2022-C - CaviDyne
Contents
1. for maximum performance The pressure at the nozzle of the zero thrust lance has to be maintained within certain limits to achieve cavitation and for best performance results If using a calibration pressure gauge situated between the pressure hose and the CaviBlaster lance the water pressure should be 2 200 psi 152 bar with the lance submerged and the lance 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 A CALIBRATION GAUGE IS RECOMMENDED WITH EVERY UNIT CONNECT BETWEAN THE END OF THE THERMOPLASTIC HOSE AND THE WHIP HOSE OR LANCE To calibrate the pressure at the zero thrust lance follow the procedure below Stop the power unit and pull the lance trigger to discharge any residual pressure in the hose lines Disconnect the lance with its whip hose from the main hose line Attach the calibration gauge and tighten the JIC connections Submerge the lance Because of the danger of the operator coming in contact with either of the water streams from the cavitating or zero thrust nozzles Cavidyne does NOT recommend calibrating the lance out of the water Use extra care to avoid both water streams if doing so Ensure that both the cavitation and zero thrust nozzles are pointed away from the diver s or operator s hands arms and body Start the power unit See Section 5 2 Pull the lance trigger to the2. Gainesville FL 32635 U S A Phone 352 275 5319 Page 22 40 EI GAVIBLASTER 2022 6 OPERATION amp MAINTENANCE MANUAL CAVIBLAS TER 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 See Figure 5 1 and then release the water pressure in the hose s by squeezing the lance trigger to the open or ON position See Figure 5 3 while under water Revert back to step 3 of the operating instructions when the diver or replacement is ready to continue cleaning Although the CaviBlaster system is safe to use when submerged in water the system generates a high pressure up to 2 200 psi 152 bar water stream which can cause injury when the lance is out of the water ALWAYS keep the lance submerged when the pressure pump is engaged Push on the red j Emergency engine knob for emergency 3 shut down knob engine shut down twist and pull the red knob out to release engine shut down Push on the red knob to release pull the cable all the way out and twist to lock Throttle cable knob Figure 5 1 Engine Emergency Shut Down and Throttle Control 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 23 40 Oe GAVIBLASTER OPERATION amp MAINTENANCE MANUAL CAVIBLASTER 5 4 Adjusting the CaviBlaster
3. 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 centrifugal clutch The CaviBlaster 2022 power unit is a complete plug and play system built into a self supporting frame that allows quick deployment and or installation of the unit Water can be supplied from either a pressurized source directly from the natural source via an electric booster pump supplied with the power unit or from a gravity storage feed tank The unit is equipped with many features to maintain operator safety while operating at pressures of 2 200 psi 152 bar 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 6 40 De GAVIBLASTER 2022 6 OPERATION amp MAINTENANCE MANUAL CaAVIBLASTCR For more information on the CaviBlaster system please visit us at www caviblaster com 3 Fuel cap Lifting eyes SG Fuel tank Pulsation dampener Fuel level gauge Relief valve Control panel Pressure pum PD see Figure 2 2 Pressure regulator Suction filter Forklift slots Figure 2 1 CaviBlaster 2022 General Features 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page
4. 7 40 De GAVIBLASTER 2022 6 OPERATION amp MAINTENANCE MANUAL es Feed pump electrical FEED PUMP PUSH O POGGGE e comers E vy BF lt Engine ignition control panel WATER INLET 3 gt Emergency engine shut down Feed pump switch pull on push off Throttle cable control push red button to release twist black knob to lock Feed or suction hose 1 74 cam lock By pass hose 1 cam lock WARNING Even though the CaviBlaster system is safe to use when submerged in water it generates a high pressure up to 2 200 psi water stream which can cause injury when out of the water ALWAYS keep the lance submerged when the pressure pump is on Pressure hose 34 JIC Figure 2 2 CaviBlaster 2022 Control Panel 2 1 Using this Manual version 1 2 Every attempt has been made to ensure that this documentation is complete and accurate at the time of publication It is imperative however 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 CaviDyne or other personnel familiar with the operation of this equipment 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635
5. This space intentionally left blank 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 25 40 L NS CAVIBLASTER 20226 OPERATION amp MAINTENANCE MANUAL CAVIBLAS TER 5 8 Whip hose Main hose Calibration gauge Whip hose al c a KI Pi Ex 3598 TA AGLOBAL HOS Figure 5 2 Lance Pressure Calibration 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 26 40 Oe GAVIBLASTER OPERATION amp MAINTENANGE MANUAL CAVIBLASTER 5 5 Recommendations for Effective Results Once the engine is throttled up to operating speed and the water trigger is pulled the diver has to find the most effective distance between the lance nozzle and the surface being cleaned When the diver is ready to commence cleaning operations ensure that the lance trigger is in the open or ON position Figure 5 3 the lance is submerged in the water and the feed pump is operating prior to throttling up the engine Ensure that the power unit operator and other people working in the vicinity of the power unit wear appropriate hearing protection when the engine is running 1 Engage the pressure pump by pulling the engine throttle lever Figure 5 1 to the operating speed position fully extended to engage the centrifugal clutch Tighten the thumb screw to hold throttle in operating sp
6. may have been removed for shipment Check fluid levels prior to starting 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 Push IN the Emergency Stop button located on the front control panel See Figure 2 2 2 Open the battery box by loosening the strap and removing the cover 3 Connect the battery terminals as follows RED to positive terminal BLACK to negative terminal 4 Tighten the terminal screws securely 5 Replace the battery cover and secure with strap 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 15 40 Oe CAVIBLASTER 2008 6 OPERATION amp MAINTENANCE MANUAL CAVIBLASICH 1 Remove Strap Positive Red Negative Black Main Battery Location 3 Connect Terminals Figure 4 3 Reconnecting the Battery Terminals 4 3 2 Connecting the 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 2022 must be flushed and rinsed with fresh water after every use in seawater 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 16 40 EI GAVIBLASTER OPERATION amp MAI
7. open or ON position See Figure 5 3 Throttle the engine to full soeed See Section 5 3 Hold the lance tight 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 2 200 psi 152 bar on the calibration gauge Turning the knob clockwise will increase the pressure and turning it counter clockwise will decrease the pressure 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 24 40 Oe GAVIBLASTER OPERATION amp MAINTENANCE MANUAL CAVIBLASTER To calibrate the pressure at the CaviBlaster power unit the water pressure at the power unit will need to be higher to account for sidewall friction loss in the pressure hose The pressure at the pump should be 2 200 psi 152 bar plus 0 5 psi per foot 0 11 bar per meter of thermoplastic pressure hose For example if using the CaviBlaster with 100 feet 30 meters of pressure hose the pressure gauge located next to the pump should indicate 2 250 psi 155 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 LANCE TO MORE THAN 2 200 PSI HIGHER PRESSURE WILL NOT IMPROVE PEFORMANCE PUMP AND HOSES ARE RATED FOR 2 500 PSI PRESSURES ABOVE 2 500 PSI COULD RESULT IN PUMP AND OR HOSE FAILURE
8. psi Remove the lance 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 or pressurized water This space intentionally left blank EOS 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 38 40 Oe GAVIBLASTER OPERATION amp MAINTENANCE MANUAL CAVIBLASTER 9 0 REPLACEMENT PARTS RECOMMENDED QTY USED PER PART ORDER QTY ASSEMBLY PART DESCRIPTION NUMBER 1 1 Feed pump base plate strainer 54274 1 1 Inlet strainer cartridge 3260 02 1 1 Engine air filter ED2175 165 S 2 1 Engine oil filter ED2175 285 S 1 1 Engine fuel filter ED2175 288 S 1 1 Timing belt ED2440 338 S 1 1 Alternator belt ED2440 308 S 2 1 Drive belt 2BX47 1 1 Pump seal kit 31280 2 2 Pump valve kit 31285 1 1 Pressure regulating unloader repair kit UB 402 K 1 1 Relief valve repair kit UB 402 K 1 1 Trigger valve assembly repair kit 20 3300 490 All parts can be CAVIDYNE LLC ordered from PO Box 358628 Gainesville FL 32635 USA Phone 352 275 5319 Email support c
9. to the engine has been disconnected See Figure 2 2 Connect the cam lock socket on the 1 1 4 clear PVC feed hose to the water inlet connection on the control panel See Figure 2 2 Connect the electrical plug on the feed pump power cable to the matching receptacle on the control panel See Figure 2 2 Submerse the feed pump into the water source Release the Emergency Engine Shut Down button Pull the feed pump ON OFF switch out to activate the feed pump See Figure 2 2 It is important not to operate the feed pump for long periods of time without the engine 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 2 Push IN the Emergency Engine Shut Down button to ensure that power to the engine has been disconnected See Figure 2 2 When feeding the CaviBlaster with an alternate water source the source must supply water at a volume of greater than 20 gallons 75 liters per minute at a maximum of 70 psi 4 8 bar Connect a 1 1 4 cam lock socket on the water supply hose to the water inlet connection on the control panel See Figure 2 2 Turn on the alternate water source Release the Emergency Engine Shut Down button 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 to the pressure pump will cause damage to the pump 2010 O a
10. E IN LAVIBLASTICPR CAVIDYNE LLC P O Box 358628 Gainesville FL 32635 Phone 352 275 5319 Web Site www caviblaster com AANA OMR S ULA VIN UTEINAVNIGLE UMULAVNIEHAVE Model 2022 C EI CAVIBLASTER 2022 OPERATION amp MAINTENANCE MANUAL CAVIBLASICHR CaviDyne LLC is not responsible for damages or injuries resulting from a failure to comply with instructions in this manual Please read entire manual carefully before use The CaviBlaster 2022 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 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 2 40 Oe GAVIBLASTER 2022 6 OPERATION amp MAINTENANCE MANUAL CAVIBLAS TER TABLE OF CONTENTS 1 0 UNIT SPECIFICATIONS BAKAT 5 2 0 GENERAL DESCRIPTION a NAG NAAN 6 2 1 Using this Manual EE 8 22 GE EE 9 2 3 SCOPE EE AA aa aa iaiia 9 2 4 Terms and Abbreviations suites 9 3 0 SAFETY INFORMATION eeneg ANA ANAN GEN aent 10 3 1 Personal EE 10 3 2 Personal Protective Equipment 11 3 3 Modification to the Equipment eiii 12 AD aR TION NA AA NAAN 13 4 1 Uncrating and Lifting E 13 4 2 Installation Loco magama KAKA dende LAG KALAN Aba NA 14 4 3 Initial Se
11. E 10W40 viscosity lubricating oil For detailed information on these routine maintenance requirements as well as other service recommendations please see the engine manufacturer s literature found in the APPENDIX 6 3 Pump Service The high pressure water pump requires minimal maintenance The pump oil should be checked on a regular basis The pump crankcase holds 84 oz 2 5 L of ISO 68 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 The water inlet strainer should be inspected after each use of the CaviBlaster 2022 To inspect and clean this strainer follow the procedure below 1 Isolate or disconnect the water source from the inlet connection to the power unit 2 Unscrew the filter housing turn CCW See Figure 6 1 Pull filter bowl DOWN Remove the strainer oO OI Push strainer back into housing N Push the bowl back onto filter housing Inspect the strainer and flush any debris clean with clean water Thread the housing nut CW by hand to tighten 8 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 32 40 Oe CAVIBLASTER 2022 OPERATION amp MAINTENANCE MANUAL CAVIBLASICR Unscrew filter housing Water strainer location Figure 6 1 Inspection Cleaning
12. NTENANCE MANUAL CAVIBLASTER Failure to flush and rinse the power unit after use in seawater will result in increased wear and tear on components and in decreased service life Failure to flush and rinse the unit can cause the pump 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 e Forced inlet water condition using the supplied electric water pump or an outside water source capable of supplying at least 25 GPM 95 LPM at a maximum pressure of 70 PSI 4 8 BAR e Gravity feeding water source See Figure 4 4 In this case the electric 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 Pump inlet must be below the tank bottom Water level Figure 4 4 Gravity Feeding Source 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 17 40 OL ANS CAVIBLAS TER To use the feed pump supplied with the system Turn the engine ignition key to OFF See Figure 2 2 Push IN the Emergency Engine Shut Down button to ensure that power
13. 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 position Run the engine at idle speed for a minimum of 20 seconds 20 at operating temperatures above 41F 5C For lower operating temperatures run engine at idle speed for a minimum of one minute 1 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 an undesirable running condition for the centrifugal clutch 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 21 40 EI GAVIBLASTER OPERATION amp MAINTENANGE MANUAL CAVIBLASTER 5 3 Normal Operation Normal operation of the CaviBlaster system is defined as user control of water flow via the lance trigger Control of the power unit from the lance trigger is accomplished by a mechanical shut off valve in the lance Should a problem develop with the control valve discontinue using the CaviBlaster until fixed The CaviBlaster 2022 power unit is designed to operate in two modes idle and full throttle Less than full throttle will result in malfunction of the belt drive system and the performance of the centrifugal clutch Review the safety requirements for PPE and safe operation befor
14. U S A Phone 352 275 5319 Page 8 40 Oe GAVIBLASTER OPERATION amp MAINTENANCE MANUAL CAVIBLASTER 2 2 Conventions The first time a component is mentioned it is typically followed by a figure reference e g Emergency Stop button See Figure 2 1 Figure numbers and section numbers are 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 manual covers installation operation and maintenance of the CaviBlaster 2022 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 in the Appendix 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 EOS 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Pa
15. 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 frequently serviced areas such as the engine and fuel tank Fuel tank Engine exhaust filling port lower part Allow access to service A belts s T PE Engine air flow Allow access to front control panel Allow access for general service Figure 4 2 Installation Guidelines 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 14 40 Oe CAMBLASTER 2022 6 OPERATION amp MAINTENANCE MANUAL CAVIBLASTEH 4 3 Initial Set Up After first receiving the CaviBlaster power unit the following must be checked and completed O O N O RAMA N Connect the battery See Section 4 3 1 Add engine oil See Engine Manual located in the APPENDIX Add engine coolant See Engine Manual located in the APPENDIX Add pump oil See Pump Manual located in the APPENDIX Connect the feed or suction hose See Section 4 3 2 Connect the bypass hose See Figure 2 2 Connect the pressure hose See Figure 2 2 Connect the electric feed pump See Section 4 3 2 Fill the fuel tank See fuel requirements in Engine Manual located in the APPENDIX Engine and or pump fluids
16. Water Filter 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 33 40 Oe GAVIBLASTER OPERATION amp MAINTENANCE MANUAL CAVIBLASTER 6 5 Inspection Maintenance of the belt drive system The CaviBlaster 2022 is equipped with belt power transmission The driver shaft has a centrifugal clutch with 1 400 RPM engagement speed FULL ENGINE SPEED IS REQUIRED FOR PROPER OPERATION OF BOTH THE CLUTCH AND THE LANCE To inspect the belts Remove the belt cover supported by 7 bolts See Figure 6 2 If belts need tightening use the tightening nut to adjust See Figure 6 2 Release the bolts holding the pump rails Adjust Belt tension Tighten pump rails bolts Close belt guard Mm ONE Gao ES This space intentionally left blank 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 34 40 EI CAVIBLASTER 2022 OPERATION amp MAINTENANCE MANUAL CAVIBLASICLCR Belt guard cover 7 bolts Centrifugal clutch Figure 6 2 Inspection Belt tension EOS 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 35 40 Oe CAMBLASTER 2022 6 OPERATION amp MAINTENANCE MANUAL CAVIBLAS TER 7 0 WINTERIZATION The power unit should be winterized only if temperatures drop below 32 degrees Fahrenheit 0
17. avidyne com Web Site http www caviblaster com EOS 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 39 40 OL as CAVBLASICLHR GAVIBLASTER 2022 6 OPERATION amp MAINTENANCE MANUAL APPENDIX COMPONENT LITERATURE Kohler Diesel Engine Model KDW 1404 NORAM Centrifugal Clutch Model 3700P008 CAT Pumps Model 2510 Udor Unloader amp Relief Valve Model UB 402 Johnson Feed Pump Model L4000 Suttner Trigger Gun Model ST 3300 Engine Spec Sheet Engine Owner s Manual Engine Work Shop Manual Engine Troubleshooting Guide Spec Sheet Clutch Drawing Pump Spec Sheet Pump Service Manual Crankcase Oil Data Sheet and MSDS Spec Sheet Instruction Manual Gun Schematic Drawing Warranties Cavidyne Kohler Engines CAT Pumps Suttner EOS 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 40 40
18. cetsccetscsetsceesaes 7 Figure 2 2 CaviBlaster 2022 Control Panel 8 Figure 4 1 Lifting Guidelines este dns 13 Figure 4 2 Installation Guidelines 14 Figure 4 3 Reconnecting the Battery Terminals anan ana nanaawawawwwwaaaannnnnna 16 Figure 4 4 Gravity Feeding Source 17 Figure 5 1 Engine Emergency Shut Down and Throttle Control 23 Figure 5 2 Lance Pressure Calibration e 23 Figure 5 3 Lance Position for Best Results ecceeeeccccccccceseaeecsccccecenan 23 Figure 6 1 Inspection Cleaning Water Filter 33 Figure 6 2 Inspection Belt tension 35 This space intentionally left blank 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 4 40 PE CAMBLASTER 2022 6 OPERATION amp MAINTENANCE MANUAL CAVIBLASTEH 1 0 UNIT SPECIFICATIONS The CaviBlaster 2022 C power unit consists of a 34HP Kohler KDW 1404 diesel power pack and a CAT 2510 triplex plunger pump Detailed performance and specifications are listed below CaviBlaster 2022 C Specifications Nominal Pump Flow 20 GPM 75 6 LPM Operating Pressure 2200 PSI 152 BAR Engine 34 HP Diesel Powered Kohler KDW 1404 Outdoor enclosed or exposed Installation Environment See Section 4 for installation requirements Fuel Requirements Diesel fuel ASTM Grade N
19. d Review this manual especially Section 3 0 SAFETY INFORMATION prior to performing any service on this equipment Equipment must be OFF prior to performing any service work Only replace parts with those supplied or approved by CaviDyne 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 the pump valve s to stick in the open position This will prevent the system from producing the correct operating pressure 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 30 40 PE CAVIBLASTER 20226 OPERATION amp MAINTENANCE MANUA CAVIBLASTEH 6 1 Basic Preventive Maintenance Recommendations Check engine oil level and add if low Check pump oil level and add if low Check coolant level and add if low Check drive belt for wear and replace if worn Check feed pump base plate strainer and clean if necessary Check in line strainer cartridge and clean if necessary Inspect hoses for wear or damage Check lance trigger for leakage X and repair if necessary X X X X X X X Replace engine oil and oil filter X Xx Replace engine f
20. degrees Celsius Total system displacement with 100 ft of hose optional 4 3 gallons Total system displacement without hose 2 0 gallons To winterize the CaviBlaster 2022 power unit R R 5 6 Fill a 5 gallon or larger tank with appropriate antifreeze solution Connect the suction of the unit to 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 lance 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 with antifreeze This space intentionally left blank EOS 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 36 40 Oe GAVIBLASTER OPERATION amp MAINTENANCE MANUAL CAVIBLASTER 8 0 TROUBLESHOOTING 1 ENGINE DOES NOT TURN OVER Verify that the Emergency Stop button is released Verify that the battery terminals are clean and tight Verify battery charge Check the alternator belt tension 2 ENGINE TURNS OVER BUT DOES NOT START Check fuel level Check fuel filter Check fuel line for air lock Verify that fuel pump solenoid is not stuck 3 ENGINE THROTTLES UP BUT STALLS AFTER FEW SECONDS Verify that drive belts are tensioned fol
21. e a flooded suction line See Figure 4 4 This space intentionally left blank EOS 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 19 40 Oe GAVIBLASTER OPERATION amp MAINTENANCE MANUAL CAVIBLASTER 5 0 OPERATION The CaviBlaster 2022 should be operated by two 2 properly trained individuals One the diver operates the zero thrust lance while the other operates the power unit Both operators should be in audio or visual communication with each other The CaviBlaster 2022 should only be operated by properly trained personnel who are familiar with the contents of the manual Review the safety requirements found in Section 3 before operating 5 1 Preparing the CaviBlaster for Operation The following checklist should 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 lance for any signs of damage DD Inspect the inline strainer to ensure that it is not clogged See Figure 6 1 Check for proper engine oil level See engine Owner s Manual found in the Appendix Add lubricating oil SAE 10W40 if necessary Check for proper pressure pump oil level See pump Owner s Manual found in the Appendix Add hydraulic oil SAE 30 non detergent if necessary Check fuel tank See Figure 2 1 for prope
22. e proceeding 1 Startup the power unit as described in Section 5 2 2 Connect the lance to the high pressure hose and unroll sufficient length of hose to reach the operating location oo When the diver is ready to commence cleaning operations ensure that the lance is submerged in water Ensure that the power unit operator and other persons working in the vicinity of the power unit wear appropriate hearing protection when the engine is running If the diver is not wearing a helmet hearing protection is recommended CaviDyne suggests vented earplugs such as Doc s Proplugs for diver hearing protection Wear neoprene or rubber gloves to protect the hands and follow all safety regulations that may be applicable to the work being performed The lance trigger should be in open or ON position See Figure 5 3 when throttling up the engine to engage the pressure pump This will prevent the pressure pump from being in a loaded condition which will cause the clutch and belt to slip while they are engaging the pressure pump Throttle the engine up by completely pulling the black throttle cable knob all the way out and twisting the knob to lock it See Figure 5 1 D 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 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628
23. eed position 2 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 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 allow for efficient cavitation performance and will degrade the cleaning capability of the CaviBlaster system 3 Follow all safety regulations that may be applicable to the work being performed 4 If the diver operating the CaviBlaster unit must be replaced or the cleaning operation must be terminated disengage the pressure pump by pushing the throttle lever in to the idle position Figure 5 1 and release the water pressure remaining in the hose s by moving the lance trigger to the open or ON position while under water Revert to step 1 of the operating instructions when the diver or replacement is ready to continue cleaning 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 27 40 EI CAVIBLASTER 2022 OPERATION amp MAINTENANCE MANUAL CAVIBLASICR SURFACE TO BE CLEANED Figure 5 3 Lance Position for Best Result
24. ge 9 40 Oe GAVIBLASTER OPERATION amp MAINTENANCE MANUAL CAVIBLASTER 3 0 SAFETY INFORMATION The CaviBlaster 2022 power unit is an inherently powerful and potentially dangerous piece of equipment however with proper care and training it can be operated safely The 2022 must only be operated by personnel that have read and understand this manual It is intended to reinforce and review safety techniques to prevent personal injuries and property damage Users must comply with all local state and national laws concerning high pressure water jetting equipment as well as all underwater work regulations It is strongly recommended that this entire manual be reviewed 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 2022 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 training can result in personal injury CaviDyne LLC is not responsible for damages resulting from a failure to comply with instructions in this manual Please read carefully before use If maintenance or
25. low procedures in Section 6 5 Check that pressure regulator unloader switches to by pass mode Check mechanical stop on the throttle cable if at end position 4 ENGINE SPEEDS UP BUT WATER DOES NOT GO OUT THE LANCE 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 inlet lines Verify that the feed pump is delivering water Pump mechanical failure Bad electrical connections Check that pressure pump inlet and discharge valves are not stuck open common problem if not flushed after use with sea water Check for water going out of the bypass pressure regulator failure 5 WATER IN CRANK CASE Check the pump seals feeding water at greater than 50 psi can force water past the seals and damage the seals Check the plungers for cracks Check the plunger rod O ring 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 37 40 Oe GAVIBLASTER OPERATION amp MAINTENANGE MANUAL CAVIBLASTER 6 AFTER RELEASING THE MECHANICAL TRIGGER WATER IS STILL LEAKING OUT OF THE LANCE Replace the mechanical trigger valve assembly in the lance handle 7 LANCE IS NOT CLEANING PROPERLY Verify that the system is operating at the correct pressure 2 200
26. mp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 18 40 GAVIBLASTER 2022 6 OPERATION amp MAINTENANCE MANUAL Oe GAVIBLASTER OPERATION amp MAINTENANCE MANUAL CAVIBLASTER To use gravity feed e Locate the water supply tank so that the bottom of the tank is higher than the water inlet on the control panel See Figures 2 2 and 4 4 e Turn the engine ignition key to OFF See Figure 2 2 e Push IN the Emergency Engine Shut Down button to ensure power has been disconnected See Figure 2 2 e Connect a minimum 1 1 4 hose to the water inlet 1 1 4 cam lock plug e Connect the other end of the hose to the water supply tank e Make sure the lowest point in the hose line is the connection with the power unit e Release the Emergency Engine Shut Down button e It is essential that 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 pump flow of 20 GPM 75 LPM A minimum flow of 25 GPM 95 LPM is recommended to ensure that the pump is not starved of water If connecting to a tank locate the bottom of the tank above the water inlet connection on the power unit to ensur
27. o 1 D or 2 D Fuel Tank Capacity 6 5 Gallons 24 5 Liters 0 PSI Atmospheric Pressure to 70 PSI Maximum ke EEN 0 BAR to 4 8 BAR See Section 4 for further requirements Overall Unit Dimensions L x W x H 47 x 38 x 37 119 cm x 97 cm x 94 cm Maximum Pressure Hose Length 600 LF 200 meters of 3 4 diameter thermoplastic Power Unit Weight Dry 820 LBS 370 KG Zero Thrust Lance Weight 13 LBS 5 9 KG Figure 1 1 CaviBlaster 2022 C Specifications This space intentionally left blank EOS 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 5 40 EI GAVIBLASTER OPERATION amp MAINTENANGE MANUAL CAVIBLASTER 2 0 GENERAL DESCRIPTION The CaviBlaster 2022 high pressure water power unit allows the operator to use the water flow and pressure to generate cavitation at the end of the proprietary nozzle The CaviBlaster cleans the surface of any underwater structure using the energy released by the implosion of the bubbles during the cavitation process When directed at the surface being cleaned the energy released by the collapsing bubbles causes marine growth to be removed from the surface The system consists of a portable zero thrust lance connecting high pressure hose and a diesel powered high pressure pumping unit The zero thrust lance uses a trigger operated valve to control the water stream off and on
28. r diesel fuel level Add diesel fuel ASTM Grade No 1 D or 2 D or EN 590 if necessary g Incorrect fuels should not be used as they may prove hazardous 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 20 40 Oe GAVIBLASTER 2022 6 OPERATION amp MAINTENANCE MANUAL CAVIBLASTEH 5 2 Startup of the CaviBlaster Before starting the CaviBlaster 2022 power unit review all safety requirements found in Section 3 0 SAFETY INFORMATION This equipment should only be operated by individuals who have read and understand the CaviBlaster Operation and Maintenance Manual 1 2 oo NE Verify that the unit has been properly prepared for operation as described in Section 4 Verify that the lance is properly connected and the mechanical trigger is released Verify that the Emergency Engine Shit Down knob See Figure 2 2 is released by twisting and pulling it out Verify that the throttle cable is fully depressed See Figure 5 1 Apply appropriate hearing protection prior to starting engine Insert the key into the ignition switch on the ignition panel See Figure 2 2 Turn the key clockwise one position to heat the glow plugs Once the plug preheat light the top right light on the panel turns off turn the key farther clockwise to start the engine If the engine does not start within 10 seconds return the key to the
29. repair of the CaviBlaster lance is being conducted out of the water remember that the zero thrust lance has front and rear jets Never direct the jet streams at a person or animal Never direct the jet streams toward power lines or other high voltage equipment 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 10 40 EI GAVIBLASTER OPERATION amp MAINTENANCE MANUAL CAVIBLASTER Ensure that there is a safe area to work while operating the CaviBlaster 2022 Seek immediate medical attention if the operator suffers an injury as the result of contact with the high pressure water stream Serious personal injury can result from an untreated water injection wound 3 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 CaviDyne 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 nails The gloves will absorb most of the energy produced by bursting cavitation bubble
30. s This space intentionally left blank 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 28 40 Oe GAVIBLASTER 2022 6 OPERATION amp MAINTENANCE MANUAL CAVIBLAS TER 5 6 Shutting Down the CaviBlaster 1 Adjust the engine speed to idle by pushing on the red throttle cable knob See Figure 5 1 This will disengage the clutch and pressure pump Run the engine at idle speed for a few minutes Push the feed pump ON OFF switch in to stop the pump See Figure 2 2 If using force feed from an alternate source or if using gravity feed shut off the supply of water to the pressure pump Shut off the engine by turning the key counter or anti clockwise or to the OFF position See Figure 2 1 Squeeze the lance trigger to the open or ON position See Figure 5 3 to release the water pressure remaining in the hose s while the lance is submerged It is now safe to remove the lance from the water Flush the system and rinse the power unit with fresh water at the end of the day This space intentionally left blank EOS 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 29 40 EI GAVIBLASTER OPERATION amp MAINTENANCE MANUAL CAVIBLASTER 6 0 MAINTENANCE Maintenance on this unit should be restricted to authorized personal that have been properly traine
31. s and prevent the cavitation bubbles from contacting the operators hands The gloves will also protect operators hands from the initial shockwave when the lance is activated Failure to wear appropriate PPE may result in personal injury 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 11 40 Oe GAVIBLASTER OPERATION amp MAINTENANCE MANUAL CAVIBLASTER 3 3 Modification to the Equipment Do not make any unauthorized modifications or repairs to this equipment Components used throughout this assembly were specifically designed or selected to safely meet the unique high pressure requirements Only replace parts with those recommended by or supplied by CaviDyne 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 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 12 40 Oe CAVIBLASTER 2022 OPERATION amp MAINTENANCE MANUAL CAVIBLASICR 4 0 INSTALLATION The CaviBlaster 2022 must be installed in accordance with the requirements outlined below The unit can be installed in a vehicle to allow for maximum mobilit
32. t UP essens Aa app a ea den ee a ee 15 4 3 1 Connecting the Battery Terminals ccccciciiiiiiiiiiiiiiiiiiiiiiiiiiiiines 15 4 3 2 Connecting the Water Source nn 16 5 DOPERATION H 20 5 1 Preparing the CaviBlaster for Operation 20 5 2 Startup of the EE EE 21 5 3 Normal Operation D 22 5 4 Adjusting the CaviBlaster for Maximum Performance 24 5 5 Recommendations for Effective Results 27 5 6 Shutting Down the CaviBlaster 1 aa 27 6 0 MAINTENANCE a ou mu ot un 30 6 1 Preventive Maintenance Recommendations ccccccccciiiii ciii 31 6 2 Diesel Engine SAUE Luren 32 6 3 Pump SN 32 6 4 Inspection Cleaning of Water Inlet Strainer essssssseneneeesseesrrnnnrneseerrerrnnrnneeee 32 6 5 Inspection Maintenance of the Belt Drive System 34 7 0 WINTERICATION BEE 37 8 0 TROUBLESHOOTING E 37 9 0 REPLACEMENT PARTS ne mienne 39 APPENDIX COMPONENT LITERATURE ccccccrccccccrrccccceaaccccnaacccennnncoennnnnn 40 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 3 40 Oe GAVIBLASTER OPERATION amp MAINTENANGE MANUAL CAVIBLASTER LIST OF FIGURES amp TABLES Figure 1 1 CaviBlaster 2022 C Specifications 5 Figure 2 1 CaviBlaster 2022 General Features ccccccsscccssccessccetsccetsc
33. uel filter Replace engine air filter X Check rocker arm valve X clearance Xx Clean and set injectors Replace pump oil X Check pump seals for wear and X change if necessary Whichever occurs first 1 If any hose damage if found replace hose immediately 2 Remove lance 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 hours of operation The oil change interval is every 125 hours if oil of a quality lower than prescribed by the manufacturer is used See engine manufacturer s literature in the Appendix for additional recommendations 4 The initial oil change is after 50 hours of operation The oil change interval is every 300 hours if oil other than CAT Pumps is used See pump manufacturer s literature in the Appendix for additional recommendations 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 31 40 Oe GAVIBLASTER OPERATION amp MAINTENANGE MANUAL CAVIBLASTER 6 2 Diesel Engine Service The diesel engine requires routine maintenance Oil must be checked and changed regularly Oil air and fuel filters must be checked and changed regularly The engine crankcase holds 3 2 qts 3 0 L and the oil filter an additional 0 2 qts 0 2 L of SA
34. y and flexibility 4 1 Uncrating and Lifting Unpack the equipment and inspect for damage If damage is found immediately contact CaviDyne and the shipping company f 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 is stable before lifting Lift Unit from Lift unit using Underneath lifting eyes Frame emm De Figure 4 1 Lifting Guidelines 2010 O amp M Manual Version 1 2 CaviDyne P O Box 358628 Gainesville FL 32635 U S A Phone 352 275 5319 Page 13 40 EI CAVIBLASTER 2022 OPERATION amp MAINTENANCE MANUAL CAVIBLASICR 4 2 Installation Location For maximum flexibility the CaviBlaster power unit should be installed in an area where it is capable of reaching both its water source and anticipated cleaning targets within acceptable hose lengths The CaviBlaster power unit can be installed in an enclosed or open environment Enclosed installations will require provisions for adequate engine cooling air flow and for venting 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
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