Manual - Combi CL 2600

USE AND
MAINTENANCE
MANUAL
MACHINE IDENTIFICATION
Equipment model: CAP COMBI CL 2600

Tank code: 3439
THIS EQUIPMENT MUST BE USED ONLY FOR SUCTIONING LIQUIDS OR SLUDGE

CONTAINED IN UNDERGROUND DUCTS.
FOR FURTHER INFORMATION CONTACT US
CAPPELLOTTO S.P.A.
VIA VIZZA 8 - 31018 GAIARINE (TV)
Tel. ++39 0434 757575 info@cappellotto.com
Fax ++39 0434 758555 www.cappellotto.com
Agent of reference:
Technical service:
USE AND MAINTENANCE MANUAL
INDEX
INTRODUCTION 4
FOREWORD 4
SCOPE OF MANUAL AND INSTRUCTIONS 4
COMPOSITION - METHOD OF CONSULTATION 4
PROCEDURES FOR ORDERING SPARE PARTS 6
HOW TO REQUEST TECHNICAL SERVICE 6
ATTACHED DOCUMENTATION 6
TABLE OF INCLUDED COMPONENTS 7
PART I - SAFETY ................................................................................................................ 8

1 GENERAL INFORMATION ............................................................................................................... 8
1.1 Safety - General .................................................................................................................................. 8
1.2 Terminology......................................................................................................................................... 8
1.3 Types of risk ......................................................................................................................................10
2 WARNINGS ON USE (SIGNS AND SIGNALS) .............................................................................. 11
3 ANALYSIS OF RISKS PRESENT IN THE USE OF THE VEHICLE ............................................... 13
3.1 Definitions of main risks ....................................................................................................................13
3.2 Table of main risks and individual safety gear ..................................................................................13
3.3 Preventive measures to be taken during positioning, transfer and parking of the
machine .............................................................................................................................................16
PART II - INSTRUCTIONS FOR USE ............................................................................... 18

1 CHECKS TO BE CARRIED OUT BEFORE STARTING ................................................................ 18
1.1 GENERAL CHECKS .........................................................................................................................18
1.2 VACUUM SYSTEM ...........................................................................................................................20
1.2.1 Blower pump .................................................................................................................................................... 21
1.3 High-pressure water system .............................................................................................................21
2 ROAD TRAVEL ............................................................................................................................... 22
3 STARTING WORK........................................................................................................................... 22
3.1 GEARS TABLE .................................................................................................................................23
4 ENGAGING THE POWER TAKE-OFF............................................................................................ 24
4.1 Cappellotto power take-off (PFT 3000/4AV-E) .................................................................................24
4.2 Troubleshooting.................................................................................................................................24
5 INTAKE OF SLUDGE ...................................................................................................................... 25
5.1 General warnings ..............................................................................................................................25
5.2 Operations to be performed before any suctioning manoeuvre ........................................................26
5.3 Suction using upper spout .................................................................................................................26
5.4 Troubleshooting.................................................................................................................................27
6 SLUDGE DISCHARGING ................................................................................................................ 28
6.1 Discharge sludge through the rear discharge valve ..........................................................................28
6.1.1 Free fall discharge ............................................................................................................................................ 28
6.1.2 Troubleshooting................................................................................................................................................ 29
2
6.2 Discharging of sludge through the opening of the rear door .............................................................29
7 DISCHARGING THE CYCLONE FILTER ....................................................................................... 31
7.1 Earth dump ........................................................................................................................................31
7.2 2nd cleaning ......................................................................................................................................31
8 HIGH PRESSURE SYSTEM ............................................................................................................ 32
8.1 Filling with water ................................................................................................................................32
8.1.1 Side boxes ....................................................................................................................................................... 32
8.2 First engagement of high pressure pump .........................................................................................33
8.3 Uses of the high pressure pump .......................................................................................................34
8.3.1 Rear flag reel .................................................................................................................................................... 34
8.3.1.1 Manual rotation of the flag reel 34
8.3.1.2 Unwinding the high pressure hose 35
8.3.1.3 Rewinding the high pressure hose 35
8.4 Flushing .............................................................................................................................................37
8.4.1 Flushing in non-ADR tank ................................................................................................................................ 37
PART III - MAINTENANCE ............................................................................................... 39

1 CHECKS .......................................................................................................................................... 39
1.1 GENERAL WEEKLY CHECKS .........................................................................................................40
1.2 GENERAL MONTHLY CHECKS ......................................................................................................41
1.3 PUMP ................................................................................................................................................42
1.3.1 BLOWER PUMP .............................................................................................................................................. 42
1.4 HIGH PRESSURE PUMP .................................................................................................................43
1.5 TANK .................................................................................................................................................44
1.6 POWER TAKE-OFF ..........................................................................................................................44
1.7 UNIVERSAL JOINT TRANSMISSIONS............................................................................................44
1.8 OIL AND WATER HEAT EXCHANGER ...........................................................................................44
1.9 V-belt tension gauge .........................................................................................................................45
2 PERIODIC LUBRICATION .............................................................................................................. 46
2.1 TRANSMISSION CARDAN SHAFT TYPE “PFT 3000/4AV-E”........................................................46
2.2 TRANSMISSION CARDAN SHAFT ..................................................................................................46
2.3 MAIN SHAFT BEARINGS .................................................................................................................48
2.3.1 GREASING TYPE SCHEDULE AND GREASING SPOT FOR Ø 65 MAIN SHAFT BEARINGS ..................... 49
2.4 RECOMMENDED LUBRICANTS .....................................................................................................50
2.5 TABLE OF LUBRICATION ................................................................................................................51
PART IV - ATTACHMENTS .............................................................................................. 53
3
INTRODUCTION
FOREWORD
The purpose of this manual is to illustrate the operation, risks in use and the actions to take in the event of
malfunction of the machinery described herein.
SCOPE OF MANUAL AND INSTRUCTIONS
This manual, which is an integral part of the machine, has been prepared by the manufacturer to provide the
information and instructions required by those who are authorized to interact with it during its life cycle. The
users, skilled operators and specialized technicians are among the intended recipients of this specialized
information.
Along with adopting proper techniques of use, the recipients of the information must also carefully read and
apply it thoroughly.
This manual must be kept for the entire life cycle of the machine in a known location that is easily accessible,
so that it is available when you need to consult it.
You will need to read the information contained here in order to use the machine correctly and to reduce
risks to the health and safety of individuals, as well as serious financial loss due to incorrect use of the
machinery, or as a result of poor or non-existent maintenance.
This manual is the first source of information for the user of the machine.
However, it is not a replacement for the training that must in any case by provided by the employer to
the operator who uses the machinery prior to performing any manoeuvre.
Each employee who is required to use the machine must first refer to this manual to avoid risks to health and
safety.
Therefore, it is necessary to carefully and constantly comply with all instructions provided here.
Failure to refer to the manual in advance may be a cause of risks for the user of the machinery,
resulting in serious harm to the health and safety of the employee.
It is therefore prohibited to use the machinery without first consulting the manual.
The manufacturer reserves the right to make modifications to this manual for technical or commercial with no
advance notice required.
In addition to the above, it is also required to consult the manuals provided by the manufacturers of the
single components of the machinery, and which are delivered with this one, prior to using the machinery.
As stated in the general sales conditions, Cappellotto shall not be held liable for damage or consequences
which occur due to use of the machines in an incorrect manner or which is different from the instructions
contained in this manual.
Cappellotto shall also not be liable in any manner for the contents of the manuals of the components of the
machinery sold, nor for errors or omissions contained therein.
COMPOSITION - METHOD OF CONSULTATION
4
This manual is composed of three parts.
The first part is dedicated to "SAFETY" and includes general instructions to be followed for greater safety
while using the vehicle, the identification of the main risks involved when using the machinery, an
explanation of the various hazard signs and signals, and a list of preventive measures to be taken.
The second part is dedicated to "INSTRUCTIONS FOR USE" and includes specific instructions on the
method of use of the machinery and its individual parts, as well as the specific risks related to their use and
the main preventive measures.
The third part is dedicated to "MAINTENANCE" and provides general information on correct routine and
special maintenance of the machinery.
Anything that is a risk is precisely identified in a table alongside the description of operation of the vehicle.
At various points in the manual, you will see the signal shown above.
This symbol identifies HIGH RISK.
If you do not comply with the instruction in the box where you see this signal, there may be risks to
the health and safety of the operator.
It is therefore COMPULSORY to comply with the instructions shown there and not to perform any
manoeuvres other than as described.
5
PROCEDURES FOR ORDERING SPARE PARTS
To ensure sufficient service, please provide the following information when ordering spare parts:
- Equipment model;
- Job order number;
- Tank code;
- Spare part code (see part IV attachments);
- Brief description;
- Quantity required;
- Name;
- Method of shipment.
Spare parts may be ordered by the client directly from Cappellotto or from the service centre listed on the
first page of the manual.
For any requests for service, specify the data of the equipment (see first page), the approximate hours of use
and the type of problem you are having.
HOW TO REQUEST TECHNICAL SERVICE
For any needs you may have, please contact the manufacturer's technical service as specified on the first
page.
For any requests for service, specify the data of the equipment (see first page), the approximate hours of use
and the type of problem you are having.
ATTACHED DOCUMENTATION
In addition to this manual, the client is provided with the following documentation:
- General layout of the system;

- Diagram of power system (PTO);
- Specific documentation of main installed components;
- List of Controls;
- Electrical system diagram;
- High pressure system diagram (if present);
- Vacuum system diagram (if present);
- Hydraulic system diagram (if present);
- Pneumatic system diagram (if present);
- Heating system diagram (if present);
- Certificates of conformity in compliance with current laws (if required);
- General guarantee conditions;
6
TABLE OF INCLUDED COMPONENTS
Equipment model
CAP COMBI CL 2600
(commercial name):
MAIN MECHANICAL COMPONENTS
In the setup furnished to you, the part indicated below is:
Included Not included Component Model Serial number

TANK CAP COMBI CL 2600 3439
FRAME ISUZU GIGA FVM 34Q 6x2
POWER TAKE-OFF PFT-3000-4AV-E 10029473
HIGH PRESSURE WATER PUMP PRATISSOLI KS 36 180 BAR 15210004 H
HIGH PRESSURE PUMP’S DRIVING N°4 XPC 2120
BELTS
PUMP HIBON 820 XL RBA 1084425
VACUUM PUMP’S DRIVING BELTS N°3 XPB 2360
WOBBLE PUMP ‘S ALPHA 02 RA
WOBBLE PUMP ‘S DRIVING BELTS N°1 XPA 1180
RADIO CONTROL
AUXILIARY MOTOR
TRANSFER PUMP
WEBASTO
FIXED BOTTOM
MOBILE BOTTOM
ROTATING BOTTOM
TILES
SIDE BOXES
UPPER SUCTION REEL WITHOUT ARM
UPPER SUCTION REEL WITH ARM
TILTING SUCTION REEL
VERTICAL NON-TILTING SUCTION REEL
SPOUT
MAIN WASH REEL
LATERAL WASH REEL
"VENTURI" MATERIAL DISCHARGE SYSTEM (“BORA” equipment)
RECYCLING SYSTEM
ROAD-WASHING BAR
ADR ADAPTATION
CONTINUOUS CIRCULATION SYSTEM
DEODORIZING SYSTEM
DISINFECTANT SYSTEM
FLUSHING IN TANK
7
P ART I - S AFETY
1 GENERAL INFORMATION
1.1 Safety - General
The machine was designed and built based on the latest technical knowledge.
Dangers to operators may be completely eliminated and/or substantially reduced only if the operators have
been properly prepared for and trained on correct use of the machinery in advance.
Personnel must be fully informed on potential risks they may encounter in carrying out their duties. This
includes both operation and the correct use of the machine's safety devices.
This personnel must also carefully observe the following safety standards in order to prevent occurrence of
hazardous situations.
Concerning the main risks inherent in the use of the equipment and the main individual safety gear,
to be used when using the equipment, refer to paragraph 3.1. of this chapter. The operator must take
into consideration the risks specified and use the individual protection gear and safety measures
listed there, both before and during use of the equipment.
1.2 Terminology
These concepts were taken from standard ENV 1070 - Terminology:
DANGER:
Source of possible injury or damage to health.
(point 3.5 - EN 292 - part 1’~)
Note: the word "danger" is generally used with other words that indicate its source of the nature of injury or
health damage which may occur. Examples may include danger of electrocution, danger of crushing, danger
of cutting, danger of poisoning, and so on.
The hazards generated by the machine are described in paragraph 4 of EN 292 - part 1’~ and standard EN
414.
Other dangers arise from the method of use of the machine on the road and in working environments that
are different due to technique/geology.
HAZARDOUS SITUATION:
Any situation in which a person is exposed to danger(s).
(point 3.6 - EN 292 - part 1’~)
DANGEROUS FUNCTION OF A MACHINE:
Any function of the machine that generates danger during its operation.
(point 3.9 - EN 292 - part 1’~)
8
RISK:
Combination of probability and gravity of possible injuries or damage to health in a dangerous situation.
(point 3.7 - EN 292 - part 1’~)
DANGEROUS ZONE:
Any zone in or around a machine where a person is exposed to injury or damage to health.
(point 3.10 - EN 292 - part 1’~)
Note : the danger that causes the risk considered in this definition
- is permanently present during the intended use of the machine (movement of hazardous moving parts,
etc.).
- may occur unexpectedly (sudden or unexpected start-up, etc.).
DANGERS AND RESIDUAL RISKS:
These are sources and/or combinations of probabilities and/or dangerous situations which can not be
effectively removed (at least not completely) by design and protective measures. They must be indicated by
means of signs, symbols and/or warnings in the instructions for use.
(point 5.5 - EN 292 - part 1’~)
QUALIFICATIONS OF SKILLED OPERATORS
Operators are anyone who performs the following tasks on the machine:
- transport and movement of parts;

- assembly, installation, adjustment and testing;
- commissioning and use;
- cleaning, maintenance and repair.
Operators must be persons who are suited to the work. They must be physically and mentally capable of
handling the activities involved with the machine in all operating phases.
To better define the field of intervention and the resulting responsibility assumed by each OPERATOR, as
well as to make it easier to read and understand this menu, the following table has been prepared that lists
professional job descriptions required for each task.
OPERATOR ASSIGNED TO USE OF THE MACHINE:
Personnel assigned to perform duties required for correct use of the machine, operation of the machine via
its controls, loading and unloading of materials during working, routine maintenance, daily cleaning and in
some cases the most basic and simple maintenance tasks.
MECHANICAL MAINTENANCE TECHNICIAN:
Qualified person capable, in normal conditions, of making normal adjustments, and of performing minor
routine mechanical maintenance and repairs.
9
ELECTRICAL TECHNICIAN:
Skilled personnel capable, in normal conditions of performing electrical work, adjustments, maintenance and
repairs.
MECHANICAL TECHNICIAN:
Specialized technician, trained and/or employed by Cappellotto, authorized to perform complex and
extraordinary mechanical work.
ELECTRICAL/ELECTRONIC TECHNICIAN:
Specialized technician, trained and/or employed by Cappellotto, authorized to perform complex and
extraordinary electrical/electronic work.
ELECTROMECHANICAL TECHNICIAN:
This is a highly specialized operator whose professional profile includes the knowledge and skills of the
mechanical technician, as well as those of the electrical/electronic technician.
- The operator must not allow anyone to approach during use of the machine, and must
prevent its use by unauthorized personnel.
- When necessary, the operator must use individual safety gear. E.g.: I.P.D. This may
include shoes, goggles, gloves, and so forth as specified by signals on the machine in
certain places.
1.3 Types of risk
Health and safety risks are identified according to the following definitions:
1. Safety risks
Risks to safety or of accidents.
2. Health risks
Risks for health, hygiene or the environment are those which may damage the biological balance of
assigned workers.
3. Risks to health and safety - transversal type
These risks can be identified in the rapport between the worker and his work organization.
10
2 WARNINGS ON USE (SIGNS AND SIGNALS)

The manual includes the main symbols found on the machine.
The following are examples used to illustrate the meanings of the various signs and their colours.
The user is required to keep the signs on the vehicle in good shape.
In case of breakage, corrosion, or loss of colour, the signs that are no longer satisfactory must be replaced. If
necessary, ask for information from the service centre and/or the manufacturer.
At the end of each shift, the vehicle must be properly cleaned, also to keep the signs and signals in good
condition.
Signals on the vehicle include:
a) Danger indications
This indication identifies a generic danger that may be better illustrated in

the manual in the various descriptive points.
This signal identifies on the vehicle points with risk of accidental contact with
parts of the body during normal operation of the machine and/or while
working near it.
b) Prohibition indications
Example
These types of signals are used to indicate prohibited manoeuvres, or parts
of the machine where certain equipment and/or workings are prohibited.
Failure to comply with the prohibition is the cause of immediate risk, with possible harm to persons
and/or the machine.
11
c) Indications of requirement to use individual safety gear
Example
This type of signal indicates the requirement to use special individual safety
gear (gloves).
Failure to use the specified individual safety gear by the machinery operator may cause him
temporary and/or permanent injury.
The instructions on the use of individual safety gear in this manual are not to be considered as all-
encompassing. Rather, they are to be integrated with instructions on the use of special individual
safety gear which arise from evaluation of risks to the user which may be acquired for operations not
included in this manual (e.g. support operations such as opening wells, access to buildings, and so
on).
Therefore, before using the machine, the user should analyze risks so as to decide whether to use
additional safety gear that is not specified in this manual.
Therefore, Cappellotto shall not be held liable for damage caused by failure to use individual safety
gear where not precisely specified and related to the use of the machinery for special operations not
covered by this manual for which the user/company shall perform a specific risk analysis and
determine appropriate measures also through the use of specific individual safety gear.
d) Indications of Required Manoeuvre
Example
These types of signals indicate the type of manoeuvre to be performed and
the indications of positions.
Since these signals are near the valves, plugs, etc., continuous maintenance must be performed to
avoid accidental opening and/or closing in the incorrect sequence.
Daily cleaning is therefore required, and in any case at the end of each shift of work with the
machinery, of said signals. Replace and/or restore them immediately if they are not compliant.
12
3 ANALYSIS OF RISKS PRESENT IN THE USE OF THE VEHICLE
3.1 Definitions of main risks
a) Safety risks
Risks for safety or of accidents are those responsible for the possible occurrence of accidents or injuries with
resulting damage or physical injury of varying degrees of seriousness, following a physical-traumatic impact
of various nature (mechanical, electrical, chemical, thermal, etc.)
In many cases, these risks are the result of unsuitable safety characteristics concerning the working
environment, the machines and equipment used, the operating methods, and the work organization.
In the specific case of Cappellotto machinery, risks shall be defined concerning the method of using the
machinery and related risks which may originate from external environmental factors.
b) Health risks
Risks for health, hygiene or the environment are those which are responsible for possible damage to the
biological balance of the workers assigned to tasks that involve the emission of environmental risk factors, of
a chemical, physical or biological nature, in the workplace with subsequent exposure of personnel.
The causes of the aforementioned risks originate from unsuitable hygienic-environmental conditions as a
result of environmental risk factors produced by the manufacturing process and/or by the equipment and the
operating methods.
In the specific case of Cappellotto machinery, these risks are to be considered as originating from prolonged
use of the machine, which is the cause of dangerous emissions as well as by the type of material that the
machine is capable of transporting (e.g. ADR transport and/or transport of materials with bacteriological risk).
c) Risks to health and safety - transversal type
These risks can be identified in the rapport between the worker and his work organization. This relationship
is built on ergonomic, psychological and organizational interactions, and can be taken into consideration also
within possible transversal relationships between safety risks and health risks.
3.2 Table of main risks and individual safety gear
The following are the main risks that may be connected with use of the machine, in addition to those
indicated on the machinery with signs and general information:
Medium RISK PERSONS FALLING FROM THE VEHICLE

Fall Danger of falling from heights of over 2 m when performing maintenance on the
vehicle or while preparing it for operation.
INDIVIDUAL SAFETY Use of safety belts (if there is not a fixed ladder)
GEAR Use of gloves
Use of hardhat
Use of safety shoes
13
Medium RISK BEING STRUCK BY MOVING PARTS

BEING RUN OVER Use of motor vehicles for the transport of materials
Danger of being run over while walking and while near the vehicle, also by other
vehicles
INDIVIDUAL SAFETY Use of hardhat
GEAR Use of gloves
Use of safety shoes
Use of high-visibility garments if you will be on the roadway with the vehicle
Use of signals compliant with traffic laws
High RISK BEING STRUCK BY MATERIALS handled during vehicle preparation, such
as hoses
Accidental contact with Danger of being struck during unloading and lifting materials and while near the
moving mechanical parts vehicle, also by other vehicles.
You must not stand under hanging or moving loads (hoses), and do not guide
hanging loads by hand
GEAR Use of gloves
Use of safety shoes
Use of high visibility garments
High RISK SPRAY/SPLASHES during the liquid suctioning phase and during the
wash/unloading phase
Accidental contact with Danger of splashes or spray when using hoses or when opening valves or plugs
parts of the body
GEAR Use of gloves
Use of goggles or transparent face masks
Use of safety shoes
Use of high visibility garments
Use of overalls of suitable resistance to the transported products
High RISK Presence of noise emissions in various zones of the machinery

NOISE Danger of prolonged hearing loss due to failure to use individual safety gear
INDIVIDUAL SAFETY Use of hearing protection with minimum reduction of 20 dBa
GEAR
14
High RISK Crushing of lower and upper limbs during opening of parts of the
machinery and while performing checks
CRUSHING Danger for the lower and upper limbs during partial opening of closures that
protect rotating parts
Incorrect use of hoses or flanges
Where the side door is located (pump compartment cowling) if it is opened

without following proper procedures.
The cowling must be opened by persons assigned to use the machine who
have been suitable trained in its operation and specific risks.
PROTECTIONS/Measures Use of safety gloves
Use of safety shoes
For the hose part, never place your upper limbs (hands and arms) near the
points where winding of the hoses takes place
Before opening the side door of the vehicle located just behind the cab (pump
compartment cowling), you must always disengage the power take-off to prevent
rotation of mechanical moving parts. Therefore, opening of the cowling is
contingent upon the aforementioned manoeuvre and is prohibited if the power
take-off has not been disengaged
High RISK Accidental contacts due to incorrect handling of hoses containing high pressure
and suctioning of clothing/limbs if you get too close to the suction point.
Whiplash due to Danger of accidental contacts with moving arm and with sections of hose being
movement of hoses and used (presence of high pressure in hoses during use)
SUCTION OF
CLOTHING/LIMBS Danger of suction of clothing / limbs if you get too close to the suction point
PROTECTIONS Do not stand in the range of action of the arm that moves the main hose.
Do not stand near the hose while it is being extracted from sewer holes, wells,
hoses, etc.
Do not start the working cycle before all personnel involved in the work or nearby
have move to a safe distance to avoid accidental contact.
Firmly hold the suction pipe during suctioning and do not get too close to the point
of suctioning
15
3.3 Preventive measures to be taken during positioning, transfer and parking of

the machine
WORKING PHASE PREVENTIVE MEASURES

POSITIONING THE VEHICLE In this phase, you must give extreme attention to traffic conditions and
the primary services in the area.
Before you position the machine, you must perform an inspection to
become fully familiar with the area where the materials are to be
unloaded/loaded.
In particular, the following actions must be performed:

- analysis of the base of support of the vehicle to prevent the ground
from giving way, resulting in overturning;
- evaluation of the need to install road signs to indicate obstructions;
- analysis and evaluation of the presence of overhead electrical lines
or other sources of energy distributed in the work area;
- verification of the possibility for access by heavy equipment, and any
permits which may be required;
- evaluation of the slope of the terrain based on the amount of material
contained in the tank. The liquid present may cause the vehicle to
become unbalanced due to the oscillation of the liquid in the vehicle.
In addition to the slope, you must also consider the surface of the
terrain, which presents various risks contingent upon the presence of
water, ice, mud, sand, gravel, and industrial paving.
Slope of terrain
The slope of the terrain where the vehicle is to be positioned may be the
cause of the vehicle overturning or of the ground giving way, and may
also cause the vehicle to malfunction.
It is prohibited to position the machine at distances of less than 1 m from

ravines if the pressure on the stabilizers is up to 12 tons.
For greater weights, the distance must be at least 2 m from the edge of
the ravine.
16
WORKING PHASE PREVENTIVE MEASURES

STARTING WORK AND While unloading hoses and preparing the vehicle, no-one on the ground
UNLOADING HOSES is to remain in the area where loads are moved.
Assistance from the ground must come from personnel located in a safe
position who aid in manoeuvring.
Verbal manoeuvring signals must be used as set forth in European

standard 92/58.
When positioning the vehicle, comply with the instructions in the

previous chapter. During manoeuvring and unloading, in any case, you
must:
- analyze the base of support of the vehicles to prevent the terrain from
giving way, resulting in overturning;
- evaluate the need to integrate road signs to signal obstructions;
- evaluate the presence of overhead electrical lines. Appropriate signs
must be placed so that a minimum distance of 5 m is kept from them.
PARKING THE VEHICLE The parking phase must include the following preventive measures:
- check that all reflective material on the vehicle is in good condition
and visible;
- check that there are no parts that protrude beyond the outline of the
machine that cannot be immediately identified, even at night;
- if the machine is left on the road, signal the presence of the vehicle
as required by traffic laws, and also obtain any authorization which
may be required for partial occupation of public property. When
working on private property, always follow the same rules as set forth
by traffic laws, as well as any directions provided by the owner of the
land concerning specific risks.
POSSIBLE UNLOADING All operations must be carried out in authorized locations. Unloading of
OPERATIONS materials is prohibited in any unauthorized areas that are not provided
with appropriate waste recovery systems.
In any case, please be advised of the following:
- The operator must not allow anyone to approach during use of the machine, and must
prevent its use by unauthorized personnel.
- When necessary, the operator must use suitable individual safety gear (shoes,
goggles, gloves, etc.) as set forth in the points indicated with special signs on the
machine.
THIS EQUIPMENT MUST BE USED ONLY FOR SUCTIONING LIQUIDS OR SLUDGE

CONTAINED IN UNDERGROUND DUCTS.
17
P ART II - INSTRUCTIONS FOR USE
Before you use the vehicle and carry out the preventive checks listed hereunder, you must carefully read
part I (safety) of this manual, which deals with measures to be followed when using the vehicle and related
risks.
1 CHECKS TO BE CARRIED OUT BEFORE STARTING
1.1 GENERAL CHECKS
WARNING: to ensure the proper functioning of all

equipment parts, at the time of equipment operating
the inclination angle MUST NOT exceed 2° in all
directions.
MAX 2°
18
Check the oil level in the lubricator of the compressed air

system located alongside the air filter. If the level is low, add
oil (see the chapter on recommended lubricants). This is an
automatic tank made of polycarbonate that dispenses a drop
of oil into the air circuit. When the tank is visibly empty, add
oil for air circuits (see the table of lubricants in Part III of this
manual). Proceed as follows:
• close the air supply valve (P1) located on the filters;
• bleed the pressure via the condensation discharge valve;
• unscrew the transparent tank;
• fill the tank with oil;
• put the tank back in place and perform the steps in the
previous point in reverse order.
P1
FILTER
AIR TANK SERVICES AREA
P1
FILTER
WARNING!
CHECK AND ADJUST THE

EARTHING, SO THAT IT
ALWAYS TOUCH THE
GROUND!
19
1.2 VACUUM SYSTEM
Check that the cyclone filter and the air filter it contains are clean by opening the upper cover of the
cyclone. If there are any impurities, and in any case periodically, it is advisable to wash the inside with
high pressure, discharging the water from the manual valve that is located under the cyclone (V30, see
fig.).
To empty the cyclone filter, you can also use the cyclone filter discharge procedure, which is described in
chapter 7.
V30
V30
The following specific controls are also to be carried out, based on the type of pump included on the
equipment:
20
1.2.1 Blower pump
Check the oil level using the indicator (see photo). If necessary, add the type of lubricant recommended by
the manufacturer (see attached booklet for use).
VACUUM
1.3 High-pressure water system
Check the oil level in the high-pressure pump. If necessary, add the type of lubricant recommended by
Check that the water filter is clean. If there are
any impurities, drain the filter via valve A51
located under the filter.
A52
A51
Valve for adjustment of pressure with oil: Check the level of oil in the valve and fill as necessary. Also
check for possible oil emulsion, recognizable by a whitish colour. Presence of emulsion requires a
complete oil change. To add or change oil, see the instructions and characteristics in the manufacturer's
manual.
21
2 ROAD TRAVEL
Check that all accessories provided with the equipment (e.g. spout, reel arm, flag reel, etc.) are in the
parking position.
Check that the power take-offs are disengaged, especially the power take-off connected to the
transmission.
Moving the vehicle while the power take-offs are engaged may cause failure of the oil
pumps.
Remember to check that the tank is lowered all the way down and locked to the frame using the appropriate
locking device. It is prohibited to move the vehicle with the tank raised or unlocked to prevent possible
personal injury or property damage.
3 STARTING WORK
- Get out of the vehicle and check that around the vehicle and in the work area there
are no persons who are not involved in loading/unloading, or other impediments to
safe work.
- Also check that under the vehicle and in the loading/unloading area there are no
sources of heat, flames, sparks, emissions of explosive gases, dangerous powders or
anything else that might make it dangerous to use the equipment.
Position the vehicle on the worksite and stabilize it so that work may be performed safely. Also refer to
the safety instructions in the point on positioning and parking (Part I, point 3.3).
Set the parking brake.
Place chocks under the wheels of the truck.
Make sure that all engine brake devices or original decelerators of the vehicle are off.
Only for vehicles with cruise control: Check that the cruise control selector, which controls engine speed,
is set to "ON".
Check that the tanks of the vehicle's compressed air system are pressurized. You can check this on the
pressure gauge in the cab or, for vehicles with an auxiliary motor, in the control box, which should
indicate approx. 8 atmospheres.
Engage the power take-off (see next chapter).
22
Engaging the power take-off automatically unlocks the tank. Depending on the
model, this unlocking is indicated by a flashing light or an acoustic signal. If the
tank does not unlock, make sure that the vehicle is not on uneven ground. If the
problem persists, contact Cappellotto customer service.
3.1 GEARS TABLE
23
4 ENGAGING THE POWER TAKE-OFF
4.1 Cappellotto power take-off (PFT 3000/4AV-E)
Engaging the power take-off
Depress the clutch in the vehicle's driver cab

Engage the power take-off with the switch located in the cab. Make sure that
the green light comes on; it tells you that the power take-off is engaged.
Switch used only on IVECO >>>
Engage the correct gear for the work to be performed as set forth in the
table on gears located in the cab
Slowly let the clutch out
Disengaging the power take-off
Depress the clutch in the vehicle's driver cab

Put the machine in neutral
Wait for the rotating parts to stop
Disengage the power take-off with the switch located in the driver's cab and check that the green
indicator light goes off
Slowly let the clutch out
4.2 Troubleshooting
Possible malfunctions Explanations / Solutions to implement
-engaging the power take-off -
Check that the pressure of the pneumatic system is more than 6

atmospheres.
a) The power take-off does not insert If the compressed air system does not charge, it means that the
system is defective and requires service by the dealer (if it is the
original compressor of the vehicle) or by Cappellotto (for the
Cappellotto auxiliary motor).
Check that the alarm buttons (red push buttons) have not been
pressed.
Check that all buttons/switches of all control boxes are in the neutral
position.
b) The electrical system does not The pressure of the pneumatic system is not sufficient. See the
work solution in point a).
The pressure switch is faulty (see pneumatic system diagram).

Contact Cappellotto customer service
Fuses burned out - refer to the diagram of fuses either attached with
or located on the machine.
24
5 INTAKE OF SLUDGE
5.1 General warnings
Check that around the vehicle and in the work area there are no persons who are not
involved in loading, or other impediments to safe work.
Also check that under the vehicle and in the surrounding area there are no sources of
heat, flames, sparks, emissions of explosive gases, dangerous powders or anything else
that might make it dangerous to use the equipment.
The type of material to be suctioned must be compatible with the tests of the equipment,
in order to comply with safety standards.
N.B. The pump must be engaged at low power.
• During suctioning, there may be the risk of intake of limbs and clothing of persons
using the vehicle or anyone who approaches its suction accessories and valves.
• During suctioning, therefore, the operator must never go near the point of suction, in
order to prevent intake of limbs or clothing.
• Also, during suctioning, the suction pipe must be held firmly to prevent harm to
persons and property.
• Also, personnel must use clothing that does not permit intake and avoid items that
may cause it, such as overcoats, loose belts, and necklaces. Personnel with long hair
should tie it up. Hats with chinstraps may not be used.
• It is prohibited to use the machinery for suction before removing from the surroundings
any equipment, mechanical pieces, or instruments that might accidentally be sucked
into the system.
• It is prohibited for the system to be used by untrained persons.
• Please note that when removing the plug from the suction joint, there may be residual
liquids which, when exiting, may cause injury to the upper and lower limbs. It is
therefore obligatory to use safety gear such as gloves, shoes, garments and goggles.
25
5.2 Operations to be performed before any suctioning manoeuvre

Ensure that the rear bottom of the tank is perfectly closed.
Close the vent of the tank via the manual valve or with the control located in the control box, if the vent is
pneumatic (see the chapter "List of Controls").
Check that all suction and discharge valves (including those of any reels or spouts) are closed (see the
chapter "List of Controls").
5.3 Suction using upper spout
Starting the suctioning procedure:
Position the arm of the spout in the working position with the following three possible movements:
• Raising - lowering of the arm
• Rotation of the arm to the left and right
• Extension - retraction of the segment of the telescopic arm.
These movements are activated via the controls located in the control box or on the radio control. In rigs
with no radio control, these controls are replicated in a portable button panel connected to the control box
with a 10-metre cable (see the chapter in the "List of Controls").
Remove the plug from the joint at the end of the spot and connect the suction pipe.
Do not use the arm to lift any sort of weights (for example, sewer covers) since this is not
what it was designed for. THIS IS NOT A LIFTING DEVICE!
Activate the pump with the control located in the control box. Check that the corresponding indicator light
comes on (see the chapter in the "List of Controls").
Open the valve of the spout with the control in the control box. Check that the indicator light of the
selector comes on (see the chapter in the "List of Controls").
The material is now suctioned through the suction pipe connected to the spout.
If necessary and desirable, you can increase engine power to increase the revs of the pump, and hence
its flow rate, using the control located in the control box (see the chapter in the "List of Controls"). The
percentage of vacuum in the tank can be seen on the vacuum metre located on the control panel.
The level of material loaded into the tank can be seen on the level indicator.
Also, during suctioning, the suction pipe must be held firmly to prevent harm to persons
and property. Individual safety gear must be used to prevent injury to upper and lower
limbs.
Ending the suctioning procedure:
Raise the arm.

Close the valve of the spout.
Reduce engine power with the appropriate control.
26
Disengage the pump.

Open the vent valve using the control in the control box (see the chapter "List of Controls"). This
operation returns the pressure in the tank to that of the atmosphere.
Upon completion of venting, the vent valve must again be closed.
Remove the suction pipe and place the plug with gasket on the joint located on the end of the spout.
Put the arm of the spout in the parking position with the aforementioned controls. Check its actual position
in the saddle.
Note: For rigs equipped with a "tank full" sensor, once the maximum fill level is reached, the pump is
automatically disengaged.
5.4 Troubleshooting
Possible malfunctions
Explanations / Solutions to implement
- sludge suctioning -
The cyclone filter is full. To empty it, follow the
sequence of commands in the list of control in the
chapter on emptying the cyclone filter.
a) The pump does not connect
If this operation does not solve the problem, contact
Cappellotto customer service (the sensor may be
defective).
The tank is actually full and therefore you cannot

continue suctioning.
b) Tank full alarm
Otherwise, contact Cappellotto customer service,
since the sensor may be defective.
If the ambient temperature is especially high, turn off

the pump and wait for the temperature to return to
within acceptable limits.
Afterwards, avoid prolonged suctioning at maximum

c) High temperature alarm of pump resulting in its
vacuum, or raise the suction pipe from time to time to
shutdown.
allow fresh air to reach the pump.
If the ambient temperature is low or the machine has

not been running for several hours, this indicates a
faulty sensor. Contact Cappellotto customer service.
Only for liquid loop vacuum pumps: Fill the water tank halfway with anti-freeze. If the
alarm persists after this, contact Cappellotto
d) Liquid loop water reserve alarm customer service as the sensor may be faulty.
27
6 SLUDGE DISCHARGING
IMPORTANT: TIPPING THE TANK WHEN FULL IS STRICTLY PROHIBITED.
6.1 Discharge sludge through the rear discharge valve
Position the vehicle suitably for discharge of material through the rear valve.
Remove the plug of the joint on the discharge valve and, if necessary, connect a hose to the joint so as to
carry the material to the desired location.
If you are using a hose, its end must be firmly held by an operator. Not holding it firmly, or
a momentary distraction, may cause violent, uncontrollable movements of the hose.
There are two methods of discharging:

• by free fall (using the force of gravity)
• under pressure (by creating pressure the tank to aid the material in exiting, which also makes it possible
to discharge at a greater height than that of the discharge valve)
6.1.1 Free fall discharge
Before any manoeuvre, make sure that no unauthorized persons are in the vehicle's
working area.
28
Open the vent valve of the tank manually (for manual venting) or with the control in the control box (for
pneumatic venting). Also see the description in the "List of Controls".
Open the discharge valve manually (for manual opening) or with the control in the control box (for
pneumatic opening). See the description in the "List of Controls"
When discharging is complete, close the discharge valve and then the vent valve.
Remove the hose connected to the discharge valve and put the plug back on the joint. Check that the
gasket is positioned correctly.
Note: It is strongly advised to clean the cyclone filter upon completion of each discharge of sludge. (See
the instructions in the chapter on emptying the cyclone filter in the "List of Controls"). This
procedure also automatically cleans the air filter of the vacuum line.
6.1.2 Troubleshooting

The tank is pressurized. Vent it via the vent valve.
Discharge valve does not open If the problem persists, contact Cappellotto customer
service.
The cyclone filter is full. Empty it as shown in the

sequence of commands in the list of control in the
chapter on emptying the cyclone filter.
The pump does not connect
If this operation does not solve the problem, contact
Cappellotto customer service (the sensor may be
defective).
6.2 Discharging of sludge through the opening of the rear door
WARNING: BOUND THE DISCHARGE ZONE BY MEANS OF SPECIAL INDICATORS

NOT ALLOWING TO ANYBODY TO COME AROUND IT AND BEFORE DOING ANY
MOVEMENT CHECK THAT ANYONE BE NEIGHBOR TO THE REAR BOTTOM,
EXCEPT FOR THE OPERATOR.
Warning: in case of air suspension equipped truck,

completely discharge the air suspension before any
working session.
NOTE: Even though this manoeuvre can be carried out at any time (even when the tank is full), IT IS
NOT ADVISABLE to open the bottom until the tank has been emptied of at least 70% of the
total capacity with the previously described systems.
Position the machine suitable for discharging material through the rear bottom. Check terrain conditions
first (slope, type of soil, underground utilities, and so forth).
If there are rear stabilizers, lower them using the plates for load distribution.
If present, retract the telescopic bumper, using care to remove any manual locks before you start the
manoeuvre.
29
You must move any spouts or arms parked over the bottom which may impede
movement of the rear bottom. All accessories anchored to the bottom must be placed in
parking position.
Open the vent valve of the tank manually (for manual venting) or with the control in the control box (for
pneumatic venting). Also see the description in the "List of Controls".
Open the locking wedges of the tank with the control.
Attention: Visually check for complete opening of all the wedges. Partial opening may cause serious
damage.
Open the door of the bottom using the control.
At this point you can tilt the tank using the control. First, make sure the vehicle is horizontal.
When discharging is complete, lower the tank.
Carefully clean the gasket of the bottom and the seal seat of any residues. Incorrect cleaning may
damage the gasket, thus compromising the seal of the bottom
Close the bottom and lock it again with the wedges.
Note: It is strongly advised to clean the cyclone filter upon completion of each discharge of sludge. See
the instructions in the chapter on emptying the cyclone filter in the "List of Controls". This procedure
also automatically cleans the air filter of the vacuum line.
Possible malfunctions
Explanations / Solutions to implement
- discharging sludge / bottom opening -
Check that there are not spouts or arms parked over
the bottom. If so, move them.
The bottom does not open. In ADR rigs, the bottom does not open if there is no
pressure in the tank. Then check that the vent is
open. If the problem persists, contact Cappellotto
customer service.
Upon connection of the power take-off, the tank is not

released. Check that the vehicle is not on uneven
The tip-up does not work.
ground. If the problem persists, contact Cappellotto
customer service.
The tank is not completely lowered. Lower it

The tank lock cannot be inserted completely. If the problem persists, contact
Cappellotto customer service.
30
7 DISCHARGING THE CYCLONE FILTER

When the cyclone filter (purifier) fills up, the pump shuts down. At this point, all operations must be halted
immediately with the pump and the decanter must be emptied as follows:
7.1 Earth dump
To do the earth dump, open the manual valve mounted under the cyclone. Note: we suggest to always
connect an hydrant connection to convey the material into a special receiver
7.2 2nd cleaning
Create the vacuum in the tank by actuating the blower
When the max. vacuum level is reached, turn off the blower
Open valve A indicated in the scheme
A
When the “VACUUM GAUGE” indicator is back to 0, this means
that the material in the cyclone was discharged in the tank
As soon as the action is performed, turn off valve

v “A” once again
31
Now, do the earth dump as per point 7.1.
NOTE: We suggest to do the cyclone filter discharge at any tank dump and at the end of any working
day, to keep cleaned the internal air filter.
IN CASE OF LIGHTING ON OF THE “FULL CYCLONE” LIGHT, DO THE OPERATION

DESCRIBED ON POINT 7.1, THEN THE OPERATION DESCRIBED ON POINT 7.2
THE ABOVE DESCRIBED OPERATIONS MUST BE DONE AT ANY TANK DUMPING,

ALWAYS REMINDING TO DO AN HIGH PRESSURE WATER CLEANING, RELATED
TO THE SUCKED MATERIALS.
8 HIGH PRESSURE SYSTEM
8.1 Filling with water
8.1.1 Side boxes
A18
A18
For these kinds of tanks, filling with water may be performed only from a hydrant, as follows:
Remove the plug from the hydrant fitting.

Connect the hose from the hydrant.
Open manual valve A18 (if present) and add water.
Check filling progress on the level indicator.
When filling is complete, close the manual valve (if present), disconnect the hose and put the plug back
on the hydrant.
32
Do not remain in the vicinity.

Do not perform work near electrical systems and/or overhead lines.
8.2 First engagement of high pressure pump
BOXES – TANK – WATER COMPARTMENT TUBS
A14
VARIOUS USES
A52
A51
A53
CLOSED OPEN DESCRIPTION
Blue indicates the water discharge valves.
Red indicates the function valves.
Check that the cut-off valve A14 (if present) is open.

Check that the vent valve of the water compartment (if present) is open.
Vent the water filter by opening valve V52.
Vent the head of the high pressure pump by opening valve V53.
33
8.3 Uses of the high pressure pump
The nozzle must always be bended to the canalization, starting with a reduced
pressure to avoid its back that could cause damages for health and security of the
operator.
OK
8.3.1 Rear flag reel
Position the reel in the direction in which washing is to take place (e.g. in the direction of the well) using,
based on the equipment of the rig, manual or hydraulic rotation of the flag reel, as described hereunder.
8.3.1.1 Manual rotation of the flag reel
Before performing any rotation, check for any fixed obstacles in the radius of action of the
arm which may be sources of risk. Also keep persons from standing, even temporarily, in
the vicinity of the machine and in the radius of action of the arm.
Release the reel by pressing the flag release button with spring return located on the control box of the
flag reel.
While holding the button down, manually turn the reel until the desired position is reached.
Release the button to lock the flag reel again.
34
Perform the same operation to place the flag reel back in parking position.
The parking and maximum rotation positions are controlled by limit switches.
8.3.1.2 Unwinding the high pressure hose
To insert the hose in the conduits to be cleaned, unwind the hose

using the wind/unwind high pressure reel located in the control box.
The speed of unwinding may be controlled using the control (see
photo) in the control box (if present). The point of maximum
unwinding is not equipped with a limit switch. Use extreme caution
to keep the hose from getting damaged.
8.3.1.3 Rewinding the high pressure hose
The high pressure hose is rewound using the control located in the
control box.
The hose must be rewound at minimum pressure (30/40 bar). If the hose is accidentally
rewound while depressurized, it must be completely unwound and then wound back up
after inserting the minimum pressure as specified above.
The use of a hose that is rewound without minimum pressure may seriously damage it.
The point of maximum winding is not equipped with a limit switch. Use extreme caution to
keep the hose from getting damaged.
Note for reel rewinding with automatic hose guide:
Make sure there are no overlaps in the hose while rewinding it.
Note for reel rewinding without automatic hose guide:
The hose must be guided manually so that it is wound up properly.
The hose must be protected against edges, sharp corners or friction that might damage
the initial part of the hose, resulting in risks to the operator.
Stop the pressure of the water hose in the last 2 m of the hose to keep it from
accidentally striking the operator.
To place water in the hoses of the reel proceed as follows:
35
Open the valve of the reel as using the control in the control box.
Engage the high pressure pump using the control located in the control box.
Increase the pressure using the proportional adjuster located in the control box. You can check current
pressure using the pressure gauge located at the back of the vehicle.
If necessary, increase engine power using the control in the control box to increase the revs of the high
pressure pump and hence its flow rate.
Use the control for unwinding/winding the high pressure reel to move the hose back and forth through the
conduit.
When washing is complete proceed as follows:
Decrease pressure using the proportional adjuster located in the control box.
Decrease engine revs. This in turn will reduce the revs and the flow rate of the water pump.
Shut down the high pressure pump.
Close the valve of the rear reel.
It is prohibited to engage the pump at high power
36
8.4 Flushing
8.4.1 Flushing in non-ADR tank
WATER BOXES
FLUSH VALVE
This operation is to be performed as described below, with the rear bottom open or with the discharge
valve open:
Open the FLUSH VALVE located on the back of the vehicle.

Engage the high pressure pump using the control located in the control box.
Adjust water pressure using the adjuster located in the control box.
If necessary, increase engine power using the control in the control box to increase the revs of the high
pressure pump and hence its flow rate.
Upon completion of flushing proceed as follows:
Decrease water pressure using the adjuster located in the control box.
Decrease engine revs. This in turn will reduce the revs and the flow rate of the water pump.
Shut down the high pressure pump.
Close the valve of the reel.
37

The high pressure pump does not engage Check that there is water in the water compartment.
If you are in water reserve, work can be completed by

selecting the water reserve control (if present). This
will de-activate the water reserve sensor and the
pump will re-start.
Attention: To prevent serious damage to the high

pressure pump, avoid using all of the water reserve.
After de-activation of the water reserve sensor, a lack
of water will no longer shut down the high pressure
pump!
If the problem persists, contact Cappellotto customer

service.
The high pressure pump does not produce pressure Check the fuse located in the
control box on the current
stabilizer (see photo). A green
LED comes on to indicate
correct operation.
If the problem persists, contact

Cappellotto customer service.
38
P ART III - MAINTEN ANCE
An operator who is going to perform maintenance or checks of the machinery must first read and understand
the safety instructions in chapter I, including the risks connected with use of the unit and the individual safety
gear to be used prior to starting checks and work.
1 CHECKS
In order to prevent risks to operators and for those who perform routine maintenance, the following are the
checks to be performed periodically to ensure proper maintenance.
Definitions:
The periods of time (daily, weekly, monthly, yearly and so on) used in this section are intended as follows:
- Daily checks or operations i.e. to be performed every day: these are checks or operations that must
be performed daily if the vehicle is used 8 hours a day.
- Weekly operations or checks i.e. to be performed every week or every 7/8 days: these are checks
and operations that must be performed every 7 days if the vehicle is used 8 hours a day.
- Monthly operations or checks i.e. to be performed every month or every 30/31 days: these are
checks and operations that must be performed every 30 days if the vehicle is used 8 hours a day.
- Semi-annual operations or checks i.e. to be performed every 6 months: these are checks and
operations that must be performed every six months in case of use of the vehicle regardless of its use.
- Annual operations or checks i.e. to be performed every 12 months: these are checks and operations
that must be performed yearly in case of use of the vehicle regardless of its use.
If the vehicle is used more intensively than indicated, checks will need to be performed in proportion to use.
Cappellotto shall not be held liable for damage that occurs due to failure to comply with prescribed times and
methods.
39
1.1 GENERAL WEEKLY CHECKS
Check the oil level in the lubricator located alongside the air filter. Add
oil if needed. This is an automatic tank made of polycarbonate that
dispenses a drop of oil into the air circuit. When the tank is clearly
empty, unscrew it an fill it with oil for air circuits as follows:
• close the air supply valve located on the filters;
• bleed the pressure via the condensation discharge valve;
• unscrew the transparent tank; P1
• fill the tank with oil;

• put the tank back in place and perform the steps in the previous point
in reverse order.
FILTER
AIR TANK
SERVICES AREA
P1
FILTER
Check that the valve (P1) for supply is open

Check the level of hydraulic oil in the tank on the level indicator located on the side of the tank. As
necessary, add the specific oil (see table of lubricants). The number and size of the tanks varies
according to the number of hydraulic components. For this reason it is important monitor the level
indicator in order to maintain the right amount to ensure proper operation of the system.
Check that the terminals are tight and the condition of the batteries.
Check for leaks on the water/air/oil circuits
Check tightening of the bolts and on the wheels of the vehicle
40
1.2 GENERAL MONTHLY CHECKS

Cleaning the hydraulic oil filter: The oil filter is located at the discharge of the oil line, directly on the
upper part of the tank (oil return). In some cases it is possible that the filter is installed at the suction (up
the line from the hydraulic pump). Any additional instructions concerning cleaning and maintenance will
be provided when the vehicle is delivered.
Other actions:
Other instructions for checks and maintenance are included in the manuals provided by the manufacturers of
the main components (see attachments).
It is important to check and maintain the highest efficiency of the vehicle and equipment, keeping it clean
inside and out based on the materials normally transported. Care in operation ensures the equipment longer
life, safe use and economic return over time.
Cappellotto shall under no circumstances be held liable for the instructions for checks and maintenance
contained in manuals provided by manufacturers of the components of the vehicles.
The manufacturer shall not be held liable for damage resulting from incorrect use of the
equipment, and LACK OF OR POOR EXECUTION OF THE CHECKS SPECIFIED
ABOVE.
41
1.3 PUMP
1.3.1 BLOWER PUMP
The following instructions do not replace the user's booklet provided by the
manufacturer of the pump, which is enclosed with this manual and must be
consulted in advance.
Before each start-up:
Check the oil level on the indicators (N.B. you need to check them both). If necessary, add the type of
lubricant recommended by the manufacturer (see attached booklet for use).
Every day:
Empty the cyclone filter (see chapter 7 of the instructions for use).
Drain the condensation in the manifold under the pump via the valve (see
photo).
Every week:
Check the wear of the trapezoidal drive belts of the vane pump, as well as their tension and proper
positioning. Correct tension of the drive belts can be determined simply by pressing with the thumb in the
middle between the two pulleys. The belt should not flex more than its thickness.
Every 3000 hours:
Replace the trapezoidal belts of the blower pump.
42
1.4 HIGH PRESSURE PUMP
The following instructions do not replace the user's booklet provided by the
manufacturer of the pump, which is enclosed with this manual and must always be
consulted in advance.
Before each start-up:
Check the oil level in the high-pressure pump. If necessary, add the type of lubricant recommended by
Discharge the impurities that have settled in the
water filter, located between the centrifugal pre-
supply pump and the high-pressure pump. To do so,
open the valve located below the filter (see photo A52
and figure).
A51
Check the oil level in the pressure adjustment valve, located in the delivery of the high-pressure pump.
Also check for possible oil emulsion, recognizable by a whitish colour. When adding oil, see the
instructions and characteristics provided by the manufacturer.
Every week:
Check the wear of the trapezoidal drive belts of the high-pressure pump, as well as their tension and
proper positioning. Correct tension of the drive belts can be determined simply by pressing with the thumb
in the middle between the two pulleys. The belt should not flex more than its thickness.
Clean the water filter, located between the centrifugal pre-supply pump and the high-pressure pump by
removing the clamps (see photo), opening the filter and removing the internal cartridge.
Every 3000 hours:
Replace the trapezoidal drive belts of the high-pressure pump and of the pre-supply centrifuge.
During the winter and with low temperatures, if the equipment is

not being used, the water must be drained from the circuits, the
pressure adjustment valve, the head of the water pump, the
filters and from any other parts where the formation of ice would
cause severe damage.
N.B. For pumps Uraca KD724 and P3.45 you must also drain
the pump's cooling radiator (see photo).
43
1.5 TANK
Each time the tank is emptied:
Check for perfect cleanliness
- of the seats of the seal and of the gaskets before closing the suction and discharge valves;
- of the gasket of the bottom before closing it.
Remaining residues may cause damage to the closing system and seal leakage.
Monthly checks:
Tighten the bolts on the fastenings of the tank tip-up piston;

Tighten the pins on the tank tip-up fork;
Check the condition of the bottom gaskets, manholes, cut-off valves of the tank and of the accessories
attached to the surface;
Check the correct positioning of the rubber bumper located above the tank
support saddle on the counter-frame (see photo).
1.6 POWER TAKE-OFF
The following instructions do not replace the user's booklet provided by the manufacturer
of the power take-off, which is enclosed with this manual and must always be consulted
in advance.
Every day:
Check the oil.
1.7 UNIVERSAL JOINT TRANSMISSIONS

After the first 50 hours or 6 working days and afterwards every 500 hours or 2 months of work:
1.8 OIL AND WATER HEAT EXCHANGER

Every week:
Check that the cooling fins are clean. If necessary, clean using compressed air.
44
1.9 V-belt tension gauge

Every 500 hours:
PUMP
16
WATER PUMP
20
45
2 PERIODIC LUBRICATION
2.1 TRANSMISSION CARDAN SHAFT TYPE “PFT 3000/4AV-E”
MAIN SHAFT
BEARINGS
LONG LIFE: REPLACE

THE CARDANS EVERY
4.000 WORKING
HOURS OR EVERY 4
YEARS
(1/2) (1)
C D
E F
2.2 TRANSMISSION CARDAN SHAFT
The greases recommended must have a drop point at 135° C and a penetration degree 2 at lithium
soap.
Greases recommended are:
MARSON FIL EP 2
MOBILUX EP 2
MOBILGREASE SPECIAL
The maximum lubrication pressure have to be of 15 bars. For the lubrication intervals see the here
under table.
LUBRICATION FREQUENCY
APPLICATIONS BEARINGS GROOVED
(1) 10.000 km. 5.000 km.
(2) 100 h 50 h
46
GROOVED BEARINGS
C D
E F
47
2.3 MAIN SHAFT BEARINGS
48
2.3.1 GREASING TYPE SCHEDULE AND GREASING SPOT FOR Ø 65 MAIN SHAFT BEARINGS
49
2.4 RECOMMENDED LUBRICANTS
LUBRICATING INSTRUCTIONS
CODE
CAPPELLOTTO
PTO OILS:
Power take-off CAPPELLOTTO VALVOLINE HP GL5 SAE 85W90 3990033319
Power take-off CAP. with clutches VALVOLINE ATF UNIVERSAL type D 3990033323
OILS FOR PUMP:

Pump HIBON VALVOLINE EPG 220 3990033322
Pump WITTIG
(RFW - WPS - SLS) VALVOLINE HD SAE 30 3990033320
If it is a liquid loop pump (Wittig Aqualine or Sihi) there is no oil but rather lubricating grease.
OILS FOR PISTON PUMP:

Uraca pump VALVOLINE HP GL5 SAE 85W90 3990033319
Uraca valve VALVOLINE ULTRAMAX HLP46 3990033317
GENERAL PURPOSE OILS:

Pneumatic system lubricator VALVOLINE ETC HL 10 3990033325
Hydraulic system VALVOLINE ULTRAMAX HLP46 3990033317
Hydraulic system for Nordic countries VALVOLINE ULTRAMAX HVLP46 3990033318
Caprari pump on recycle VALVOLINE ULTRAMAX HVLP 32 3990033332
GREASE:
General purpose REPSOL GRASA LITICA ESPECIAL EP2/3 3990033324
Main shaft bearings BECHEM HIGH LUB LT2 EP 3990033335
Liquid loop pump VALVOLINE MARINE GREASE 3990056940
ANTIFREEZE:
For pumps
with rotors and liquid loop VALVOLINE ANTIFROST VA9001 3990031188
50
2.5 TABLE OF LUBRICATION
every every
PART TO LUBRICATE 50 hours 200 hours
of work of work
TANK
Tank tip-up hinge
Cylinder joints for tank lifting
Hinge for opening of rear bottom
Wedge closure (if present)
Handwheel closure (if present)
Pin for rotation of float indicator level
FRAME
Tank locking pin
SPOUT
Spout rotation turntable
Joints of hydraulic cylinders for raising arm
Hinge for raising arm
Hydraulic cylinder joints for extension
Bushes for movement of telescopic arm
UPPER SUCTION REEL

Arm rotation worm screw
Arm rotation turntable
Rotating joint between arm and tank
Wind-unwind chain
Arm raising hinge
Joints of hydraulic cylinders for raising arm
TILTING SUCTION HOSE REEL

Tilting rotation pins
Joints of hydraulic cylinders for tilting
Rotating joint between suction hose reel and its support
Hose clamp rotation pin
Suction hose reel wind-unwind chain
51
every every
PART TO LUBRICATE 50 hours 200 hours
of work of work
FRONT/REAR MAIN REEL / FLAG REELS

Rotating joints of reels
Reel traction chains
Worm screw of the automatic hose guide
Flag rotation upper bearing (only for flag reels)
Flag rotation lower bearing (only for flag reels)
Reel rotation shaft bearings
Automatic hose guide shaft bearing
Cursor on hose guide carriage
Flag rotation locking pin (only for flag reels)
SIDE REEL
Rotating joints of reels
Reel traction chains (only for hydraulic reels)
Worm screw of the automatic hose guide (only for reels with automatic
hose reel)
Rotation upper bearing (only for rotating lateral reel)
Rotation lower bearing (only for rotating lateral reel)
Automatic hose guide shaft bearing (if present)
Cursor on hose guide carriage (if present)
Rotation locking pin (only for rotating lateral reel)
CAP RECY
Centrifugal filter support shaft rotation bushes
Internal filter paddle joint bushes
Internal filter rotation turntable
CAP BORA
Filter compartment upper cover hinge
Filter compartment cover wedge closure
52
P ART IV - ATTACHMENTS
B - FORM FOR OPERATOR TRAINING AT TIME OF VEHICLE DELIVERY
The purpose of this form is to certify that training has been provided to one or more OPERATORS by the
Cappellotto upon delivery of the vehicle to the client on the date…………………….
During training, all hazards present during use of the machine are pointed out.
Also explained are operation, checks, operating procedures for routing maintenance, alarms, emergencies,
and methods of signalling failures.
Topics covered Yes No

Method of positioning the machine
Vehicle starting system
Operating methods of hydraulic parts
Method of operation of electrical parts
Safety systems
Illustration of alarms
Troubleshooting of sources of alarms
Indication of hazards
List of prohibited operations
Generic hazards in use of machine
Description of work phases for various types of machinery
Signs/individual safety gear
Upon completion of training, the participant(s) shall declare that they possess all knowledge to use the
machine correctly and safety. Declaration i hereby made of complete understanding of instructions and
compliance with the instructions in the user's manual.
Name(s) of participant(s) in block letters Signature(s) of participant(s)
…………………………………………….. ……………………………………………..
…………………………………………….. ……………………………………………..
…………………………………………….. ……………………………………………..
Signature of instructor
……………………………………………..
53

Manual - Combi CL 2600

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Manual - Combi CL 2600

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USE AND

Equipment model: CAP COMBI CL 2600

THIS EQUIPMENT MUST BE USED ONLY FOR SUCTIONING LIQUIDS OR SLUDGE

FOR FURTHER INFORMATION CONTACT US

PART I - SAFETY ................................................................................................................ 8

PART II - INSTRUCTIONS FOR USE ............................................................................... 18

PART III - MAINTENANCE ............................................................................................... 39

PART IV - ATTACHMENTS .............................................................................................. 53

SCOPE OF MANUAL AND INSTRUCTIONS

COMPOSITION - METHOD OF CONSULTATION

This manual is composed of three parts.

This symbol identifies HIGH RISK.

PROCEDURES FOR ORDERING SPARE PARTS

HOW TO REQUEST TECHNICAL SERVICE

- General layout of the system;

TABLE OF INCLUDED COMPONENTS

MAIN MECHANICAL COMPONENTS

In the setup furnished to you, the part indicated below is:

Included Not included Component Model Serial number

1.1 Safety - General

These concepts were taken from standard ENV 1070 - Terminology:

Source of possible injury or damage to health.

(point 3.5 - EN 292 - part 1’~)

Any situation in which a person is exposed to danger(s).

(point 3.6 - EN 292 - part 1’~)

DANGEROUS FUNCTION OF A MACHINE:

(point 3.9 - EN 292 - part 1’~)

(point 3.7 - EN 292 - part 1’~)

(point 3.10 - EN 292 - part 1’~)

DANGERS AND RESIDUAL RISKS:

(point 5.5 - EN 292 - part 1’~)

QUALIFICATIONS OF SKILLED OPERATORS

- transport and movement of parts;

OPERATOR ASSIGNED TO USE OF THE MACHINE:

MECHANICAL MAINTENANCE TECHNICIAN:

1.3 Types of risk

Risks to safety or of accidents.

3. Risks to health and safety - transversal type

2 WARNINGS ON USE (SIGNS AND SIGNALS)

Signals on the vehicle include:

This indication identifies a generic danger that may be better illustrated in

c) Indications of requirement to use individual safety gear

d) Indications of Required Manoeuvre

3 ANALYSIS OF RISKS PRESENT IN THE USE OF THE VEHICLE

3.1 Definitions of main risks

c) Risks to health and safety - transversal type

3.2 Table of main risks and individual safety gear

Medium RISK PERSONS FALLING FROM THE VEHICLE

Medium RISK BEING STRUCK BY MOVING PARTS

High RISK Presence of noise emissions in various zones of the machinery

Where the side door is located (pump compartment cowling) if it is opened

3.3 Preventive measures to be taken during positioning, transfer and parking of

WORKING PHASE PREVENTIVE MEASURES

In particular, the following actions must be performed:

It is prohibited to position the machine at distances of less than 1 m from

WORKING PHASE PREVENTIVE MEASURES

Verbal manoeuvring signals must be used as set forth in European

When positioning the vehicle, comply with the instructions in the

In any case, please be advised of the following:

THIS EQUIPMENT MUST BE USED ONLY FOR SUCTIONING LIQUIDS OR SLUDGE

P ART II - INSTRUCTIONS FOR USE

1 CHECKS TO BE CARRIED OUT BEFORE STARTING

1.1 GENERAL CHECKS

WARNING: to ensure the proper functioning of all