Caviblaster 1325-D, Operation & Maintenance Manual

Page 1: ...CAVIDYNETM LLC 5077 Fruitville Rd Suite 109 157 Sarasota FL 34232 Phone 352 275 5319 Operation Maintenance Manual Model 1325 D ...

Page 2: ...nnel This equipment generates high pressure water and is intended for underwater use only Serious personal injury or death may result from improper use Commercial Diver s gear should be used to operate the CaviBlaster system CAUTION DO NOT USE THIS EQUIPMENT TO CLEAN SENSITIVE SURFACES as LED Lights Underwater Lights Electronic Equipment Etc Page 2 CaviBlaster 1325 D Operations Manual For More inf...

Page 3: ...7 5 1 OPERATION 20 5 2 Preparing the CaviBlaster for Operation 20 5 3 Startup of the CaviBlaster 21 5 4 Normal Operation 22 5 5 Adjusting the CaviBlaster for Maximum Performance 24 5 6 Recommendations for Effective Results 28 6 1 MAINTENANCE 31 6 2 Basic Preventive Maintenance Recommendations 32 6 3 Diesel Engine Service 33 6 4 Pump Service 33 6 5 Inspection Cleaning of Water Inlet Strainer 33 6 6...

Page 4: ...llation Guidelines 14 Figure 4 3 Reconnecting the Battery Terminals 16 Figure 4 4 Gravity Feeding Source 17 Figure 6 1 Inspection Cleaning Water Filter 35 Figure 6 2 Clean Dirty Inlet Water Filter 36 Figure 6 3 Zero Thrust Gun 37 This space intentionally left blank Page 4 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 5: ...r installation requirements Fuel Requirements Diesel fuel ASTM Grade No 1 D or 2 D or EN 590 Fuel Tank Capacity 13 Gallons 50 Liters Water Inlet Pressure Limits 0 PSI Atmospheric Pressure to 50 PSI Maximum 0 BAR to 3 5 BAR See Section 4 for further requirements Overall Unit Dimensions L x W x H 56 x 24 x 42 Maximum Pressure Hose Length 328 LF 100 meters of 1 2 12 7 mm diameter thermoplastic Power ...

Page 6: ...ntrol the water stream off and on If the valve is closed the power unit goes into bypass mode unloading the engine and the pump FULL LOAD is defned as the engine at full throtle full speed If partially throttled the engine will stall creating an undesirable running condition for the centrifugal clutch The CaviBlaster 1325 D power unit is a complete plug and play system built into a self supporting...

Page 7: ...Figure 2 1 CaviBlaster 1325 D General Features Page 7 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 8: ...Figure 2 2a CaviBlaster 1325 D Engine Ignition Box Page 8 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 9: ...Figure 2 2b CaviBlaster 1325 D Hose Connections Page 9 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 10: ...ays coincident When other sections are referenced the SECTION NAME will appear in italic caps The electronic version allows users to click on the section name or figure reference to jump to that section The words This space intentionally left blank will appear where there is more than 3 inches of white space EOS will appear above the page number on the last page of each section Scope This manual c...

Page 11: ...rotective Equipment PSI Pounds Per Square Inch without suffix assumed to be gauge pressure This space intentionally left blank EOS Page 11 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 12: ...pplicable section in this manual for the correct procedures prior to any installation setup or maintenance work Personal Safety Operation of the CaviBlaster 1325 D underwater cleaning system must only be attempted by commercial divers or other personnel who have been trained in its use Appropriate protective equipment should always be worn Operation of the system without the proper equipment and t...

Page 13: ...iver is not wearing a diving helmet hearing protection is recommended CaviDyneTM suggest wearing vented earplugs such as Doc s Proplugs for diver hearing protection The operators of the CaviBlaster system should always wear neoprene or heavy rubber gloves to provide protection to the hands and in particular to the fingernails The gloves will absorb most of the energy produced by bursting cavitatio...

Page 14: ...mmended by or supplied by CaviDyneTM Any unapproved modifications will void the equipment warranty Unauthorized modification or part substitution can result in serious personal injury or property damage Unauthorized replacement of any part may lead to catastrophic equipment failure and serious personal injury This space intentionally left blank EOS Page 14 CaviBlaster 1325 D Operations Manual For ...

Page 15: ...y If the unit will not be installed immediately provide adequate indoor storage to protect against damage The CaviBlaster power unit is designed to work with forklifts and also can be lifted with the lifting eyes provided on top of the frame Verify that lifting equipment is rated for the weight listed in Section 1 0 UNIT SPECIFICATIONS and that the unit is stable before lifting Figure 4 1 Lifting ...

Page 16: ...enting of engine exhaust See Figure 4 2 below Installation location must be a level surface able to safely support the unit weight listed in Section 1 0 UNIT SPECIFICATIONS Orient unit to allow unrestricted access to the hose connection plate and control panel located on the front of the unit Allow a minimum of three feet around the unit and access from above to conduct service and repair work Tak...

Page 17: ...he Engine Manual located in the APPENDIX Engine and or pump fluids may have been removed for shipment Check fluid levels prior to starting Connecting the Battery Terminals For shipping purposes the battery terminals have been disconnected To reconnect the battery reference Figure 4 3 and the procedure below 1 Ensure the ignition is turned OFF and the keys are removed 2 Open the battery box by loos...

Page 18: ...Figure 4 3 Reconnecting the Battery Terminals Page 16 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 19: ...p valve s to stick in the open position This will prevent the system from producing the correct operating pressure The feed water inlet connection is located on the control panel See Figure 2 2 An electric submersible water pump is supplied to provide positive inlet water pressure to the main pressure pump Two water supply conditions are acceptable for the CaviBlaster power unit a Forced inlet wat...

Page 20: ... feed pump is not required Use a hose with a diameter of at least 1 1 4 to connect the water tank to the power unit This space intentionally left blank Page 18 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 21: ...Figure 4 4 Gravity Feeding Source Page 19 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 22: ...d from an alternate source Turn the engine ignition to OFF See Figure 2 2 When feeding the CaviBlaster with an alternate water source the source must be capable to supply water at a volume of greater than 150 of the main pressure pump flow rating 20 GPM 76 LPM at a maximum pressure of 50 PSI 3 5 BAR Connect a 1 1 4 cam lock socket on the water supply hose to the water inlet connection See Figure 2...

Page 23: ... inches above the bottom of the tank Failure to maintain an adequate water level in the supply tank could starve the pressure pump of water causing damage to the seals or other components of the pressure pump Ensure that the water source can reliably deliver the maximum pump flow of 150 of the main pressure pump flow rating 20 GPM 76 LPM A minimum flow of 20 GPM 76 LPM is recommended to ensure tha...

Page 24: ...should be completed after each use 1 Inspect the CaviBlaster power unit hoses fittings and gun for any signs of damage 2 Inspect the inline strainer to ensure that it is not clogged See Figure 6 1 Clean if necessary 3 Check for proper engine oil level See engine Owner s Manual found in the Appendix Add lubricating oil SAE 10W40 if necessary 4 Check for proper pressure pump oil level See pump Owner...

Page 25: ...ribed in Section 4 2 Verify that all hoses are installed correctly 3 Verify that the gun is properly connected and the mechanical trigger is released 4 Apply appropriate hearing protection prior to starting engine DO NOT THROTTLE UP THE ENGINE UNTIL THE DIVER IS READY FOR UNDERWATER OPERATION The engine must be run at full throttle full speed If partially throttled the engine will stall creating a...

Page 26: ... full throttle Less than full throttle will result in reduced or no cavitation Review the safety requirements for PPE and safe operation before proceeding 1 Ensure that all hoses are connected properly 2 Connect the gun to the high pressure hose and unroll sufficient length of hose to reach the operating location 3 When the diver is ready to commence cleaning operations ensure that the gun is subm...

Page 27: ... to lock it See Figure 5 1 8 Activate the cleaning cavitation stream by squeezing the trigger to the open or ON position See Figure 5 3 Release trigger to stop the water flow and direct to bypass 9 If the diver operating the unit must be replaced or the cleaning operation must be interrupted or terminated disengage the pressure pump by pushing the throttle lever in to the idle position See Figure ...

Page 28: ...m the main hose line Attach the calibration gauge and tighten the JIC connections Submerge the gun Because of the danger of the operator coming in contact with either of the water streams from the cavitating or zero thrust nozzles CaviDyneTM does NOT recommend calibrating the gun out of the water Use extra care to avoid both water streams if doing so Ensure that both the cavitation and zero thrust...

Page 29: ...of pressure hose the pressure gauge located next to the pump should indicate 2 500 psi 172 BAR Pressure adjustments are made by turning the knob on top of the pressure regulating valve in the same manner as described above DO NOT ADJUST THE PRESSURE AT THE GUN TO MORE THAN 2 500 psi HIGHER PRESSURE WILL NOT IMPROVE PEFORMANCE PUMP AND HOSES ARE RATED FOR 2 500 PSI PRESSURES ABOVE 2 500 PSI COULD R...

Page 30: ...Figure 5 2 Gun Pressure Calibration Page 28 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 31: ...be cleaned and at a 25 to 45 degree angle to the surface being cleaned See Figure 5 3 The diver needs to observe the shape of the cavitating jet cone At greater depths the higher ambient pressure will cause the jet cone to be shorter The widest zone of the cone is the most efficient part of the cavitating jet Placing the nozzle closer than 2 inches 5 cm from the surface being cleaned will not allo...

Page 32: ...Figure 5 3 Gun Position for Best Results This space intentionally left blank Page 30 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 33: ...ressure pump Shut off the engine by turning the key counter or anti clockwise or to the OFF position See Figure 2 1 Squeeze the gun trigger to the open or ON position See Figure 5 3 to release the water pressure remaining in the hose s while the gun is submerged It is now safe to remove the gun from the water Flush the system and rinse the power unit with fresh water at the end of the day This spa...

Page 34: ...e been properly trained Review this manual especially Section 3 0 SAFETY INFORMATION prior to performing any service on this equipment This space intentionally left blank Page 32 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 35: ...d set injectors X Replace pump oil 4 X Check pump valves and seals for wear change if necessary X Whichever occurs first 1 If any hose damage if found replace hose immediately 2 Remove gun from water with system at operating pressure and trigger in the closed or OFF position If water is leaking out of barrel or handle the valve is worn and should be replaced 3 The initial oil change is after 50 ho...

Page 36: ...oz 1 3 L of SAE 30 viscosity non detergent hydraulic oil See pump manufacturer s literature found in the APPENDIX for further information Inspection Cleaning of Water Inlet Strainer The water inlet strainer should be inspected after each use of the CaviBlaster 1325 D To inspect and clean this strainer follow the procedure below 1 Isolate or disconnect the water source from the inlet connection to ...

Page 37: ...Figure 6 1 Inspection Cleaning InLet Water Strainer Page 35 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 38: ...y InLet Water Strainer FAILURE TO CLEAN THE STRAINER BEFORE OPERATION WILL RESULT IN PRESSURE LOSS EOS Page 36 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 39: ... the gun will not be used for a period of several days remove the whip hose from the super swivel and with the gun turned upside down pour approx 5ml of lubricating oil into the water inlet while opening and closing the trigger This will allow oil to reach the positioning pin and valve cone to minimize the possibility of corrosion or mineral crystals forming that would freeze the pin or valve cone...

Page 40: ...mp into the antifreeze tank Start the unit and make sure the pump is primed Attach a minimal amount of pressure hose and direct the outlet of the hose into the antifreeze tank Run the unit without gun attached until antifreeze comes out of the end of the hose for 10 seconds Stop the unit Following this procedure will ensure that all the critical system components exposed to water have been flushed...

Page 41: ...ise compromised splices and connections that may increase electrical resistance and reduce power to operate and reduce the electrical feed pump performance Ensure that the power unit does not exceed the lif capacity of the feed pump max 5 to 6 feet lif Verify that the feed pump is sufciently submerged to prevent drawing air into the system which can cause signifcant damage the pressure pump and ot...

Page 42: ...or unloader failure 6 WATER IN CRANK CASE OF PRESSURE PUMP Check the pump seals for damage feed water source supplied at greater than 50 psi 3 bar can force water past the seals and damage the seals and starving the pressure pump of water can overheat and damage the seals Check the plungers for cracks Check the plunger rod O ring for damage 7 GUN IS NOT CLEANING PROPERLY Verify that the system is ...

Page 43: ...LC 6441 19th Street East Building C Sarasota FL 34243 Phone 352 275 5319 Email support cavidyne com www caviblaster com EOS Page 41 CaviBlaster 1325 D Operations Manual For More information please email sales cavidyne com or call 1 352 275 5319 ...

Page 44: ...e com or call 1 352 275 5319 Kohler Diesel Engine Udor Pump Udor Pressure Regulating Unloader Relief Valve Model UB 402 Suttner Small Trigger Gun Model ST 2720 Engine Spec Sheet Engine Owner s Manual Engine Work Shop Manual Engine Troubleshooting Guide Pump Spec Sheet Pump Exploded View Pump Dimensions Pump Service Guide Pump Torque Specs Valve Spec Sheet Gun Schematic Drawing ...