CAVIDYNE CaviBlaster 2828-D, Operation And Maintenance Manua

Page 1: ...CAVIDYNETM LLC 5077 Fruitville Rd Suite 109 157 Sarasota FL 34232 Phone 352 275 5319 Operation Maintenance Manual Model 2828 D ...

Page 2: ...y with instructions in this manual Please read entire manual carefully before use The CaviBlaster 2828 must only be operated and maintained by trained personnel 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 ...

Page 3: ... 17 4 3 1 Connecting the Battery Terminals 17 4 3 2 Connecting the Water Source 18 5 0 OPERATION 22 5 1 Preparing the CaviBlaster for Operation 22 5 2 Startup of the CaviBlaster 23 5 3 Normal Operation 24 5 4 Adjusting the CaviBlaster for maximum performance 26 5 5 Recommendations for Effective Results 29 6 0 MAINTENANCE 32 6 1 Basic Preventive Maintenance Recommendations 33 6 2 Diesel Engine Serv...

Page 4: ...e 4 1 Lifting Guidelines 15 Figure 4 2 Installation Guidelines 16 Figure 4 3 Reconnecting the Battery Terminals 18 Figure 4 4 Gravity Feeding Source 19 Figure 5 1 Engine Emergency Shut Down and Throttle Control 26 Figure 5 2 Gun Pressure Calibration 28 Figure 5 3 Gun Position for Best Results 30 Figure 6 1 Inspection Cleaning Water Strainer Filter 35 Figure 6 2 Inspection Belt tension 36 Figure 6 ...

Page 5: ...Engine 51 HP 38kW Diesel Powered Kubota V2403 Turbo Installation Environment Outdoor enclosed or exposed See Section 4 for installation requirements Fuel Requirements Diesel fuel ASTM Grade No 1 D or 2 D 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 ...

Page 6: ...ter to dump through the dump valve in the handle of the gun When operating with two 1428 Zero Thrust guns closing the trigger valve of one gun allow the other gun to function normally while the flow for the closed gun goes to bypass at the unit Closing both trigger valves causes the power unit to go into full bypass mode unloading the engine and the pump The DoubleDome is also equipped with a trig...

Page 7: ...email sales cavidyne com or call 1 352 275 5319 2828 Zero Thrust Dump Gun Flow Capacity 28 GPM 106 LPM 1428 Zero Thrust Gun Flow Capacity 14 GPM 53 LPM Per Gun DoubleDome Flow Rate 28 GPM 106 LPM Figure 2 1 CaviBlaster 2828 Cleaning Options ...

Page 8: ... cavidyne com or call 1 352 275 5319 Pressure pump Suction filter Lifting eyes Forklift slots Control panel See Fig 2 2 Figure 2 2 CaviBlaster 2828 General Features For more information on the CaviBlaster system please visit us at www caviblaster com ...

Page 9: ... Figure 2 3 CaviBlaster 2828 Control Panel Feed pump switch pull on push off Feed pump electrical connection Engine ignition Throttle cable control Push red button to release Twist black knob to lock Pressure hose 3 4 JIC By pass hose Dump 1 cam lock Feed or suction hose 1 1 2 cam lock ...

Page 10: ...e always 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 2 3 Scope This...

Page 11: ...9 2 4 Terms and Abbreviations CCW Counterclockwise CW Clockwise EOS End of Section GPM Gallons Per Minute HP Horsepower LPM Liters Per Minute PPE Personal Protective Equipment PSI Pounds Per Square Inch without suffix assumed to be gauge pressure This space intentionally left blank EOS ...

Page 12: ...d in depth before operating or servicing this equipment Service work should only be performed by individuals who are 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 2828 underwater cleaning system must only be attempted by commercial dive...

Page 13: ...2 Personal Protective Equipment Always wear appropriate Personal Protective Equipment PPE when operating this equipment Personnel operating or working in the vicinity of the power unit should wear appropriate hearing protection 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...

Page 14: ...assembly were specifically designed or selected to safely meet the unique 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 This space intentionally left blank Unauthorized replacement o...

Page 15: ... 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 16: ... cooling air flow and for venting of engine exhaust Figure 4 2 Installation Guidelines 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 abo...

Page 17: ... 3 8 Connect the electric feed pump See Section 4 3 2 and Figure 2 3 9 Fill the fuel tank using diesel fuel ASTM Grade 1 D or 2 D or EN 590 See fuel requirements in Engine Manual located in the APPENDIX 4 3 1 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 Remove the engine i...

Page 18: ...he Water Source The CaviBlaster power unit can be used with seawater or fresh water It must be flushed with fresh water for 1 2 minutes after each use in seawater to ensure long service life The CaviBlaster 2828 must be flushed and rinsed with fresh water after every use in seawater 1 Remove Strap Main Battery Location 2 Lift Off Cover 3 Connect Terminals Negative Black Positive Red ...

Page 19: ...trol panel See Figure 2 3 A 12V electric bilge 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 supplied electric water pump or an outside water source capable of supplying at least 28 GPM 106 LPM at a maximum pressure of 70 PSI 4 8 BAR Gravity f...

Page 20: ...e operating as this will discharge the battery To use force feed from an alternate source Turn the engine ignition key to OFF See Figure 2 3 When feeding the CaviBlaster with an alternate water source the source must supply water at a volume of greater than 28 GPM 106 LPM at a maximum pressure of 70 psi 4 8 BAR Connect a 1 1 2 cam lock socket on the water supply hose to the water inlet connection ...

Page 21: ...adequate water is supplied to the water supply tank to maintain the water level several 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 pressure pump flow of 28 GPM 106 LPM A min...

Page 22: ...ould be completed in advance so that the unit is always 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 cartridge to ensure they are not clogged See Figure 6 1 Clean strainer or replace filter cartridge if necessary 3 Check for proper engine oil level See...

Page 23: ...hearing protection prior to starting engine 5 Insert the key into the ignition switch on the ignition panel See Figure 2 3 Turn the key clockwise to start the engine If the engine does not start within 10 seconds return the key to the OFF position and wait at least 30 seconds before operating the starter again Once the engine starts release the key allowing it to return to the ON or running positi...

Page 24: ...ation before proceeding 1 Verify that the gun s or DoubleDome are properly connected and the gun mechanical trigger is released and the DoubleDome ball valve is closed 2 When the diver ROV operator is ready to commence cleaning operations ensure that the gun DoubleDome is submerged in water Ensure that the power unit operator and other persons working in the vicinity of the power unit wear appropr...

Page 25: ...zles to function 8 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 and turning the ignition key to the OFF position See Figure 5 1 Then release the water pressure in the hose s by squeezing the gun trigger to the open or ON position See Figure 5 3 while und...

Page 26: ...ubmerged and the gun trigger in the open or ON position For best results repeat this calibration procedure if cleaning performance degrades or every 3 months at a maximum To calibrate the pressure at the zero thrust gun follow the procedure below Stop the power unit and pull the gun trigger to discharge any residual pressure in the hose lines Disconnect the gun DoubleDome with its whip hose from t...

Page 27: ...ight and observe the calibration gauge See Figure 5 2 The power unit operator should turn the knob on top of the pressure regulating valve until pressure reads 2 800 psi 193 BAR on the calibration gauge Turning the knob clockwise will increase the pressure and turning it counter clockwise will decrease the pressure To calibrate the pressure at the CaviBlaster power unit the water pressure at the p...

Page 28: ...Page 28 43 For more information please email sales cavidyne com or call 1 352 275 5319 Figure 5 2 Gun Pressure Calibration Calibration gauge Whip hose Main hose Whip hose Gun trigger Calibration gauge ...

Page 29: ...sets the DoubleDome flat on the surface to be cleaned and moves it in the desired direction 3 The most efficient operating technique is to hold the nozzle 2 5 inches 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 3 The diver needs to observe the shape of the cavitating jet cone At greater depths the higher ambient pressure will ...

Page 30: ...Page 30 43 For more information please email sales cavidyne com or call 1 352 275 5319 Figure 5 3 Gun Position for Best Results This space intentionally left blank EOS ...

Page 31: ...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 If using a DoubleDome close the ball valve on the DoubleDome to stop the nozzles from rotating After turning off the ...

Page 32: ...y service work Only replace parts with those supplied or approved by CaviDyneTM Use of any other parts will void all warranties and 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...

Page 33: ...ions X Replace engine oil and oil filter 3 X Replace engine fuel filter X Replace engine air filter X Replace pump oil 4 X Replace engine fan belt 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 le...

Page 34: ...s The pump crankcase holds 89 oz 2 6 L of SAE 30 viscosity non detergent hydraulic oil See pump manufacturer s literature found in the APPENDIX for further information 6 4 Inspection Cleaning of Water Inlet Strainer and Filter The CaviBlaster 2828 is equipped with a water inlet strainer and a water inlet filter plus a strainer on the water feed pump suction The feed pump inlet strainer should be i...

Page 35: ...ilter head turn CCW See Figure 6 1 3 Pull filter bowl DOWN 4 Remove the filter element 5 Inspect the filter element and flush any debris clean with clean water 6 Replace with a new filter element if necessary 7 Push the filter element back into housing 8 Push the filter bowl back onto filter head 9 Turn the housing CW by hand to tighten Figure 6 1 Inspection Cleaning Water Strainer Filter Water fi...

Page 36: ...has a centrifugal clutch with 1 400 RPM engagement speed FULL ENGINE SPEED IS REQUIRED FOR PROPER OPERATION OF BOTH THE CLUTCH AND THE GUN To inspect the belts 1 Remove the belt cover See Figure 6 2 2 If belts need tightening use the tightening nut to adjust See Figure 6 3 3 Release the bolts holding the pump rails 4 Adjust Belt tension 5 Tighten pump rails bolts 6 Close belt guard Figure 6 2 Insp...

Page 37: ...Page 37 43 For more information please email sales cavidyne com or call 1 352 275 5319 Figure 6 3 Inspection Belt tension This space intentionally left blank EOS Pump rail bolts Belt tension adjustment ...

Page 38: ... if it cannot be completely submerged make sure it is thoroughly sprayed or washed 4 If the DoubleDome cannot be completely submerged make sure it is thoroughly sprayed or washed 5 If the either of the guns or the DoubleDome 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 ...

Page 39: ...arger tank with appropriate antifreeze solution 2 Set the tank above the water inlet on the control panel 3 Connect the suction of the unit to the antifreeze tank 4 Start the unit and make sure the pump is primed 5 Attach a minimal amount of pressure hose and direct the outlet of the hose into the antifreeze tank 6 Run the unit without gun attached until antifreeze comes out of the end of the hose...

Page 40: ...eck that the bolt connecting the throttle cable to the throttle lever is tight 4 ENGINE SPEEDS UP BUT WATER DOES NOT GO OUT THE GUN Verify inlet water supply 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 inl...

Page 41: ...bly and backflush with compressed air or pressurized water 9 SMOKING BLACK EXHAUST FEW REASONS COULD CAUSE THIS The muffler clogged with soot or the spark arrestor plated been tightened too much on the top of the muffler is a nut and it should not be too tight Muffler configuration is not efficient in some atmospheric conditions Air filter is clogged or some other way restricting the air flow Fuel...

Page 42: ...rtridge 1 1 Inlet filter element 1 1 Engine air filter 2 1 Engine oil filter 1 1 Engine fuel filter 1 1 Timing belt 1 1 Alternator belt 2 1 Drive belt 1 1 Seal kit 04 KIT 139 1 1 Valve kit 04 KIT 142 1 1 Plunger rod o ring kit 1 1 Pressure regulating unloader repair kit 1 1 Relief valve repair kit 1 1 Trigger valve assembly repair kit 202700490 All parts can be ordered from CAVIDYNE TM LLC 5077 Fr...

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