Cavidyne, LLC Caviblaster 3040-D, Operation & Maintenance Manual

Page 1: ...CAVIDYNETM LLC 5077 Fruitville Rd Sarasota FL 34232 Phone 352 275 5319 www cavidyne com Operation Maintenance Manual Model 3040 D ...

Page 2: ...quipment Generates High Pressure Water Jet And Is Intended For Underwater Use Only Serious Personal Injury Or Death May Result From Improper Use Commercial Diver s Gear Should Be Used When Operating The Caviblaster System Offshore Unit Do Not Use Air Pressure In Excess Of 120 Psi 8 Bar When Starting The Equipment Serious Damage To The Equipment Will Occur CAUTION DO NOT USE THIS EQUIPMENT TO CLEAN...

Page 3: ...5 0 OPERATION 19 5 1 Preparing the Unit for Operation 19 5 2 Startup 20 5 3 Normal Operation 21 5 4 Adjusting the CaviBlaster for Maximum Performance 23 5 5 Recommendations for Effective Results 27 5 6 Shutting Down the CaviBlaster 28 6 0 MAINTENANCE 29 6 1 Basic Preventive Maintenance Recommendations 30 6 2 Diesel Engine Service 31 6 3 Pump Service 31 6 4 Inspection Cleaning of water inlet strain...

Page 4: ...s 13 Figure 4 2 Installation Guidelines 14 Figure 4 3 Gravity Feeding Source 16 Figure 5 1 Emergency Shut Down and Throttle Up Control 23 Figure 5 2 PTO Lever 25 Figure 5 3 Gun Pressure Calibration 26 Figure 5 4 Gun Position for Best Results 27 Figure 6 1 Water Filter Inspection Cleaning 32 Figure 6 2 Belt Inspection Tension 33 Figure 6 3 Zero Thrust Gun 34 This space intentionally left blank ...

Page 5: ...Outdoor enclosed or exposed See Section 4 for installation requirements Fuel Requirements Diesel fuel ASTM Grade No 1 D or 2 D or EN 590 Fuel Tank Capacity 50 Gallons 190 Liters Water Inlet Pressure Limits 0 PSI Atmospheric Pressure to 70 PSI Maximum 0 BAR to 4 8 BAR See Section 4 for further requirements Overall Unit Dimensions L x W x H 64 x 55 x 62 163 cm x 140 cm x 157 cm Maximum Pressure Hose...

Page 6: ...ero thrust gun uses a trigger operated valve to control 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 Defined As The Engine At Full Throttle Full Speed If Partially Throttled The Engine Will Stall Creating An Undesirable Running Condition For The Belt Drive System The CaviBlaster 3040 D power unit is a complet...

Page 7: ...Figure 2 1 CaviBlaster 3040 D General Features For more information on the CaviBlaster system please visit us at www caviblaster com ...

Page 8: ...wever that anyone attempting to use this manual must have good comprehension of how this equipment operates Further this manual can in no way replace the common sense of an individual If at any time this manual seems to contradict itself or common sense discontinue the procedure re read the section and seek assistance from CaviDyneTM or other personnel familiar with the operation of this equipment...

Page 9: ...f white space EOS will appear above the page number on the last page of each section 2 3 Scope This manual covers installation operation and maintenance of the CaviBlaster 3040 D It is essential that personnel who will operate and or service this equipment familiarize themselves with this manual Standard components such as the unit engine and pump are covered by the manufacturer s literature found...

Page 10: ...proficient in using this equipment Refer to the applicable section in this manual for the correct procedures prior to any installation setup or maintenance work 3 1 Personal Safety Operation of the CaviBlaster 3040 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 Opera...

Page 11: ...ction when the CaviBlaster system is in use If the diver is not wearing a diving helmet hearing protection is recommended CaviDyneTM suggest wearing vented earplugs such as Doc s Proplugs or equivalent 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 nails The gloves w...

Page 12: ...ue high pressure requirements Only replace parts with those recommended 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 left blank on ...

Page 13: ... and the shipping company If the unit will not be installed immediately provide adequate indoor storage to protect against damage The CaviBlaster power unit should be lifted from underneath the frame using the forklift channels or by using 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 ...

Page 14: ... 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 behind the unit and access from above to conduct service and repair work Take note of...

Page 15: ...ore unit Connect the air starter hose See Figure 2 2 8 Electric Start unit Connect battery terminals 9 Fill the fuel tank Use diesel fuel ASTM Grade No 1 D or 2 D or EN 590 or as specified in the Engine Manual located in the APPENDIX Engine And Or Pump Fluids May Have Been Removed For Shipment Check Fluid Levels Prior To Starting 4 3 1 Connecting the Water Source The CaviBlaster power unit can be ...

Page 16: ...driven self priming centrifugal 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 Forced inlet water condition using the centrifugal water pump or an outside water source capable of supplying at least 45 GPM 170 L M flow plus 50 at a maximum pressure of 70 PSI 4 8 BAR Gravity feeding w...

Page 17: ...urce It is important to keep the water source on when the engine is running or damage to the feed pump shaft seal will result Ensure That The Feed Hose Is Connected To The Inlet Connection And The Water Supply Is On Prior To Starting The Pressure Pump Failure To Supply Water To The Pressure Pump Will Cause Damage To The Pump To use gravity feed Locate the water supply tank so that the supply tank ...

Page 18: ... L M A minimum delivery of 45 GPM 170 L M is required to ensure that the pump is not starved of water If connecting to a gravity feed tank locate the tank outlet above the water inlet connection on the power unit to ensure a flooded suction line See Figure 2 2 This space left blank on purpose EOS ...

Page 19: ...ready for immediate use This should be completed after each use 1 Inspect the CaviBlaster power unit hoses JIC fittings and gun for any signs of damage 2 Inspect the inline strainer and filter cartridges to ensure that they are not clogged See Figure 6 1 Clean or change cartridge s if necessary 3 Check for proper engine oil level See engine Owner s Manual found in the Appendix Add lubricating oil ...

Page 20: ...igure 2 2 IN to activate the air starter If the engine does not start within 10 seconds turn the air supply off and wait at least 30 seconds before operating the air starter again Once the engine starts turn off the air supply to the air starter Warning air supply to the starter should not exceed 120psi 8 bar 4b Electric Starter units Disengage the PTO clutch Insert the key into the ignition switc...

Page 21: ...ormance Review The Safety Requirements For PPE And Safe Operation Before Proceeding 1 Startup the power unit as described in Section 5 2 2 Verify that the gun is properly connected and that the mechanical trigger is released 3 Confirm the pump system is fully primed with no air pockets visible in the clear supply lines 4 When the diver is ready to commence cleaning operations ensure that the gun i...

Page 22: ...ow will then direct to bypass 10 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 control to the idle position and pushing the PTO handle to the off position See Figure 5 2 Release the water pressure in the hose s by squeezing the gun trigger to the open or ON position See Figure 5 3 whi...

Page 23: ...uge situated between the pressure hose and the CaviBlaster gun the water pressure should be 4 000 psi 275 Bar with the gun submerged and the gun trigger in the open or ON position For best results repeat the calibration procedure if cleaning performance degrades or every 3 months at a maximum A Calibration Gauge Is Recommended With Every Unit Connect Between The End Of The Pressure Hose And The Wh...

Page 24: ...ttle the engine to full speed See Section 5 3 Hold the gun tight and observe the gauge See Figure 5 3 The power unit operator should turn the knob on top of the pressure regulating valve until pressure reads 4 000 psi 275 Bar on the test gauge set at the gun Turning the knob clockwise will increase the pressure and turning it counter clockwise will decrease the pressure To calibrate the pressure a...

Page 25: ... Are Rated For Maximum 5 000 Psi 345 Bar Pressures Above 5 000 Psi Could Result In Hose Failure Figure 5 2 PTO Lever This space left sblank on purpose PTO Lever Pull to engage clutch push to disengage clutch ...

Page 26: ...Test gauge Main hose Figure 5 3_ _ Gun Pressure_ _ Calibration Whip hose ...

Page 27: ...nches 5 12 cm away from the surface to be cleaned and at a 25 to 45 degree angle to the surface being cleaned See Figure 5 4 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 ...

Page 28: ...See Figure 5 1 4 If using force feed from an alternate source or if using gravity feed shut off the supply of water to the pressure pump 5 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 6 It is now safe to remove the gun from the water 7 Flush the system and rinse the power unit with fresh water at ...

Page 29: ...Work Only Replace Parts With Those Supplied Or Approved By Cavidynetm Use Of Any Other Parts May Lead To Equipment Failure And Severe Personal Injury Caviblaster Must Be Flushed And Rinsed With Fresh Water After Each Use In Sea Water Failure To Flush And Rinse The Unit Will Result In Premature Wear And Tear On The Components And Decreased Service Life Failure To Flush And Rinse The Unit Can Cause ...

Page 30: ... 3 X Replace pump oil 4 X Replace engine fan and feed pump belts 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 and filter change is after 50 hours of operation The...

Page 31: ...se holds 4 2 qt 4 L of SAE 30 ISO 68 viscosity non detergent lubricating oil See pump manufacturer s literature found in the APPENDIX for further information 6 4 Inspection Cleaning of water inlet strainer The CaviBlaster 3040 D is equipped with a water strainer before the water feed pump and a media sock filter system between the feed pump and the pressure pump The process for inspecting and clea...

Page 32: ...p retainers 2 Lift out and inspect for debris and or damage Clean by flushing with clean water or replace sock media 3 Inspect cover o ring for damage replace if necessary 4 Replace cap and tighten securely Figure 6 1 Water Filter Inspection Cleaning Water strainer locations ...

Page 33: ...ke off Full Engine Speed Is Required For Proper Operation Of The Gun To inspect the belt 1 Remove the belt guard cover supported by bolts 2 If belts need tightening use the tightening nut to adjust 3 Release the bolts holding the pump rails 4 Adjust Belt tension 5 Tighten pump rail bolts 6 Replace belt guard cover Figure 6 2 Belt Inspection tension Belt guard cover ...

Page 34: ...ompletely submerged 3 If the gun will not be used for a period of several days remove the super swivel from the gun handle 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 and minimize the possibility of corrosion or mineral crystals forming that would fr...

Page 35: ...k with appropriate antifreeze solution 2 Insert the suction hose into the antifreeze tank 3 Start the unit and make sure the pump is primed 4 Attach a minimal amount of pressure hose and direct the outlet of the hose into the antifreeze tank 5 Run the unit without gun attached until antifreeze comes out of the end of the hose for 10 seconds 6 Stop the unit Following this procedure will ensure that...

Page 36: ... inlet water supply is functioning and the system is fully primed Ensure that the power unit is not located too far above the water level exceeding the capacity of the feed pump Check that feed pump and inlet water strainers are clear Check for leaks in the water lines Check for an air lock in the water inlet lines Verify that the feed pump is delivering water Pump mechanical failure Drive belt fa...

Page 37: ... from water with the system at operating pressure and trigger in the closed or OFF position If water is leaking out of the barrel or handle the trigger valve assembly should be replaced Check cavitation and zero thrust nozzles for foreign particles Visual inspection Insert a small wire into nozzle orifices to check for obstruction s Remove trigger valve assembly and backflush with compressed air o...

Page 38: ...t filter bag multifilament Nylon KO100K4S 1 1 Engine air filter P828889 2 1 Engine oil filter HH1C0 32430 1 1 Engine fuel filter 16631 42560 1 1 Engine fan belt 17112 97010 2 1 Pressure pump drive belt Banded 6 B59 Banded 2 1 Feed pump drive belt BP46 1 1 Pump seal kit 5019 0211 00 1 1 Pump valve kit 5025 0044 00 1 1 Valve seal kit 5019 0139 00 1 1 Pressure regulating unloader 8116 2543 00 1 1 Pre...

Page 39: ...09 290 Pump Spec Sheet Pump Service Manual Crankcase Oil Data Sheet and MSDS Regulating Unloader Model VB 200 280 Relief Safety Valve Model VS 450 300 Spec Sheet PACER Pumps Centrifugal Series I Pump Exploded View Pump Capacity Curve Suttner Trigger Gun Model ST 3600 Gun Schematic Drawing Warranties Cavidyne Kubota Engines NACD Comet HPP Suttner EOS ...