mm thick) and insert it into a groove on the gearbox shaft, until it matches up with the appendix (3) with the end of the stem to be chamfered.

3) Lock in the clamp the protruding part of the profile and, acting with a punch of the dimensions shown in the figure, perform the chamfering of the threaded end of the bushing on the cross (2). Once the chamfering has been carried out as described above, insert the 3rd and 4th speed coupling cross in the transmission gears shaft, screw the control stem (left thread and tightening torque 19 - 21 Nm-1.9

- 2.1 Kgm) and chamfer using the appendix (4) of the profile, operating as described above. Reassemble the gears, the shoulder ring and the circlip.

N.B.

AFTER REASSEMBLING THE GEAR UNIT PROCEED TO CHECK THE AXIAL CLEARANCE AS INDICATED IN THE SPECIFIC SECTION "FITTING CLEARANCES"

GE - 89

Gear-box APE TM Benzina

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 control levers to neutral position, fit a new gasket on the transmission support joining surface, engage the shoe of the upper lever on the groove of the stanchion of the y and [4]3 speed and the slider of the lower lever on the groove of the control bushing ^ and [2]8 speed then lock the gear change support with the two bolts and their washers. Once the locking is done, check the regular operation of the transmission.

CHANGE CONTROL SUPPORT VEHICLES VERSION WITH HANDLEBAR

The assembly of units such as the stator, flywheel, cylinder-piston unit, cylinder head, silencer, etc., requires no special precautions; it is sufficient to operate in reverse order of disassembly.

WARNING

FOR THE LOCKING OF NUTS, BOLTS AND SCREWS, SEE THE TABLE "TIGHTENING TORQUE".

GE - 90

INDEX OF TOPICS

DIFFERENTIAL DI

Differential APE TM Benzina

DIFFERENTIAL BOX - REMOVAL

Remove, using the specific pliers, the circlip (1), the washer (2) and the planetarium (3), then straighten the tabs of the retaining ring (5) of the satellites pin remove the ring itself, the pin, the satellites and the remaining sprocket. By removing the six bolts, remove the differential sprocket (4).

Specific tooling

T.0022465 Pliers for circlips

DIFFERENTIAL BOX - FITTING

The replacement of the differential box is done in the reverse order of disassembly, taking care in reassembly to carefully fold the tabs of the retaining ring (5) of the satellite pin.

CHANGE GEARS AND GEARBOX STEM CONTROL - APE TM P703 - REMOVAL

Specific tooling

T.0022465 Pliers for circlips

DI - 92

APE TM Benzina Differential

CHANGE GEARS AND GEARBOX STEM CONTROL - APE TM P703 - FITTING

N.B.

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. Unscrew the control stem of the 3rd and 4th speed and the 1st and 2nd speed bushing (left-hand thread), then pull out the two crosses.

N.B.

AFTER REASSEMBLING THE GEAR UNIT PROCEED TO CHECK THE AXIAL CLEARANCE AS INDICATED IN THE SPECIFIC SECTION "FITTING CLEARANCES"

DI - 93

Differential APE TM Benzina

KEY:

*= 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)

- 2.1 Kgm) and chamfer using the appendix (4) of the profile, operating as described above. Reassemble the gears, the shoulder ring and the circlip.

N.B.

AFTER REASSEMBLING THE GEAR UNIT PROCEED TO CHECK THE AXIAL CLEARANCE AS INDICATED IN THE SPECIFIC SECTION "FITTING CLEARANCES"

DI - 94

APE TM Benzina Differential

CHANGE CONTROL SUPPORT VEHICLES VERSION WITH STEERING WHEEL

CHANGE CONTROL SUPPORT VEHICLES VERSION WITH HANDLEBAR

The assembly of units such as the stator, flywheel, cylinder-piston unit, cylinder head, silencer, etc., requires no special precautions; it is sufficient to operate in reverse order of disassembly.

WARNING

FOR THE LOCKING OF NUTS, BOLTS AND SCREWS, SEE THE TABLE "TIGHTENING TORQUE".

DI - 95

INDEX OF TOPICS

BRAKING SYSTEM BS

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. b) The cloth or rubber flexible pipes do not show swellings or are soaked with oil or mineral grease: as these substances can dissolve rubber. c) All pipe clamps are adequately secured to the supporting brackets and plates: inadequate fixing would lead to pipe vibration and oscillation, and in turn, to pipe breaking. d) There are no fluid leaking from the different couplings; if there are, tighten well being careful not to damage the pipes.

BRAKES OVERHAUL

- Separate from the pump the brake pedal and fix the pump body on the vice, taking care to interpose the aluminium bushings between the shoes of the vice in order not to damage it.

- Remove the piston and the springs from the body; to do this remove the end travel screw (8), the protective ring and push on the rod of the control piston (11) so that you can remove the retaining circlip with the specific pliers; gradually loosen until the pressure on the control rod to allow, through the action of the spring, the leakage of the piston from the cylinder of the pump body.

- If while acting as above, the piston does not go out, it is advisable to blow air at slight pressure from the end of the threaded oil delivery joints. Clean the different components with alcohol: do not use petroleum or petrol as they can adhere to rubber parts and damage them.

Specific tooling

T.0022465 Pliers for circlips

BS - 97

Braking system APE TM Benzina

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. Piston control rod

12. Pedal

Once washed, the parts must be dried with jets of compressed air; afterwards, make sure that:

- That the pump body does not show signs of internal damage or corrosion as this may result in sealing ring or piston failure; the latter must also be replaced if worn or scratched or if mating with the cylinder has a clearance higher than that prescribed in the specific section "Fitting clearances."

- That the rubber parts in the piston and the valve are not dilated or damaged as this most likely leads to poor braking.

- That the piston return spring is in good condition.

BS - 98

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. To facilitate the operation, lubricate the surfaces of the rubber elements with grease; this must also be done for the piston when fitting in the cylinder. Once these parts are fitted, check that the pump works properly by pushing and quickly releasing the piston into the cylinder: the piston should quickly go back to its rest position.

SHOW CONTROL CYLINDER

Once the shoe assembly has been removed from the frame and the cylinder disassembled in all its components, inspect following the same procedure as per the brake pump, always bearing in mind the warnings mentioned before regarding rubber gaskets, the central spring, the wear level of all parts as well as the cleaning procedure for the different parts. For this specific assembly, it also important to make sure that the air bleed opening (screw "2") and the oil intake hole are not clogged (blow in compressed air through the holes). The max. clearance between the metal pistons and the cylinder must not exceed that specified in the special section "Assembly clearances".

BRAKE CYLINDERS UNIT KEY:

1. Brake cylinder body

2. Air bleeding screw

3. Pistons

4. Sealing ring

Brake pump

LOADING PUMP OIL

Once all the above checks have been completed, the pump (always on the vice) must be filled with specific oil, as follows:

- Completely fill the reservoir (it must be kept in the same position as when it is mounted on the vehicle).

- Acting on the control rod, push two or three times the piston for a short stroke, to let the oil fill the pump body.

BS - 99

Braking system APE TM Benzina

- 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.

- Gradually release the pressure on the piston, making sure that it returns to the end of the stroke so that the oil may flow out of the reservoir into the pump body;

- Repeat the above steps until, pushing the piston to the end of its stroke, a jet of air-free oil comes out of the oil discharge hole on the threaded shank; then plug the hole and return the piston to rest position. When the operations as described above are carried out, add oil in the pump reservoir to keep it always filled. Once ascertained that the fluid intake conduit is not damaged especially where the connections are, the complete braking assembly is ready to be refitted on the frame, and the pump, full of oil, may be connected to the hydraulic circuit.

Recommended products

AGIP BRAKE 4 Brake fluid

Specifications - FMVSS DOT 4

OIL REFILL IN THE HYDRAULIC CIRCUIT

A) - Push down the pedal to the end of its travel and slowly let it return to its starting position, repeating the operation until the pedal feels a back pressure. As this operation is carried out add oil to the tank to prevent the pump from discharging. B) - Lower the pedal, loosen the bleed screws on the front wheel, let the air out, after this bleed point has been connected through a small rubber pipe to a tray full of brake oil. C) - Repeat the operation as from point A) until all air bubbles have come out of through the pipe: at this point fit back the bleed screw, while keeping the pedal pushed down. D) - Repeat the above procedures for the other tires.

Shoes and drums

CHECKING THE BRAKE SHOES AND DRUMS

Check the thickness of the gaskets: if they are deteriorated or worn, replace the entire shoe assembly. Check the efficiency of the return springs: if these are deformed, replace them. Inspect the brake drums: replace them if they are scored or oval-shaped or, whenever possible, turn and lap the inside diameter. In the filling operations, a maximum oversize of 0.6 mm on the regular drum ø is allowed.

N.B.

THE BRAKE DRUMS ARE FITTED WITH AN INSPECTION HOLE (WITH A SCREW CAP) WHICH ALLOWS THE WEAR CHECK OF THE BRAKE GASKETS WITHOUT REMOVING THE DRUM.

CAUTION

BRAKING CIRCUIT FLUID IS HYGROSCOPIC, IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR. IF THE HUMIDITY IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, THE RESULT IS AN INEFFICIENT BRAKE. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS THE FLUID SHOULD BE REPLACED EVERY TWO YEARS. IF THE BRAKES UNDERGO SEVERE OPERATING CONDITIONS THE LIQUID SHOULD BE REPLACED MORE FREQUENTLY.

BS - 100

Piaggio APE TM 2012 User Manual [it]

Specifications and Main Features

Frequently Asked Questions

User Manual